Yamaha FJR1300A(D) Service Manual Download Page 265

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FRONT FORK

4-88

• Washer

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a. Pull up the inner tube completely, fill it with oil

up to the top, and then install the cap bolt.

TIP

Do not install the fork spring.

b. Place the front fork leg in a press and gradu-

ally apply pressure to remove the oil seal.

NOTICE

EC3P61026

• Be careful not to damage the top of the cap

bolt.

• Place an oil drain pan under the press be-

fore applying pressure to the front fork leg.

• Stop applying pressure when oil begins to

leak from between the oil seal and the outer
tube.

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5. Remove:

• Damper rod assembly bolt
• Copper washer

TIP

While holding the damper rod assembly with the
damper rod holder “1”, loosen the damper rod
assembly bolt.

6. Remove:

• Inner tube

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a. Hold the front fork leg horizontally.
b. Securely clamp the brake caliper bracket in a

vise with soft jaws.

c. Separate the inner tube from the outer tube

by pulling the inner tube forcefully but careful-
ly.

NOTICE

ECA1MC1031

• Excessive force will damage the bushings.

Damaged bushings must be replaced.

• Avoid bottoming the inner tube into the out-

er tube during the above procedure, as the
damper rod assembly will be damaged.

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EAS23010

CHECKING THE FRONT FORK LEGS

The following procedure applies to both of 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:

• Spring free length “a”

Out of specification

→

Replace.

1. Oil drain pan

Damper rod holder

90890-01447
YM-01447

Summary of Contents for FJR1300A(D)

Page 1: ...2013 SERVICE MANUAL FJR1300A D 1MC 28197 E0 ...

Page 2: ...300A D 2013 SERVICE MANUAL 2012 by Yamaha Motor Co Ltd First edition August 2012 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 EAS20081 IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following notations This is the safety alert symbol I...

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

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

Page 6: ......

Page 7: ...EAS20110 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: ...T FUNCTIONS 1 19 ABS OPERATION 1 25 ABS SELF DIAGNOSIS FUNCTION 1 28 ABS WARNING LIGHT AND OPERATION 1 31 OUTLINE OF THE TCS Traction Control System 1 32 MULTI FUNCTION METER UNIT 1 35 IMPORTANT INFORMATION 1 46 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 46 REPLACEMENT PARTS 1 46 GASKETS OIL SEALS AND O RINGS 1 46 LOCK WASHERS PLATES AND COTTER PINS 1 46 BEARINGS AND OIL SEALS 1 47 CIRCLIPS 1 47 RU...

Page 10: ...S20140 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the steering head pipe EAS20150 MODEL LABEL The model label 1 is affixed to the frame This information will be needed to order spare parts 1 ...

Page 11: ...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 engine at all times by using a microprocessor that regulates the fuel injection volume according to the engine operating conditions dete...

Page 12: ...osition sensor accelerator position sensor coolant temperature sensor cylinder identification sensor lean angle sensor crankshaft position sensor intake air pressure sensor atmospheric pres sure sensor 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 posi tion sensor ...

Page 13: ...respond extremely quickly to the slightest adjustments made by the rider In par ticular optimized control of the throttle valve opening provides the optimum volume of intake air for easy to use torque even in a high revving engine Aims and advantages of using YCC T Increased engine power By shortening the air intake path higher engine speed is possible Increased engine power Improved driveability ...

Page 14: ...6 7 8 9 3 2 1 4 1 Throttle position sensor 2 Throttle servo motor 3 Accelerator position sensor 4 ECU engine control unit 5 Sensor input 6 Gear position switch 7 Crankshaft position sensor 8 Rear wheel sensor 9 Coolant temperature sensor ...

Page 15: ...o maintain a set cruising speed without operating the throttle the system reduces the burden of maintaining a constant speed during long distance touring In addition the cruise control system is equipped with a self diagnosis function GEAR N 25 A TEMP C Lo C TEMP C 0 06 TIME TRIP 16 15 14 13 10 11 12 9 8 7 6 5 4 3 2 1 1 Battery 2 Main switch 3 Meter assembly 4 ECU engine control unit 5 Clutch swit...

Page 16: ...etween about 50 km h 31 mph and 160 km h 100 mph or 4th or 5th gear at speeds between about 50 km h 31 mph and 180 km h 112 mph Operating range of cruise control system Adjusting the set cruising speed While the cruise control system is operating push the RES side of the cruise control setting switch to increase the set cruising speed or the SET side to decrease the set speed TIP Pushing the setti...

Page 17: ...trol system The traveling speed will return to the previously set cruising speed The cruise control setting indicator light SET will come on If the SET side of the cruise control setting switch is pushed during the resume operation the current traveling speed will be set as the new cruising speed WARNING EWA1MC1007 It is dangerous to use the resume function when the previously set cruising speed i...

Page 18: ...ca tor warning light flashes Traction control system is turned off and wheel slip or wheel spin is detected The changes in the vehicle speed signals exceed a preset value The start engine stop switch is set to the position The engine stalls The sidestand is extended SET SET SET SET RES SET RES SET A C D E F B a b d c e b f g b j h i A Operation B Indication C Speed D 180 km h 112 mph E 50 km h 31 ...

Page 19: ...ing switch cannot be used to adjust the set cruising speed To reduce the traveling speed apply the brakes When the brakes are applied the cruise control system will become deactivated If the cruise control system turns off automatically while the cruising speed is not set the cruise control setting indicator light SET will not flash Automatic deactivation condition Vehicle condition for detection ...

Page 20: ...uld be checked as soon as possible in order to avoid engine damage C D B A d c b a a A Cruise control system is activated cruising speed is set B Cruise control system is turned off cruise control system indicator light flashes C Cruise control system is turned off D Cruise control system is turned on cruising speed is not set a Condition for automatically deactivating cruise control system is det...

Page 21: ...ruise control system is activated cruising speed is set B Cruise control system is turned off engine trouble warning light comes on cruise control system is deactivated and cruise control system indicator light flashes C Cruise control system is turned off engine trouble warning light goes off cruise control system is deactivated and cruise control system indicator light flashes D Cruise control s...

Page 22: ...brake line from the rear brake master cylinder is split at the hydraulic unit to transmit brake fluid pressure to both the rear brake caliper and part of the right front brake caliper in the unified brake system The brake fluid pressure transmitted to the rear brake caliper and part of the right front brake caliper is controlled by the proportioning valve and metering valve respectively The operat...

Page 23: ...rake fluid pressure to the rear brake caliper is con trolled when there is a high amount of brake pedal input NOTICE EC3P61017 The unified brake system is a system to assist the brake operation However both the brake lever and the brake pedal must be operated for maximum braking effect Because the balance between the right front brake caliper and the rear brake caliper in the uni fied brake system...

Page 24: ...s conventional brakes on other vehicles with a brake lever for operating the front brake and a brake pedal for operating the rear brake However part of the front brake is operated together with rear brake When wheel lock is detected during emergency braking hydraulic control is performed by the hydraulic system on the front and rear brakes independently Useful terms Wheel speed The rotation speed ...

Page 25: ...el speed 100 The wheel speed is 0 but the chassis is moving i e wheel lock Brake force and vehicle stability When the brake pressure is increased wheel speed is reduced Slipping occurs between the tire and the road surface and brake force is generated The limit of this brake force is determined by the friction force between the tire and the road surface and is closely related to wheel slippage Whe...

Page 26: ...ished after the brake fluid 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 conditio...

Page 27: ...e 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 The ABS ...

Page 28: ... sensor rotor rotates the Hall element in the Hall IC installed in the wheel sensor generates pulses The pulse frequency which is proportional to the magnetic flux density is converted into a wave in the Hall IC so that it can be output The ABS ECU calculates the wheel rotation speed by detecting the pulse frequency 10 11 12 3 4 1 4 4 7 7 7 8 9 9 14 15 16 17 2 5 6 6 13 1 Rear brake master cylinder...

Page 29: ...cks and servicing are completed the ABS warning light will go off when the vehicle is rid den or pushed at a speed of 7 km h 4 mph or faster To check the ABS electrical circuit the ABS warning light comes on while the side of the start en gine stop switch is being pushed NOTICE ECA1MC1011 If the rear wheel is raced with the vehicle on the centerstand the ABS warning light may flash or come on If t...

Page 30: ...ctromagnetic force generated in the inlet solenoid valve varies proportionally with the duty cy cle 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 closed The brake line bet...

Page 31: ...1 controls the hydraulic pressure difference between the brake fluid in the upper brake lines brake master cylin der side and the brake 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 1 2 1 Buffer chamber pressurizing phase 2 Buffer chamber depressurizing phase 3 Raised piston ...

Page 32: ...or 4 Main fuse 5 ABS motor fuse 6 ABS solenoid fuse 7 Main switch 8 ABS ECU fuse 9 Signaling system fuse 10 Front brake light switch 11 Brake light fuse 12 Rear brake light switch 13 Brake switch relay 14 Brake light relay 15 Tail brake light 16 Hydraulic unit assembly 17 ABS ECU 18 Solenoid relay 19 ABS motor relay 20 Front brake inlet solenoid 21 Front brake outlet solenoid 22 Rear brake inlet s...

Page 33: ...ABS ECU e g a blown ABS ECU fuse The ABS performs a self diagnosis test for a few seconds each time the vehicle first starts off after the main switch was turned on During this test a clicking noise can be heard from under the seat and if the brake lever or brake pedal are even slightly applied a vibration can be felt at the lever and pedal but these do not indicate a malfunction 2 1 3 4 5 6 7 8 1...

Page 34: ...lic 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 the orifice the brake master cylinder directly pressurizes the brake caliper during normal braking When the brake lever is released the brake fluid in the brake caliper returns to the brake ma...

Page 35: ...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 36: ...e 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 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 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 T...

Page 37: ...mains on while the ABS is performing a self diagnosis then goes off if there are no problems The ABS self diagnosis starts when the main switch is turned to ON and finishes when the vehicle is ridden at a speed of approximately 10 km h 6 mph Refer to ABS warning light on page 1 20 GEAR N 25 A TEMP C Lo C TEMP C 0 06 TIME TRIP 1 a e d d b c f a ABS warning light b Main switch OFF c Main switch ON d...

Page 38: ...ght flashes while riding If the ABS warning light flashes while riding there is no problem with the function of the ABS How ever the ABS ECU input has unstable factors For details refer to ABS TROUBLESHOOTING OUTLINE on page 8 131 TIP The ABS warning light comes on or flashes if the vehicle is ridden with the test coupler adapter con nected to the ABS test coupler b c d e a f i f f h g a ABS warni...

Page 39: ...per inner panel When the test coupler adapter is connected to the ABS test coupler the ABS warning light starts flashing and the multi function meter right display indicates all the fault codes recorded in the ABS ECU TIP The ABS warning light comes on or flashes if the vehicle is ridden with the test coupler adapter con nected to the ABS test coupler a d b c a ABS warning light b Comes on c Goes ...

Page 40: ...ance or improve the cornering performance 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 brakin...

Page 41: ...control system block diagram The signals from the front and rear wheel sensors are sent to the ECU through the ABS ECU and the ECU calculates the amount of slip according to the difference between the detected front and rear wheel speeds If the amount of slip exceeds the preset value the ECU controls the ignition timing fuel cut off and throttle valve opening of the YCC T system so that the amount...

Page 42: ...nd cannot prevent front wheel slip ping As with any motorcycle approach surfaces that may be slippery with caution and avoid especially slippery surfaces When the main switch is turned to ON the traction control system automatically turns on The traction control system can be turned on or off manually only when the main switch is in the ON position and the motorcycle is stopped To turn off the tra...

Page 43: ...ht will go off Resetting The traction control system will be disabled in the following condition The rear wheel is rotated with the centerstand down and the main switch in the ON position Either the front wheel or rear wheel comes off the ground while riding Excessive rear wheel spinning If the traction control system has been disabled both the traction control system indicator warning light and t...

Page 44: ...to set select or reset the items shown in the in formation display a self diagnosis device TIP Be sure to turn the main switch to ON before using the select switch menu switch MENU RESET button and TCS button For the UK only To switch the meter displays between kilometers and miles Tachometer The electric tachometer allows the rider to mon itor the engine speed and keep it within the ideal power r...

Page 45: ... be ing operated in an environmentally friendly fuel efficient manner The indicator goes off when the vehicle is stopped TIP Consider the following tips to reduce fuel con sumption Avoid high engine speeds during acceleration Travel at a constant speed Select the transmission gear that is appropri ate for the vehicle speed Transmission gear display This display shows the selected gear The neu tral...

Page 46: ... using the grip warmers and replace the grips Selecting the information display There are 3 information displays The selected information display can be switched by pushing the select switch The following items are shown in the information displays an odometer display tripmeter displays a fuel reserve tripmeter display an estimated traveling range display an elapsed time display an ambient tempera...

Page 47: ... so that the tripmeter flashes and then push the RESET button again for at least 2 seconds while the tripmeter is flashing If you do not reset the fuel reserve tripmeter manually it will reset itself automatically and the display will return to the prior mode after refueling and traveling 5 km 3 mi Estimated traveling range display The distance that can be traveled with the re maining fuel in the ...

Page 48: ...lay modes km L L 100km or MPG for the UK only show the average fuel consumption since the display was last reset The km L display shows the average dis tance that can be traveled on 1 0 L of fuel The L 100km display shows the average amount of fuel necessary to travel 100 km For the UK only The MPG display shows the average distance that can be traveled on 1 0 Imp gal of fuel To reset the average ...

Page 49: ...the oil change interval distance traveled and 2 other maintenance inter vals This function can also be reset MENU Grip Warmer Maintenance Time Trip Unit Display Brightness Clock 1 Time Trip This function allows you to check and reset the TIME 2 and TIME 3 functions These time trips show the to tal elapsed time that the main switch has been in the ON position When the main switch is turned to OFF t...

Page 50: ...to return to the setting mode menu TIP The setting can be set to 10 temperature levels Resetting the maintenance counters 1 Use the select switch to highlight Mainte nance 2 Push the menu switch MENU and then push the RESET button to select the item to reset 3 While the selected item is flashing push the RESET button for at least 2 seconds 4 Push the menu switch MENU to return to the setting mode ...

Page 51: ... switch to select km or mile and then push the menu switch MENU TIP When km is selected L 100km or km L can be set as the fuel consumption units To set the fuel consumption units proceed as follows If mile was selected skip steps 5 and 6 5 Use the select switch to select km L or L 100km 6 Push the menu switch MENU use the se lect switch to select L 100km or km L and then push the menu switch MENU ...

Page 52: ...o return to the previous display 6 Use the select switch to highlight and then push the menu switch MENU to return to the setting mode menu Adjusting the meter panel brightness 1 Use the select switch to highlight Bright ness 2 Push the menu switch MENU 3 Use the select switch to select the desired brightness level and then push the menu switch MENU to return to the setting mode menu Display Displ...

Page 53: ...light will come on and the informa tion display will indicate a fault code If the information display indicates any fault codes note the code number and then check the fuel injection system Refer to FUEL IN JECTION SYSTEM on page 8 33 The self diagnosis device also detects problems in the immobilizer system circuits If a problem is detected in the immobilizer sys tem circuits the immobilizer syste...

Page 54: ...rive mode D mode is an electronically controlled engine performance system with two mode selections touring mode T and sports mode S Push the drive mode switch MODE to switch between modes TIP Before using D mode make sure you under stand its operation along with the operation of the drive mode switch Touring mode T The touring mode T is suitable for various riding conditions This mode allows the ...

Page 55: ... correct installation of all parts 5 Keep all parts away from any source of fire EAS20200 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace ments Use oil and grease recommended by Yamaha for all lubrication jobs Other brands may be similar in function and appearance but inferior in quality EAS20210 GASKETS OIL SEALS AND O RINGS 1 When overhauling the engine replace all gaskets seals ...

Page 56: ...d air because this will damage the bearing surfac es EAS20240 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 EAS1MC1085 RUBBER PARTS Check rubber parts for deterioration during ...

Page 57: ...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 58: ...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 59: ... 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 60: ...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 61: ...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 03112 Analog pocket tester YU 03112 C Pocket tester 90890 03112 Analog pocket tester YU 03112 C Intake air temperature sensor re sistance 5 40 6 60 kΩ a...

Page 62: ...ist provided below to 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 Test coupler adapter 90890 03149 1 30 4 72 4 74 Pocket tester 90890 03112 Analog pocket tester YU 03112 C 1 52 5 41 8 159 8 171 8 172 8 173 8 177 8 180 8 181 8 182 8 183 8 184 8 185 8 187 8 188 8 1...

Page 63: ...20 3 26 Oil pressure adapter B 90890 03124 3 26 Hexagon wrench 41 90890 01525 YM 01525 4 33 4 35 Damper rod holder 90890 01447 YM 01447 4 88 4 89 Slide metal installer 90890 01508 YM 01508 4 90 Fork seal driver 90890 01502 Fork seal driver 48 YM A0948 4 90 4 91 Ring gear fix bolt M14 90890 01524 YM 01524 4 112 Tool name Tool No Illustration Reference pages 41 41 M14 P1 5 ...

Page 64: ...remover YM 04050 4 115 4 118 Fork seal driver weight 90890 01184 Replacement hammer YM A9409 7 4 120 Fork seal driver attachment 90890 01186 Replacement 27 mm YM A9409 1 4 120 Oil seal installing tool 90890 01512 YM 01512 4 120 Compression gauge 90890 03081 Engine compression tester YU 33223 5 1 Extension 90890 04136 5 1 Pivot shaft wrench 90890 01471 Frame spanner socket YM 01471 5 8 5 9 Tool nam...

Page 65: ...spring compressor 90890 04019 YM 04019 5 24 5 29 Valve spring compressor attachment 90890 04114 Valve spring compressor adapter 19 5 mm YM 04114 5 24 5 29 Valve guide remover ø5 90890 04097 Valve guide remover 5 0 mm YM 04097 5 26 Valve guide installer ø5 90890 04098 Valve guide installer 5 0 mm YM 04098 5 26 Valve guide reamer ø5 90890 04099 Valve guide reamer 5 0 mm YM 04099 5 26 Tool name Tool ...

Page 66: ...0 03180 Feeler gauge set YU 26900 9 5 50 Bearing retainer wrench 90890 04137 Middle drive shaft bearing retainer wrench YM 04137 5 69 5 71 Damper spring compressor 90890 04090 Middle drive gear damper spring com pressor YM 33286 5 69 5 70 Bearing retainer wrench 90890 04140 Middle drive shaft bearing retainer wrench YM 04140 5 70 Gear lash measurement tool 90890 01467 YM 01467 5 73 Tool name Tool ...

Page 67: ...ompressor 90890 05158 YM 08037 5 91 Slide hammer bolt 90890 01083 Slide hammer bolt 6 mm YU 01083 1 5 102 Weight 90890 01084 YU 01083 3 5 102 Radiator cap tester 90890 01325 Mityvac cooling system tester kit YU 24460 A 6 3 Tool name Tool No Illustration Reference pages YU 01304 YU 01083 3 YU 24460 A ...

Page 68: ... bearing driver 90890 04058 Middle drive bearing installer 40 50 mm YM 04058 6 13 Pressure gauge 90890 03153 YU 03153 7 10 Fuel injector pressure adapter 90890 03210 YU 03210 7 10 Fuel pressure adapter 90890 03176 YM 03176 7 10 Yamaha diagnostic tool 90890 03215 8 38 Ignition checker 90890 06754 Oppama pet 4000 spark checker YM 34487 8 182 Tool name Tool No Illustration Reference pages YU 33984 ...

Page 69: ... 03209 8 183 Digital circuit tester 90890 03174 Model 88 Multimeter with tachometer YU A1927 8 184 8 190 Test harness speed sensor 3P 90890 03208 YU 03208 8 189 Test harness S pressure sensor 3P 90890 03207 YU 03207 8 190 Tool name Tool No Illustration Reference pages ...

Page 70: ...SPECIAL TOOLS 1 61 ...

Page 71: ...TORQUES 2 16 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 16 ENGINE TIGHTENING TORQUES 2 17 CHASSIS TIGHTENING TORQUES 2 22 LUBRICATION POINTS AND LUBRICANT TYPES 2 27 ENGINE 2 27 CHASSIS 2 29 LUBRICATION SYSTEM CHART AND DIAGRAMS 2 31 ENGINE OIL LUBRICATION CHART 2 31 LUBRICATION DIAGRAMS 2 33 COOLING SYSTEM DIAGRAMS 2 43 CABLE ROUTING 2 47 ...

Page 72: ...US Dimensions Overall length 2230 mm 87 8 in Overall width 750 mm 29 5 in Overall height 1325 1455 mm 52 2 57 3 in Seat height 805 825 mm 31 7 32 5 in Wheelbase 1545 mm 60 8 in Ground clearance 130 mm 5 12 in Minimum turning radius 3100 mm 122 0 in Weight Curb weight 289 kg 637 lb Maximum load 215 kg 474 lb ...

Page 73: ... 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 Total amount 4 90 L 5 18 US qt 4 31 Imp qt Without oil filter cartridge replacement 3 80 L 4 02 US qt 3 34 Imp qt With oil filter cartridge replacement 4 00 L 4 23 US qt 3 52 Imp qt Oil pressure 30 0 kPa 1050 r min 0 30 kgf cm 1050 r min 4 4 psi 1050 r min at oil t...

Page 74: ...60 0 mm 14 17 in Height 273 8 mm 10 78 in Depth 22 0 mm 0 87 in Water pump Water pump type Single suction centrifugal pump Reduction ratio 75 48 25 28 1 395 Impeller shaft tilt limit 0 15 mm 0 006 in Spark plug s Manufacturer model NGK CPR8EA 9 Spark plug gap 0 8 0 9 mm 0 031 0 035 in Cylinder head Combustion chamber volume 23 03 cm 1 41 cu in Warpage limit 0 10 mm 0 0039 in Camshaft Drive system ...

Page 75: ...eat width C exhaust 0 90 1 10 mm 0 0354 0 0433 in Valve margin thickness D intake 0 80 1 20 mm 0 0315 0 0472 in Valve margin thickness D exhaust 0 50 0 90 mm 0 0197 0 0354 in Valve stem diameter intake 4 975 4 990 mm 0 1959 0 1965 in Valve stem diameter exhaust 4 965 4 980 mm 0 1955 0 1961 in Valve guide inside diameter intake 5 000 5 012 mm 0 1969 0 1973 in Limit 5 050 mm 0 1988 in Valve guide in...

Page 76: ...9 kgf mm 161 82 lbf in Spring rate K1 exhaust 21 85 N mm 2 23 kgf mm 124 76 lbf in Spring rate K2 exhaust 28 34 N mm 2 89 kgf mm 161 82 lbf in Installed compression spring force intake 136 00 158 00 N 13 87 16 11 kgf 30 57 35 52 lbf Installed compression spring force exhaust 136 00 158 00 N 13 87 16 11 kgf 30 57 35 52 lbf Spring tilt intake 2 5 1 7 mm 2 5 0 067 in Spring tilt exhaust 2 5 1 7 mm 2 ...

Page 77: ...lled 0 20 0 30 mm 0 0079 0 0118 in Limit 0 55 mm 0 0217 in Ring side clearance 0 030 0 070 mm 0 0012 0 0028 in Limit 0 120 mm 0 0047 in 2nd ring Ring type Taper Dimensions B T 1 00 2 90 mm 0 04 0 11 in End gap installed 0 35 0 45 mm 0 0138 0 0177 in Limit 0 80 mm 0 0315 in Ring side clearance 0 020 0 060 mm 0 0008 0 0024 in Limit 0 120 mm 0 0047 in Oil ring Dimensions B T 2 00 2 50 mm 0 08 0 10 in...

Page 78: ...in Plate quantity 8 pcs Friction plate 2 thickness 2 92 3 08 mm 0 115 0 121 in Plate quantity 1 pc Wear limit 2 82 mm 0 111 in Clutch plate thickness 1 90 2 10 mm 0 075 0 083 in Plate quantity 8 pcs Warpage limit 0 10 mm 0 0039 in Clutch spring height 6 78 mm 0 27 in Minimum height 6 44 mm 0 25 in Spring quantity 1 pc Long clutch push rod bending limit 0 370 mm 0 0146 in Transmission Transmission ...

Page 79: ...cation sensor output voltage ON More than 4 8 V Cylinder identification sensor output voltage OFF Less than 0 8 V Intake air pressure sensor output voltage 3 57 3 71 V Atmospheric pressure sensor output voltage 3 57 3 71 V Air temperature sensor resistance 5 4 6 6 kΩ at 0 C 32 0 F 290 390 Ω at 80 0 C 176 0 F Coolant temperature sensor resistance 2 32 2 59 kΩ at 20 0 C 68 0 F 310 326 Ω at 80 0 C 17...

Page 80: ...ENGINE SPECIFICATIONS 2 9 Ring gear to stopper bolt clearance 0 30 0 60 mm 0 0118 0 0236 in Ring gear to thrust washer clearance 0 20 mm 0 0079 in Final gear backlash 0 22 0 45 mm 0 0087 0 0177 in ...

Page 81: ... 0 02 in Front tire Type Tubeless Size 120 70 ZR17M C 58W Manufacturer model METZELER Roadtec Z8 BRIDGESTONE BT023F F Wear limit front 1 6 mm 0 06 in Europe 1 0 mm 0 04 in AUS Rear tire Type Tubeless Size 180 55 ZR17M C 73W Manufacturer model METZELER Roadtec Z8 C BRIDGESTONE BT023R F Wear limit rear 1 6 mm 0 06 in Europe 1 0 mm 0 04 in AUS Tire air pressure measured on cold tires Loading conditio...

Page 82: ...e disc thickness limit 4 5 mm 0 18 in Brake disc deflection limit 0 15 mm 0 0059 in Brake pad lining thickness inner 6 3 mm 0 25 in Limit 0 8 mm 0 03 in Brake pad lining thickness outer 6 3 mm 0 25 in Limit 0 8 mm 0 03 in Master cylinder inside diameter 15 0 mm 0 59 in Caliper cylinder inside diameter 41 30 mm 1 63 in Specified brake fluid DOT 4 Clutch Specified brake and clutch fluid DOT 4 Master...

Page 83: ...rd 11 clicks out Maximum 1 click out Rear suspension Type Swingarm link suspension Spring shock absorber type Coil spring gas oil damper Rear shock absorber assembly travel 60 0 mm 2 36 in Spring free length 157 6 mm 6 20 in Spring installed length 145 9 mm 5 74 in Spring free length 67 8 mm 2 67 in Spring installed length 62 0 mm 1 26 in Soft Spring rate K1 171 00 N mm 17 44 kgf mm 976 41 lbf in ...

Page 84: ...2 Ω Voltage regulator Rectifier regulator Regulator type Semi conductor short circuit Regulated voltage DC 14 3 14 7 V Rectifier capacity DC 50 0 A Withstand voltage 40 0 V Battery Model GT14B 4 Voltage capacity 12 V 12 0 Ah Manufacturer GS YUASA Ten hour rate amperage 1 20 A Headlight Bulb type Halogen bulb Bulb voltage wattage quantity Headlight 12 V 60 0 W 55 0 W 2 Auxiliary light LED Tail brak...

Page 85: ... oz Commutator diameter 24 5 mm 0 96 in Limit 23 5 mm 0 93 in Mica undercut depth 1 50 mm 0 06 in Starter relay Amperage 180 0 A Coil resistance 4 18 4 62 Ω Horn Horn type Plane Quantity 1 pc Maximum amperage 3 0 A Performance 105 118 dB 2 m 6 6 ft Turn signal hazard function Built in self canceling device No Turn signal blinking frequency 89 91 cycles min Fuel sender unit Sender unit resistance f...

Page 86: ...iary DC jack fuse 3 0 A Hazard lighting fuse 7 5 A Fuel injection system fuse 15 0 A ABS motor fuse 30 0 A ABS solenoid fuse 20 0 A ABS ECU fuse 7 5 A Cruise control fuse 1 0 A Windshield drive system fuse 20 0 A Electronic throttle valve fuse 7 5 A Backup fuse 7 5 A Spare fuse 30 0 A 2 Spare fuse 25 0 A Spare fuse 20 0 A Spare fuse 15 0 A Spare fuse 10 0 A Spare fuse 7 5 A Spare fuse 3 0 A Spare ...

Page 87: ...l 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 kg ft lb 10 mm 6 mm 6 0 6...

Page 88: ...0 Nm 1 0 m kg 7 2 ft lb Rear balancer shaft pinch bolt M6 1 10 Nm 1 0 m kg 7 2 ft lb Timing chain tensioner bolt M6 2 10 Nm 1 0 m kg 7 2 ft lb Timing chain tensioner cap bolt M6 1 6 Nm 0 6 m kg 4 3 ft lb Camshaft sprocket bolt M7 4 24 Nm 2 4 m kg 17 ft lb Water pump assembly bolt M6 3 12 Nm 1 2 m kg 8 7 ft lb Water pump housing cover bolt M6 1 10 Nm 1 0 m kg 7 2 ft lb Coolant drain bolt M6 1 10 Nm...

Page 89: ...r protector bolt M6 1 10 Nm 1 0 m kg 7 2 ft lb Muffler protector clamp screw 1 5 Nm 0 5 m kg 3 6 ft lb Crankcase bolt M9 10 See TIP Crankcase bolt shoulder bolt M6 2 12 Nm 1 2 m kg 8 7 ft lb Crankcase bolt M6 16 10 Nm 1 0 m kg 7 2 ft lb Crankcase bolt M6 1 10 Nm 1 0 m kg 7 2 ft lb Crankcase bolt M8 2 24 Nm 2 4 m kg 17 ft lb Crankcase blind plug M10 1 20 Nm 2 0 m kg 14 ft lb Lower crankcase plug bo...

Page 90: ... 2 m kg 8 7 ft lb Bearing retainer middle drive shaft M88 1 110 Nm 11 0 m kg 80 ft lb Stake Middle driven pinion gear nut M28 1 180 Nm 18 0 m kg 130 ft lb Stake Bearing retainer middle driven shaft M68 1 110 Nm 11 0 m kg 80 ft lb Stake Middle driven shaft bearing hous ing bolt M8 3 25 Nm 2 5 m kg 18 ft lb Shift drum retainer bolt M6 2 10 Nm 1 0 m kg 7 2 ft lb Shift shaft spring stopper M8 1 22 Nm ...

Page 91: ... 14 ft lb and then tighten them further to reach the specified angle 115 125 TIP Crankcase bolt Tighten the crankcase bolts to 20 Nm 2 0 m kg 14 ft lb in the proper tightening sequence loosen and retighten the bolts to 20 Nm 2 0 m kg 14 ft lb in the proper tightening sequence and then tighten them further to reach the specified angle 115 125 in the proper tightening sequence Radiator cover bolt M6...

Page 92: ...se tightening sequence TIP Middle gear case cover bolt Apply locking agent LOCTITE only to the threads of the 2 upper middle gear case cover bolts and then tighten all of the bolts to 12 Nm 1 2 m kg 8 7 ft lb 9 8 3 6 1 2 5 4 7 10 LT ...

Page 93: ...1 6 m kg 11 ft lb Engine bracket and engine bolt top M10 2 37 Nm 3 7 m kg 27 ft lb Pinch bolt front side M8 2 24 Nm 2 4 m kg 17 ft lb Pinch bolt rear lower side M8 2 24 Nm 2 4 m kg 17 ft lb Main frame and rear frame bolt upper side M8 4 28 Nm 2 8 m kg 20 ft lb Main frame and rear frame bolt lower side M10 2 48 Nm 4 8 m kg 35 ft lb Rear frame and hydraulic unit bracket bolt M6 4 11 Nm 1 1 m kg 8 0 ...

Page 94: ... hose joint bracket bolt M6 2 7 Nm 0 7 m kg 5 1 ft lb Lower bracket cover bolt M6 2 7 Nm 0 7 m kg 5 1 ft lb Windshield drive unit bracket and frame nut M10 2 32 Nm 3 2 m kg 23 ft lb Electrical components board nut M6 2 7 Nm 0 7 m kg 5 1 ft lb Windshield bracket and wind shield drive unit bolt M6 4 7 Nm 0 7 m kg 5 1 ft lb Rearview mirror nut M6 4 7 Nm 0 7 m kg 5 1 ft lb Windshield drive unit nut M6...

Page 95: ...ear wheel sensor rotor bolt M5 3 8 Nm 0 8 m kg 5 8 ft lb Brake torque rod nut M8 2 30 Nm 3 0 m kg 22 ft lb Rear wheel dust cover screw M5 3 5 Nm 0 5 m kg 3 6 ft lb Rear wheel bearing retainer M56 1 80 Nm 8 0 m kg 58 ft lb Left hand thread Brake pipe union bolt M10 4 30 Nm 3 0 m kg 22 ft lb Brake hose union bolt M10 7 30 Nm 3 0 m kg 22 ft lb Brake pipe flare nut M10 5 16 Nm 1 6 m kg 11 ft lb Brake ...

Page 96: ...nger footrest and muffler bracket bolt M8 4 28 Nm 2 8 m kg 20 ft lb Shift arm pinch bolt M6 1 10 Nm 1 0 m kg 7 2 ft lb Shift rod locknut M6 2 7 Nm 0 7 m kg 5 1 ft lb Drive shaft dust cover bolt M5 2 4 Nm 0 4 m kg 2 9 ft lb Final gear oil drain bolt M14 1 23 Nm 2 3 m kg 17 ft lb Final gear oil filler bolt M14 1 23 Nm 2 3 m kg 17 ft lb Final drive assembly nut M10 4 42 Nm 4 2 m kg 30 ft lb Final dri...

Page 97: ... bolt 1 Insert the front wheel axle from the right side and tighten it with the front wheel axle bolt from the left side to 91 Nm 9 1 m kg 66 ft lb 2 In the order pinch bolt 2 pinch bolt 1 pinch bolt 2 tighten each bolt to 21 Nm 2 1 m kg 15 ft lb without performing temporary tightening 3 Check that the right end of the front axle is flush with the front fork If necessary manually push the front ax...

Page 98: ...ump impeller shaft Oil pump rotors inner and outer and oil pump shaft Oil pump drive sprocket Oil filter union bolt Oil nozzle O ring Starter clutch idle gear inner surface Starter clutch and starter clutch gear Primary driven gear Push rods and ball Transmission gears wheel and pinion and collars Main axle and drive axle Shift drum Shift forks and shift fork guide bars Shift shaft Shift pedal bol...

Page 99: ...er head cover gasket Yamaha bond No 1215 Three Bond No 1215 Crankcase mating surface Yamaha bond No 1215 Three Bond No 1215 Crankshaft position sensor lead grommet Yamaha bond No 1215 Three Bond No 1215 Stator coil assembly lead grommet Yamaha bond No 1215 Three Bond No 1215 Lubrication point Lubricant ...

Page 100: ... spring and spring bracket contact points Tube guide throttle grip inner surface and throttle cables Brake lever pivoting point and metal to metal moving parts Clutch lever pivoting point and metal to metal moving parts Swingarm bearing and oil seal lips Pivot shaft and pivot shaft thread Pivot shaft bearing Pivot shaft oil seal lip Relay arm bearing and oil seal lips Drive shaft spline final driv...

Page 101: ...LUBRICATION POINTS AND LUBRICANT TYPES 2 30 ...

Page 102: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 31 EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART 15 13 12 6 5 4 3 2 1 7 8 9 10 11 9 9 9 14 ...

Page 103: ...Oil pump 3 Relief valve assembly 4 Oil filter cartridge 5 Oil cooler 6 Main gallery 7 Front balancer shaft 8 Rear balancer shaft 9 Oil nozzle 10 Intake camshaft 11 Exhaust camshaft 12 Main axle 13 Oil delivery pipe 1 14 Drive axle 15 Middle drive shaft assembly ...

Page 104: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 33 EAS20410 LUBRICATION DIAGRAMS 5 6 7 1 2 3 4 ...

Page 105: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 34 1 Intake camshaft 2 Cylinder head 3 Exhaust camshaft 4 Oil check bolt 5 Main gallery bolt 6 Crankshaft 7 Oil nozzle ...

Page 106: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 35 1 3 2 ...

Page 107: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 36 1 Main axle 2 Drive axle 3 Oil delivery pipe 1 ...

Page 108: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 37 6 5 4 3 2 1 ...

Page 109: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 38 1 Oil check bolt 2 Crankshaft 3 Oil cooler 4 Oil strainer 5 Oil delivery pipe 3 6 Oil pump ...

Page 110: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 39 1 2 3 4 5 6 7 8 9 ...

Page 111: ...CATION SYSTEM CHART AND DIAGRAMS 2 40 1 Rear balancer 2 Oil delivery pipe 2 3 Engine oil drain bolt 4 Oil level switch 5 Crankshaft 6 Front balancer 7 Crank pin 8 Oil delivery pipe 3 9 Relief valve assembly ...

Page 112: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 41 4 5 3 2 1 9 8 6 7 ...

Page 113: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 42 1 Oil strainer 2 Oil delivery pipe 2 3 Oil cooler 4 Engine oil drain bolt 5 Oil level switch 6 Oil filter cartridge 7 Oil delivery pipe 3 8 Oil pan 9 Oil pump ...

Page 114: ...COOLING SYSTEM DIAGRAMS 2 43 EAS20420 COOLING SYSTEM DIAGRAMS 3 13 4 5 6 7 7 7 8 1 2 10 9 14 15 16 17 11 12 3 ...

Page 115: ...olant reservoir breather hose 6 Thermostat inlet pipe 2 7 Coolant reservoir hose 8 Radiator inlet hose 9 Thermostat inlet hose 2 10 Thermostat assembly 11 Water jacket joint 12 Oil cooler 13 Oil cooler inlet hose 14 Water pump outlet pipe 15 Water pump breather hose 16 Radiator outlet hose 17 Water jacket joint inlet hose ...

Page 116: ...COOLING SYSTEM DIAGRAMS 2 45 7 1 2 3 4 5 5 8 9 6 8 9 10 11 12 ...

Page 117: ...1 2 Thermostat inlet hose 2 3 Radiator inlet hose 4 Radiator 5 Radiator outlet hose 6 Oil cooler outlet hose 7 Water jacket joint inlet hose 8 Water pump outlet pipe 9 Water pump outlet hose 10 Water pump 11 Water jacket joint 12 Water pump breather hose ...

Page 118: ...CABLE ROUTING 2 47 EAS20430 CABLE ROUTING Handlebar front view 1 2 3 4 5 6 7 7 8 8 10 9 1 3 13 12 12 12 17 16 19 A B C D E G F H 2 3 13 13 21 11 14 15 18 19 20 20 20 19 2 ...

Page 119: ...ght switch lead and clutch switch lead through the guide B Route the main switch lead to the inside of the clutch hose C Fasten the right handlebar switch lead right grip warmer lead front brake light switch lead main switch lead and immobilizer unit lead with a plastic locking tie Face the end of the plastic locking tie downward angled inward and then cut off the excess end of the tie D Route the...

Page 120: ...CABLE ROUTING 2 49 Radiator and battery right side view 1 3 4 5 6 7 8 14 14 14 14 18 22 23 24 25 J H K E F G C D D 2 N I 1 21 1 L A A B 10 9 13 12 11 15 15 M 15 16 16 17 17 15 20 19 ...

Page 121: ...e hole in the electrical components tray F Fasten the right radiator fan motor lead with the holder on the air guide G Route the right radiator fan motor lead between the leads starter motor lead negative battery lead and O2 sensor lead and the base of the holder that is fastening the leads H Fasten the negative battery lead starter motor lead O2 sensor lead and water pump breather hose with a pla...

Page 122: ...CABLE ROUTING 2 51 Rear brake hose right side view 4 5 6 7 8 9 10 11 1 12 13 14 15 2 3 16 1 A B C F E D ...

Page 123: ...4 Brake pipe brake pipe upper joint assembly to front brake calipers 15 Rear brake light switch 16 Brake hose brake pipe to rear brake caliper A Route the rear wheel sensor lead to the inside of the swingarm making sure that the lead does not protrude above the swingarm B 45 55 mm 1 77 2 17 in C 20 30 mm 0 79 1 18 in D Fasten the rear brake light switch lead and rear wheel sensor lead with the hol...

Page 124: ...CABLE ROUTING 2 53 Horn and radiator left side view A B 1 1 2 3 4 5 5 6 C 7 7 8 ...

Page 125: ...tion the coupler between the left side cowling and the left lower inner panel B Fasten the left radiator fan motor lead to the radiator inlet hose with the plastic band Be sure to position the plastic band above the radiator hose band Make sure that there is no slack in the left radiator fan motor lead and that the lead does not contact the metal hose fitting of the radiator C Face the end of the ...

Page 126: ...CABLE ROUTING 2 55 Front brake hose and engine left side view 18 15 15 16 16 1 1 A B 2 C S R Q P J O M N 14 15 13 I 9 9 10 11 G 5 4 17 18 2 W X 21 20 1 17 18 19 6 H 7 8 8 2 K L 3 F E D 22 12 T V U ...

Page 127: ...the fuel tank breather overflow hose through the guide on the universal joint dust cover H Pass the air filter case breather hose through the guide on the muffler bracket I When installing the left side cowling make sure that the end of the coolant reservoir breather hose protrudes from the bottom of the cowling J Make sure that the paint mark on the coolant reservoir breather hose is positioned t...

Page 128: ...CABLE ROUTING 2 57 Rear fender left side view 2 1 3 4 6 5 7 A C B 8 4 5 4 5 J I K 9 10 1 11 12 13 14 15 D F G H E 16 ...

Page 129: ...ecurely connect the ABS ECU coupler E Secure the plastic band by inserting the projection on the band into the hole in the rear fender and then fasten the wire harness at the positioning tape with the band F Insert the projection on the wire harness holder into the hole in the rear fender G Route the rear right turn signal light lead under the right tail brake light bulb socket H Route the rear ri...

Page 130: ...CABLE ROUTING 2 59 Throttle bodies top view 1 2 3 4 5 6 6 7 7 8 9 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 34 35 36 37 38 39 41 A B C D E F G H I J M N O P 40 Q R K L S 33 10 ...

Page 131: ...d of the plastic locking tie B Position the plastic locking tie 0 20 mm 0 0 79 in from the end of the protective sleeve of the front wheel sensor lead C Position the plastic locking tie 10 30 mm 0 39 1 18 in from the end of the protective sleeve of the immobilizer unit lead D Route the throttle cables and brake hoses through the right opening in the frame E Install the immobilizer unit coupler hol...

Page 132: ...CABLE ROUTING 2 61 Rear fender top view 1 2 3 B C A B ...

Page 133: ...d license plate light lead between the rib and the U lock holder on the rear fender making sure that the leads are not routed on top of the holder B Fasten the tail brake light assembly lead and license plate light lead with the holder C Route the tail brake light assembly lead and license plate light lead between the ribs on the rear fender ...

Page 134: ...CABLE ROUTING 2 63 Front cowling assembly and electrical components board 4 1 2 3 4 5 6 7 8 9 10 14 11 12 13 14 15 16 18 19 20 21 22 23 A B C D D D E I J F G H K L M N P Q R S T T A 17 O ...

Page 135: ...oute the headlight relay dimmer lead to the front of the headlight beam adjusting knob shaft I Blue tape J Route the relay leads meter assembly lead and leads to electrical components board in the order listed from top to bottom K Fasten the wire harness at the white tape on both portions of the harness with a plastic locking tie Position the end of the plastic locking tie under the meter assembly...

Page 136: ...CABLE ROUTING 2 65 Hydraulic unit assembly top and side view 1 1 2 3 4 5 6 7 7 8 9 10 1 2 3 4 5 6 7 8 9 10 10 1 3 4 5 6 7 8 9 13 13 11 12 12 A 2 1 5 4 3 ...

Page 137: ...rtioning valve to rear brake hose 8 Brake pipe front brake master cylinder to brake pipe lower joint assembly 9 Brake pipe brake pipe upper joint assembly to front brake calipers 10 Brake pipe metering valve to right front brake caliper 11 Metering valve 12 Brake hose rear brake master cylinder to brake pipe middle joint assembly 13 Proportioning valve A Position the brake pipe proportioning valve...

Page 138: ...CABLE ROUTING 2 67 ...

Page 139: ... CHECKING THE FRONT BRAKE PADS 3 16 ADJUSTING THE REAR DISC BRAKE 3 16 CHECKING THE REAR BRAKE PADS 3 17 CHECKING THE BRAKE HOSES 3 17 CHECKING THE WHEELS 3 17 CHECKING THE TIRES 3 17 CHECKING THE WHEEL BEARINGS 3 19 CHECKING THE SWINGARM PIVOT 3 19 LUBRICATING THE SWINGARM PIVOT 3 19 CHECKING AND ADJUSTING THE STEERING HEAD 3 19 LUBRICATING THE STEERING HEAD 3 20 CHECKING THE CHASSIS FASTENERS 3 ...

Page 140: ... OIL 3 29 CHECKING THE BRAKE LIGHT SWITCHES 3 30 ADJUSTING THE REAR BRAKE LIGHT SWITCH 3 30 CHECKING AND LUBRICATING THE CABLES 3 30 CHECKING THE THROTTLE GRIP OPERATION 3 31 CHECKING THE SWITCHES LIGHTS AND SIGNALS 3 32 ADJUSTING THE HEADLIGHT BEAMS 3 32 REPLACING THE HEADLIGHT BULBS 3 32 ...

Page 141: ......

Page 142: ...or 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 ODOMETER READING ANNUAL CHECK 1000 km 600 mi 10000 km 6000 mi 20000 km 12000 mi 30000 km 18000 m...

Page 143: ...Lubricate with lithium soap based grease 17 Sidestand center stand Check operation Lubricate with lithium soap based grease 18 Sidestand switch Check operation 19 Front fork Check operation and for oil leakage 20 Shock absorber assembly Check operation and shock absorber for oil leakage 21 Rear suspension relay arm and connecting arm pivoting points Check operation Lubricate with lithium soap base...

Page 144: ...and clutch service Regularly check and if necessary correct the brake and clutch fluid levels Every two years replace the internal components of the brake master cylinders and calipers as well as clutch master and release cylinders and change the brake and clutch fluids Replace the brake and clutch hoses every four years and if cracked or damaged ...

Page 145: ... Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 T bar Refer to GENERAL CHASSIS on page 4 1 2 Remove Ignition coil 3 Remove Spark plug NOTICE ECA13320 Before removing the spark plugs blow away any dirt accumulated in the spark plug wells with compressed air to prevent it from falling into the cylinders 4 Check Spark plug type Incorrect Change 5 Check Electrodes 1 Dama...

Page 146: ...r cut off valve Refer to AIR INDUCTION SYSTEM on page 7 13 Thermostat inlet pipe 1 Refer to THERMOSTAT on page 6 6 2 Remove Spark plugs Cylinder head cover Cylinder head cover gasket Refer to CAMSHAFTS on page 5 11 3 Remove Hose holder 1 Lead holders 2 Pickup rotor cover 3 4 Measure Valve clearance Out of specification Adjust a Turn the crankshaft clockwise b When piston 1 is at TDC on the compres...

Page 147: ...into the crankcase Make a note of the position of each valve lifter 1 and valve pad 2 so that they can be in stalled in the correct place b Calculate the difference between the speci fied valve clearance and the measured valve clearance Example Specified valve clearance 0 15 0 22 mm 0 0059 0 0087 in Measured valve clearance 0 25 mm 0 0098 in 0 25 mm 0 0098 in 0 22 mm 0 0087 in 0 03 mm 0 001 in c C...

Page 148: ...5 11 Lubricate the camshaft lobes and camshaft journals First install the exhaust camshaft Align the camshaft sprockets marks with the cylinder head edge Turn the crankshaft clockwise several full turns to seat the parts h Measure the valve clearance again i If the valve clearance is still out of specifica tion repeat all of the valve clearance adjust ment steps until the specified clearance is ob...

Page 149: ...eather hoses Checking the throttle body synchronization 1 Stand the vehicle on a level surface TIP Place the vehicle on the centerstand 2 Remove Rider seat Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 T bar Refer to GENERAL CHASSIS on page 4 1 3 Remove Caps 1 4 Install Vacuum gauge 1 5 Install Fuel tank 6 Check Throttle body synchronization a Start the engine warm ...

Page 150: ...nd check the synchronization again If a bypass air screw was removed turn the screw in fully and be sure to synchronize the throttle bodies If the throttle body synchronization can not be adjusted using the bypass air screw clean or replace the throttle bodies The difference in vacuum pressure between the throttle bodies should not exceed 1 33 kPa 10 mmHg 3 Stop the engine and remove the measuring...

Page 151: ...ears 3 Press the TCS button to select the CO ad justment mode CO 1 or the diagnostic mode DIAG 4 After selecting CO simultaneously press the TCS button 1 and RESET button 2 for 2 seconds or more to execute the selec tion 5 Press the TCS button or RESET button to select a cylinder number 3 TIP The selected cylinder number appears on the multi function meter right display To decrease the selected cy...

Page 152: ... seat Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 T bar Air filter case Refer to GENERAL CHASSIS on page 4 1 2 Check Crankcase breather hose 1 Cracks damage Replace Loose connection Connect properly NOTICE ECA13450 Make sure the crankcase breather hose is routed correctly 3 Install Air filter case T bar Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL ...

Page 153: ...clutch fluid to the proper level WARNING EWA13370 Use only the designated clutch fluid Other clutch fluids may cause the rubber seals to deteriorate causing leakage and poor clutch performance Refill with the same type of clutch fluid that is already in the system Mixing clutch flu ids may result in a harmful chemical reac tion leading to poor clutch performance When refilling be careful that wate...

Page 154: ...the clutch lever to contact the handlebar grip h Tighten the bleed screw and then release the clutch lever i Repeat steps e to h until all of the air bub bles have disappeared from the clutch fluid in the plastic hose j Tighten the bleed screw to specification k Fill the clutch master cylinder reservoir to the proper level with the specified brake and clutch fluid Refer to CHECKING THE CLUTCH FLUI...

Page 155: ...ervoir Water will sig nificantly 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 TIP In order to ensure a correct reading of the brake fluid level make sure the top of the brake master cylinder reservoir and brake fluid reservoir are horizontal...

Page 156: ...r or fully depress the brake pedal and hold it in position g Loosen the bleed screw TIP Loosening the bleed screw will release the pres sure and cause the brake lever to contact the throttle grip or the brake pedal to fully extend h Tighten the bleed screw and then release the brake lever or brake pedal i Repeat steps e to h until all of the air bub bles have disappeared from the brake fluid in th...

Page 157: ...k Brake pedal position distance a from the top of the rider footrest to the top of the brake pedal Out of specification Adjust 2 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...

Page 158: ...Brake fluid leakage Replace the damaged hose Refer to FRONT BRAKE on page 4 38 REAR BRAKE on page 4 50 and ABS AN TI LOCK BRAKE SYSTEM on page 4 63 EAS21670 CHECKING THE WHEELS The following procedure applies to both of the wheels 1 Check Wheel Damage out of round Replace WARNING EWA13260 Never attempt to make any repairs to the wheel TIP After a tire or wheel has been changed or re placed always ...

Page 159: ...proved by Yamaha Motor Co Ltd for this model The front and rear tires should always be by the same manufacturer and of the same design No guarantee con cerning handling characteristics can be giv en if a tire combination other than one approved by Yamaha is used on this vehicle Tire air pressure measured on cold tires Loading condition 0 90 kg 0 198 lb Front 250 kPa 2 50 kgf cm 36 psi Rear 290 kPa...

Page 160: ... Lubricate Bearings Oil seals Refer to INSTALLING THE SWINGARM on page 4 104 EAS21510 CHECKING AND ADJUSTING THE STEERING HEAD 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 front wheel is elevated 2 Check Steering head Grasp the bottom of the front fork legs an...

Page 161: ...acket Refer to STEERING HEAD on page 4 94 EAS1MC1040 LUBRICATING THE STEERING HEAD 1 Lubricate Upper bearing Lower bearing Bearing races Ring nut threads EAS1MC1041 CHECKING THE CHASSIS FASTENERS Make sure that all nuts bolts and screws are properly tightened Refer to CHASSIS TIGHTENING TORQUES on page 2 22 EAS21700 LUBRICATING THE LEVERS Lubricate the pivoting point and metal to metal moving part...

Page 162: ... and check if the front fork rebounds smoothly Rough movement Repair Refer to FRONT FORK on page 4 82 EAS21580 ADJUSTING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over Spring preload WARNING EWA1MC1011 Always adjust both front fork legs evenly Uneven adjustment can result...

Page 163: ...tandard 10 0 mm 0 39 in Maximum hard 0 mm 0 in A Left side B Right side Direction a Rebound damping is increased sus pension is harder Direction b Rebound damping is decreased sus pension is softer Rebound damping adjusting posi tions Minimum soft 16 click s out Standard 12 click s out Maximum hard 1 click out With the adjusting knob fully turned in A B 1 1 a b a b Direction a Compression damping ...

Page 164: ...NING EWA13120 Securely support the vehicle so that there is no danger of it falling over Spring preload NOTICE ECA13590 Never go beyond the maximum or minimum adjustment positions 1 Adjust Spring preload a Move the adjusting lever 1 in direction a or b b Adjust the adjusting lever to HARD or SOFT Rebound damping NOTICE ECA13590 Never go beyond the maximum or minimum adjustment positions 1 Adjust R...

Page 165: ...s to enter the crankcase TIP Before checking the engine oil level wait a few minutes until the oil has settled 4 Start the engine warm it up for several min utes and then turn it off 5 Check the engine oil level again TIP Before checking the engine oil level wait a few minutes until the oil has settled EAS20780 CHANGING THE ENGINE OIL 1 Start the engine warm it up for several min utes and then tur...

Page 166: ... 1 c Start the engine and keep it idling until engine oil starts to seep from the engine oil check bolt If no engine oil comes out after one minute turn the engine off so that it will not seize d Check the engine oil passages the oil filter cartridge and the oil pump for damage or leakage Refer to OIL PUMP on page 5 60 e Start the engine after solving the problem s and check the engine oil pressur...

Page 167: ...l Main gallery bolt 8 Install Right side cowling Refer to GENERAL CHASSIS on page 4 1 EAS21110 CHECKING THE COOLANT LEVEL 1 Stand the vehicle on a level surface TIP Place the vehicle on the centerstand Make sure the vehicle is upright 2 Remove Left side panel Refer to GENERAL CHASSIS on page 4 1 3 Check Coolant level The coolant level should be between the min imum level mark a and maximum level m...

Page 168: ...e 4 1 EAS21120 CHECKING THE COOLING SYSTEM 1 Remove Side cowlings Refer to GENERAL CHASSIS on page 4 1 Exhaust pipe assembly Refer to ENGINE REMOVAL on page 5 3 2 Check Radiator 1 Oil cooler outlet hose 2 Radiator inlet hose 3 Radiator outlet hose 4 Oil cooler inlet hose 5 Oil cooler 6 Water jacket joint 7 Water jacket joint inlet hose 8 Water pump outlet pipe 9 Water pump outlet hose 10 Cracks da...

Page 169: ...r 1 Coolant reservoir cap 2 7 Drain Coolant from the coolant reservoir 8 Install Coolant reservoir 9 Connect Radiator outlet hose 10 Install Coolant drain bolt water pump along with the copper washer 11 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 WARNING EWA13040 If coola...

Page 170: ...ANT LEV EL on page 3 26 TIP Before checking the coolant level wait a few minutes until the coolant has settled 17 Install Side cowlings Refer to GENERAL CHASSIS on page 4 1 EAS21460 CHECKING THE FINAL GEAR OIL LEVEL 1 Stand the vehicle on a level surface TIP Place the vehicle on the centerstand Make sure the vehicle is upright 2 Remove Final gear oil filler bolt 1 along with the gasket 2 3 Check F...

Page 171: ...djustment is correct when the brake light comes on by depressing the brake pedal less than 10 0 14 0 mm 0 39 0 55 in If the switch is not properly adjusted ABS fault code number 23 may be displayed 1 Check Rear brake light operation timing Incorrect Adjust 2 Adjust Rear brake light operation timing a Hold the main body 1 of the rear brake light switch so that it does not rotate and turn the adjust...

Page 172: ...ay 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 tle body synchronization should be adjusted properly a Slide back the rubber covers 1 b Loosen the locknut 2 c Turn the adjusting nut 3 in direction a or b until the specified throttle grip free play is ob tained d Tighten ...

Page 173: ... headlight EAS21790 REPLACING THE HEADLIGHT BULBS The following procedure applies to both of the headlight bulbs 1 Remove Right upper inner panel Left side cowling Refer to GENERAL CHASSIS on page 4 1 2 Disconnect Headlight coupler 1 3 Remove Headlight bulb cover 2 TIP When removing the right headlight bulb cover it is necessary to remove the ABS test coupler 3 and main fuse holder 4 4 Detach Head...

Page 174: ...d touching the glass part of the head light bulb to keep it free from oil otherwise the transparency of the glass the life of the bulb and the luminous flux will be adversely affected If the headlight bulb gets soiled thoroughly clean it with a cloth moistened with alcohol or lacquer thinner 7 Attach Headlight bulb holder 8 Install Headlight bulb cover TIP If the ABS test coupler and main fuse hol...

Page 175: ...STALLING THE CENTER COVERS 4 12 INSTALLING THE FRONT COWLING ASSEMBLY 4 13 INSTALLING THE HEADLIGHT BEAM ADJUSTING KNOB JOINTS 4 13 INSTALLING THE WINDSHIELD DRIVE UNIT 4 16 FRONT WHEEL 4 22 REMOVING THE FRONT WHEEL 4 25 DISASSEMBLING THE FRONT WHEEL 4 25 CHECKING THE FRONT WHEEL 4 25 MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR 4 26 ASSEMBLING THE FRONT WHEEL 4 27 ADJUSTING THE FRONT WH...

Page 176: ...HE REAR BRAKE CALIPER 4 58 INSTALLING THE REAR BRAKE CALIPER 4 59 REMOVING THE REAR BRAKE MASTER CYLINDER 4 60 CHECKING THE REAR BRAKE MASTER CYLINDER 4 60 ASSEMBLING THE REAR BRAKE MASTER CYLINDER 4 61 INSTALLING THE REAR BRAKE MASTER CYLINDER 4 61 ABS ANTI LOCK BRAKE SYSTEM 4 63 ABS COMPONENTS CHART 4 63 REMOVING THE HYDRAULIC UNIT ASSEMBLY 4 68 CHECKING THE HYDRAULIC UNIT ASSEMBLY 4 68 CHECKING...

Page 177: ...SWINGARM 4 102 REMOVING THE SWINGARM 4 104 CHECKING THE SWINGARM 4 104 INSTALLING THE SWINGARM 4 104 SHAFT DRIVE 4 106 TROUBLESHOOTING 4 110 CHECKING THE FINAL DRIVE OIL FOR CONTAMINATION AND CHECKING THE SHAFT DRIVE FOR LEAKS 4 112 MEASURING THE FINAL GEAR BACKLASH 4 112 ADJUSTING THE FINAL GEAR BACKLASH 4 113 MEASURING THE RING GEAR TO STOPPER BOLT CLEARANCE 4 114 ADJUSTING THE RING GEAR TO STOP...

Page 178: ...at 1 3 Grab bar 1 4 Center rear cowling 1 5 Left rear cowling 1 6 Right rear cowling 1 7 Left side cover 1 8 Right side cover 1 9 Rider seat height position adjuster 1 For installation reverse the removal proce dure 3 1 5 4 7 2 6 9 8 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 21 Nm 2 1 m kg 15 ft Ib T R ...

Page 179: ...cowling into the holes in the left and right rear cowlings and sliding it forward b Fit the projections on the center rear cowling into the holes in the rear fender EAS1MC1050 REMOVING THE REAR COWLINGS The following procedure applies to both of the rear cowlings 1 Remove Rear cowling 1 a Pull the rear of the rear cowling outward to re move it from the grommet on the tail brake light assembly b Sl...

Page 180: ...ts into the slot in the side cover EAS1MC1055 INSTALLING THE SEATS 1 Install Rider seat height position adjuster Rider seat TIP The rider seat height can be adjusted to one of two positions to suit the rider s preference To install the rider seat in the high posi tion a Move the rider seat holder cover 1 to the lower position as shown b Install the rider seat height position adjuster 2 so that the...

Page 181: ...ront of the rid er seat 2 into seat holder d as shown c Align the projection e on the bottom of the rider seat 2 with the L position slot f and then push the rear of the seat down to lock it in place as shown 2 Install Passenger seat 1 TIP Insert the projections a on the rear of the pas senger seat into the seat holders b as shown and then push the front of the seat down to lock it in place 3 2 c ...

Page 182: ...ner panel 1 5 Right side panel 1 6 Right side cowling 1 7 Front right turn signal light coupler 1 Disconnect 8 Bottom cowling 1 9 Left lower inner panel 1 10 Left side panel 1 11 Left side cowling 1 12 Front left turn signal light coupler 1 Disconnect 13 Accessory box solenoid sub lead coupler 1 Disconnect 14 Auxiliary DC jack coupler 1 Disconnect 15 Left upper inner panel 1 1 5 3 6 7 4 8 9 11 12 ...

Page 183: ...7 Accessory box solenoid 1 18 Auxiliary DC jack 1 19 Left upper inner panel 2 1 For installation reverse the removal proce dure Removing the side cowlings Order Job Parts to remove Q ty Remarks 5 3 6 7 4 8 9 11 12 10 19 15 16 1 17 2 13 18 14 ...

Page 184: ...ions a into the upper slots c and then slide the panel backward d Install the quick fastener 1 To close a side panel a Remove the quick fastener 1 b Slide the side panel 2 forward to unhook its projections a from the upper slots b and then pull the panel off c Insert the projections a into the lower slots c and then slide the panel backward d Install the quick fastener 1 TIP Make sure that the sid...

Page 185: ...INNER PANEL 1 Install Right upper inner panel 1 TIP Place the right upper inner panel in its original position 2 Install Front cowling inner panel 1 a Fit the projections a on the bottom of the front cowling inner panel into the holes in the upper inner panels TIP Make sure to align the projections b on the headlight beam adjusting knob joint with the slots c in the front cowling inner panel b Fit...

Page 186: ...oid coupler and then fasten the front left turn signal light lead a auxiliary DC jack lead b and accessory box solenoid lead c with a plastic locking tie TIP Make sure that the couplers are aligned as shown in the illustration b Fit the projections on the left side cowling into the holes in the front cowling 2 Install Right side cowling 1 a Connect the front right turn signal light cou pler and th...

Page 187: ...cover 2 5 Center cover assembly 1 6 Upper center cover 1 7 Lower center cover 1 8 Rearview mirror 2 9 Headlight beam adjusting knob joint 2 10 Headlight beam adjusting knob shaft 2 11 Auxiliary light coupler 2 Disconnect 12 Headlight coupler 2 Disconnect 13 Lower bracket cover bolt 2 14 Front cowling assembly 1 15 Front cowling 1 2 3 3 3 3 4 12 11 11 1 3 4 5 6 7 8 14 13 13 15 16 5 4 9 9 10 7 Nm 0 ...

Page 188: ...y 1 For installation reverse the removal proce dure Removing the front cowling assembly Order Job Parts to remove Q ty Remarks 2 3 3 3 3 4 12 11 11 1 3 4 5 6 7 8 14 13 13 15 16 5 4 9 9 10 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R ...

Page 189: ...e windshield brack et inner cover 1 onto the windshield bracket 2 Install Windshield Windshield bracket outer cover 1 TIP Fit the projections on the windshield bracket out er cover into the holes in the windshield and then slide the cover downward EAS1MC1062 REMOVING THE CENTER COVERS 1 Remove Center cover assembly 1 TIP Unhook the projections on the lower center cov er from the front cowling and ...

Page 190: ...nt cowling assembly 1 TIP After installing the front cowling assembly oper ate the windshield drive unit and check that the windshield drive unit arms a do not contact the front cowling when they move up and down EAS1MC1080 INSTALLING THE HEADLIGHT BEAM ADJUSTING KNOB JOINTS The following procedure applies to both of the headlight beam adjusting knob joints 1 Install Headlight beam adjusting knob ...

Page 191: ...lebar switch coupler 2 Disconnect 4 Left handlebar switch coupler 2 Disconnect 5 Front brake light switch coupler 1 Disconnect 6 Windshield drive unit sub lead coupler 1 Disconnect 7 Air temperature sensor coupler 1 Disconnect 8 Right grip warmer coupler 1 Disconnect Gray coupler 9 Left grip warmer coupler 1 Disconnect Black coupler 10 Clutch switch coupler 1 Disconnect 11 Electrical components bo...

Page 192: ...ssembly and electrical components board 1 Windshield drive unit relay up 1 2 Windshield drive unit relay down 1 3 Headlight relay dimmer 1 4 Relay unit 1 5 Relay bracket 1 6 Air temperature sensor 1 7 Windshield drive unit sub lead 1 8 Windshield drive unit 1 9 Windshield drive unit bracket 1 For installation reverse the removal proce dure 32 Nm 3 2 m kg 23 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 1...

Page 193: ...ket check the opera tion of the drive unit a Install the windshield drive unit sub lead 1 and then connect the windshield drive unit sub lead to the wire harness b Install the windshield bracket 2 c Operate the windshield drive unit and check that the windshield drive unit arms can be moved fully up and down within the specified operation time Specified operation time 1 9 3 8 seconds 2 1 ...

Page 194: ...battery lead 1 Disconnect 2 Positive battery lead 1 Disconnect 3 Battery 1 4 Main fuse 1 5 ABS test coupler 1 6 Starter relay 1 7 Radiator fan motor relay 1 8 Headlight relay on off 1 9 Right radiator fan motor coupler 1 Disconnect 10 Air guide 1 For installation reverse the removal proce dure 10 Nm 1 0 m kg 7 2 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 3 7 6 9 10 1 2 4 5 8 ...

Page 195: ...1 3 Fuse box 2 Hazard lighting fuse 1 1 4 Cruise control system fuse Brake light fuse 1 1 5 ECU engine control unit 1 6 Electrical components tray 1 7 Electrical components tray bracket 1 For installation reverse the removal proce dure 5 4 2 3 6 1 7 7 Nm 0 7 m kg 5 1 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R ...

Page 196: ...rts to remove Q ty Remarks Rider seat Refer to Removing the seats and covers Fuel tank Refer to FUEL TANK on page 7 1 1 T bar 1 2 Heat protector 1 For installation reverse the removal proce dure 1 2 37 Nm 3 7 m kg 27 ft Ib T R 37 Nm 3 7 m kg 27 ft Ib T R ...

Page 197: ...ement 1 5 Owner s tool kit 1 6 Storage compartment 1 7 Rear lower fuel tank bracket 1 8 Crankcase breather hose 1 Disconnect 9 Air induction system hose air filter case joint assembly to 3 way joint 1 Disconnect 10 Air filter case joint clamp screw 4 Loosen 11 Air filter case assembly 1 12 Air filter case breather hose 2 T R 8 Nm 0 8 m kg 5 8 ft Ib T R 8 Nm 0 8 m kg 5 8 ft Ib T R 4 Nm 0 4 m kg 2 9...

Page 198: ...r case 1 For installation reverse the removal proce dure Removing the air filter case Order Job Parts to remove Q ty Remarks T R 8 Nm 0 8 m kg 5 8 ft Ib T R 8 Nm 0 8 m kg 5 8 ft Ib T R 4 Nm 0 4 m kg 2 9 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib New 5 6 1 2 4 11 7 10 3 4 10 12 13 11 15 14 8 12 10 4 9 ...

Page 199: ... brake caliper 2 5 Front wheel axle pinch bolt 4 Loosen 6 Front wheel axle bolt 1 7 Front wheel axle 1 8 Front wheel 1 9 Front wheel sensor housing 1 10 Collar left side 1 l 13 5 mm 0 53 in 11 Collar right side 1 l 18 0 mm 0 71 in T R 18 Nm 1 8 m kg 13 ft Ib T R 21 Nm 2 1 m kg 15 ft Ib T R 91 Nm 9 1 m kg 66 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 40 Nm 4 0 m kg 29 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T...

Page 200: ... housing Order Job Parts to remove Q ty Remarks T R 18 Nm 1 8 m kg 13 ft Ib T R 21 Nm 2 1 m kg 15 ft Ib T R 91 Nm 9 1 m kg 66 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 40 Nm 4 0 m kg 29 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 6 Nm 0 6 m kg 4 3 ft Ib T R 6 Nm 0 6 m kg 4 3 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib 11 12 8 12 10 9 3 5 5 7 6 6 6 4 2 LT LT LT LT 4 1 ...

Page 201: ...RONT WHEEL 4 24 Disassembling the front wheel Order Job Parts to remove Q ty Remarks 1 Oil seal 2 2 Front wheel sensor rotor 1 3 Wheel bearing 2 4 Spacer 1 For assembly reverse the disassembly pro cedure ...

Page 202: ...hat the front wheel is elevated EAS21910 DISASSEMBLING THE FRONT WHEEL NOTICE ECA3P6D003 Keep magnets including magnetic pick up tools magnetic screwdrivers etc away from the wheel sensor rotor Do not drop the wheel sensor rotor or sub ject it to shocks If any solvent gets on the wheel sensor ro tor wipe it off immediately 1 Remove Oil seals Wheel bearings a Clean the surface of the front wheel hu...

Page 203: ...ty replace with a new one Keep magnets including magnetic pick up tools magnetic screwdrivers etc away from the wheel sensor rotor Do not drop or shock the wheel sensor or the wheel sensor rotor 1 Check Front wheel sensor 1 Cracks bends distortion Replace Iron powder dust Clean 2 Check Front wheel sensor rotor 1 Cracks damage scratches Replace the front wheel sensor rotor Iron powder dust solvent ...

Page 204: ... the wheel sensor rotor Do not drop the wheel sensor rotor or sub ject it to shocks If any solvent gets on the wheel sensor ro tor wipe it off immediately 1 Install Wheel bearings a Install the new wheel bearing right side NOTICE EC3P61021 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 w...

Page 205: ...lace the front wheel on a suitable balancing stand a Spin the front wheel b When the front wheel stops put an X1 mark at the bottom of the wheel c Turn the front wheel 90 so that the X1 mark is positioned as shown d Release the front wheel e When the wheel stops put an X2 mark at the bottom of the wheel f Repeat steps c through e several times until all the marks come to rest at the same spot g Th...

Page 206: ...IP Tighten the brake disc bolts in stages and in a crisscross pattern 2 Check Front brake discs Refer to CHECKING THE FRONT BRAKE DISCS on page 4 43 3 Lubricate Oil seal lips 4 Install Collars Front wheel sensor housing Front wheel TIP Align the slot in the front wheel sensor housing with the projection of the front fork before as sembly 5 Install Front wheel axle Front wheel axle bolt Front wheel...

Page 207: ...ing temporary tightening 6 Measure TIP Measure the distance a only if the wheel bear ings wheel sensor rotor or both were replaced Distance a between the wheel sensor rotor 1 and wheel sensor housing 2 Out of specification Reinstall the bearing or replace the wheel sensor rotor 7 Install Front brake calipers Front wheel sensor TIP When installing the front wheel sensor check the wheel sensor lead ...

Page 208: ...Rear wheel axle pinch bolt 1 Loosen 4 Rear wheel axle nut 1 5 Brake torque rod 1 6 Rear wheel axle 1 7 Rear brake caliper 1 8 Rear wheel 1 9 Rear wheel sensor housing 1 10 Collar 1 11 Collar 1 12 Rear brake disc 1 For installation reverse the removal proce dure T R 23 Nm 2 3 m kg 17 ft Ib T R 125 Nm 12 5 m kg 90 ft lb T R 30 Nm 3 0 m kg 22 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft...

Page 209: ...1 Dust cover 1 2 Rear wheel drive hub 1 3 Dust seal 1 4 Wheel bearing 1 5 Rear wheel drive hub damper 6 6 Oil seal 1 7 Bearing retainer 1 Left hand threads 8 Rear wheel sensor rotor 1 9 Wheel bearing 1 10 Spacer 1 11 Spacer 1 12 Bearing 1 For assembly reverse the disassembly pro cedure ...

Page 210: ... rear wheel sensor before removing the rear wheel sensor housing otherwise the sensor could be damaged TIP Move the rear wheel to the right to separate it from the final drive assembly ET3P6D002 DISASSEMBLING THE REAR WHEEL NOTICE ECA3P6D003 Keep magnets including magnetic pick up tools magnetic screwdrivers etc away from the wheel sensor rotor Do not drop the wheel sensor rotor or sub ject it to ...

Page 211: ...p magnets including magnetic pick up tools magnetic screwdrivers etc away from the wheel sensor rotor Do not drop or shock the wheel sensor or the wheel sensor rotor 1 Check Rear wheel sensor Refer to MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR on page 4 26 2 Check Rear wheel sensor rotor Refer to MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR on page 4 26 3 Measure Rear wheel s...

Page 212: ...coun terclockwise 5 Measure Wheel sensor rotor deflection Out of specification Correct the wheel sen sor rotor deflection or replace the wheel sen sor rotor Refer to MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR on page 4 34 EAS22150 ADJUSTING THE REAR WHEEL STATIC BALANCE TIP After replacing the tire wheel or both the rear wheel static balance should be adjusted Adjust the rear wheel stat...

Page 213: ...using is aligned with the projection d on the bracket NOTICE ECA14470 Make sure there are no foreign materials in the wheel hub Foreign materials cause dam age to the inner sensor rotor and wheel sen sor WARNING EWA13500 Make sure the brake hose is routed properly 5 Tighten Brake torque rod nuts Rear wheel axle nut Rear wheel axle pinch bolt 6 Measure TIP Measure the distance a only if the wheel b...

Page 214: ... rear wheel sensor check the rear wheel sensor lead for twists and the sensor electrode for foreign materials 8 Check Rear wheel sensor installation Check if the wheel sensor housing is installed properly Distance a between the wheel sensor rotor and wheel sensor housing 28 84 29 64 mm 1 135 1 167 in T R Rear wheel sensor bolt 7 Nm 0 7 m kg 5 1 ft lb a 2 1 ...

Page 215: ... both of the front brake calipers 1 Brake hose holder 1 2 Front brake caliper 1 3 Brake pad bolt 2 4 Brake pad spring 2 5 Front brake pad 4 For installation reverse the removal proce dure 4 T R 6 Nm 0 6 m kg 4 3 ft Ib T R 6 Nm 0 6 m kg 4 3 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 40 Nm 4 0 m kg 29 ft Ib T R 17 Nm 1 7 m kg 12 ft Ib 1 2 5 4 5 3 3 ...

Page 216: ...der reservoir diaphragm hold er 1 3 Brake master cylinder reservoir diaphragm 1 4 Brake lever 1 5 Brake hose union bolt 1 6 Copper washer 2 7 Brake hose front brake master cylinder to brake pipe lower joint assembly 1 8 Front brake master cylinder holder 1 9 Front brake master cylinder 1 10 Front brake light switch 1 For installation reverse the removal proce dure 9 6 5 7 8 10 S T R 30 Nm 3 0 m kg...

Page 217: ...ront brake master cylinder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder push rod 1 2 Dust boot 1 3 Circlip 1 4 Brake master cylinder kit 1 5 Brake master cylinder body 1 For assembly reverse the disassembly pro cedure S ...

Page 218: ...ke hose union bolt 1 3 Copper washer 2 4 Brake hose brake pipe upper joint assembly to right front brake caliper 1 5 Brake hose union bolt unified brake system 1 Right side only 6 Copper washer 2 Right side only 7 Brake hose metering valve to right front brake caliper 1 Right side only 8 Front brake caliper 1 For installation reverse the removal proce dure T R 7 Nm 0 7 m kg 5 1 ft Ib T R 40 Nm 4 0...

Page 219: ...rake pad spring 2 3 Front brake pad 4 4 Brake caliper piston 4 5 Brake caliper piston dust seal 4 6 Brake caliper piston seal 4 7 Bleed screw 1 8 Bleed screw 1 Right side only For assembly reverse the disassembly pro cedure 3 4 4 1 2 2 1 7 3 5 5 5 5 6 6 6 6 8 T R 6 Nm 0 6 m kg 4 3 ft Ib T R 6 Nm 0 6 m kg 4 3 ft Ib T R 17 Nm 1 7 m kg 12 ft Ib New New New New S S BF BF S New New New New ...

Page 220: ...re applies to both brake discs 1 Remove Front wheel Refer to FRONT WHEEL on page 4 22 2 Check Brake disc Damage galling Replace 3 Measure Brake disc deflection Out of specification Correct the brake disc deflection or replace the brake disc a Place the vehicle on a suitable stand so that the front wheel is elevated b Before measuring the front brake disc deflec tion turn the handlebar to the left ...

Page 221: ...liper 1 Measure Brake pad wear limit a Out of specification Replace the brake pads as a set 2 Install Brake pads Brake pad springs TIP Always install new brake pads and new brake pad springs as a set a Connect a clear plastic hose 1 tightly to the bleed screw 2 Put the other end of the hose into an open container b Loosen the bleed screw and push the brake caliper pistons into the brake caliper wi...

Page 222: ...stem 1 Remove Brake hose holder 1 Brake hose union bolts 2 Copper washers Brake hose brake pipe upper joint assembly to right front brake caliper 3 Brake hose metering valve to right front brake caliper 4 TIP Put the end of the brake hoses into a container and pump out the brake fluid carefully EAS22360 DISASSEMBLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake cal...

Page 223: ...lvents on internal brake com ponents as they will cause the brake caliper piston dust seals and brake caliper piston seals to swell and distort Whenever a brake caliper is disassembled replace the brake caliper piston dust seals and brake caliper piston seals EAS22440 INSTALLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers 1 Install Front brake caliper 1 t...

Page 224: ...nt 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 5 Bleed Brake system Refer to BLEEDING THE 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...

Page 225: ...rnal brake com ponents EAS22530 INSTALLING THE FRONT BRAKE MASTER CYLINDER 1 Install Brake master cylinder 1 Brake master cylinder holder 2 TIP Install the brake master cylinder holder with the UP mark facing up Fit the projection a on the brake master cylin der holder into the hole b in the right handle bar First tighten the upper bolt then the lower bolt 2 Install Copper washers Brake hose front...

Page 226: ...er reser voir and brake fluid reservoir 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 leve...

Page 227: ...AKE Removing the rear brake pads Order Job Parts to remove Q ty Remarks 1 Rear brake caliper bolt 2 2 Rear brake caliper 1 3 Brake pad shim 2 4 Rear brake pad 2 5 Brake pad spring 2 For installation reverse the removal proce dure S S ...

Page 228: ...gm holder 1 3 Brake fluid reservoir diaphragm 1 4 Brake fluid reservoir 1 5 Brake fluid reservoir hose 1 6 Rear brake light switch coupler 1 Disconnect 7 Right footrest assembly 1 8 Rear brake light switch 1 9 Brake hose union bolt 1 10 Copper washer 2 11 Brake hose rear brake master cylinder to brake pipe middle joint assembly 1 1 2 3 4 5 6 7 9 10 11 8 12 New New 10 New LT LT T R 28 Nm 2 8 m kg 2...

Page 229: ...everse the removal proce dure Removing the rear brake master cylinder Order Job Parts to remove Q ty Remarks 1 2 3 4 5 6 7 9 10 11 8 12 New New 10 New LT LT T R 28 Nm 2 8 m kg 20 ft Ib T R 28 Nm 2 8 m kg 20 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib T R 18 Nm 1 8 m kg 13 ft Ib ...

Page 230: ...er Order Job Parts to remove Q ty Remarks 1 Dust boot 1 2 Circlip 1 3 Brake master cylinder push rod 1 4 Brake master cylinder kit 1 5 Brake master cylinder body 1 For assembly reverse the disassembly pro cedure S T R 16 Nm 1 6 m kg 11 ft Ib New New 3 2 1 4 5 ...

Page 231: ... SYSTEM ABS on page 3 14 1 Brake hose union bolt 1 2 Copper washer 2 3 Brake hose proportioning valve to rear brake caliper 1 4 Rear brake caliper bolt 2 Loosen 5 Rear wheel axle pinch bolt 1 Loosen 6 Rear wheel axle nut 1 7 Brake torque rod 1 8 Rear wheel axle 1 9 Rear brake caliper assembly 1 For installation reverse the removal proce dure ...

Page 232: ... Rear brake caliper bolt 2 2 Brake pad shim 2 3 Rear brake pad 2 4 Brake pad spring 2 5 Rear brake caliper bracket 1 6 Brake caliper piston 1 7 Brake caliper piston dust seal 1 8 Brake caliper piston seal 1 9 Bleed screw 1 For assembly reverse the disassembly pro cedure 7 8 New New 9 S S S S BF ...

Page 233: ...ck Brake disc Damage galling Replace 3 Measure Brake disc deflection Out of specification Correct the brake disc deflection or replace the brake disc Refer to CHECKING THE FRONT BRAKE DISCS on page 4 43 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 43 5 Adjust Brake disc d...

Page 234: ...stall Rear brake caliper 5 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 14 6 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 EAS22590 REMOVING THE REAR BRAKE CALIPER TIP Before disassembling the brake ...

Page 235: ...n Brake caliper cylinder 2 Scratches wear Replace the brake caliper assembly Brake caliper body 3 Cracks damage Replace the brake caliper assembly Brake fluid delivery passage brake caliper body Obstruction Blow out with compressed air WARNING EWA3P6D003 Whenever a brake caliper is disassembled replace the brake caliper piston dust seal and brake caliper piston seal 2 Check Brake caliper bracket C...

Page 236: ... housing is aligned with the projection d on the bracket NOTICE ECA14470 Make sure there are no foreign materials in the wheel hub Foreign materials cause dam age to the inner sensor rotor and wheel sen sor WARNING EWA13500 Make sure the brake hose is routed properly 2 Tighten Brake torque rod nuts Rear wheel axle nut Rear wheel axle pinch bolt 3 Install Copper washers Brake hose proportioning val...

Page 237: ...up any spilt brake fluid immediately 7 Bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS on page 3 14 8 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 14 9 Check Brake pedal operation Soft or spongy feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTE...

Page 238: ...e brake master cylinder make sure the brake pipe touches the projection a as shown 2 Install Rear brake light switch 1 TIP Install the rear brake light switch spring as shown in the illustration 3 Fill Brake fluid reservoir with the specified amount of the specified brake fluid WARNING EWA13090 Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing...

Page 239: ...he proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 14 6 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 7 Adjust Brake pedal position Refer to ADJUSTING THE REAR DISC BRAKE on page 3 16 8 Adjust Rear brake light operation timing Refer to ADJUSTING THE REAR BRAKE LIGHT SWITCH on page 3 30 ...

Page 240: ...ng valve to rear brake hose 6 Hydraulic unit assembly 7 Rear wheel sensor 8 Rear wheel sensor rotor 9 Rear brake caliper 10 Brake hose brake pipe to rear brake caliper 11 Metering valve 12 Left front brake caliper 13 Right front brake caliper partially operated together with the rear brake 14 Front wheel sensor 15 Front wheel sensor rotor 16 Brake hose rear brake master cylinder to brake pipe midd...

Page 241: ...servoir 1 2 Tail brake light assembly coupler 1 Disconnect 3 License plate light connector 2 Disconnect 4 Tail brake light assembly 1 5 Lean angle sensor 1 6 Brake light relay 1 7 Brake switch relay 1 8 Plastic band 1 9 Seat lock cable assembly 1 10 Rear fender assembly 1 For installation reverse the removal proce dure T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib 4 1 2 10 9 8 6 7 3 5 ...

Page 242: ... rear brake hose 1 7 Brake pipe hydraulic unit to proportioning valve 1 8 Proportioning valve 1 9 Brake pipe union bolt Gasket 2 4 10 Brake hose union bolt Gasket 1 2 11 Brake pipe brake pipe upper joint assembly to front brake calipers 1 Disconnect 9 9 11 15 16 14 17 9 9 10 13 1 1 1 1 3 2 5 8 6 7 4 12 T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 30 Nm 3 ...

Page 243: ...verse the removal proce dure Removing the metering valve proportioning valve and brake pipes Order Job Parts to remove Q ty Remarks 9 9 11 15 16 14 17 9 9 10 13 1 1 1 1 3 2 5 8 6 7 4 12 T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib T R 16 Nm 1 6 m kg 11 ft Ib T R 16 Nm 1 6 m kg 11 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 16 Nm 1 6 m kg...

Page 244: ...SYSTEM ABS on page 3 14 Rear fender Metering valve Proportioning valve Brake pipes Refer to ABS ANTI LOCK BRAKE SYS TEM on page 4 63 1 ABS ECU coupler 1 Disconnect 2 Cap nut 3 3 Hydraulic unit assembly bracket 1 4 Hydraulic unit assembly 1 For installation reverse the removal proce dure 4 3 2 2 2 1 T R 16 Nm 1 6 m kg 11 ft Ib T R 16 Nm 1 6 m kg 11 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m k...

Page 245: ...rque and bleed the brake system 1 Remove Brake pipes Brake hoses Metering valve Proportioning valve Brake hose holder TIP Do not operate the brake lever or brake pedal while removing the brake hoses and brake pipes NOTICE ECA3P6D011 When removing the brake hoses and brake pipes cover the area around the hydraulic unit assembly to catch any spilt brake fluid Do not allow the brake fluid to contact ...

Page 246: ...IP Push the coupler ejection slider down until a click is heard making sure that is installed se curely 4 Install Brake pipe lower joint assembly 1 Brake pipe middle joint assembly 2 Brake pipe joint assembly stay 3 Brake pipe upper joint assembly 4 TIP Temporarily tighten the brake pipe joint assem bly flare nuts and bolts 5 Tighten Brake pipe joint assembly flare nuts 5 Brake pipe joint assembly...

Page 247: ...ut 4 on the proportioning valve end 9 Install Brake pipe proportioning valve to rear brake hose 1 Brake hose holder 2 TIP Temporarily tighten the brake pipe flare nuts and brake hose holder bolt 10 Tighten Brake pipe flare nuts 3 Brake hose holder bolt 4 NOTICE ECA3P6D022 If the brake pipe flare nut does not turn easi ly replace the hydraulic unit brake pipes and related parts as a set TIP First t...

Page 248: ... the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake performance When refilling be careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could c...

Page 249: ...t falling over TIP Two people are necessary to perform hydraulic unit operation test 1 1 Place the vehicle on the centerstand 2 Turn the main switch to OFF 3 Remove Right upper inner panel Refer to GENERAL CHASSIS on page 4 1 4 Check Battery voltage Lower than 12 8 V Charge or replace the battery TIP If the battery voltage is lower than 12 8 V charge the battery and then perform hydraulic unit ope...

Page 250: ...es are con nected correctly to the hydraulic unit as sembly If the pulse is hardly felt in either the brake lever or brake pedal check that the brake hoses and brake pipes are connected cor rectly to the hydraulic unit assembly If the operation of the hydraulic unit is normal delete all of the fault codes Hydraulic unit operation test 2 WARNING EWA13120 Securely support the vehicle so that there i...

Page 251: ...nd after the brake lever and the brake pedal are operated simultaneously and continues for approxi mately 1 5 seconds TIP The reaction force pulsating action consists of quick pulses Be sure to continue operating the brake lever and brake pedal even after the pulsating action has stopped 11 After the pulsating action has stopped in the brake lever it is generated in the brake pedal 1 0 5 second la...

Page 252: ...ulic unit assembly If the pulsating action is hardly felt in either the brake lever or brake pedal check that the brake hoses and brake pipes are con nected correctly to the hydraulic unit as sembly 13 Turn the main switch to OFF 14 Remove the test coupler adapter from the ABS test coupler 15 Turn the main switch to ON 16 Shift the transmission into neutral and retract the sidestand 17 Check for b...

Page 253: ...t handlebar 1 4 Left handlebar switch holder 2 5 Left handlebar switch 1 6 Grip end 1 7 Handlebar grip 1 8 Lead holder 1 9 Clutch switch lead 1 10 Left handlebar switch lead 1 11 Left grip warmer lead 1 For installation reverse the removal proce dure 1 8 9 10 11 3 2 4 4 5 7 6 A A 8 A A 11 10 9 10 Nm 1 0 m kg 7 2 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib T R 65 Nm 6 5 m kg 47 ft Ib T R ...

Page 254: ...2 5 Throttle cable 2 Disconnect 6 Throttle grip 1 7 Right handlebar 1 8 Lead holder 1 9 Right grip warmer lead 1 10 Right handlebar switch lead 1 11 Front brake light switch lead 1 12 Right handlebar switch 1 For installation reverse the removal proce dure LT LS LS LS LS A A 5 5 4 12 6 2 10 11 9 8 1 7 3 8 A A 11 9 10 10 Nm 1 0 m kg 7 2 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib T R 65 Nm 6 5 m kg 47 ft Ib ...

Page 255: ...alled in the same position e Install the handlebar bolts 3 and nuts 2 temporarily f Tighten the handlebar bolts and nuts TIP First tighten the bolts then tighten the nuts EAS22870 REMOVING THE HANDLEBARS 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 Remove Handlebar grip 1 TIP Blow compressed air between the han...

Page 256: ...the left handle bar c Wipe off any excess rubber adhesive with a clean rag WARNING EWA13700 Do not 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 3 Install Right handlebar switch 1 TIP Align the projection a on the right handlebar switch with the hole b on the right handlebar 4 ...

Page 257: ...le housing align the projection a on the housing with the hole b in the right handlebar and be sure not to pinch the right grip warmer lead There should be 1 3 mm 0 04 0 12 in of clearance c between the throttle grip and the grip end 9 Install Front brake master cylinder assembly Front brake master cylinder holder 1 TIP Install the brake master cylinder holder with the UP mark facing up Align the ...

Page 258: ...Align the mating surfaces of the clutch master cylinder holder with the punch mark a on the left handlebar First tighten the upper bolt then the lower bolt 11 Adjust Throttle grip free play Refer to CHECKING THE THROTTLE GRIP OPERATION on page 3 31 T R Clutch master cylinder holder bolt 10 Nm 1 0 m kg 7 2 ft lb Throttle grip free play 3 0 5 0 mm 0 12 0 20 in b a 1 ...

Page 259: ...rk legs Lower inner panels Refer to GENERAL CHASSIS on page 4 1 Front wheel Refer to FRONT WHEEL on page 4 22 1 Upper bracket pinch bolt 1 Loosen 2 Cap bolt 1 Loosen 3 Lower bracket pinch bolt 2 Loosen 4 Front fork leg 1 For installation reverse the removal proce dure 1 3 2 4 23 Nm 2 3 m kg 17 ft Ib T R 25 Nm 2 5 m kg 18 ft Ib T R 26 Nm 2 6 m kg 19 ft Ib T R ...

Page 260: ...st seal 1 7 Oil seal clip 1 8 Oil seal 1 9 Washer 1 10 Damper rod assembly bolt 1 11 Copper washer 1 12 Damper rod assembly 1 13 Inner tube 1 14 Outer tube bushing 1 1 D 52 mm 2 05 in l 12 mm 0 47 in 15 Outer tube bushing 2 1 D 51 mm 2 01 in l 15 mm 0 59 in 16 Inner tube bushing 1 New LS 17 16 15 14 13 12 10 11 9 8 7 6 5 4 3 3 2 1 35 Nm 3 5 m kg 25 ft Ib T R ...

Page 261: ...7 Outer tube 1 For assembly reverse the disassembly pro cedure Disassembling the left front fork leg Order Job Parts to remove Q ty Remarks New LS 17 16 15 14 13 12 10 11 9 8 7 6 5 4 3 3 2 1 35 Nm 3 5 m kg 25 ft Ib T R ...

Page 262: ...er adjusting rod 1 7 Damper adjusting valve 1 8 Damper adjusting valve spring 1 9 Fork spring 1 10 Dust seal 1 11 Oil seal clip 1 12 Oil seal 1 13 Washer 1 14 Damper rod assembly bolt 1 15 Copper washer 1 16 Damper rod assembly 1 17 Inner tube 1 17 20 15 21 16 19 18 13 12 11 10 9 5 4 3 6 2 1 7 8 14 35 Nm 3 5 m kg 25 ft Ib T R 14 Nm 1 4 m kg 10 ft Ib T R ...

Page 263: ...1 mm 2 01 in l 15 mm 0 59 in 20 Inner tube bushing 1 21 Outer tube 1 For assembly reverse the disassembly pro cedure Disassembling the right front fork leg Order Job Parts to remove Q ty Remarks 17 20 15 21 16 19 18 13 12 11 10 9 5 4 3 6 2 1 7 8 14 35 Nm 3 5 m kg 25 ft Ib T R 14 Nm 1 4 m kg 10 ft Ib T R ...

Page 264: ...WA13640 Before loosening the upper and lower brack et pinch bolts support the front fork leg EAS22980 DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Hold the nut 1 and loosen the cap bolt 2 Right side only 2 Drain Fork oil TIP Stroke the inner tube several times while drain ing the fork oil 3 Remove Dust seal 1 Oil seal clip 2 with a flat head sc...

Page 265: ...d assembly bolt 6 Remove Inner tube a Hold the front fork leg horizontally b Securely clamp the brake caliper bracket in a vise with soft jaws c Separate the inner tube from the outer tube by pulling the inner tube forcefully but careful ly NOTICE ECA1MC1031 Excessive force will damage the bushings Damaged bushings must be replaced Avoid bottoming the inner tube into the out er tube during the abo...

Page 266: ...bility TIP When assembling the front fork leg be sure to replace the following parts Inner tube bushing Outer tube bushing 1 Outer tube bushing 2 Oil seal Dust seal Before assembling the front fork leg make sure all of the components are clean 1 Install Inner tube bushing Damper rod assembly NOTICE ECA1MC1018 Allow the damper rod assembly to slide slowly down the inner tube until it protrudes from...

Page 267: ...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 7 Remove Suitable washer 8 Install Oil seal clip 1 TIP Adjust the oil seal clip so that it fits into the outer tube s groove Slide metal installer 90890 01508 YM 01508 Fork seal driver 90890 01502 Fork seal driver 48 YM A0...

Page 268: ...ay spurt out 12 Slowly stroke the inner tube 1 up and down 13 Before measuring the fork oil level wait ten minutes until the oil has settled and the air bubbles have dispersed TIP Be sure to bleed the front fork leg of any residual air 14 Measure Front fork leg oil level a from the top of the inner tube with the outer tube fully compressed and without the fork spring Out of specification Correct T...

Page 269: ...lve 5 and damper ad justing rod 6 d Install the cap bolt 7 and finger tighten it WARNING EWA13670 Always use a new cap bolt O ring e Hold the cap bolt and tighten the nut 3 to specification 17 Install left side Washers 1 Spacer 2 18 Install Cap bolt to the outer tube TIP Temporarily tighten the cap bolt EAS23050 INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fo...

Page 270: ... brake hoses are routed prop erly 3 Adjust Spring preload Rebound damping right side only Compression damping right side only Refer to ADJUSTING THE FRONT FORK LEGS on page 3 21 T R Lower bracket pinch bolt 23 Nm 2 3 m kg 17 ft lb T R Cap bolt 25 Nm 2 5 m kg 18 ft lb T R Upper bracket pinch bolt 26 Nm 2 6 m kg 19 ft lb 2 3 ...

Page 271: ...K on page 4 82 1 Immobilizer unit coupler cover holder 1 2 Immobilizer unit coupler cover 2 3 Immobilizer unit coupler 1 Disconnect 4 Main switch coupler 2 Disconnect 5 Lower bracket cover 1 6 Brake hose joint bracket bolt 2 7 Steering stem nut 1 8 Upper bracket 1 9 Handlebar bracket 1 10 Lock washer 1 LS LS 14 18 6 5 12 LS LT LT LT 7 8 9 22 21 3 1 2 2 17 16 15 13 11 10 4 4 19 20 T R 1st 52 Nm 5 2...

Page 272: ...e 1 20 Dust seal 1 21 Upper bearing outer race 1 22 Lower bearing outer race 1 For installation reverse the removal proce dure Removing the lower bracket Order Job Parts to remove Q ty Remarks LS LS 14 18 6 5 12 LS LT LT LT 7 8 9 22 21 3 1 2 2 17 16 15 13 11 10 4 4 19 20 T R 1st 52 Nm 5 2 m kg 37 ft lb 2nd 18 Nm 1 8 m kg 13 ft lb T R 115 Nm 11 5 m kg 85 ft lb T R 7 Nm 0 7 m kg 5 1 ft Ib 7 Nm 0 7 m...

Page 273: ...es a Remove the bearing races from the steering head pipe 1 with a long rod 2 and hammer b Remove the bearing race from the lower bracket 3 with a floor chisel 4 and ham mer c Install new bearing races 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 4 Check Upper bracket Lower bracket a...

Page 274: ... 3 19 3 Install Upper bracket Steering stem nut TIP Temporarily tighten the steering stem nut 4 Install Front fork legs Refer to FRONT FORK on page 4 82 TIP Temporarily tighten the upper and lower bracket pinch bolts 5 Tighten Steering stem nut T R Steering stem nut 115 Nm 11 5 m kg 85 ft lb ...

Page 275: ... adjusting lever nut 3 2 Rear shock absorber assembly lower nut Wash er Bolt 1 1 1 3 Connecting arm nut Washer Bolt 2 2 2 4 Connecting arm 2 5 Rear shock absorber assembly upper nut Bolt Spacer 1 1 1 6 Rear shock absorber assembly 1 7 Centerstand 1 8 Relay arm nut Bolt Spacer 1 1 1 9 Relay arm 1 10 Spacer 1 New New New New T R 7 Nm 0 7 m kg 5 1 ft Ib T R 40 Nm 4 0 m kg 29 ft Ib T R 48 Nm 4 8 m kg ...

Page 276: ...re Removing the rear shock absorber assembly Order Job Parts to remove Q ty Remarks New New New New T R 7 Nm 0 7 m kg 5 1 ft Ib T R 40 Nm 4 0 m kg 29 ft Ib T R 48 Nm 4 8 m kg 35 ft Ib 3 T R 64 Nm 6 4 m kg 46 ft Ib T R 40 Nm 4 0 m kg 29 ft Ib T R 55 Nm 5 5 m kg 40 ft Ib 5 5 8 1 8 LS LS 6 11 13 10 15 13 13 13 3 4 1414 1312 15 9 3 3 4 13 2 2 7 LS ...

Page 277: ...gh the rear shock absorber at a point 15 20 mm 0 59 0 79 in from its end as shown WARNING EWA13760 Wear eye protection to prevent eye damage from released gas or metal chips EAS23230 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...

Page 278: ...e 3 Check Spacers Damage scratches Replace EAS23270 INSTALLING THE RELAY ARM 1 Lubricate Spacer Bearings 2 Install Bearings 1 2 to the relay arm 3 Install Relay arm TIP Make sure that the embossed mark 5JW on the relay arm faces to the left EAS23310 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 1 Install Rear shock absorber assembly TIP Make sure that the warning label on the rear shock absorber ass...

Page 279: ... Universal joint Refer to SHAFT DRIVE on page 4 106 1 Right footrest assembly bolt 2 2 Pivot shaft end cover 1 3 Pivot shaft nut retainer 1 4 Pivot shaft self lock nut 1 5 Pivot shaft nut 1 6 Pivot shaft 1 7 Swingarm 1 8 Spacer 1 9 Oil seal 2 10 Bearing 2 11 Collar 1 LT LT T R 10 Nm 1 0 m kg 7 2 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 28 Nm 2 8 m kg 20 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib T R 125 Nm 12...

Page 280: ...removal proce dure Removing the swingarm Order Job Parts to remove Q ty Remarks LT LT T R 10 Nm 1 0 m kg 7 2 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 28 Nm 2 8 m kg 20 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib T R 125 Nm 12 5 m kg 90 ft lb T R 115 Nm 11 5 m kg 85 ft lb New LS LS LS New LS New 3 5 6 1 4 2 LS 1 17 16 15 12 11 10 8 9 18 14 13 9 10 7 ...

Page 281: ...s not smooth or if there is binding check the spacers bear ings washers and dust covers EAS23360 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 Spacers Washer Bearings Collar 4 Check Spacers Washer Collar Oil seals Damage w...

Page 282: ...nut Pivot shaft self lock nut 3 Swingarm 4 Connecting arm A Left side B Right side T R Pivot shaft 23 Nm 2 3 m kg 17 ft lb T R Pivot shaft nut 115 Nm 11 5 m kg 85 ft lb T R Pivot shaft self lock nut 125 Nm 12 5 m kg 90 ft lb 1 3 a A 3 2 b 2 A B b 4 4 ...

Page 283: ...he final drive assembly Order Job Parts to remove Q ty Remarks Final gear oil Drain Refer to CHANGING THE FINAL GEAR OIL on page 3 29 Rear wheel Refer to REAR WHEEL on page 4 31 1 Final drive assembly 1 For installation reverse the removal proce dure ...

Page 284: ...destand switch coupler 1 Disconnect 3 Sidestand 1 4 Left footrest assembly 1 5 Drive shaft dust cover 1 6 Universal joint dust cover 1 7 Universal joint 1 For installation reverse the removal proce dure 2 3 1 4 5 6 7 LT LT LT LT LS 4 Nm 0 4 m kg 2 9 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib...

Page 285: ...eft hand threads 9 Stopper bolt shim Refer to ADJUSTING THE RING GEAR TO STOPPER BOLT CLEARANCE on page 4 114 10 Ring gear shim Refer to ADJUSTING THE FINAL GEAR BACKLASH on page 4 113 and ALIGNING THE FINAL DRIVE PINION GEAR AND RING GEAR on page 4 116 11 Ring gear 1 12 Bearing 1 13 Thrust washer 1 Refer to ADJUSTING THE FINAL GEAR BACKLASH on page 4 113 and ALIGNING THE FINAL DRIVE PINION GEAR A...

Page 286: ...l drive pinion gear 1 19 Bearing 1 20 Final drive pinion gear shim Refer to ALIGNING THE FINAL DRIVE PINION GEAR AND RING GEAR on page 4 116 21 Final drive pinion gear bearing 1 22 Ring gear bearing 1 23 Oil seal 1 24 Collar 1 25 Final gear case 1 For assembly reverse the disassembly pro cedure Disassembling the final drive assembly Order Job Parts to remove Q ty Remarks ...

Page 287: ...ly indicates these symptoms stop riding immediately to minimize gear damage c A slight clunk evident at low speed operation not to be confused with normal vehicle operation Broken gear teeth WARNING EWA13790 Stop riding immediately if broken gear teeth are suspected This condition could result in the shaft drive assembly locking up causing a loss of control and possible injury to the rider Symptom...

Page 288: ...l bearings damaged Replace the wheel bearing s Refer to FRONT WHEEL on page 4 22 2 Place the vehicle on a suitable stand so that the rear wheel is ele vated and then spin the rear wheel Is the wheel bearing damaged Rear wheel bearings and shaft drive bear ings are probably not damaged Repeat the test or remove and check the compo nents 3 Remove the rear wheel Are the wheel bearings damaged Replace...

Page 289: ...hicle long enough to locate a leak Oil leak Repair or replace the faulty part s TIP What may appear to be an oil leak on a new or fairly new vehicle may result from the applica tion of a rust preventive coating or excessive seal lubrication Always clean the vehicle and recheck the area where the leak is thought to originate from EAS23580 MEASURING THE FINAL GEAR BACKLASH 1 Secure the final drive a...

Page 290: ...klash EAS23590 ADJUSTING THE FINAL GEAR BACKLASH 1 Remove Ring gear bearing housing bolts 1 Ring gear bearing housing nuts 2 TIP Working in a crisscross pattern loosen each bolt and nut 1 4 of a turn After all of the bolts and nuts are fully loosened remove them 2 Remove Ring gear bearing housing 1 Dust cover 2 Ring gear 3 Ring gear shim s 4 Thrust washer 5 3 Adjust Final gear backlash a Select th...

Page 291: ...topper bolt shim s 3 Ring gear bearing housing 4 2 Select Stopper bolt shim s 3 Install Ring gear bearing housing 1 Stopper bolt shim s 2 Stopper bolt 3 Ring gear 4 NOTICE ECA14320 The stopper bolt has left hand threads To tighten the stopper bolt turn it counter clockwise Apply LOCTITE onto the stopper bolt 4 Measure Ring gear to stopper bolt clearance Ring gear shims Thickness mm 0 25 0 30 0 40 ...

Page 292: ...ng retainer has left hand threads To loosen the bearing retainer turn it clock wise 4 Remove Final drive pinion gear WARNING EWA13800 Always use new bearings NOTICE ECA14340 The final drive pinion gear should only be re moved if ring gear replacement is necessary TIP Lightly tap on the end of the final drive pinion gear with a soft hammer EAS23630 REMOVING AND INSTALLING THE BEARINGS 1 Check Beari...

Page 293: ... the inner race onto the final drive pin ion gear 5 Install Collar 1 Oil seal 2 Bearing 3 with an appropriate press tool 4 and press TIP The bearing can be reused but Yamaha recom mends installing a new one EAS23640 ALIGNING THE FINAL DRIVE PINION GEAR AND RING GEAR TIP Aligning the final drive pinion gear and ring gear is necessary when any of the following parts are replaced Final gear case Ring...

Page 294: ...m The chart instructs you to round off the 1 to 0 Thus you should use a 0 50 mm final drive pinion gear shim c To find ring gear shim thickness B use the following formula Where c a numeral on the final gear case to be di vided by 100 and added to 45 d a numeral usually on the surface of the ring gear bearing housing to be divided by 100 and added to 3 e a numeral positive or negative on the in si...

Page 295: ...earing retainer wrench 1 NOTICE ECA14350 The bearing retainer has left hand threads To tighten the bearing retainer turn it coun terclockwise 3 Install Coupling gear 1 Coupling gear nut with the coupling gear middle shaft tool 2 4 Stake the coupling gear nut 1 at a cutout a in the final drive pinion gear 5 Install Ring gear bearing housing along with the ring gear but without the thrust washer Rin...

Page 296: ... gear to thrust washer clearance is out of specification select the correct thrust washer as follows h Select the suitable thrust washer from the fol lowing chart i Repeat the measurement steps until the ring gear to thrust washer clearance is within the specified limits EAS23650 CHECKING THE DRIVE SHAFT 1 Check Drive shaft splines Damage wear Replace the drive shaft EAS23660 INSTALLING THE DRIVE ...

Page 297: ...trest assembly bolt M10 3 tempo rarily and then tighten them to the specified torques in the proper tightening sequence as shown Fork seal driver weight 90890 01184 Replacement hammer YM A9409 7 Fork seal driver attachment 90890 01186 Replacement 27 mm YM A9409 1 Fork seal driver weight 90890 01184 Replacement hammer YM A9409 7 Oil seal installing tool 90890 01512 YM 01512 Installed depth a 8 5 10...

Page 298: ...in the shift shaft with the slot in the shift arm 10 Install Rear wheel Refer to REAR WHEEL on page 4 31 11 Fill Final gear case Refer to CHECKING THE FINAL GEAR OIL LEVEL on page 3 29 12 Check Shift pedal position Refer to ADJUSTING THE SHIFT PEDAL on page 5 58 2 1 3 ...

Page 299: ...ER HEAD 5 21 INSTALLING THE CYLINDER HEAD 5 21 VALVES AND VALVE SPRINGS 5 23 REMOVING THE VALVES 5 24 CHECKING THE VALVES AND VALVE GUIDES 5 24 CHECKING THE VALVE SEATS 5 26 CHECKING THE VALVE SPRINGS 5 28 CHECKING THE VALVE LIFTERS 5 28 INSTALLING THE VALVES 5 28 GENERATOR AND STARTER CLUTCH 5 31 REMOVING THE GENERATOR 5 33 REMOVING THE STARTER CLUTCH 5 33 CHECKING THE STARTER CLUTCH 5 33 INSTALL...

Page 300: ...SHIFT SHAFT 5 58 CHECKING THE STOPPER LEVER 5 58 INSTALLING THE SHIFT SHAFT 5 58 ADJUSTING THE SHIFT PEDAL 5 58 OIL PUMP 5 60 CHECKING THE OIL PUMP 5 63 CHECKING THE RELIEF VALVE 5 63 CHECKING THE OIL DELIVERY PIPES 5 63 CHECKING THE OIL STRAINER 5 64 ASSEMBLING THE OIL PUMP 5 64 INSTALLING THE OIL PAN 5 64 MIDDLE GEAR 5 65 REMOVING THE MIDDLE DRIVE SHAFT ASSEMBLY 5 69 DISASSEMBLING THE MIDDLE DRI...

Page 301: ...HE PISTON PIN 5 88 CHECKING THE CONNECTING RODS 5 89 INSTALLING THE CONNECTING RODS AND PISTONS 5 90 CRANKSHAFT 5 93 REMOVING THE CRANKSHAFT JOURNAL BEARINGS 5 94 CHECKING THE OIL NOZZLES 5 94 CHECKING THE CRANKSHAFT 5 94 INSTALLING THE CRANKSHAFT 5 95 TRANSMISSION 5 97 REMOVING THE TRANSMISSION 5 102 CHECKING THE SHIFT FORKS 5 102 CHECKING THE SHIFT DRUM ASSEMBLY 5 102 CHECKING THE TRANSMISSION 5...

Page 302: ... falling into the cylinders 7 Install Compression gauge 1 Extension 2 8 Measure Compression pressure Out of specification Refer to steps c and d a Set the main switch to ON b With the throttle wide open crank the engine until the reading on the compression gauge stabilizes TIP The difference in compression pressure be tween cylinders should not exceed 100 kPa 1 kg cm 14 psi c If the compression pr...

Page 303: ...l tank Refer to FUEL TANK on page 7 1 Rider seat Refer to GENERAL CHASSIS on page 4 1 Compression pressure with oil applied into the cylinder Reading Diagnosis Higher than without oil Piston ring s wear or damage Repair Same as without oil Pistons valves cylin der head gasket or piston ring s possi bly defective Re pair T R Spark plug 13 Nm 1 3 m kg 9 4 ft lb ...

Page 304: ...ge 3 27 Radiator Refer to RADIATOR on page 6 1 1 O2 sensor coupler 1 Disconnect 2 Left muffler 1 3 Right muffler 1 4 Muffler protector 1 5 Gasket 2 6 Exhaust pipe assembly 1 7 Gasket 4 For installation reverse the removal proce dure 6 4 7 8 2 1 3 New 5 New 5 New T R 20 Nm 2 0 m kg 14 ft Ib T R 45 Nm 4 5 m kg 32 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib T R 17 Nm 1 7 m kg 12 ft Ib T R 25 Nm 2 5 m kg 18 ft ...

Page 305: ...stat inlet pipe 1 Refer to THERMOSTAT on page 6 6 Engine oil Oil filter cartridge Drain Refer to CHANGING THE ENGINE OIL on page 3 24 Oil cooler Refer to OIL COOLER on page 6 4 Water pump Refer to WATER PUMP on page 6 10 Starter motor Refer to ELECTRIC STARTER on page 5 39 Left footrest assembly Sidestand Refer to SHAFT DRIVE on page 4 106 1 Clutch release cylinder 1 2 Dowel pin 2 3 Crankcase brea...

Page 306: ... Disconnect 8 Cylinder identification sensor coupler 1 9 Ignition coil coupler 4 10 Wire harness holder 1 11 Ground lead 1 Disconnect For installation reverse the removal proce dure Disconnecting the leads and hose Order Job Parts to remove Q ty Remarks E 9 10 9 9 2 2 1 3 5 4 6 7 8 11 T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib ...

Page 307: ... right front lower side 1 11 Spacer 2 12 Engine mounting bolt right front upper side 1 13 Engine mounting bolt left front lower side 1 14 Engine mounting bolt left front upper side 1 15 Engine mounting nut rear upper side 1 T R 32 Nm 3 2 m kg 23 ft Ib T R 16 Nm 1 6 m kg 11 ft Ib T R 18 Nm 1 8 m kg 13 ft Ib T R 37 Nm 3 7 m kg 27 ft Ib T R 37 Nm 3 7 m kg 27 ft Ib T R 45 Nm 4 5 m kg 32 ft Ib T R 45 N...

Page 308: ...e Q ty Remarks T R 32 Nm 3 2 m kg 23 ft Ib T R 16 Nm 1 6 m kg 11 ft Ib T R 18 Nm 1 8 m kg 13 ft Ib T R 37 Nm 3 7 m kg 27 ft Ib T R 37 Nm 3 7 m kg 27 ft Ib T R 45 Nm 4 5 m kg 32 ft Ib T R 45 Nm 4 5 m kg 32 ft Ib T R 49 Nm 4 9 m kg 35 ft Ib T R 49 Nm 4 9 m kg 35 ft Ib T R 49 Nm 4 9 m kg 35 ft Ib T R 24 Nm 2 4 m kg 17 ft Ib T R 24 Nm 2 4 m kg 17 ft Ib T R 8 Nm 0 8 m kg 5 8 ft Ib E E 9 9 15 11 1 11 12...

Page 309: ...nting bolt right front lower side 9 Pinch bolts front side 10 Pinch bolts rear lower side 11 TIP Lubricate the engine mounting bolt rear lower side threads with engine oil Do not fully tighten the bolts 3 Tighten Engine mounting bolt left front upper side 5 4 Tighten Engine mounting bolt rear lower side 4 5 Tighten Spacer bolt 1 TIP Tighten the spacer bolt 1 to specification with the pivot shaft w...

Page 310: ... bolts top 14 temporarily tighten TIP When temporarily tightened the bolts 13 and 14 should be flat against the engine and frame surface 12 Tighten Engine bracket and engine bolts top 13 Engine bracket bolts top 14 Pivot shaft wrench 90890 01471 Frame spanner socket YM 01471 Pivot shaft wrench adapter 90890 01476 T R Engine mounting nut rear upper side 45 Nm 4 5 m kg 32 ft lb T R Engine mounting b...

Page 311: ...d frame bolt left rear side 2 15 Tighten Engine bracket and engine bolts left rear side 3 16 Install Brake pedal 1 TIP Align the punch mark a on the brake pedal with the punch mark b on the brake pedal pivot shaft T R Engine bracket and frame bolt left rear side 32 Nm 3 2 m kg 23 ft lb T R Engine bracket and engine bolt left rear side 16 Nm 1 6 m kg 11 ft lb T R Brake pedal pinch bolt 8 Nm 0 8 m k...

Page 312: ...3 1 Ignition coil coupler 4 Disconnect 2 Cylinder head cover plate 1 3 Cylinder identification sensor coupler 1 Disconnect 4 Ignition coil 4 5 Cylinder identification sensor 1 6 Spark plug 4 7 Cylinder head cover 1 8 Cylinder head cover gasket 1 9 Dowel pin 4 10 Timing chain guide upper side 1 For installation reverse the removal proce dure New 6 New 8 9 9 9 5 3 8 10 7 T R 10 Nm 1 0 m kg 7 2 ft Ib...

Page 313: ...CKUP ROTOR on page 5 36 1 Timing chain tensioner 1 2 Timing chain tensioner gasket 1 3 Intake camshaft cap 4 4 Exhaust camshaft cap 4 5 Intake camshaft 1 6 Exhaust camshaft 1 7 Intake camshaft sprocket 1 8 Exhaust camshaft sprocket 1 9 Timing chain guide exhaust side 1 10 Pin 1 11 Timing chain guide intake side 1 For installation reverse the removal proce dure ...

Page 314: ...er 1 TIP Make sure that the tensioner rod has been fully set clockwise 4 Remove Timing chain tensioner Timing chain tensioner gasket 5 Remove Camshaft caps Dowel pins 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 6 Remove Intake camshaft 1 Exhaust camshaft 2 TIP To p...

Page 315: ...haft into the cylinder head without the dowel pins and camshaft caps b Position a strip of Plastigauge 1 onto the camshaft journal as shown c Install the dowel pins and camshaft caps Camshaft lobe dimensions Intake A 33 050 33 150 mm 1 3012 1 3051 in Limit 32 050 mm 1 2618 in Intake B 24 997 25 097 mm 0 9841 0 9881 in Limit 23 997 mm 0 9448 in Exhaust A 33 050 33 150 mm 1 3012 1 3051 in Limit 32 9...

Page 316: ...heck Timing chain guide exhaust side Timing chain guide intake side Timing chain guide upper side Damage wear Replace the defective part s EAS23970 CHECKING THE TIMING CHAIN TENSIONER 1 Check Timing chain tensioner Cracks damage rough movement Re place a Lightly press the timing chain tensioner rod into the timing chain tensioner housing by hand TIP While pressing the timing chain tensioner rod wi...

Page 317: ...camshaft 2 Intake camshaft 3 with the camshaft sprockets NOTICE ECA13740 Do not turn the crankshaft when installing the camshaft s to avoid damage or improper valve timing a Install the timing chain onto both camshaft sprockets and then install the camshafts TIP Make sure the holes a on each camshaft fac es up When installing the timing chain start with the exhaust camshaft and be sure to keep the...

Page 318: ...er caps out 5 Align T mark on the pickup rotor with the crankcase mating surface a Turn the crankshaft clockwise b When piston 1 is at TDC on the compres sion stroke align the T mark a on the pick up rotor with the crankcase mating surface b 6 Install Timing chain tensioner Timing chain tensioner gasket a While lightly pressing the timing chain ten sioner rod by hand turn the tensioner rod ful ly ...

Page 319: ...learance Out of specification Adjust Refer to ADJUSTING THE VALVE CLEAR ANCE on page 3 5 10 Install Cylinder head cover gasket Cylinder head cover TIP Apply Three Bond 1514C 1 onto the mating surfaces of the cylinder head cover and cylin der head cover gasket Apply Yamaha bond No 1215 2 onto the mating surfaces of the cylinder head cover gasket and cylinder head Install a new cylinder head cover g...

Page 320: ...CAMSHAFTS 5 19 11 Install Cylinder head cover plate 1 TIP Be sure the UP mark a is facing up New 2 2 a 1 3 a a 1 ...

Page 321: ...OVAL on page 5 3 Camshafts Refer to CAMSHAFTS on page 5 11 1 Cylinder head 1 2 Cylinder head gasket 1 3 Dowel pin 2 For installation reverse the removal proce dure T R 12 Nm 1 2 m kg 8 7 ft Ib T R 1st 25 Nm 2 5 m kg 18 ft lb 2nd 25 Nm 2 5 m kg 18 ft lb Final Specified angle 175 185 T R 15 Nm 1 5 m kg 11 ft Ib New New 3 3 2 New 1 10 E ...

Page 322: ... c If the limit is exceeded resurface the cylinder head as follows d Place a 400 600 grit wet sandpaper on the surface plate and resurface the cylinder head using a figure eight sanding pattern TIP To ensure an even surface rotate the cylinder head several times EAS24240 INSTALLING THE CYLINDER HEAD 1 Install Cylinder head TIP Pass the timing chain through the timing chain cavity 2 Tighten Cylinde...

Page 323: ...new one and perform the procedure again NOTICE EC3P61033 Do not use a torque wrench to tighten the bolt to the specified angle Tighten the bolt until it is at the specified angle TIP On a hexagonal bolt note that the angle from one corner to another is 60 f Tighten the cylinder head bolts M6 in proper tightening sequence as shown T R Cylinder head bolt M10 2nd 25 Nm 2 5 m kg 18 ft lb T R Cylinder ...

Page 324: ...inder head Refer to CYLINDER HEAD on page 5 20 1 Valve lifter 16 2 Valve pad 16 3 Valve cotter 32 4 Upper spring seat 16 5 Intake valve spring 8 6 Exhaust valve spring 8 7 Intake valve 8 8 Exhaust valve 8 9 Valve stem seal 16 10 Lower spring seat 16 11 Intake valve guide 8 12 Exhaust valve guide 8 For installation reverse the removal proce dure ...

Page 325: ...5 26 a Pour a clean solvent a into the intake and exhaust ports b Check that the valves properly seal TIP There should be no leakage at the valve seat 1 3 Remove Valve cotters TIP Remove the valve cotters by compressing the valve spring with the valve spring compressor 1 and the valve spring compressor attachment 2 4 Remove Upper spring seat 1 Valve spring 2 Valve 3 Valve stem seal 4 Lower spring ...

Page 326: ...uide with the valve guide installer 2 and valve guide remover 1 c After installing the valve guide bore the valve guide with the valve guide reamer 3 to 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 ...

Page 327: ...es to all of the valves and valve seats 1 Eliminate Carbon deposits from the valve face and valve seat 2 Check Valve seat Pitting wear Replace the cylinder head 3 Measure Valve seat width C a Out of specification Replace the cylinder head a Apply Mechanic s blueing dye Dykem b onto the valve face Valve guide remover ø5 90890 04097 Valve guide remover 5 0 mm YM 04097 Valve guide installer ø5 90890 ...

Page 328: ...enum disulfide oil onto the valve stem c Install the valve into the cylinder head d Turn the valve until the valve face and valve seat are evenly polished then clean off all of the lapping compound TIP For the best lapping results lightly tap the valve seat while rotating the valve back and forth be tween your hands e Apply a fine lapping compound to the valve face and repeat the above steps f Aft...

Page 329: ...ge scratches Replace the valve lift ers and cylinder head EAS24340 INSTALLING THE VALVES The following procedure applies to all of the valves and related components 1 Deburr Valve stem end with an oil stone Free length intake 39 73 mm 1 56 in Limit 37 74 mm 1 49 in Free length exhaust 39 73 mm 1 56 in Limit 37 74 mm 1 49 in Installed compression spring force intake 136 00 158 00 N 13 87 16 11 kgf ...

Page 330: ... Install Valve cotters TIP Install the valve cotters by compressing the valve spring with the valve spring compressor 1 and the valve spring compressor attachment 2 5 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 Recommended lubricant Molybdenum disulfide oil New b ...

Page 331: ...lifter with the recommended lubricant 7 Install Valve pad Valve lifter TIP The valve lifter must move smoothly when ro tated with a finger Each valve lifter and valve pad must be rein stalled in its original position Recommended lubricant Engine oil ...

Page 332: ...o FUEL TANK on page 7 1 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 24 1 Stator coil coupler 1 Disconnect 2 Generator cover 1 3 Generator cover gasket 1 4 Dowel pin 2 5 Starter clutch idle gear shaft 1 6 Starter clutch idle gear 1 7 Generator rotor 1 8 Woodruff key 1 9 Starter clutch gear 1 10 Starter clutch 1 For installation reverse the removal proce dure 6 ...

Page 333: ...OR AND STARTER CLUTCH 5 32 Removing the stator coil assembly Order Job Parts to remove Q ty Remarks 1 Stator coil assembly lead holder 1 2 Stator coil assembly 1 For installation reverse the removal proce dure ...

Page 334: ... CLUTCH 1 Remove Starter clutch bolts 1 TIP While holding the generator rotor with the sheave holder remove the starter clutch bolts EAS24570 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 Starter clutch gear s contacting surfaces Damage pitting wear ...

Page 335: ...rator 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 the crankshaft Lubricate the generator rotor bolt threads and washer mating surfaces with engine oil 2 Tighten Generator rotor bolt 1 TIP While holding the generator rotor 2 with the s...

Page 336: ...ATOR AND STARTER CLUTCH 5 35 4 Install Generator cover gasket Generator cover TIP Tighten the generator cover bolts in stages and in a crisscross pattern T R Generator cover bolt 12 Nm 1 2 m kg 8 7 ft lb New ...

Page 337: ...on page 7 1 Generator cover Refer to GENERATOR AND STARTER CLUTCH on page 5 31 1 Pickup rotor cover 1 2 Pickup rotor cover gasket 1 3 Dowel pin 2 4 Crankshaft position sensor coupler 1 Disconnect 5 Crankshaft position sensor 1 6 Pickup rotor 1 For installation reverse the removal proce dure LT New 2 1 6 3 3 5 4 LT 6 T R 4 Nm 0 4 m kg 2 9 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib 65 Nm 6 5 m kg 47 ft Ib T...

Page 338: ...ckup rotor align the groove a in the crankshaft sprocket with the projection b in the pickup rotor 2 Tighten Pickup rotor bolt 1 TIP While holding the generator rotor 2 with the sheave holder 3 tighten the pickup rotor bolt 3 Apply Sealant onto the crankshaft position sensor lead grommet Sheave holder 90890 01701 Primary clutch holder YS 01880 A 1 2 3 T R Pickup rotor bolt 65 Nm 6 5 m kg 47 ft lb ...

Page 339: ...ecification Reinstall or replace 5 Install Pickup rotor cover gasket Pickup rotor cover TIP Tighten the pickup rotor cover bolts in stages and in a crisscross pattern Gap between the crankshaft po sition sensor and pickup rotor 0 5 mm 0 02 in T R Pickup rotor cover bolt 12 Nm 1 2 m kg 8 7 ft lb a 1 2 New ...

Page 340: ...IC STARTER Removing the starter motor Order Job Parts to remove Q ty Remarks Throttle bodies Refer to THROTTLE BODIES on page 7 4 1 Starter motor lead 1 Disconnect 2 Starter motor assembly 1 For installation reverse the removal proce dure ...

Page 341: ...arks 1 O ring 1 2 Starter motor front cover 1 3 Brush 2 4 Brush seat along with brushes 1 5 Washer 1 6 Lock washer 1 7 Oil seal 1 8 Bearing 1 9 Starter motor rear cover 1 10 Collar 1 11 O ring 2 12 Starter motor yoke 1 13 Armature assembly 1 For assembly reverse the disassembly pro cedure ...

Page 342: ... commutator and insulation Out of specification Replace the starter motor a Measure the armature assembly resistances with the pocket tester b If any resistance is out of specification re place the starter motor 5 Measure Brush length a Out of specification Replace the brushes as a set 6 Measure Brush spring force Out of specification Replace the brush springs as a set Limit 23 5 mm 0 93 in Mica u...

Page 343: ... ASSEMBLING THE STARTER MOTOR 1 Install Brush seat 1 TIP Align the slot a on the brush seat with the tab b in the starter motor front cover 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 starter mo tor front and rear covers ...

Page 344: ...AL CHASSIS on page 4 1 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 24 1 Clutch cover 1 2 Clutch cover gasket 1 3 Dowel pin 2 4 Damper cover 1 5 Damper 1 For installation reverse the removal proce dure LT 3 4 5 2 1 10 5 3 New T R 12 Nm 1 2 m kg 8 7 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib ...

Page 345: ...sh rod 1 7 Ball 1 8 Long clutch push rod 1 9 Friction plate 1 1 Inside diameter 124 mm 4 88 in 10 Clutch plate 7 11 Friction plate 2 7 Inside diameter 124 mm 4 88 in 12 Lock washer 1 13 Wire circlip 1 14 Clutch plate 1 15 Friction plate 3 1 Inside diameter 135 mm 5 31 in 16 Clutch damper spring 1 21 20 19 18 17 16 15 14 13 12 1110 9 8 7 6 5 4 3 2 1 6 New New New LT T R 90 Nm 9 0 m kg 65 ft Ib T R ...

Page 346: ... 21 Clutch housing 1 For installation reverse the removal proce dure Removing the clutch Order Job Parts to remove Q ty Remarks 21 20 19 18 17 16 15 14 13 12 1110 9 8 7 6 5 4 3 2 1 6 New New New LT T R 90 Nm 9 0 m kg 65 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 8 Nm 0 8 m kg 5 8 ft Ib E 9 15 11 ...

Page 347: ...linder reservoir cap 1 2 Clutch master cylinder reservoir diaphragm holder 1 3 Clutch master cylinder reservoir diaphragm 1 4 Clutch lever 1 5 Clutch master cylinder push rod pin 1 6 Clutch hose union bolt 1 7 Copper washer 2 8 Clutch hose 1 Disconnect 9 Clutch switch 1 10 Clutch master cylinder holder 1 11 Clutch master cylinder 1 For installation reverse the removal proce dure LT ...

Page 348: ...master cylinder Order Job Parts to remove Q ty Remarks 1 Clutch master cylinder push rod 1 2 Dust boot 1 3 Circlip 1 4 Washer 1 5 Clutch master cylinder kit 1 6 Clutch master cylinder body 1 For assembly reverse the disassembly pro cedure ...

Page 349: ...remove Q ty Remarks Clutch fluid Drain Refer to BLEEDING THE HYDRAULIC CLUTCH SYSTEM on page 3 12 1 Clutch hose union bolt 1 2 Copper washer 2 3 Clutch hose 1 Disconnect 4 Clutch release cylinder 1 5 Dowel pin 2 6 Plate 1 For installation reverse the removal proce dure ...

Page 350: ... nut 6 Remove Clutch boss nut 1 Washer 2 Clutch boss assembly 3 TIP There is a built in damper between the clutch boss and the clutch plate It is not necessary to remove the wire circlip 4 and disassemble the built in damper unless there is serious clutch chattering 7 Remove Spacer 1 Clutch housing TIP Insert a cross headed screwdriver into one of the holes of the clutch housing and primary driven...

Page 351: ...late and thickness gauge 1 Out of specification Replace the clutch plates as a set EAS25130 CHECKING THE CLUTCH SPRING PLATE 1 Check Clutch spring plate retainer Damage Replace 2 Check Clutch spring plate seat Damage Replace 3 Measure Clutch spring free height Out of specification Replace the clutch spring plate Friction plate 1 3 thickness 2 90 3 10 mm 0 114 0 122 in Wear limit 2 80 mm 0 110 in F...

Page 352: ...atic clutch operation EAS25170 CHECKING THE PRESSURE PLATE 1 Check Pressure plate Cracks damage Replace Bearing Damage wear Replace EAS25190 CHECKING THE CLUTCH PUSH RODS 1 Check O ring Short clutch push rod Long clutch push rod Ball Cracks damage wear Replace the defec tive part s 2 Measure Long clutch push rod bending limit Out of specification Replace the long clutch push rod EAS25210 CHECKING ...

Page 353: ...allation 2 Install Spacer 1 TIP Install the spacer with the two screw holes facing towards the clutch boss 3 Install Clutch boss assembly 1 TIP If the wire circlip 2 has been removed care fully install a new one Install the clutch damper spring 3 with the OUTSIDE mark facing out 4 Install Clutch boss 1 Lock washer 2 Clutch boss nut 3 TIP Install the clutch boss nut with its large inner di ameter s...

Page 354: ...ystem must be disassembled drained cleaned properly filled and bled after reas sembly Never use solvents on internal clutch com ponents Use only clean or new clutch fluid for clean ing clutch components Clutch fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt fluid immediately Avoid clutch fluid coming into contact with the eyes as it can cause serious injury ...

Page 355: ...1 Install Clutch master cylinder 1 Clutch master cylinder holder 2 WARNING EW3P61016 Install the clutch lever holder with the UP mark facing up Align the end of the clutch lever holder with the punch mark a on the left handlebar First tighten the upper bolt then the lower bolt 2 Install Copper washers 1 Clutch hose 2 Clutch hose union bolt 3 WARNING EW3P61017 Proper clutch hose routing is essentia...

Page 356: ... to BLEEDING THE HYDRAULIC CLUTCH SYSTEM on page 3 12 5 Check Clutch fluid level Below the minimum level mark a Add the specified brake and clutch fluid to the proper level Refer to CHECKING THE CLUTCH FLUID LEVEL on page 3 12 6 Check Clutch lever operation Soft or spongy feeling Bleed the clutch system Refer to BLEEDING THE HYDRAULIC CLUTCH SYSTEM on page 3 12 ET3P61024 REMOVING THE CLUTCH RELEAS...

Page 357: ...chemical reac tion leading to poor clutch performance When refilling be careful that water does not enter the clutch master cylinder reser voir Water will significantly lower the boil ing point of the clutch fluid and could cause vapor lock NOTICE ECA13420 Clutch fluid may damage painted surfaces or plastic parts Therefore always clean up any spilt clutch fluid immediately TIP In order to ensure a...

Page 358: ...ve Q ty Remarks Clutch housing Refer to CLUTCH on page 5 43 1 Oil baffle plate 1 1 2 Shift arm 1 3 Circlip 1 4 Shift shaft 1 5 Shift shaft spring 1 6 Spacer 1 7 Stopper lever spring 1 8 Stopper lever 1 9 Circlip 1 10 Collar 1 11 Shift shaft spring stopper 1 For installation reverse the removal proce dure ...

Page 359: ...d of the shift shaft spring onto the shift shaft spring stopper 2 3 Install Shift arm 1 TIP Align the punch mark a in the shift shaft with the slot in the shift arm EAS21380 ADJUSTING THE SHIFT PEDAL 1 Check Shift pedal position Check that the center of the shift pedal end 1 is aligned with the center of the middle gear case cover bolt 2 as shown in the illus tration when viewed directly from the ...

Page 360: ...SHIFT SHAFT 5 59 c Tighten both locknuts to specification T R Shift rod locknut 7 Nm 0 7 m kg 5 1 ft lb 1 2 c d a b ...

Page 361: ...Refer to THROTTLE BODIES on page 7 4 Exhaust pipe assembly Refer to ENGINE REMOVAL on page 5 3 Sidestand Refer to SHAFT DRIVE on page 4 106 Water pump Refer to WATER PUMP on page 6 10 1 Oil level switch coupler 1 Disconnect 2 Oil level switch 1 3 Oil pan 1 4 Oil pan gasket 1 5 Dowel pin 2 6 Oil delivery pipe 2 1 7 Oil delivery pipe 3 1 8 Oil strainer 1 9 Dowel pin 2 10 Oil pump 1 12 ...

Page 362: ...OIL PUMP 5 61 11 Relief valve assembly 1 12 O2 sensor lead bracket 1 For installation reverse the removal proce dure Removing the oil pan and oil pump Order Job Parts to remove Q ty Remarks 12 ...

Page 363: ... Order Job Parts to remove Q ty Remarks 1 Oil pump housing cover 1 2 Pin 2 3 Oil pump inner rotor 1 4 Oil pump outer rotor 1 5 Pin 1 6 Washer 1 7 Oil pump driven sprocket 1 8 Oil pump housing 1 For assembly reverse the disassembly pro cedure ...

Page 364: ... and 2 or replace the defective part s EAS24970 CHECKING THE RELIEF VALVE 1 Check Relief valve body 1 Relief valve 2 Spring 3 O ring 4 Damage wear Replace the defective part s EAS24980 CHECKING THE OIL DELIVERY PIPES The following procedure applies to all of the oil delivery pipes 1 Inner rotor 2 Outer rotor 3 Oil pump housing Inner rotor to outer rotor tip clearance Less than 0 12 mm 0 0047 in Li...

Page 365: ...t 2 Install Oil pump driven sprocket Oil pump housing 1 Washer 2 Pin 3 Oil pump inner rotor 4 Oil pump outer rotor TIP When installing the inner rotor align the pin 3 in the oil pump shaft with the groove a in the in ner rotor 4 3 Check Oil pump operation Refer to CHECKING THE OIL PUMP on page 5 63 EAS25050 INSTALLING THE OIL PAN 1 Install Oil pan gasket Oil pan TIP Tighten the oil pan bolts in st...

Page 366: ...Middle gear case cover gasket 1 3 Dowel pin 2 4 Damper cover 1 5 Damper 1 6 Middle drive shaft bearing housing 1 7 Bearing 1 8 Middle driven shaft end cover 1 9 Middle driven shaft assembly 1 10 Middle driven pinion gear shim Refer to ADJUSTING THE MIDDLE GEAR BACKLASH on page 5 73 11 Middle drive pinion gear nut 1 12 Lock washer 1 13 Middle drive pinion gear 1 110 Nm 11 0 m kg 80 ft lb T R 160 Nm...

Page 367: ...ring retainer 1 18 Bearing 1 19 Middle drive pinion gear shim Refer to ALIGNING THE MIDDLE GEAR on page 5 74 20 Bearing 1 For installation reverse the removal proce dure Removing the middle gear Order Job Parts to remove Q ty Remarks 110 Nm 11 0 m kg 80 ft lb T R 160 Nm 16 0 m kg 115 ft lb T R ...

Page 368: ... middle drive shaft assembly Order Job Parts to remove Q ty Remarks 1 Spring retainer 2 2 Spring seat 1 3 Damper spring 1 4 Damper driven cam 1 5 Damper drive cam 1 6 Middle drive shaft 1 For assembly reverse the disassembly pro cedure ...

Page 369: ...ty Remarks 1 Oil seal 1 2 Middle driven pinion gear nut 1 3 Middle driven shaft 1 4 Middle driven pinion gear 1 5 Bearing retainer 1 6 Bearing 1 7 Middle driven shaft bearing housing 1 For assembly reverse the disassembly pro cedure 110 Nm 11 0 m kg 80 ft lb T R 180 Nm 18 0 m kg 130 ft lb T R ...

Page 370: ...S25750 DISASSEMBLING THE MIDDLE DRIVE SHAFT ASSEMBLY 1 Remove Spring retainers 1 TIP While compressing the spring with the damper spring compressor 2 remove the spring retain ers EAS25770 DISASSEMBLING THE MIDDLE DRIVEN SHAFT ASSEMBLY 1 Remove Middle driven pinion gear nut a Straighten the thread on the middle driven pinion gear nut b Loosen the middle driven pinion gear nut TIP Secure the middle ...

Page 371: ...90 CHECKING THE MIDDLE DRIVEN SHAFT ASSEMBLY 1 Check Middle driven pinion gear Galling pitting wear Replace 2 Check Bearings Damage pitting Replace EAS25800 ASSEMBLING THE MIDDLE DRIVE SHAFT ASSEMBLY 1 Install Spring retainers 1 TIP While compressing the spring with the damper spring compressor 2 install the spring retain ers EAS25820 ASSEMBLING THE MIDDLE DRIVEN SHAFT ASSEMBLY 1 Tighten Bearing r...

Page 372: ...ck the threads with a drift punch EAS25860 INSTALLING THE MIDDLE DRIVE SHAFT ASSEMBLY 1 Tighten Bearing retainer 1 a Attach the bearing retainer wrench 2 b Tighten the bearing retainer to specification c Lock the threads with a drift punch 2 Install Lock washer 1 T R Bearing retainer 110 Nm 11 0 m kg 80 ft lb T R Middle driven pinion gear nut 180 Nm 18 0 m kg 130 ft lb LOCTITE 1 New Bearing retain...

Page 373: ...aft end cover Middle driven shaft bearing housing bolts TIP Finger tighten the middle driven shaft bearing housing bolts 2 Tighten Middle driven shaft bearing housing bolts TIP Before tightening the bolts 1 Adjust the middle gear backlash Refer to ADJUSTING THE MIDDLE GEAR BACKLASH on page 5 73 2 Check that the middle gears turns smoothly ET3P61025 INSTALLING THE MIDDLE GEAR CASE COVER 1 Install M...

Page 374: ...ts NOTICE ECA14050 Do not overtighten the middle driven shaft bearing housing bolts or you may obtain too little middle gear backlash and damage the middle gears If the bolts are overtightened loosen them until the crankcase to middle driven shaft bearing housing clearance is within specification as stated below Then repeat all of the previous steps TIP Tighten the middle driven shaft bearing hous...

Page 375: ...wing thickness es 8 Loosen Middle driven shaft bearing housing bolts 9 Install Middle driven pinion gear shim s 10 Tighten Middle driven shaft bearing housing bolts 11 Measure Middle gear backlash Out of specification Refer to MEASUR ING THE MIDDLE GEAR BACKLASH on page 5 73 EAS25930 ALIGNING THE MIDDLE GEAR TIP Aligning the middle gear is necessary when any of the following parts are replaced Cra...

Page 376: ...en pinion gear shim thick ness B use the following formula d a numeral on the middle driven pinion gear to be divided by 100 and either added to or subtracted from 34 e Measured value f a numeral on the lower crankcase to be divided by 100 and added to 87 Example If the middle driven pinion gear is marked 03 d is 33 97 i e 34 00 0 03 33 97 e is 54 49 If the lower crankcase is marked 95 f is 87 95 ...

Page 377: ...MIDDLE GEAR 5 76 Middle driven pinion gear shim Thickness mm 0 10 0 15 0 20 0 30 0 40 0 50 ...

Page 378: ...to MIDDLE GEAR on page 5 65 Clutch housing Refer to CLUTCH on page 5 43 1 Timing chain 1 2 Oil pump drive chain guide 1 3 Oil pump drive chain 1 4 Oil pump drive sprocket 1 5 Spacer 1 6 Collar 1 7 Spring washer 1 8 Gear position switch 1 T R 24 Nm 2 4 m kg 17 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib T R 1st 20 Nm 2 0 m kg 14 ft lb 2nd 20 Nm 2 0 m kg 14 ft lb Final Specified ...

Page 379: ...y Remarks T R 24 Nm 2 4 m kg 17 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib T R 1st 20 Nm 2 0 m kg 14 ft lb 2nd 20 Nm 2 0 m kg 14 ft lb Final Specified angle 115 125 T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib LT LT New LS T R 4 Nm 0 4 m kg 2 9 ft Ib E E E E E E E E E LT LT LT LT 8 10 10 7 6 5 4 1 2 3 10 9 3 10 10 2 2 ...

Page 380: ... 1 1 3 Upper crankcase plate 1 4 Oil baffle plate 3 1 5 Bearing 1 6 Oil seal 1 7 Bearing 1 8 Upper crankcase 1 9 Bearing 1 10 Oil filter cartridge bolt 1 11 Upper crankcase damper 1 12 Crankcase plug 1 10 LS LS 2 LT LT LT LT LT LT LT LT 4 8 3 LT 5 7 6 12 1 9 13 T R 12 Nm 1 2 m kg 8 7 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 70 Nm 7 0 m kg 50 ...

Page 381: ... remove Q ty Remarks 10 LS LS 2 LT LT LT LT LT LT LT LT 4 8 3 LT 5 7 6 12 1 9 13 T R 12 Nm 1 2 m kg 8 7 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 70 Nm 7 0 m kg 50 ft lb New New New New LS LS New E E T R 12 Nm 1 2 m kg 8 7 ft Ib 11 E T R 20 Nm 2 0 m kg 14 ft Ib 3 8 Nm 0 8 m kg 5 8 ft Ib T R ...

Page 382: ...oughly 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 Obstruction Blow out with compressed air EAS25600 CHECKING THE OIL DELIVERY PIPES The following procedure applies to all of the oil delivery pipes 1 Check Oil delivery pipe Damage Replace Obstruction Wash and blow ...

Page 383: ...e crankshaft journal bearings 3 Install Dowel pins 4 Set the shift drum assembly and transmission gears in the neutral position 5 Install Lower crankcase 1 onto the upper crankcase 2 NOTICE ECA13980 Before tightening the crankcase bolts make sure the transmission gears shift correctly when the shift drum assembly is turned by hand 6 Install Crankcase bolts Recommended lubricant Engine oil Yamaha b...

Page 384: ...er tightening sequence as shown b Loosen and retighten the crankcase bolts in the proper tightening sequence as shown c Tighten the crankcase bolts further to reach the specified angle 115 125 in the proper tightening sequence as shown WARNING EW3P61014 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 with a new one and ...

Page 385: ...bolts in the proper tight ening sequence as shown T R Crankcase bolt 11 12 24 Nm 2 4 m kg 17 ft lb Crankcase bolt 13 14 12 Nm 1 2 m kg 8 7 ft lb Crankcase bolt 15 31 10 Nm 1 0 m kg 7 2 ft lb 9 8 3 6 1 2 5 4 7 10 13 21 18 15 16 17 20 19 22 14 24 29 30 23 25 31 28 26 27 11 12 ...

Page 386: ...der Job Parts to remove Q ty Remarks Crankcase Separate Refer to CRANKCASE on page 5 77 1 Connecting rod cap 4 2 Big end lower bearing 4 3 Piston pin clip 8 4 Piston pin 4 5 Piston 4 6 Connecting rod 4 7 Big end upper bearing 4 8 Top ring 4 9 2nd ring 4 10 Oil ring 4 For installation reverse the removal proce dure ...

Page 387: ... reference during installation put an identi fication mark on each piston crown Before removing the piston pin deburr the pis ton pin clip s groove and the piston s pin bore area If both areas are deburred and the piston pin is still difficult to remove remove it with the piston pin puller set 5 4 Remove Top ring 2nd ring Oil ring TIP When removing a piston ring open the end gap with your fingers ...

Page 388: ...ace the piston and piston rings as a set EAS24430 CHECKING 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 79 000 79 010 mm 3 1102 3 1106 in Taper limit 0 050 mm 0 0020 in Out of round limit 0 05...

Page 389: ... then check the lubrication sys tem 2 Measure Piston pin outside diameter a Out of specification Replace the piston pin 3 Measure Piston pin bore diameter b Out of specification Replace the piston Piston ring Top ring Ring side clearance 0 030 0 070 mm 0 0012 0 0028 in Limit 0 120 mm 0 0047 in 2nd ring Ring side clearance 0 020 0 060 mm 0 0008 0 0024 in Limit 0 120 mm 0 0047 in a 5 mm 0 20 in Pist...

Page 390: ...od and the big end lower bearing into the connecting rod cap TIP Align the projections a on the big end bearings with the notches b in the connecting rod and connecting rod cap c Put a piece of Plastigauge 1 on the crank shaft pin d Assemble the connecting rod halves TIP Do not move the connecting rod or crankshaft until the clearance measurement has been completed Lubricate the bolt threads and n...

Page 391: ... the replacement big end bearing sizes P1 P4 refer to the bearings shown in the crank shaft illustration For example if the connecting rod P1 and the crankshaft web P1 numbers are 6 and 1 re spectively then the bearing size for P1 is EAS26170 INSTALLING THE CONNECTING RODS AND PISTONS The following procedure applies to all of the pis tons and connecting rods 1 Install Top ring 1 2nd ring 2 Upper o...

Page 392: ...d bearings Connecting rod assembly 1 into the cylinder and onto the crankshaft pin Connecting rod cap onto the crankshaft pin TIP Align the projections on the big end bearings with the notches in the connecting rods and connecting rod caps Be sure to reinstall each big end bearing in its original place While compressing the piston rings with piston ring compressor 2 install the connecting rod asse...

Page 393: ... rod nuts further to reach the specified angle 115 125 WARNING EWA13400 If the connecting rod nut is tightened more than the specified angle do not loosen the nut and then retighten it Instead replace the connecting rod bolt and nut with a new one and perform the procedure again NOTICE ECA13950 Do not use a torque wrench to tighten the connecting rod nut to the specified angle TIP On a hexagonal n...

Page 394: ... to CRANKCASE on page 5 77 Front balancer weight Refer to BALANCERS on page 5 106 Connecting rod caps Refer to CONNECTING RODS AND PIS TONS on page 5 85 1 Crankshaft 1 2 Crankshaft journal upper bearing 5 3 Crankshaft journal lower bearing 5 4 Oil nozzle 4 For installation reverse the removal proce dure 3 1 2 2 E E New 4 LS ...

Page 395: ...urnal to crankshaft journal bearing clearance Out of specification Replace the crank shaft journal 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 bearing...

Page 396: ...ication select replacement crankshaft journal bear ings 4 Select Crankshaft journal bearings J1 J5 TIP The numbers A stamped into the lower crank case and the numbers B stamped into the crankshaft web are used to determine the re placement crankshaft journal bearing sizes J1 J5 refer to the bearings shown in the lower crankcase and crankshaft web illustration If J1 J5 are the same use the same siz...

Page 397: ...CRANKSHAFT 5 96 TIP Align the projections a on the crankshaft jour nal bearings 1 with the notches b in the crankcases Be sure to install each crankshaft journal bear ing in its original place ...

Page 398: ...marks Crankcase Separate Refer to CRANKCASE on page 5 77 Stopper lever Refer to SHIFT SHAFT on page 5 57 1 Drive axle assembly 1 2 Bearing 1 3 Washer 1 4 Bearing 1 5 Shift drum retainer 1 6 Long shift fork guide bar 1 7 Shift fork L 1 8 Shift fork R 1 9 Short shift fork guide bar 1 10 Spring 4 11 Shift drum assembly 1 12 Shift fork C 1 ...

Page 399: ...TRANSMISSION 5 98 13 Main axle assembly 1 For installation reverse the removal proce dure Removing the transmission shift drum assembly and shift forks Order Job Parts to remove Q ty Remarks ...

Page 400: ...ed lock washer retainer 1 4 5th pinion gear 1 5 Toothed spacer 1 6 Toothed washer 2 7 Circlip 2 8 3rd pinion gear 1 9 4th pinion gear 1 10 Collar 1 11 Main axle 1st pinion gear 1 12 Bearing 1 13 Washer 1 14 Main axle bearing housing 1 For assembly reverse the disassembly pro cedure 14 13 12 11 10 9 New New New New 7 8 7 6 5 4 3 2 1 6 E M M M M M ...

Page 401: ...nd wheel gear 1 4 Collar 1 5 Washer 1 6 5th wheel gear 1 7 Circlip 2 8 Toothed washer 2 9 3rd wheel gear 1 10 Toothed spacer 1 11 Toothed lock washer 1 12 Toothed lock washer retainer 1 13 4th wheel gear 1 14 Washer 1 15 1st wheel gear 1 16 Bearing 1 17 Washer 1 1 18 17 16 15 14 8 7 12 11 10 2 3 4 6 7 8 9 13 E M M M M M M 5 New New ...

Page 402: ... 101 18 Drive axle 1 For assembly reverse the disassembly pro cedure Disassembling the drive axle assembly Order Job Parts to remove Q ty Remarks 1 18 17 16 15 14 8 7 12 11 10 2 3 4 6 7 8 9 13 E M M M M M M 5 New New ...

Page 403: ...to straighten a bent shift fork guide bar 3 Check Shift fork movement along the shift fork guide bar Rough movement Replace the shift forks and shift fork guide bar as a set EAS26270 CHECKING THE SHIFT DRUM ASSEMBLY 1 Check Shift drum groove Damage scratches wear Replace the shift drum assembly Shift drum segment 1 Damage wear Replace the shift drum as sembly Shift drum bearing 2 Damage pitting Re...

Page 404: ...efective part s 6 Check Circlips Bends damage looseness Replace ET3P61030 ASSEMBLING THE MAIN AXLE AND DRIVE AXLE 1 Install Toothed washer 1 Circlip 2 TIP Be sure the circlip sharp edged corner a is positioned opposite side to the toothed washer and gear For main axle Install the circlip so that both ends b rest on the sides of a spline c with both axles aligned 2 Install Toothed lock washer retai...

Page 405: ...ousing hole with the corresponding hole in the upper crankcase Stake the main axle assembly screws at a cut out a in the main axle bearing housing 2 Install Shift fork C Shift drum assembly Springs Short shift fork guide bar Shift fork R Shift fork L Long shift fork guide bar TIP The embossed marks on the shift forks should face towards the right side of the engine and be in the following sequence...

Page 406: ...IP The bearing pin 1 must face towards the rear of the upper crankcase Make sure the bearing circlip 2 is inserted into the groove in the upper crankcase 5 Check Transmission Rough movement Repair TIP Oil each gear shaft and bearing thoroughly 1 1 1 2 ...

Page 407: ...er Job Parts to remove Q ty Remarks Crankcase Separate Refer to CRANKCASE on page 5 77 1 Front balancer lever 1 2 Front balancer shaft 1 3 Washer 2 4 Bearing 2 5 Front balancer gear 1 6 Damper 4 7 Front balancer weight 1 For installation reverse the removal proce dure ...

Page 408: ...7 4 Pickup rotor cover Refer to PICKUP ROTOR on page 5 36 Clutch cover Refer to CLUTCH on page 5 43 1 Rear balancer cover 1 2 Rear balancer cover gasket 1 3 Rear balancer lever 1 4 Rear balancer shaft 1 5 Washer 2 6 Bearing 2 7 Rear balancer gear 1 8 Damper 4 9 Rear balancer weight 1 For installation reverse the removal proce dure ...

Page 409: ...ach damper is positioned to the outside of the gear projec tions as shown in the illustration Align the punch mark b in the balancer weight with the mark c in the balancer gear 2 Align T mark on the pickup rotor with the crankcase mating surface a Turn the crankshaft clockwise b When piston 1 is at TDC on the compres sion stroke align the T mark a on the pick up rotor with the crankcase mating sur...

Page 410: ...om the balancer gear If noise is abnormal adjust the gear lash by turning the balancer shaft TIP With each adjustment turn the balancer shaft one scale ET3P61033 INSTALLING THE REAR BALANCER 1 Install Rear balancer gear 1 Dampers 2 Rear balancer weight 3 Bearings Washers TIP Install the dampers onto the balancer gear so that the middle section a of each damper is positioned to the outside of the g...

Page 411: ...haft a Align the punch marks a in the balancer weight with the punch mark b in the upper crankcase b Align the balancer gear punch mark c with the primary driven gear point d as shown TIP Make sure that the rear balancer gear teeth and the primary driven gear teeth mesh cor rectly Make sure that the balancer gear punch mark c is aligned with the projection e on the up per crankcase Make sure that ...

Page 412: ... Rear balancer lever bolt 1 Rear balancer shaft pinch bolt 2 TIP Make sure that the balancer shaft does not ro tate 7 Start the engine and check that there is no abnormal noise coming from the balancer gear If noise is abnormal adjust the gear lash by turning the balancer shaft TIP With each adjustment turn the balancer shaft one scale T R Rear balancer shaft 0 4 Nm 0 04 m kg 0 29 ft lb f e c 2 1 ...

Page 413: ...TOR 6 3 OIL COOLER 6 4 CHECKING THE OIL COOLER 6 5 INSTALLING THE OIL COOLER 6 5 THERMOSTAT 6 6 CHECKING THE THERMOSTAT 6 8 INSTALLING THE THERMOSTAT ASSEMBLY 6 8 WATER PUMP 6 10 DISASSEMBLING THE WATER PUMP 6 12 CHECKING THE WATER PUMP 6 12 ASSEMBLING THE WATER PUMP 6 12 INSTALLING THE WATER PUMP 6 13 ...

Page 414: ... cooler outlet hose 1 6 Horn 1 7 Coolant reservoir bracket 1 8 Water pump breather hose 1 9 Radiator outlet hose 1 10 Left radiator fan motor coupler 1 Disconnect 11 Right radiator fan motor coupler 1 Disconnect 12 Air guide bolt 1 T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft...

Page 415: ...or 1 For installation reverse the removal proce dure Removing the radiator Order Job Parts to remove Q ty Remarks T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib LT LT LT T R 7 Nm 0 7 m kg 5 1 ft Ib 12 Nm 1 2 m kg 8 7 ft Ib T R 19 2 3 4 5 1 6 7 8 10 11 20 12 13 13 14 15 16 17...

Page 416: ...2 to the radiator cap 3 b Apply the specified pressure for ten seconds and make sure there is no drop in pressure 4 Check Radiator fans Damage Replace Malfunction Check and repair Refer to COOLING SYSTEM on page 8 29 EAS26400 INSTALLING THE RADIATOR 1 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 27 2 Check Cooling system Leaks Re...

Page 417: ...in Refer to CHANGING THE COOLANT on page 3 27 Radiator Refer to RADIATOR on page 6 1 Exhaust pipe assembly Refer to ENGINE REMOVAL on page 5 3 1 Water pump outlet hose 1 2 Water pump outlet pipe 1 3 Water jacket joint inlet hose 1 4 Water jacket joint 1 5 Oil cooler inlet hose 1 6 Oil cooler outlet hose 1 7 Oil cooler 1 For installation reverse the removal proce dure New ...

Page 418: ...r thinner 2 Install O ring Oil cooler TIP Make sure the O ring is positioned properly 3 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 27 Crankcase with the specified amount of the recom mended engine oil Refer to CHANGING THE ENGINE OIL on page 3 24 4 Check Cooling system Leaks Repair or replace any faulty part 5 Measure Radiator ...

Page 419: ...cap 1 2 Coolant reservoir hose 1 Disconnect 3 Radiator inlet hose 1 Disconnect 4 Thermostat inlet hose 2 1 5 Thermostat cover radiator filler pipe 1 6 Thermostat housing 1 7 Thermostat 1 8 Thermostat inlet pipe 2 1 9 Thermostat inlet hose 1 1 10 Coolant temperature sensor coupler 1 Disconnect 11 Coolant temperature sensor 1 LS New New 7 Nm 0 7 m kg 5 1 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 22 Nm ...

Page 420: ...on reverse the removal proce dure Removing the thermostat assembly Order Job Parts to remove Q ty Remarks LS New New 7 Nm 0 7 m kg 5 1 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 22 Nm 2 2 m kg 16 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 1 12 11 10 2 7 5 3 4 6 8 9 3 ...

Page 421: ...mostat hoses Thermostat pipes Radiator inlet hose Thermostat cover radiator filler pipe EAS26490 INSTALLING THE THERMOSTAT ASSEMBLY 1 Install Copper washer Coolant temperature sensor NOTICE EC3P61019 Use extreme care when handling the coolant temperature sensor Replace any part that was dropped or subjected to a strong im pact 2 Install Thermostat 1 Thermostat housing 2 TIP Install the thermostat ...

Page 422: ...THERMOSTAT 6 9 5 Measure Radiator cap opening pressure Below the specified pressure Replace the radiator cap Refer to CHECKING THE RADIATOR on page 6 3 ...

Page 423: ... page 4 1 Coolant Drain Refer to CHANGING THE COOLANT on page 3 27 1 Water pump breather hose 1 Disconnect 2 Radiator outlet hose 1 Disconnect 3 Water pump outlet hose 1 Disconnect 4 Water pump assembly 1 5 Water pump tray 1 For installation reverse the removal proce dure LS New 1 2 5 4 3 12 Nm 1 2 m kg 8 7 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib T R ...

Page 424: ...arts to remove Q ty Remarks 1 Water pump housing cover 1 2 O ring 1 3 Circlip 1 4 Impeller shaft 1 5 Rubber damper holder 1 6 Rubber damper 1 7 Water pump seal 1 8 Oil seal 1 9 Bearing 2 10 Water pump housing 1 For assembly reverse the disassembly pro cedure ...

Page 425: ...r pump housing Impeller shaft Cracks damage wear Replace 2 Check Bearing Rough movement Replace EAS26560 ASSEMBLING THE WATER PUMP 1 Install Oil seal 1 into the water pump housing TIP Before installing the oil seal apply tap water or coolant onto its outer surface Install the oil seal with a socket that matches its outside diameter 2 Install Water pump seal 1 NOTICE ECA14080 Never lubricate the wa...

Page 426: ...Install Water pump tray 1 O ring 2 Water pump assembly 3 TIP Install the water pump tray completely onto the crankcase Align the slit a on the impeller shaft with the projection b on the oil pump driven sprocket Lubricate the O ring with a thin coat of lithium soap base grease Mechanical seal installer 90890 04078 Water pump seal installer YM 33221 A Middle driven shaft bearing driv er 90890 04058...

Page 427: ...e recom mended coolant Refer to CHANGING THE COOLANT on page 3 27 3 Check Cooling system Leaks Repair or replace any faulty part 4 Measure Radiator cap opening pressure Below the specified pressure Replace the radiator cap Refer to CHECKING THE RADIATOR on page 6 3 3 1 2 ...

Page 428: ...WATER PUMP 6 15 ...

Page 429: ...NJECTORS 7 7 CHECKING THE INJECTORS 7 7 CHECKING AND CLEANING THE THROTTLE BODIES 7 7 CHECKING THE THROTTLE BODY JOINTS 7 9 REPLACING THE THROTTLE BODIES 7 9 INSTALLING THE INJECTORS 7 9 CHECKING THE INJECTOR PRESSURE 7 9 CHECKING THE FUEL PRESSURE 7 10 ADJUSTING THE THROTTLE POSITION SENSOR 7 11 ADJUSTING THE ACCELERATOR POSITION SENSOR 7 11 AIR INDUCTION SYSTEM 7 13 CHECKING THE AIR INDUCTION SY...

Page 430: ...nk panel 1 2 Fuel sender coupler 1 Disconnect 3 Fuel pump coupler 1 Disconnect 4 Fuel tank breather hose 1 5 Fuel tank overflow hose 1 6 Fuel hose holder 1 7 Fuel hose 1 8 Fuel tank 1 9 Fuel pump 1 For installation reverse the removal proce dure T R 16 Nm 1 6 m kg 11 ft Ib New T R 4 Nm 0 4 m kg 2 9 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib 1 5 4 3 7 6 8 9 2 6 ...

Page 431: ... shock Do not touch the base section of the fuel sender EAS26670 CHECKING THE FUEL PUMP BODY 1 Check Fuel pump body Obstruction Clean Cracks damage Replace fuel pump as sembly EAS26700 INSTALLING THE FUEL PUMP 1 Install Fuel pump TIP Do not damage the installation surfaces of the fuel tank when installing the fuel pump Always use a new fuel pump gasket Install the fuel pump as shown in the illustr...

Page 432: ...fuel hose holder is in the correct position other wise the fuel hose will not be properly in stalled TIP Install the fuel hose connector securely onto the fuel tank until a distinct click is heard and then make sure that it does not come loose After installing the fuel hose holder 1 make sure that the sections a b and c of the holder are installed securely 1 1 a b c ...

Page 433: ...t 4 Intake air pressure sensor coupler 1 Disconnect 5 Air cut off valve coupler 1 Disconnect 6 Grip cancel switch coupler 1 Disconnect 7 Throttle servo motor coupler 1 Disconnect 8 Accelerator position sensor coupler 1 Disconnect 9 Throttle body joint clamp screw 8 Loosen 10 Throttle bodies 1 11 Throttle cable holder 1 12 Throttle cable decelerator cable 1 Disconnect 13 Throttle cable accelerator ...

Page 434: ... installation reverse the removal proce dure Removing the throttle bodies Order Job Parts to remove Q ty Remarks LT 9 9 9 9 9 14 9 10 1 2 2 2 3 4 5 8 6 7 11 13 12 14 4 Nm 0 4 m kg 2 9 ft Ib T R 3 Nm 0 3 m kg 2 2 ft Ib T R 3 Nm 0 3 m kg 2 2 ft Ib T R ...

Page 435: ...l rail 1 5 Injector 4 6 Throttle position sensor 1 7 Accelerator position sensor 1 8 Grip cancel switch 1 For installation reverse the removal proce dure New New New New New 2 3 1 1 1 1 4 5 5 5 7 6 8 3 5 Nm 0 35 m kg 2 5 ft lb T R 3 5 Nm 0 35 m kg 2 5 ft lb T R 3 5 Nm 0 35 m kg 2 5 ft lb T R 3 5 Nm 0 35 m kg 2 5 ft lb T R 5 Nm 0 5 m kg 3 6 ft Ib T R 5 Nm 0 5 m kg 3 6 ft Ib T R ...

Page 436: ...nce Refer to CHECKING THE FUEL INJEC TORS on page 8 191 EAS1MC1072 CHECKING AND CLEANING THE THROTTLE BODIES TIP Clean the throttle bodies only if they cannot be synchronized using the bypass air screws Be fore cleaning the throttle bodies check the fol lowing items Valve clearance Spark plugs Air filter element Throttle body joints Fuel hose Exhaust system Cylinder head breather hose WARNING EWA1...

Page 437: ...ts between 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 ECA1MC1021 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 allow carbon deposits or other for eign materials to e...

Page 438: ...re to the injectors fuel rail O rings or seals Be careful not to twist or pinch the O rings when installing the injectors If an injector is subject to strong shocks or excessive force replace it If installing the original fuel rail and screws remove the white paint marks using a cleaning solvent Otherwise paint chips on the screw seats could prevent the screws from being tightened 1 Install new O ...

Page 439: ...re a Remove the fuel tank bolts 1 and lift up the fuel tank NOTICE ECA1MC1024 When lifting up the fuel tank be careful not to pull the fuel tank breather overflow hose b Disconnect the fuel hose 2 from the fuel rail WARNING EWA1MC1018 Cover fuel hose connections with a cloth when disconnecting them Residual pres sure in the fuel lines could cause fuel to spurt out when removing the hose NOTICE ECA...

Page 440: ...buttons for 8 seconds more TIP All displays on the multi function meter right dis play disappear and DIAG appears f Simultaneously press the TCS button 1 and RESET button 2 for 2 seconds or more to set the diagnostic mode TIP The diagnostic code number 01 appears on the multi function meter right display g Diagnostic code number 01 is selected h Adjust the position of the throttle position sen sor...

Page 441: ...ed posi tion j Adjust the position of the accelerator position sensor angle so that 12 22 can appear in the meter display k After adjusting the accelerator position sen sor angle tighten the accelerator position sensor bolts 3 l Turn the throttle grip to the fully open position m Check the meter display value If the meter display value is not 97 107 adjust the accel erator position sensor angle n ...

Page 442: ...AIR INDUCTION SYSTEM 7 13 EAS27040 AIR INDUCTION SYSTEM 1 2 3 5 6 7 8 1 1 2 1 1 3 6 7 8 2 2 3 5 4 ...

Page 443: ...ver 3 Air induction system hose air cut off valve to 3 way joint 4 Air induction system hose 3 way joint to air cut off valve 5 Air cut off valve 6 Air induction system hose 3 way joint to hose plug 7 Air induction system hose air filter case joint assembly to 3 way joint 8 Air filter case joint assembly ...

Page 444: ...pler 1 Disconnect 2 Air induction system hose air filter case joint assembly to 3 way joint 1 3 Air induction system hose 3 way joint to hose plug 1 4 Air induction system hose 3 way joint to air cut off valve 1 5 Air induction system hose 3 way joint to reed valve cover 4 6 Air induction system hose air cut off valve to 3 way joint 2 7 Air cut off valve 1 For installation reverse the removal proc...

Page 445: ...on system hoses 3 way joint to reed valve cover Refer to Removing the air cut off valve Thermostat inlet pipe 1 Refer to THERMOSTAT on page 6 6 1 Reed valve cover cylinder 1 1 2 Reed valve cover cylinders 2 3 1 3 Reed valve cover cylinder 4 1 4 Reed valve assembly 4 5 Reed valve plate 4 For installation reverse the removal proce dure LT LT LT LT 1 4 5 2 3 4 4 4 5 5 5 14 Nm 1 4 m kg 10 ft Ib T R ...

Page 446: ...nd closes to cut off the flow when the vehicle is be ing driven However if the coolant temperature is below the specified value the air cut off valve remains open and allows the air to flow into the exhaust pipe until the temperature becomes higher than the specified value 1 Check Hoses Loose connections Connect properly Cracks damage Replace 3 way joint Cracks damage Replace 2 Check Reed valve Re...

Page 447: ...7 CIRCUIT DIAGRAM 8 17 TROUBLESHOOTING 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 36 DIAGNOSTIC MODE 8 37 YAMAHA DIAGNOSTIC TOOL 8 38 TROUBLESHOOTING DETAILS 8 40 CRUISE CONTROL SYSTEM 8 85 CIRCUIT DIAGRAM...

Page 448: ...REQUIREMENTS 8 117 TROUBLESHOOTING 8 121 SELF DIAGNOSIS FAULT CODE INDICATION 8 122 ABS ANTI LOCK BRAKE SYSTEM 8 125 CIRCUIT DIAGRAM 8 125 ABS COMPONENTS CHART 8 127 ABS COUPLER LOCATION CHART 8 129 MAINTENANCE OF THE ABS ECU 8 131 ABS TROUBLESHOOTING OUTLINE 8 131 BASIC INSTRUCTIONS FOR TROUBLESHOOTING 8 132 BASIC PROCESS FOR TROUBLESHOOTING 8 133 A CHECKING THE ABS WARNING LIGHT 8 134 A 1 ONLY T...

Page 449: ...CKING THE OIL LEVEL SWITCH 8 184 CHECKING THE FUEL SENDER 8 185 CHECKING THE FUEL METER FUEL LEVEL WARNING LIGHT 8 185 CHECKING THE FRONT TURN SIGNAL LIGHT ASSEMBLIES 8 186 CHECKING THE RADIATOR FAN MOTORS 8 186 CHECKING THE COOLANT TEMPERATURE SENSOR 8 186 CHECKING THE THROTTLE POSITION SENSOR 8 187 CHECKING THE ACCELERATOR POSITION SENSOR 8 188 CHECKING THE THROTTLE SERVO MOTOR 8 188 CHECKING TH...

Page 450: ...Br L B R B R G W B W B W B W B W B W B W Y G B L L Gy R R B O R B L L L L L B B W B W B W B B W B O G G Y L Y L B Gy R Y W B B Gy O P G B R B W R W R Lg R Y R R L L B W O B Br R Br W R W B Y R B R B L B L B L Y L B Y Y G L Y Gy W Y B W P W W G Lg L Lg B P L L L R R L W B W B B W O W Br L Br W G L L W L B Gy W G W R B R B R B R B R B B L Gy W L G B W R B R W W L B Y W B R L W Sb P B Y Br W L W R B ...

Page 451: ... 32 Relay unit 35 Sidestand switch 41 Right handlebar switch 43 Start engine stop switch 45 Gear position switch 90 Crankshaft position sensor 94 Lean angle sensor 102 ECU engine control unit 103 Ignition coil 1 104 Ignition coil 2 105 Ignition coil 3 106 Ignition coil 4 107 Spark plug A Wire harness B Negative battery sub wire harness ...

Page 452: ...spark However the engine continues to run under the following con ditions 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 ...

Page 453: ...CKING AND CHARGING THE BATTERY on page 8 174 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 8 182 Ignition system is OK 5 Check the ignition coils Refer to CHECKING THE IGNI TION COILS on page 8 181 Re...

Page 454: ... Check the sidestand switch Refer to CHECKING THE SWITCHES on page 8 169 Replace the sidestand switch 11 Check the relay unit diode Refer to CHECKING THE RELAY UNIT DIODE on page 8 180 Replace the relay unit 12 Check the lean angle sensor Refer to CHECKING THE LEAN ANGLE SENSOR on page 8 183 Replace the lean angle sensor 13 Check the entire ignition system wiring Refer to CIRCUIT DIAGRAM on page 8...

Page 455: ...IGNITION SYSTEM 8 6 ...

Page 456: ... B B R R B W B W B W B W Sb Br L R W R R R L W Br Y B L W R W L W R Br L R R P Sb Y W L W B R B Y B B Br Y B G Y G W R B B R W W L R Br L B Y B Y B Y W L W L W L B R B R G W B W B W B W B W B W B W L W L W L W L W L W B B W B W B W B B W Y B B Y Y W G W R L W R W B L G B W R B R W W L B Y W B R L W Sb P B Y Br W L W R B R L W L L W L Y R W L G B R B Y Sb W Sb A B A B B G B G B 2 5 5 5 5 5 5 9 25 2...

Page 457: ...n fuse 26 Battery 27 Engine ground 29 Starter relay 30 Starter motor 32 Relay unit 33 Starting circuit cut off relay 35 Sidestand switch 36 Clutch switch 41 Right handlebar switch 43 Start engine stop switch 45 Gear position switch A Wire harness B Negative battery sub wire harness ...

Page 458: ...arter motor from operating when neither of these condi tions has been met In this instance the starting circuit cut off relay stays 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 pushing 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 ...

Page 459: ...inals Recharge or replace the battery 3 Check the starter motor operation Refer to CHECKING THE START ER MOTOR OPERATION on page 8 183 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 41 Repair or replace the starter motor 5 Check the relay unit starting circuit cut off relay Refer...

Page 460: ...destand switch Refer to CHECKING THE SWITCHES on page 8 169 Replace the sidestand switch 11 Check the clutch switch Refer to CHECKING THE SWITCHES on page 8 169 Replace the clutch switch 12 Check the start engine stop switch Refer to CHECKING THE SWITCHES on page 8 169 The start engine stop switch is faulty Replace the right handlebar switch 13 Check the entire starting system wiring Refer to CIRC...

Page 461: ...ELECTRIC STARTING SYSTEM 8 12 ...

Page 462: ...CHARGING SYSTEM 8 13 EAS27200 CHARGING SYSTEM EAS27210 CIRCUIT DIAGRAM A R B W W W B B B B B R R R R R A B A B B G B G B R R W W W B R B Gy 3 4 25 26 27 ...

Page 463: ...CHARGING SYSTEM 8 14 3 AC magneto 4 Rectifier regulator 25 Main fuse 26 Battery 27 Engine ground A Wire harness B Negative battery sub wire harness ...

Page 464: ...battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 174 Clean the battery terminals Recharge or replace the battery 3 Check the stator coil Refer to CHECKING THE STATOR COIL on page 8 184 Replace the stator coil 4 Check the rectifier regulator Refer to CHECKING THE RECTI FIER REGULATOR on page 8 184 Replace the rectifier regulator 5 Check the entire charging system wiring Refer to CIRCUIT...

Page 465: ...CHARGING SYSTEM 8 16 ...

Page 466: ... R B L R R B R B Y B G B Y B G B B B B B B L B L R L R L R L R L R B B W B W B W B B W B W B W B W B W B W B L R Y R W Y W G L Br R Dg Y Ch B L R Y B P W R W G G L L B L B B G Y G L B R W W L W G W R G W L R L B G B G R R G R G R G Ch Br B Br W Br B Br W B R L W Y W B Y P W P B Br Y W Y W B B W B W P Dg Sb W Y W Gy B O G G Y L Y L B Gy R Y W B B Gy O P G B R B W R W R Lg R Y R R L L B W O B Br R B...

Page 467: ... 26 Battery 27 Engine ground 48 Left handlebar switch 51 Dimmer pass switch 56 Headlight relay dimmer 57 Tail brake light assembly 58 Tail brake light 61 License plate light 62 Headlight assembly 63 Auxiliary light 64 Headlight 72 Meter assembly 73 Multi function meter 76 Meter light 86 High beam indicator light 102 ECU engine control unit A Wire harness B Negative battery sub wire harness ...

Page 468: ...fuel injec tion system backup and hazard lighting Refer to CHECKING THE FUS ES on page 8 173 Replace the fuse s 3 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 174 Clean the battery terminals Recharge or replace the battery 4 Check the main switch Refer to CHECKING THE SWITCHES on page 8 169 Replace the main switch immobilizer unit 5 Check the dimmer pass switch Refer to C...

Page 469: ...k the entire lighting system wiring Refer to CIRCUIT DIAGRAM on page 8 17 Properly connect or replace the wire har ness Replace the ECU meter assembly or headlight assembly Refer to RE PLACING THE ECU engine control unit on page 8 174 ...

Page 470: ...W B L B O G G Y L Y L B Gy R Y W B B Gy O P G B R B W R W R Lg R Y R R L L B W O B Br R Br W R W B Y R B R B L B L B L Y L B Y Y G L Y Gy W Y B W P W W G Lg L Lg B P L L L R R L W B W B B W O W Br L Br W G L L W L B Gy W G W W G B W L R Br Y Dg Y Ch B L R B Br W Br W B W B Br B Br B B W Y B P W R W G G L L B Y W B R L W Sb P B Y G W B W G W Y W G Y Y B B W Y W B Y B O W L R Br L G L W L B W B O W ...

Page 471: ...y 47 Brake light relay 48 Left handlebar switch 52 Horn switch 55 Turn signal switch 57 Tail brake light assembly 58 Tail brake light 59 Rear left turn signal light 60 Rear right turn signal light 65 Front right turn signal light 66 Front left turn signal light 72 Meter assembly 73 Multi function meter 75 Neutral indicator light 78 Oil level warning light 81 Left turn signal indicator light 82 Rig...

Page 472: ...ing system hazard lighting backup fuel injec tion system brake light and ABS ECU Refer to CHECKING THE FUS ES on page 8 173 Replace the fuse s 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 174 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 169 Replace the main switch immobilizer unit 4 Check th...

Page 473: ... CHECKING THE BULBS AND BULB SOCKETS on page 8 172 Replace the tail brake light bulb socket or both 2 Check the front brake light switch Refer to CHECKING THE SWITCHES on page 8 169 Replace the front brake light switch 3 Check the rear brake light switch Refer to CHECKING THE SWITCHES on page 8 169 Replace the rear brake light switch 4 Check the brake switch relay Refer to CHECKING THE RE LAYS on ...

Page 474: ...front turn signal light assem bly ies 3 Check the turn signal switch Refer to CHECKING THE SWITCHES on page 8 169 The turn signal switch is faulty Replace the left handlebar switch 4 Check the hazard switch Refer to CHECKING THE SWITCHES on page 8 169 The hazard switch is faulty Replace the right handlebar switch 5 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 8 21 Prop...

Page 475: ...WITCH on page 8 184 Replace the oil level switch 2 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 8 21 Properly connect or replace the wire har ness Replace the meter assembly 1 Check the fuel sender Refer to CHECKING THE FUEL SENDER on page 8 185 Replace the fuel pump 2 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 8 21 Properly connect or re...

Page 476: ...te white gray gray Between ABS ECU coupler and ECU coupler blue yellow blue yellow white yellow white yellow Between ECU coupler and meter assembly coupler blue black blue black blue red blue red 2 Check the entire speed sensor wir ing Refer to TIP Properly connect or replace the wire har ness Replace the hydraulic unit assembly ECU or meter assembly ...

Page 477: ...SIGNALING SYSTEM 8 28 ...

Page 478: ... W R Br L R R B L B B L B R Br L B B L B B Y L B B W B W B W B B W R L W R W B B O G G Y L Y L B Gy R Y W B B Gy O P G B R B W R W R Lg R Y R R L L B W O B Br R Br W R W B Y R B R B L B L B L Y L B Y Y G L Y Gy W Y B W P W W G Lg L Lg B P L L L R R L W B W B B W O W Br L Br W G L L W L B Gy W G W B L G W B A B A B B G B G B B L B B L B L B L B L B L B L B L R R W G Y Br B Y 2 5 5 9 12 13 16 22 23 ...

Page 479: ...adiator fan motor fuse 16 Fuel injection system fuse 22 Radiator fan motor relay 23 Left radiator fan motor 24 Right radiator fan motor 25 Main fuse 26 Battery 27 Engine ground 28 Cooling system fuse 101 Coolant temperature sensor 102 ECU engine control unit A Wire harness B Negative battery sub wire harness ...

Page 480: ...ry Refer to CHECKING AND CHARGING THE BATTERY on page 8 174 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 169 Replace the main switch immobilizer unit 4 Check the radiator fan motors Refer to CHECKING THE RADIA TOR FAN MOTORS on page 8 186 Replace the radiator fan motor s 5 Check the radiator fan motor relay Refer to CH...

Page 481: ...M 8 32 NG OK 7 Check the entire cooling system wiring Refer to CIRCUIT DIAGRAM on page 8 29 Properly connect or replace the wire har ness Replace the ECU Refer to REPLAC ING THE ECU engine control unit on page 8 174 ...

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

Page 483: ...Crankshaft position sensor 91 Intake air pressure sensor 92 Atmospheric pressure sensor 93 Cylinder identification sensor 94 Lean angle sensor 95 Yamaha diagnostic tool coupler 97 O2 sensor 98 Throttle position sensor 99 Accelerator position sensor 100 Air temperature sensor 101 Coolant temperature sensor 102 ECU engine control unit 103 Ignition coil 1 104 Ignition coil 2 105 Ignition coil 3 106 I...

Page 484: ...stop switch is pushed Checking the engine trouble warning light The engine trouble warning light comes on for around 2 seconds after the main switch has been turned 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 th...

Page 485: ...l not erase the malfunction history The engine operation is not normal but the engine trouble warning light does not come on 1 Check the operation of the following sensors and actuators in the diagnostic mode Refer to TROUBLESHOOTING DETAILS on page 8 40 If a malfunction is detected in the sensors or actuators repair or replace all faulty parts If no malfunction is detected in the sensors and actu...

Page 486: ...g to the fault code number by pressing the TCS button and RESET button TIP To decrease the selected diagnostic code number press the RESET button Press the RESET button for 1 second or more to automatically decrease the diagnostic code numbers To increase the selected diagnostic code number press the TCS button Press the TCS button for 1 second or more to automatically increase the diagnostic code...

Page 487: ...ble you can display information that is necessary for identifying mal functions and for maintenance to display on the computer The displayed information includes the sen sor output data and information recorded in the ECU Functions of the Yamaha diagnostic tool However the diagnostic tool cannot be used to freely change the basic vehicle functions such as adjusting the ignition timing Yamaha diagn...

Page 488: ...c tool Remove the protective cap and then connect the Yamaha diagnostic tool to the coupler 1 TIP When the Yamaha diagnostic tool is connected to the vehicle the operation of the multi function meter and indicators will be different from the normal operation 1 ...

Page 489: ...ylinder identification sensor Fail safe system Unable to start engine Able to drive vehicle Diagnostic code No Meter display Procedure Item Probable cause of mal function and check Maintenance job Confirmation of service completion 1 Connection of cylinder identi fication sensor coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or bro ken terminals a...

Page 490: ...hed Fault code number is dis played Go to item 5 5 Defective cylinder identifica tion sensor Check the cylinder identifica tion sensor Refer to CHECKING THE CYLINDER IDENTIFICA TION SENSOR on page 8 189 Replace if defective Crank the engine Fault code number is not dis played Service is finished Fault code number is dis played Go to item 6 6 Malfunction in ECU Replace the ECU Refer to REPLACING TH...

Page 491: ... white gray white Between crankshaft position sensor coupler and joint cou pler black blue black blue Between joint coupler and ECU coupler black blue black blue Crank the engine Fault code number is not dis played Service is finished Fault code number is dis played Go to item 4 4 Installed condition of crank shaft position sensor Check for looseness or pinching Check the gap between the crankshaf...

Page 492: ...Go to item 2 2 Connection of wire harness ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or bro ken terminals and locking condition of the pins Improperly connected Connect the coupler secure ly or replace the wire har ness Turn the main switch to ON Fault code number is not dis played Service is finished Fault code number is dis played Go to ...

Page 493: ...ensor Replace if defective Refer to CHECKING THE INTAKE AIR PRESSURE SENSOR on page 8 189 Turn the main switch to ON Fault code number is not dis played Service is finished Fault code number is dis played Go to item 6 6 Malfunction in ECU Replace the ECU Refer to REPLACING THE ECU engine control unit on page 8 174 Fault code No 14 Item Intake air pressure sensor hose system malfunction clogged or ...

Page 494: ...nHg 2000 m 6700 ft above sea level Approx 80 kPa 600 0 mmHg 23 6 inHg 3000 m 9800 ft above sea level 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 INTAKE AIR PRESSURE SENSOR on page 8 189 Fault code No 15 Item Thr...

Page 495: ...lace the wire har ness Turn the main switch to ON Fault code number is not dis played Service is finished Fault code number is dis played Go to item 3 3 Wire harness continuity Open or short circuit Re place the wire harness Between throttle position sensor coupler and ECU coupler black blue black blue white white black black blue blue Turn the main switch to ON Fault code number is not dis played...

Page 496: ... throttle position sensor Turn the main switch to ON Fault code number is not dis played Service is finished Fault code number is dis played Go to item 7 7 Malfunction in ECU Replace the ECU Refer to REPLACING THE ECU engine control unit on page 8 174 Fault code No 19 Item Sidestand switch a break or disconnection of the black red lead of the ECU is detected Fail safe system Unable to start engine...

Page 497: ...he coupler and check the pins bent or bro ken terminals and locking condition of the pins Improperly connected Connect the coupler secure ly or replace the wire har ness 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 dis played Go to item 4 4 Wire harness continuity Open or short circuit Re place the...

Page 498: ...ays the atmospheric pressure Procedure Compare the actually measured atmospheric pressure with the meter display value Item Probable cause of mal function and check Maintenance job Confirmation of service completion 1 Defective intake air pressure sensor Execute the diagnostic mode Code No 03 When engine is stopped Atmospheric pressure at the current altitude and weather conditions is indicated 0 ...

Page 499: ...open or short circuit detected Fail safe system Able to start engine Able to drive vehicle Diagnostic code No 06 Meter display Displays the coolant temperature Procedure Compare the actually measured coolant temperature with the meter display value Item Probable cause of mal function and check Maintenance job Confirmation of service completion 1 Connection of coolant tem perature sensor coupler Ch...

Page 500: ...ervice is finished Fault code number is dis played Go to item 4 4 Installed condition of coolant temperature sensor Check for looseness or pinching Improperly installed sensor Reinstall or replace the sensor Turn the main switch to ON Fault code number is not dis played Service is finished Fault code number is dis played Go to item 5 5 Defective coolant tempera ture sensor Execute the diagnostic m...

Page 501: ...upler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or bro ken terminals and locking condition of the pins Improperly connected Connect the coupler secure ly or replace the wire har ness Turn the main switch to ON Fault code number is not dis played Service is finished Fault code number is dis played Go to item 3 3 Wire harness continuity Open or short c...

Page 502: ...measured atmospheric pressure with the meter display value Item Probable cause of mal function and check Maintenance job Confirmation of service completion 1 Connection of atmospheric pressure sensor coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or bro ken terminals and locking condition of the pins Improperly connected Connect the coupler secure...

Page 503: ... dis played Go to item 5 5 Defective atmospheric pres sure sensor Execute the diagnostic mode Code No 02 When engine is stopped Atmospheric pressure at the current altitude and weather conditions is indicated At sea level Approx 101 kPa 757 6 mmHg 29 8 inHg 1000 m 3300 ft above sea level Approx 90 kPa 675 1 mmHg 26 6 inHg 2000 m 6700 ft above sea level Approx 80 kPa 600 0 mmHg 23 6 inHg 3000 m 980...

Page 504: ...nd then race it or execute the diagnostic mode Code No 63 Fault code number is not dis played Service is finished Fault code number is dis played Go to item 3 3 Connection of wire harness ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or bro ken terminals and locking condition of the pins Improperly connected Connect the coupler secure ly or r...

Page 505: ...etected 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 de grees Item Probable cause of mal function and check Maintenance job Confirmation of service completion 1 The vehicle has overturned Raise the vehicle upri...

Page 506: ...e completion 1 Connection of cylinder 1 ig nition coil coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or bro ken terminals and locking condition of the pins Improperly connected Connect the coupler secure ly or replace the wire har ness Start the engine and let it idle for approximately 5 seconds Fault code number is not dis played Service is fini...

Page 507: ...rcuit detected in the primary lead of the cylinder 2 ignition coil Fail safe system Able to start engine 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 in tervals Illuminates the engine trouble warning light Procedure Check that a spark is ge...

Page 508: ...is played Service is finished Fault code number is dis played Go to item 5 5 Defective cylinder 2 igni tion coil Measure the primary coil re sistance of the cylinder 2 ignition coil Replace if out of specifica tion Refer to CHECKING THE IGNITION COILS on page 8 181 Start the engine and let it idle for approximately 5 seconds Fault code number is not dis played Service is finished Fault code number...

Page 509: ...t circuit Re place the wire harness Between cylinder 3 ignition coil coupler and ECU cou pler orange green orange green 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 dis played Go to item 4 4 Installed condition of cylin der 3 ignition coil Check for looseness or pinching Improperly installed ignition coil ...

Page 510: ...ion of the coupler Disconnect the coupler and check the pins bent or bro ken terminals and locking condition of the pins Improperly connected Connect the coupler secure ly or replace the wire har ness 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 dis played Go to item 3 3 Wire harness continuity Open or sho...

Page 511: ...2 is actuated five times by listening for the op erating sound 38 Actuation Actuates injector 3 five times at one second intervals Illuminates the engine trouble warning light Procedure Check that injector 3 is actuated five times by listening for the op erating sound 39 Actuation Actuates injector 4 five times at one second intervals Illuminates the engine trouble warning light Procedure Check th...

Page 512: ...nt or bro ken terminals and locking condition of the pins Improperly connected Connect the coupler secure ly or replace the wire har ness Execute the diagnostic mode Code Nos 36 37 38 39 No operating sound Go to item 5 Operating sound Go to item 7 5 Wire harness continuity Open or short circuit Re place the wire harness Between injector coupler and ECU coupler Injector 1 red black red black Inject...

Page 513: ...ition of the coupler Disconnect the coupler and check the pins bent or bro ken terminals and locking condition of the pins Improperly connected Connect the coupler secure ly or replace the wire har ness 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 dis played Go to item 3 3 Wire harness continuity Open or sho...

Page 514: ...k that the indi cated value increases Value does not increase Go to item 2 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 Incorrect indication Go to item 2 in section B for the neutral switch When the transmission is in gear with the clutch lever squeezed and the sidestand retracted ON Incorrect ind...

Page 515: ...Go to item 8 and delete the fault code Value does not increase Go to item 5 5 Wire harness continuity Open or short circuit Re place the wire harness Between rear wheel sensor coupler and ABS ECU cou pler gray gray white white Between ABS ECU coupler and ECU coupler white yellow white yellow Execute the diagnostic mode Code No 07 Rotate the rear wheel by hand and check that the indi cated value in...

Page 516: ... clutch lever re leased Procedure Shift the transmission Item Probable cause of mal function and check Maintenance job Confirmation of service completion 1 Locate the malfunction Execute the diagnostic mode Code No 07 Rotate the rear wheel by hand and check that the indi cated value increases Value does not increase Go to item 2 in section A for the rear wheel sensor Execute the diagnostic mode Co...

Page 517: ...lever is squeezed ON Correct indication Go to item 9 Incorrect indication Go to item 4 4 Wire harness continuity Open or short circuit Re place the wire harness Between ECU coupler and joint coupler black yellow black yellow Between joint coupler and relay unit coupler black yellow black yellow Between relay unit coupler and gear position switch cou pler sky blue sky blue Execute the diagnostic mo...

Page 518: ...e the ECU Refer to REPLACING THE ECU engine control unit on page 8 174 9 Delete the fault code Turn the main switch to ON and then rotate the rear wheel by hand Start the engine and input the vehicle speed signals by operating the vehicle at 20 to 30 km h 19 mph The fault code can also be delete by activating the diag nostic mode and selecting di agnostic code number 63 Fault code No 42 Item A Rea...

Page 519: ...utral switch When the transmission is in gear with the clutch lever squeezed and the sidestand retracted ON Incorrect indication Go to item 2 2 Clutch lever adjustment Refer to ADJUSTING THE CLUTCH LEVER on page 3 12 Execute the diagnostic mode Code No 21 When the clutch lever is re leased OFF When the clutch lever is squeezed ON Correct indication Go to item 9 Incorrect indication Go to item 3 3 ...

Page 520: ...agnostic mode Code No 21 When the clutch lever is re leased OFF When the clutch lever is squeezed ON Correct indication Go to item 9 Incorrect indication Go to item 6 6 Defective relay unit Check the relay unit Refer to CHECKING THE RELAY UNIT DIODE on page 8 180 Execute the diagnostic mode Code No 21 When the clutch lever is re leased OFF When the clutch lever is squeezed ON Correct indication Go...

Page 521: ... is low recharge the battery 50 Actuation Actuates the relay unit five times at one second intervals Illuminates the engine trouble warning light Procedure Check that the relay unit is actuated five times by listening for the operating sound Item Probable cause of mal function and check Maintenance job Confirmation of service completion 1 Connection of relay unit cou pler Check the locking conditi...

Page 522: ...itch coupler and main fuse coupler red red Between main fuse coupler and battery terminal red red Start the engine and let it idle for approximately 30 sec onds Fault code number is not dis played Service is finished Fault code number is dis played Go to item 4 4 Defective relay unit Execute the diagnostic mode Code No 50 No operating sound Re place the relay unit Start the engine and let it idle ...

Page 523: ...ion and check Maintenance job Confirmation of service completion 1 Locate the malfunction Execute the diagnostic mode Code No 60 00 Go to item 7 01 Go to item 2 02 Go to item 3 03 Go to item 4 04 Go to item 5 17 Go to item 6 2 01 is indicated in diagnostic mode code No 60 EEP ROM data error for adjust ment of CO concentration of cylinder 1 Change the CO concentra tion of cylinder 1 and re write in...

Page 524: ...ntrol unit on page 8 174 Turn the main switch to ON Fault code number is not dis played Service is finished Fault code number is dis played Repeat item 1 If the same number is indicat ed go to item 7 5 04 is indicated in diagnostic mode code No 60 EEP ROM data error for adjust ment of CO concentration of cylinder 4 Change the CO concentra tion of cylinder 4 and re write in EEPROM Refer to ADJUSTIN...

Page 525: ...proximately 5 seconds Fault code number is not dis played Service is finished Fault code number is dis played Repeat the mainte nance job 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 multi function meter right display Fail safe system Able Unable to start engine Able Unable to drive vehicle Diagnostic code No Met...

Page 526: ...e the wire har ness Turn the main switch to ON Fault code number is not dis played Service is finished Fault code number is dis played Go to item 2 2 Connection of wire harness ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or bro ken terminals and locking condition of the pins Improperly connected Connect the coupler secure ly or replace the ...

Page 527: ... dis played Service is finished Fault code number is dis played Go to item 7 Check accelerator position sensor signal 2 Execute the diagnostic mode Code No 15 When the throttle grip is fully closed A value of 10 24 is indicat ed When the throttle grip is fully open A value of 95 109 is indicat ed An indicated value is out of the specified range Re place the accelerator posi tion sensor 7 Malfuncti...

Page 528: ...er is dis played Go to item 4 4 Wire harness continuity Open or short circuit Re place the wire harness light green light green yellow red yellow red Turn the main switch to ON Fault code number is not dis played Service is finished Fault code number is dis played Go to item 5 5 Defective throttle servo mo tor Check the throttle servo mo tor Replace the throttle bodies if defective Refer to CHECKI...

Page 529: ...r Disconnect the coupler and check the pins bent or bro ken terminals and locking condition of the pins Improperly connected Connect the coupler secure ly or replace the wire har ness Execute the diagnostic mode Code No 16 Rotate the front wheel by hand and check that the indi cated value increases Value increases Go to item 9 and delete the fault code Value does not increase Go to item 3 3 Connec...

Page 530: ...de Code No 16 Rotate the front wheel by hand and check that the indi cated value increases Value increases Go to item 9 and delete the fault code Value does not increase Go to item 6 6 Defective front wheel sensor Improperly installed sensor Reinstall or replace the sensor Execute the diagnostic mode Code No 16 Rotate the front wheel by hand and check that the indi cated value increases Value incr...

Page 531: ...d check the pins bent or bro ken terminals and locking condition of the pins Improperly connected Connect the coupler secure ly or replace the wire har ness Turn the main switch to ON Fault code number is not dis played Service is finished Fault code number is dis played Go to item 2 2 Connection of wire harness ECU coupler Check the locking condition of the coupler Disconnect the coupler and chec...

Page 532: ... Service is finished Fault code number is dis played Go to item 5 5 Malfunction in ECU Replace the ECU Refer to REPLACING THE ECU engine control unit on page 8 174 Fault code No 89 Yamaha diagnostic tool Err multi function meter center display Item Multi function meter signals cannot be transmitted between the ECU and the multi function meter ...

Page 533: ...FUEL INJECTION SYSTEM 8 84 ...

Page 534: ...L Br L L R A B A R Br L Lg L Y W G B Y B B Y Y W G W G W Y W G Y Y B B W Y W B Y B O W L R Br L G L W L B W B B R W W L W G W R G W L R L B G B G R R G R G R G Ch Br B Br W Br B Br W B R L W Y W B Y P W P B Br Y W Y W B B W B W P Dg Sb W Y W Gy B B G B G B G W G Y Y W Y B B B B B B B L B B B W B W B W B B W B W B W B W B W B W B L Br G B Y Y B G Y Y W G W B B G Y G W B Lg B B O G G Y L Y L B Gy R ...

Page 535: ...37 Brake light fuse 38 Rear brake light switch 39 Grip cancel switch 40 Front brake light switch 46 Brake switch relay 47 Brake light relay 48 Left handlebar switch 49 Cruise control power switch 50 Cruise control setting switch 72 Meter assembly 73 Multi function meter 83 Cruise control system indicator light 84 Cruise control setting indicator light 102 ECU engine control unit A Wire harness B N...

Page 536: ...CRUISE CONTROL SYSTEM 8 87 EAS1MC1012 CRUISE CONTROL CIRCUIT OPERATION 21 20 19 18 17 16 15 14 13 12 11 10 7 6 3 2 1 9 8 5 4 ...

Page 537: ...e 9 Cruise control system fuse 10 Cruise control power switch 11 Cruise control setting switch 12 Clutch switch 13 Front brake light switch 14 Rear brake light switch 15 Grip cancel switch 16 Brake switch relay 17 Brake light relay 18 ECU engine control unit 19 Multi function meter 20 Cruise control system indicator light 21 Cruise control setting indicator light ...

Page 538: ...lowed in a different order or omitted Use sufficiently charged regular batteries only A Malfunction check using the cruise control system indicator light B Use the diagnostic mode or Yamaha diagnostic tool to determine the cause of the malfunction for the stored fault code from the condition and place where the malfunction occurred C Servicing the cruise control system Execute the final check afte...

Page 539: ...deactivation history for the cruise control system Check the malfunction history using the multi function meter unit Is there any malfunction history Diagnosis using the fault codes Diagnosis using the malfunction history codes Yes Yes OK The cruise control power switch is defective The cruise control system fuse is blown The ECU is defective Delete the fault codes Final check Return to A Return t...

Page 540: ... control system indicator light flashes B 1 3 The cruise control system indicator light come on B 2 EAS1MC1017 B 1 DIAGNOSIS USING THE FAULT CODES 1 Information for the fault codes from the cruise control system is contained in the following table Re fer to this table or troubleshooting Fault code table Fault code No Symptom Check point 90 No normal signals from the switch are received by the ECU ...

Page 541: ...condition of the pins Improperly connected Connect the coupler secure ly or replace the wire har ness Turn the main switch to ON Operate the brake lever Fault code number is not dis played Service is finished Fault code number is dis played Go to item 4 4 Connection of main switch coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or bro ken terminals...

Page 542: ...n yellow Between brake switch relay coupler and ECU coupler light green black light green black Turn the main switch to ON Operate the brake lever Fault code number is not dis played Service is finished Fault code number is dis played Go to item 8 8 Defective front brake light switch Replace the front brake light switch Turn the main switch to ON Operate the brake lever Fault code number is not di...

Page 543: ...and check the pins bent or bro ken terminals and locking condition of the pins Improperly connected Connect the coupler secure ly or replace the wire har ness Turn the main switch to ON Operate the brake pedal Fault code number is not dis played Service is finished Fault code number is dis played Go to item 4 4 Connection of main switch coupler Check the locking condition of the coupler Disconnect...

Page 544: ...nd brake switch relay coupler green white green white Between brake switch relay coupler and joint coupler black black Between joint coupler and negative battery sub wire harness coupler black black Between negative battery sub wire harness coupler and engine ground black black Turn the main switch to ON Operate the brake pedal Fault code number is not dis played Service is finished Fault code num...

Page 545: ...rol set ting switch is released OFF Malfunction Go to item 2 in section B for the cruise control setting switch SET 2 Connection of left handlebar switch coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or bro ken terminals and locking condition of the pins Improperly connected Connect the coupler secure ly or replace the wire har ness Turn the main...

Page 546: ...battery and main fuse coupler red red Between main fuse coupler and main switch coupler red red Between main switch coupler and fuse box 1 ignition fuse brown blue brown blue Between fuse box 1 ignition fuse and cruise control sys tem fuse red white red white Between cruise control sys tem fuse and left handlebar switch coupler yellow black yellow black Between left handlebar switch coupler and EC...

Page 547: ...N When the cruise control set ting switch is released OFF Malfunction Go to item 2 in section A for the cruise control setting switch RES Execute the diagnostic mode Code 81 When the cruise control set ting switch SET is pushed ON When the cruise control set ting switch is released OFF Malfunction Go to item 2 2 Connection of left handlebar switch coupler Check the locking condition of the coupler...

Page 548: ...ruise con trol system fuse Abnormality Replace the fuse cruise control system fuse Turn the main switch to ON Push the SET side of the cruise control setting switch Fault code number is not dis played Service is finished Fault code number is dis played Go to item 6 6 Wire harness continuity Open or short circuit Re place the wire harness Between battery and main fuse coupler red red Between main f...

Page 549: ...SPLAYED 1 Information for the fault codes Refer to TROUBLESHOOTING DETAILS on page 8 40 7 Defective cruise control switch Replace the left handlebar switch Turn the main switch to ON Push the RES side and SET side of the cruise control setting switch Fault code number is not dis played Service is finished Fault code number is dis played Go to item 8 8 Malfunction in ECU Replace the ECU Refer to RE...

Page 550: ...fer to DIAGNOSTIC MODE on page 8 37 2 Execute the diagnostic mode code No 62 to erase the malfunction history in the diagnostic mode Refer to SELF DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE on page 9 5 EAS1MC1023 C 2 FINAL CHECK 1 Check the brake lever and brake pedal operation 2 Check the rear brake light switches Refer to ADJUSTING THE REAR BRAKE LIGHT SWITCH on page 3 30 3 Execute the diagno...

Page 551: ...CRUISE CONTROL SYSTEM 8 102 ...

Page 552: ...L R R R B B R W W L A B A R Br L B O G G Y L Y L B Gy R Y W B B Gy O P G B R B W R W R Lg R Y R R L L B W O B Br R Br W R W B Y R B R B L B L B L Y L B Y Y G L Y Gy W Y B W P W W G Lg L Lg B P L L L R R L W B W B B W O W Br L Br W G L L W L B Gy W G W R B R W W L B R L B B B G B G B Br W L W R B R L W L L W L Y R W L G B R B Y Sb W Sb Dg B B B B B L B B B W B W B W B B W 2 9 16 25 26 27 32 34 43 8...

Page 553: ...ition fuse 16 Fuel injection system fuse 25 Main fuse 26 Battery 27 Engine ground 32 Relay unit 34 Fuel pump relay 41 Right handlebar switch 43 Start engine stop switch 88 Fuel pump 102 ECU engine control unit A Wire harness B Negative battery sub wire harness ...

Page 554: ...harge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 169 Replace the main switch immobilizer unit 4 Check the start engine stop switch Refer to CHECKING THE SWITCHES on page 8 169 Replace the right handlebar switch 5 Check the relay unit fuel pump re lay Refer to CHECKING THE RE LAYS on page 8 177 Replace the relay unit 6 Check the fuel pump Refer to CHECKI...

Page 555: ...FUEL PUMP SYSTEM 8 106 ...

Page 556: ... B R R R R R R W Br L R W W G W R B L B P R Y Y O W Y B W B W Y W L B W G L Br L L R D A C Y B P W R W G G L L B Br R W Y W B Y B O W L R Br L G L W L B W B B R W W L W G W R G W L R L B G B G R R G R G R G Ch Br B Br W Br B Br W B R L W Y W B Y P W P B Br Y W Y W B B W B W P Dg Sb W Y W Gy R Br R Br Br P W Br G B Br Br P B Br G B R B B B R Br L R R A B A R Br L B B G B G B B B B B B L B B W B W B...

Page 557: ...17 Backup fuse 25 Main fuse 26 Battery 27 Engine ground 48 Left handlebar switch 53 Menu switch 54 Select switch 69 Windshield drive unit 70 Windshield drive unit relay down 71 Windshield drive unit relay up 72 Meter assembly 73 Multi function meter A Wire harness B Negative battery sub wire harness D Windshield drive unit sub lead ...

Page 558: ...l 3 Check the fuses Main ignition signaling system backup and windshield drive sys tem Refer to CHECKING THE FUS ES on page 8 173 Replace the fuse s 4 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 174 Clean the battery terminals Recharge or replace the battery 5 Check the main switch Refer to CHECKING THE SWITCHES on page 8 169 Replace the main switch immobilizer unit 6 Ch...

Page 559: ...ld drive unit re lay down Refer to CHECKING THE RE LAYS on page 8 177 Replace the windshield drive unit relay down 10 Check the windshield drive motor Refer to CHECKING THE WIND SHIELD DRIVE UNIT on page 8 192 Replace the windshield drive unit 11 Check the entire windshield drive system wiring Refer to CIRCUIT DIAGRAM on page 8 107 Properly connect or replace the wire har ness Replace the meter as...

Page 560: ... 8 111 ET3P61009 ACCESSORY BOX SYSTEM ET3P61010 CIRCUIT DIAGRAM P ON OFF B B A Br L R Br B B B B B R R B B B Br Br Br B B Br L R R A B C A A B B B G B G B B Br B Br R Br L R R R Br L Br B B B B B B B L B 2 11 25 26 27 67 5 ...

Page 561: ...STEM 8 112 2 Main switch 5 Joint coupler 11 Signaling system fuse 25 Main fuse 26 Battery 27 Engine ground 67 Accessory box solenoid A Wire harness B Negative battery sub wire harness C Accessory box solenoid sub lead ...

Page 562: ... Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 174 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 169 Replace the main switch immobilizer unit 4 Check the accessory box solenoid Refer to CHECKING THE ACCES SORY BOX SOLENOID on page 8 192 Replace the accessory box solenoid 5 Check the entire acces...

Page 563: ...ACCESSORY BOX SYSTEM 8 114 ...

Page 564: ...G R G R G R W R W B O G G Y L Y L B Gy R Y W B B Gy O P G B R B W R W R Lg R Y R R L L B W O B Br R Br W R W B Y R B R B L B L B L Y L B Y Y G L Y Gy W Y B W P W W G Lg L Lg B P L L L R R L W B W B B W O W Br L Br W G L L W L B Gy W G W B W R G Y L G B R W B R W W L W G W R G W L R L B G B G R R G R G R G Ch Br B Br W Br B Br W B R L W Y W B Y P W P B Br Y W Y W B B W B W P Dg Sb W Y W Gy B B G B ...

Page 565: ... fuse 16 Fuel injection system fuse 17 Backup fuse 25 Main fuse 26 Battery 27 Engine ground 72 Meter assembly 73 Multi function meter 74 Immobilizer system indicator light 96 Yamaha diagnostic tool connector 102 ECU engine control unit A Wire harness B Negative battery sub wire harness ...

Page 566: ... 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 safe place ...

Page 567: ...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 immo bilizer unit Standard key ECU Ac...

Page 568: ...n switch 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 ins...

Page 569: ... 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 570: ...se s 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 174 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 169 Replace the main switch immobilizer unit 4 Check the entire immobilizer sys tem wiring Refer to CIRCUIT DIAGRAM on page 8 115 Properly connect or replace the wire har ness Check the conditi...

Page 571: ...istered stan dard key 1 Place the immo bilizer unit at least 50 mm away from the transponder of other vehicles 2 Register the standard key 53 IMMOBILIZER UNIT Codes cannot be transmitted be tween the ECU and the immobilizer unit Noise interference or disconnected lead ca ble 1 Interference due to radio wave noise 2 Disconnected com munication harness 3 Immobilizer unit mal function 4 ECU malfuncti...

Page 572: ...IT Key code registra tion malfunction Same standard key was attempted to be regis tered two consecutive times Register another standard key 56 ECU Unidentified code is received Noise interference or disconnected lead ca ble 1 Check the wire harness and connector 2 Replace the main switch im mobilizer unit 3 Replace the ECU Refer to RE PLACING THE ECU engine control unit on page 8 174 Fault code Pa...

Page 573: ...IMMOBILIZER SYSTEM 8 124 ...

Page 574: ...B W Gy L W L W L W L W L W B W B W B W R L W R W B B O G G Y L Y L B Gy R Y W B B Gy O P G B R B W R W R Lg R Y R R L L B W O B Br R Br W R W B Y R B R B L B L B L Y L B Y Y G L Y Gy W Y B W P W W G Lg L Lg B P L L L R R L W B W B B W O W Br L Br W G L L W L B Gy W G W Sb B W L R L B R B R W W L B G W Y W G Y Y B B R W W L W G W R G W L R L B G B G R R G R G R G Ch Br B Br W Br B Br W B R L W Y W ...

Page 575: ... circuit cut off relay 37 Brake light fuse 38 Rear brake light switch 40 Front brake light switch 41 Right handlebar switch 43 Start engine stop switch 46 Brake switch relay 47 Brake light relay 57 Tail brake light assembly 58 Tail brake light 72 Meter assembly 73 Multi function meter 85 ABS warning light 102 ECU engine control unit 116 ABS test coupler 117 ABS ECU electronic control unit 118 Fron...

Page 576: ...ight 3 ABS ECU fuse 4 ABS solenoid fuse 5 ABS motor fuse 6 Proportioning valve 7 Hydraulic unit assembly 8 Rear wheel sensor 9 Rear wheel sensor rotor 10 Rear brake caliper 11 Metering valve 12 Left front brake caliper 13 Right front brake caliper partially operated together with the rear brake 14 Front wheel sensor 15 Front wheel sensor rotor ...

Page 577: ...ABS ANTI LOCK BRAKE SYSTEM 8 128 ...

Page 578: ...HART B W L R L B Sb W B W Gy Gy W W Gy R W W L W G W R G W L R L B G B G R R G R G R G Ch Br B Br W Br B Br W B R L W Y W B Y P W P B Br Y W Y W B B W B W P Dg Sb W Y W W B G W L W W Y L B B W Gy W G R L R Y W L G Y Sb Br W B W B G R R L L Y 2 4 5 1 3 B B B B Gy Gy ...

Page 579: ...ABS ANTI LOCK BRAKE SYSTEM 8 130 1 Meter assembly coupler 2 ABS test coupler 3 Rear wheel sensor coupler 4 ABS ECU coupler 5 Front wheel sensor coupler ...

Page 580: ... C 3 FINAL CHECK on page 8 160 ABS operation when the ABS warning light comes on 1 The ABS warning light remains on ABS operates as a normal brake system A malfunction was detected using the ABS self diagnosis function The ABS self diagnosis has not been completed The ABS self diagnosis starts when the main switch is turned to ON and finishes when the vehicle has traveled at a speed of approximate...

Page 581: ...ecause the past fault codes will be displayed again if another malfunction occurs EAS27800 BASIC INSTRUCTIONS FOR TROUBLESHOOTING WARNING EWA1MC1001 Perform the troubleshooting A B C in order Be sure to follow the order since a wrong diagnosis could result if the steps are followed in a different order or omitted Use sufficiently charged regular batteries only A Malfunction check using the ABS war...

Page 582: ...shes Is the test coupler adapter connected to the ABS test coupler The T C terminal sky blue of the ABS test coupler is grounded The meter assembly circuit is defective The hydraulic unit assembly is defective Diagnosis using the fault codes The ABS ECU fuse is blown The meter assembly circuit is defective The hydraulic unit assembly is defective There is a break in the wire harness between the AB...

Page 583: ...ce the meter assembly If the ABS warning light comes on ABS ECU is defective Replace the hydraulic unit assembly EAS1MC1002 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 8 169 If there is no continuity replace the main switch immobilizer unit 2 Battery Check the condition of the battery Refer to CHECKING AND CHARG...

Page 584: ...ace the hydraulic unit assembly EAS1MC1004 A 4 THE ABS WARNING LIGHT COME ON Turn the main switch to OFF Remove front cowling inner panel and right upper inner panel to access the ABS test coupler 1 Re move the protective cap from the ABS test coupler and then connect the test coupler adapter 2 to the coupler The T C terminal sky blue is now grounded Turn the main switch to ON and then check the m...

Page 585: ...8 174 If the battery voltage is low clean the battery terminals and recharge it or replace the battery 2 ABS ECU fuse Check the ABS ECU fuse for continuity Refer to CHECKING THE FUSES on page 8 173 If the ABS ECU fuse is blown replace the fuse 3 ABS ECU coupler Check that the ABS ECU coupler is connected properly Connect the couplers properly if necessary 4 There is a break in the wire harness bet...

Page 586: ...om the front wheel sensor is detected Installation of the front wheel sensor Front wheel Front wheel sensor housing Front wheel sensor rotor Hydraulic unit assembly ABS_14 ABS_27 Incorrect signal from the rear wheel sensor is detected Installation of the rear wheel sensor Rear wheel Rear wheel sensor housing Rear wheel sensor rotor Hydraulic unit assembly ABS_15 No continuity in the front wheel se...

Page 587: ...it solenoid relay is short circuited Hydraulic unit assembly ABS_33 ABS motor is defective Power is not supplied to the ABS mo tor Battery voltage ABS motor fuse Wire harness ABS circuit Connection of the ABS ECU coupler and starter relay coupler Hydraulic unit assembly ABS_34 Hydraulic unit ABS motor relay is short circuited Hydraulic unit assembly ABS_41 Front wheel will not recover from the loc...

Page 588: ...gh Battery voltage Battery terminal Refer to CHARGING SYSTEM on page 8 13 ABS_53 Power voltage is too low Battery voltage Connection of the ABS ECU coupler Wire harness Refer to CHARGING SYSTEM on page 8 13 ABS_54 Power voltage is too low Battery voltage Connection of the ABS ECU coupler and starter relay coupler Wire harness Refer to CHARGING SYSTEM on page 8 13 ABS_56 Hydraulic unit sensor power...

Page 589: ... 4 Defective sensor rotor Check the surface of the sensor rotor for damage Replace the sensor rotor if there is visible damage Refer to MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR on page 4 26 Fault code No ABS_12 Symptom Rear wheel sensor signal is not received proper ly Order Item components and probable cause Check or maintenance job 1 Installed condition of wheel sensor Check for lo...

Page 590: ...place the sensor rotor Refer to MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR on page 4 26 5 Hydraulic unit assembly internal mal function Replace the hydraulic unit assembly Fault code No ABS_14 ABS_27 Symptom Incorrect signal from the rear wheel sensor is detected Order Item components and probable cause Check or maintenance job 1 Installed condition of wheel sensor Check for looseness ...

Page 591: ...te terminal 3 and between the black terminal 2 and the black terminal 4 If there is no continuity the wire harness is defec tive Replace the wire harness Check that there is no continuity between the ground and the white terminal 1 or white termi nal 3 and between the ground and the black ter minal 2 or black terminal 4 If there is continuity the wire harness is defective Replace the wire harness ...

Page 592: ... checks and maintenance Fault code No ABS_16 Symptom No continuity in the rear wheel sensor circuit Order Item components and probable cause Check or maintenance job 1 Connections Rear wheel sensor coupler ABS ECU coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction replace the wire harness and connect the coupler secure...

Page 593: ...ive wheel sensor If the above items were performed and no malfunc tions were found connect the ABS ECU coupler and rear wheel sensor coupler and then delete the fault codes If fault code number ABS_16 could not be deleted the rear wheel sensor is defective Replace the rear wheel sensor TIP Before deleting the fault codes record all of the fault codes and perform the related checks and maintenance ...

Page 594: ...or of the sensor housing and the surface of the sensor rotor for foreign material such as metal particles Clean the sensor housing and sensor rotor if necessary Refer to MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR on page 4 34 3 Defective sensor rotor Check the surface of the sensor rotor for damage If there is visible damage replace the sensor ro tor Fault code No ABS_21 Symptom Hydraul...

Page 595: ...to ON brake light cir cuit or front or rear brake light switch circuit Order Item components and probable cause Check or maintenance job 1 Brake light operation Burned out brake light bulb Defective brake switch and brake light relays Check the brake light Repair or replace the tail brake light if necessary Refer to CHECKING THE BULBS AND BULB SOCKETS on page 8 172 Check the brake switch and brake...

Page 596: ...efective front and rear brake light switches Check the brake light Repair or replace the tail brake light if necessary Refer to CHECKING THE BULBS AND BULB SOCKETS on page 8 172 Check the brake switch and brake light relays Refer to CHECKING THE RELAYS on page 8 177 Check the rear brake light switch for proper ad justment Refer to ADJUSTING THE REAR BRAKE LIGHT SWITCH on page 3 30 Check the front ...

Page 597: ...ECKING AND CHARGING THE BAT TERY on page 8 174 2 Blown ABS solenoid fuse Check the ABS solenoid fuse If the ABS solenoid fuse is blown replace the fuse and check the wire harness Refer to CHECKING THE FUSES on page 8 173 3 Connections ABS ECU coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction replace the wire harness a...

Page 598: ...nections ABS ECU coupler Starter relay coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction replace the wire harness and connect the coupler securely TIP Turn the main switch to OFF before disconnecting or connecting a coupler 4 Open or short circuit in wire harness and or negative battery sub wire har ness Replace if th...

Page 599: ...the pressure decreases when the lever is released 3 Brake fluid Visually check the brake fluid in the brake master cylinder reservoir and the brake fluid reservoir for water foreign materials solidification and con tamination Check for air in the brake lines 4 Brake lines Check the brake lines for kinks and deterioration WARNING EWA3P6D005 Only use genuine Yamaha parts Using other brake pipes hose...

Page 600: ...oportioning valve and the metering valve are switched during assembly the brakes will continue to operate as normal However the reduction of the hydraulic pressure for the rear brake and part of the right front brake will be reversed during the ABS operation when the final check on page C 3 FINAL CHECK on page 8 160 is performed Fault code No ABS_42 ABS_47 Symptom Rear wheel will not recover from ...

Page 601: ...CK on page 8 160 is performed 4 Brake lines Check the brake lines for kinks and deterioration particularly between the hydraulic unit and the rear brake caliper WARNING EWA3P6D005 Only use genuine Yamaha parts Using other brake pipes hoses and union bolts may close the brake lines Check that the connections of the brake lines from the brake master cylinder to the hydraulic unit and from the hydrau...

Page 602: ...oreign material such as metal particles Clean the sensor housing and sensor rotor if necessary Refer to MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR on page 4 26 4 Defective sensor rotor Check the surface of the sensor rotor for damage If there is visible damage replace the sensor ro tor Fault code No ABS_44 Symptom Incorrect signal from the rear wheel sensor is detected Order Item compo...

Page 603: ...Check the locking condition of the coupler If there is a malfunction replace the wire harness and connect the coupler securely TIP Turn the main switch to OFF before disconnecting or connecting a coupler 3 Open or short circuit in wire harness Replace if there is an open or short circuit Between ABS ECU coupler and ABS ECU fuse brown white brown white 4 Charging system Check the charging system Re...

Page 604: ...te Between joint coupler and starter relay coupler blue white blue white 4 Charging system Check the charging system Refer to CHARGING SYSTEM on page 8 13 Fault code No ABS_56 Symptom Hydraulic unit sensor power monitor circuit is abnormal Order Item components and probable cause Check or maintenance job 1 Defective internal monitor circuit sen sor power Replace the hydraulic unit assembly Fault c...

Page 605: ... is de fective Replace the wire harness TIP Disconnect the ABS ECU coupler before checking the wire harness 2 Short circuit in front wheel sensor lead Check that there is no short circuit between the white terminal 3 and the gray terminal 4 Check that there is no short circuit between the frame ground and the white terminal 3 If there is a short circuit the front wheel sensor is defective Replace ...

Page 606: ... is de fective Replace the wire harness TIP Disconnect the ABS ECU coupler before checking the wire harness 2 Short circuit in rear wheel sensor lead Check that there is no short circuit between the white terminal 3 and the gray terminal 4 Check that there is no short circuit between the frame ground and the white terminal 3 If there is a short circuit the rear wheel sensor is defective Replace th...

Page 607: ...e starter motor gear or other parts may be damaged 5 Push the side of the start engine stop switch 1 at least 10 times in 4 seconds to delete the fault codes 6 The multi function meter right display switch es to the normal display and the ABS warning light flashes in 0 5 second intervals while the fault codes are being deleted 7 Turn the main switch to OFF 8 Turn the main switch to ON again TIP If...

Page 608: ...r DC 20 V to the ABS ECU coupler Battery voltage Higher than 12 8 V Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe brown white 1 Negative tester probe ground Continuity is all right Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe white blue 1 ABS ECU Negative tester probe white blue 2 right handlebar switch W B G W L W W Y L B B W Gy...

Page 609: ...eservoir Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 14 2 Check the wheel sensor housings and wheel sensors for proper installation Refer to INSTALLING THE FRONT WHEEL FRONT BRAKE DISCS on page 4 29 and IN STALLING THE REAR WHEEL REAR BRAKE DISC on page 4 36 3 Perform hydraulic unit operation test 1 or 2 Refer to HYDRAULIC UNIT OPERATION TESTS on page 4 72 4 Delete the fault codes Refer to C...

Page 610: ... A R Br L L R L R L R L B L B L B B O G G Y L Y L B Gy R Y W B B Gy O P G B R B W R W R Lg R Y R R L L B W O B Br R Br W R W B Y R B R B L B L B L Y L B Y Y G L Y Gy W Y B W P W W G Lg L Lg B P L L L R R L W B W B B W O W Br L Br W G L L W L B Gy W G W Y B P W R W G G L L B W Y W B Y B O W L R Br L G L W L B W B B R W W L W G W R G W L R L B G B G R R G R G R G Ch Br B Br W Br B Br W B R L W Y W B...

Page 611: ... system fuse 17 Backup fuse 25 Main fuse 26 Battery 27 Engine ground 48 Left handlebar switch 53 Menu switch 54 Select switch 72 Meter assembly 73 Multi function meter 102 ECU engine control unit 114 Left grip warmer 115 Right grip warmer A Wire harness B Negative battery sub wire harness ...

Page 612: ...mers are not turned off Adjust the temperature levels of the grip warmer settings 3 Check the fuses Main ignition backup and fuel injection system Refer to CHECKING THE FUS ES on page 8 173 Replace the fuse s 4 Check that the engine is started Start the engine 5 Check the grip warmers Refer to CHECKING THE GRIP WARMERS on page 8 193 Replace the grip warmer s 6 Check the entire grip warmer sys tem ...

Page 613: ...perature level of the high grip warmer setting is set to 10 Adjust the temperature levels of the grip warmer settings 2 Check that the engine trouble warn ing light is on and that fault code No 42 is displayed in the multi function meter right display Perform the troubleshooting for fault code No 42 Refer to TROUBLESHOOTING DETAILS on page 8 40 Replace the ECU Refer to REPLAC ING THE ECU engine co...

Page 614: ...ELECTRICAL COMPONENTS 8 165 EAS27970 ELECTRICAL COMPONENTS 1 24 2 3 4 5 6 9 11 12 10 8 7 13 14 15 16 17 18 19 23 22 21 20 ...

Page 615: ...rive system fuse 8 Fuse box 1 9 Fuse box 2 10 Hazard lighting fuse 11 Cruise control system fuse 12 Brake light fuse 13 Right radiator fan motor 14 Left radiator fan motor 15 Gear position switch 16 Sidestand switch 17 Oil level switch 18 Rear brake light switch 19 Horn 20 Ignition coil 1 21 Ignition coil 2 22 Ignition coil 3 23 Ignition coil 4 24 Main fuse ...

Page 616: ...ELECTRICAL COMPONENTS 8 167 7 1 3 2 18 21 20 19 9 11 12 13 14 15 16 17 6 8 4 5 10 ...

Page 617: ...lay 7 Hydraulic unit assembly 8 Lean angle sensor 9 Brake switch relay 10 Cylinder identification sensor 11 O2 sensor 12 Crankshaft position sensor 13 Accessory box solenoid 14 Windshield drive unit relay up 15 Windshield drive unit relay down 16 Headlight relay dimmer 17 Relay unit 18 ECU engine control unit 19 Radiator fan motor relay 20 Headlight relay on off 21 Air temperature sensor ...

Page 618: ...G L R 2 3 9 8 7 G W G Y Y W Y B G W G Y Y B Y W PULL Br B Y G PRESS Br G B Y P Sb Y W L W B R B Y B B Br Y B G Y G W Br Y B G Y G W PULL B W W G MODE R B W L B R W B W Br G W G L R R B B R W W L 15 W L B W MENU W R B W W G L B R Y Y PASS G L Y B Br L RES SET W G W R B L B P R Y Y O W Y B W B W Y W L B W G L Br L L R Y B O W P ON OFF ...

Page 619: ...tch 4 Front brake light switch 5 Main switch 6 Rear brake light switch 7 Gear position switch 8 Sidestand switch 9 Clutch switch 10 Horn switch 11 Dimmer pass switch 12 Cruise control power switch 13 Cruise control setting switch 14 Turn signal switch 15 Menu switch 16 Select switch ...

Page 620: ...ge 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 position ...

Page 621: ...ulbs 1 Remove Bulb WARNING EW3P61001 Since headlight bulbs get extremely hot keep flammable products and your hands away from them until they have cooled down NOTICE EC3P61002 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 a headlight bulb to keep it free from oil otherwis...

Page 622: ...to Ω 1 b If the pocket tester indicates replace the fuse 3 Replace Blown fuse a Turn 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 use a fuse with an amperage rating other than that specified Improvising or u...

Page 623: ...ASE OF 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 ECA1MC1001 This is a VRLA Valve Regulated Lead Acid battery Never remove the sealing caps be cause the balance between cells w...

Page 624: ... be sure to remove it from the vehicle If charging has to be done with the battery mounted on the vehi 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 batte...

Page 625: ...e charging time suitable for the open circuit voltage f If charging requires more than 5 hours it is advisable to check the charging current after 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 ...

Page 626: ...the relay from the wire harness 2 Connect the pocket tester Ω 1 and battery 12 V to the relay terminals as shown Check the relay operation Out of specification Replace Starter relay Relay unit starting circuit cut off relay 12 8 V or more Charging is complete 12 7 V or less Recharging is required Under 12 0 V Replace the battery Recommended lubricant Dielectric grease Pocket tester 90890 03112 Ana...

Page 627: ...battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 B Y Br W R Y G L R W Y W 1 2 3 4 1 Positive tester probe 2 Negative tester probe 3 Negative tester probe Result Continuity between 1 and 2 No continuity between 1 and 3 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe 5 Negative tester probe Resu...

Page 628: ...lt Continuity between 1 and 2 1 Positive battery terminal 2 Negative battery terminal G Y G W B 1 2 3 4 Lg B Y Lg B 2 1 Br B Y Lg B 1 2 4 3 Br B 3 Positive tester probe 4 Negative tester probe Result No 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 tester probe 2 Negati...

Page 629: ...ative tester probe 5 Negative tester probe Result No continuity between 3 and 4 Continuity between 3 and 5 1 Positive tester probe 2 Negative tester probe 3 Negative tester probe Result Continuity between 1 and 2 No continuity between 1 and 3 Br B Br P W 1 2 3 5 4 Br G R B Br P B 1 3 2 Br G 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe 5 Ne...

Page 630: ...nuity Positive tester probe black yellow 2 Negative tester probe sky blue 1 Continuity Positive tester probe sky blue 1 Negative tester probe black red 3 No continuity Positive tester probe black red 3 Negative tester probe sky blue 1 Continuity Positive tester probe sky blue 1 Negative tester probe sky blue white 4 No continuity Positive tester probe sky blue white 4 Negative tester probe sky blu...

Page 631: ...e start engine stop switch and gradually in crease the spark gap until a misfire occurs EAS28120 CHECKING THE CRANKSHAFT POSITION SENSOR 1 Disconnect Crankshaft position sensor coupler from the wire harness 2 Check Crankshaft position sensor resistance Out of specification Replace the crank shaft position sensor a Connect the pocket tester Ω 100 to the crankshaft position sensor coupler as shown P...

Page 632: ...s not operate Perform the electric starting system troubleshooting starting with step 4 Refer to TROUBLESHOOTING on page 8 10 a Connect the positive battery terminal 1 and starter motor lead 2 with a jumper lead 3 WARNING EWA13810 A wire that is used as a jumper lead must have at least the same capacity of the bat tery lead otherwise the jumper lead may burn This check is likely to produce sparks ...

Page 633: ...VEL SWITCH 1 Drain Engine oil 2 Remove Oil level switch from the oil pan 3 Check Oil level switch continuity Out of specification Replace a Connect the pocket tester Ω 1 to the oil level switch terminal as shown Stator coil resistance 0 128 0 192 Ω Digital circuit tester 90890 03174 Model 88 Multimeter with ta chometer YU A1927 Positive tester probe white 1 Negative tester probe white 2 Positive t...

Page 634: ...urn 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 sender Replace the fuel pump assembly Pocket tester 90890 03112 Analog pocket tester YU 03112 C Minimum level position A Positive...

Page 635: ...vement Replace a Disconnect the radiator fan motor coupler from the wire harness b Connect the battery DC 12 V as shown c Check the radiator fan motor movement EAS28260 CHECKING THE COOLANT TEMPERATURE SENSOR 1 Remove Coolant temperature sensor Refer to THERMOSTAT on page 6 6 WARNING EWA14130 Handle the coolant temperature sensor with special care Never subject the coolant temperature sen sor to s...

Page 636: ...l care Never subject the throttle position sensor to strong shocks If the throttle position sensor is dropped replace it 2 Check Throttle position sensor maximum resistance Out of specification Replace the throttle position sensor a Connect the pocket tester Ω 1k to the throttle position sensor terminals as shown b Measure the throttle position sensor maxi mum resistance 3 Install Throttle positio...

Page 637: ...or TIP When installing the accelerator position sensor adjust its angle properly Refer to ADJUSTING THE ACCELERATOR POSITION SENSOR on page 7 11 EAS1MC1083 CHECKING THE THROTTLE SERVO MOTOR 1 Remove Air filter case Refer to GENERAL CHASSIS on page 4 1 2 Check Throttle valve operation Throttle valves do not fully close Replace the throttle bodies a Connect two C size batteries to the throttle servo...

Page 638: ... of white black and black blue Turn the crankshaft twice and check that the output voltage rises to approx imately 4 8 V once EAS1MC1028 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 Solenoid resistance 20 24 Ω Pocket...

Page 639: ...ch to ON d Measure the atmospheric pressure sensor output voltage EAS1MC1025 CHECKING THE AIR TEMPERATURE SENSOR 1 Remove Air temperature sensor from the windshield drive unit WARNING EWA1MC1020 Handle the air temperature sensor with special care Never subject the air temperature sensor to strong shocks If the air temperature sen sor is dropped replace it 2 Check Air temperature sensor resistance ...

Page 640: ...n Replace the fuel injec tor Air temperature sensor resis tance 5 4 6 6 kΩ at 0 C 32 0 F 290 390 Ω at 80 0 C 176 0 F Pocket tester 90890 03112 Analog pocket tester YU 03112 C Pocket tester 90890 03112 Analog pocket tester YU 03112 C 3 1 2 Result Neutral position Continuity Positive tester probe sky blue 1 Negative tester probe Switch terminal a 1st position Continuity Positive tester probe black y...

Page 641: ...ACCESSORY BOX SOLENOID 1 Check Accessory box solenoid resistance Out of specification Replace a Disconnect the accessory box solenoid cou pler from the wire harness b Connect the pocket tester Ω 10 to the ac cessory box solenoid terminals as shown Resistance 12 0 Ω Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe Injector terminal 1 Negative tester probe Injector ter...

Page 642: ...ce Out of specification Replace the grip warmer a Disconnect the grip warmer coupler from the wire harness b Connect the pocket tester Ω 1 to the grip warmer coupler as shown c Measure the grip warmer resistance Grip warmer resistance L 1 21 1 48 Ω Grip warmer resistance R 1 17 1 43 Ω Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe black 1 Negative tester probe blac...

Page 643: ... AND HIGH SPEED PERFORMANCE 9 2 FAULTY GEAR SHIFTING 9 2 SHIFT PEDAL DOES NOT MOVE 9 2 JUMPS OUT OF GEAR 9 2 FAULTY CLUTCH 9 2 OVERHEATING 9 3 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 SELF DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE 9 5 ...

Page 644: ...tle 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 Ignition coil s Cracked or broken ignition coil body Broken or sho...

Page 645: ...shift fork guide bar Transmission Seized transmission gear Foreign object between transmission gears Improperly assembled transmission EAS28550 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 EAS28570 FAULTY CLUTCH Clutch slips 1 Clutch Improp...

Page 646: ... hydraulic brake system Leaking brake fluid Faulty brake caliper kit Faulty 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 EAS28660 FAULTY FRONT FORK LEGS Leaking oil Bent damaged or rusty inner tube Cracked or damaged outer tube Improperly installed oil seal Damaged oil seal lip Incorrect oil level ...

Page 647: ...ght bulb life expired Tail brake light does not come on Wrong tail brake light bulb Too many electrical accessories Incorrect connection Burnt out tail brake light bulb Tail brake light bulb burnt out Wrong tail brake light bulb Faulty battery Incorrectly adjusted rear brake light switch Tail brake light bulb life expired Turn signal does not come on Faulty turn signal switch Faulty meter assembly...

Page 648: ... pressure sensor open or short circuit detected 8 53 24 O2 sensor no normal signals are received from the O2 sensor 8 55 30 Latch up detected 8 56 33 Cylinder 1 ignition coil open or short circuit detected in the primary lead of the cylinder 1 ignition coil 8 57 34 Cylinder 2 ignition coil open or short circuit detected in the primary lead of the cylinder 2 ignition coil 8 58 35 Cylinder 3 ignitio...

Page 649: ... signals are received from the front wheel sensor 8 79 70 Engine idling stop 90 Front brake light switch open or short circuit is detected 8 91 Rear brake light switch open or short circuit is detected 8 93 91 Cruise control setting switch RES open or short circuit is detected 8 96 Cruise control setting switch SET open or short circuit is detected 8 98 Fault code No Item Reference pages 89 Yamaha...

Page 650: ...e number in creases when the rear wheel is rotated The num ber is cumulative and does not reset each time the wheel is stopped 08 Lean angle sensor Lean angle sensor output voltage Remove the lean angle sensor and incline it more than 65 degrees Upright 0 4 1 4 Overturned 3 7 4 4 09 Fuel system voltage battery voltage Approximately 12 0 Set the start engine stop switch to and then compare the actu...

Page 651: ...tive and does not reset each time the wheel is stopped 20 Sidestand switch Extend and retract the sid estand with the transmis sion in gear Stand retracted ON Stand extended OFF 21 Gear position switch and clutch switch Operate the transmission clutch lever and side stand Transmission is in neu tral ON Transmission is in gear or the clutch lever re leased OFF Clutch lever is squeezed with the tran...

Page 652: ... control learning values 61 Malfunction history code display No history 00 History exists Fault codes 11 91 If more than one code number is detected the display alternates every two seconds to show all the detected code num bers When all code numbers are shown the display repeats the same pro cess 62 Malfunction history code erasure No history 00 History exists Displays the total num ber of malfun...

Page 653: ...ontrol 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 con trol learning data To erase the ISC idle speed control learning data set the start engine stop switch from to 3 times in 5 seconds 70 Control number 0 254 80 Cruise control setting switch RES...

Page 654: ... Procedure Diagnostic code No Item Actuation Procedure 30 Cylinder 1 ignition coil Actuates the cylinder 1 ignition coil five times at one second intervals Illuminates the engine trouble warning light Check that a spark is gen erated five times Connect an ignition checker 31 Cylinder 2 ignition coil Actuates the cylinder 2 ignition coil five times at one second intervals Illuminates the engine tro...

Page 655: ...d intervals Illuminates the engine trouble warning light Check that the air induc tion system solenoid is ac tuated five times by listening for the operating sound 50 Relay unit Actuates the relay unit five times at one second inter vals Illuminates the engine trouble warning light The engine trouble warn ing light is OFF when the relay is ON and the en gine trouble warning light is ON when the re...

Page 656: ...dlight assembly 63 Auxiliary light 64 Headlight 65 Front right turn signal light 66 Front left turn signal light 67 Accessory box solenoid 68 Auxiliary DC jack 69 Windshield drive unit 70 Windshield drive unit relay down 71 Windshield drive unit relay up 72 Meter assembly 73 Multi function meter 74 Immobilizer system indicator light 75 Neutral indicator light 76 Meter light 77 Tachometer 78 Oil le...

Page 657: ...en Blue G R Green Red G W Green White G Y Green Yellow Gy R Gray Red Gy W Gray White L B Blue Black L G Blue Green L R Blue Red L W Blue White L Y Blue Yellow Lg B Light green Black Lg L Light green Blue Lg R Light green Red O B Orange Black O G Orange Green O W Orange White P B Pink Black P W Pink White R B Red Black R G Red Green R L Red Blue R W Red White R Y Red Yellow Sb W Sky blue White W B ...

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Page 661: ...B L B B L B B W Gy B W Gy B B B B B B Gy B Br Y B Br G B Y P Sb Y W L W B R B Y B B B Gy Br Y B G Y G W B W Br G W G L R R B B R W W L W G W R B L B P R Y Y O W Y B W B W Y W L B W G L Br L L R A B C D A A B A C R Br L B L Y Ch Dg Y B G Y Y W G W B B Lg L Y W G B B L R B L R R B R B Y B G B Y B G B W B Y B Y B Y L R L R L R L B L B L B W L W L W L B R B R G W R G R G R G B W B W R W R W B W B W B ...

Page 662: ...y Gy Gy B B B B B B B B Gy B B Gy Gy B Gy B B B B B B B Dg Y B B B B B B B 1 2 3 4 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 63 64 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 101 102 103 104 105 10...

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