Yamaha FZ 25 2021 Supplementary Service Manual Download Page 69 | Manualshive

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2-32

SPEC

CABLE ROUTING

1

Taillight lead

2

Battery

3

Relay

4

Positive battery lead

5

MAQS (Modularized air quantity sensor)

6

Starter motor lead

7

Clutch cable

8

Rear brake light switch lead

9

Rear brake light switch

0

Rear wheel sensor

A

Negative battery lead

B

Fuse box

C

Rectifier regulator

D

Air filter assembly

E

ABS test coupler lead

F

Fender

G

Wire harness

H

Rear turn signal leads (LH & RH)

I

Coupler cover

J

License plate light lead

K

Frame

L

Service tool

M

Plastic band

N

Starter relay lead

O

ABS unit lead

P

Fuse box lead

È

Wire harness shall be passed from inside the
seat rail, also it should not touch the rectifier reg-
ulator.

É

Fix clamp to the end of bracket tank fitting of
frame.

Ê

The negative battery terminal lead shall be set to
the upside.

Ë

Pass the wire harness along with battery box
guide.

Ì

Starter relay shall be properly covered with wire
harness cover.

Í

Clamp shall be inserted in the hole of frame.

Î

Set large diameter open mouth of clamp to
inside and assemble bend tube to clutch cable.
Set small diameter of open mouth of the clamp
to downward and assemble non protector part of
starting motor lead.

Ï

Fit the band to the end of rear arm frame
bracket.

Ð

Rear brake light switch lead shall be clamped at
the yellow tape.

Ñ

Rear brake light switch lead shall be adjusted
without slack lower side of this band.

Ò

Wire harness, negative battery lead and battery
shall be fixed by battery band.

Ó

Clamp shall be inserted in the hole rear fender
(right) bracket.

Ô

Taillight lead shall be passed inside of fender
pin.

Õ

Layout in coupler cover can be in random order.

Ö

Set the tip of the clamp to the inner side, tip of
the band should not be cut.

×

Set the tip of the clamp to the front side, cut the
tip of the band, maximum length of band tip 5
mm.

Ø

Set the tip of the band to the backward.

Ù

License plate light lead & both rear turn signal
light leads (LH & RH) shall be passed through
hole of fender, leads shall not be pinched by
other parts.

B9X-F8197-E0.book Page 32 Thursday, July 16, 2020 2:28 PM

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Summary of Contents for FZ 25 2021

Page 1: ......

Page 2: ...ary service manual together with the following manual FZN250 2017 SERVICE MANUAL B97 F8197 E0 FZ 25 FZS 25 FZN250 A FZN250D A BS VI 2021 SUPPLEMENTARY SERVICE MANUAL 2021 by India Yamaha Motor Pvt Ltd First edition July 2020 All rights reserved Any reproduction or unauthorized use without the written permission of India Yamaha Motor Pvt Ltd is expressly prohibited B9X F8197 E0 book Page 1 Thursday...

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

Page 4: ...er print than the section title To help identify parts and clarify procedure steps there are exploded diagrams 3 at the start of each removal and disassembly section Numbers 4 are given in the order of the jobs in the exploded diagram A number indicates a dis assembly step Symbols 5 indicate parts to be lubricated or replaced Refer to SYMBOLS A job instruction chart 6 accompanies the exploded diag...

Page 5: ...h engine mounted Molybdenum disulfide oil Filling fluid Brake fluid Lubricant Wheel bearing grease Special tool Lithium soap based grease Tightening torque Molybdenum disulfide grease Wear limit clearance Silicone grease Engine speed Apply locking agent LOCTITE Electrical data Replace the part with a new one Engine oil M BF B LS T R M S LT E B9X F8197 E0 book Page 4 Thursday July 16 2020 2 28 PM ...

Page 6: ...TABLE OF CONTENTS GENERAL INFORMATION 1 SPECIFICATIONS 2 PERIODIC CHECKS AND ADJUSTMENTS 3 CHASSIS 4 ENGINE 5 ELECTRICAL SYSTEM 6 TROUBLESHOOTING 7 B9X F8197 E0 book Page 5 Thursday July 16 2020 2 28 PM ...

Page 7: ...B9X F8197 E0 book Page 6 Thursday July 16 2020 2 28 PM ...

Page 8: ...S 1 1 ABS COMPONENT FUNCTIONS 1 5 ABS OPERATION 1 10 ABS WARNING LIGHT AND OPERATION 1 13 INDICATOR LIGHTS AND WARNING LIGHT 1 15 MULTI FUNCTION DISPLAY 1 15 HANDLEBAR SWITCHES 1 18 SIDESTAND 1 18 SPECIAL TOOLS 1 19 B9X F8197 E0 book Page 1 Thursday July 16 2020 2 28 PM ...

Page 9: ...GEN INFO B9X F8197 E0 book Page 2 Thursday July 16 2020 2 28 PM ...

Page 10: ... to help maintain the basic maneuverability of the vehicle 3 The hydraulic unit assembly which is the main component of the ABS is centrally located on the vehicle to increase mass centralization ABS layout 1 ABS test coupler 2 ABS control unit fuse 3 ABS solenoid fuse 4 ABS motor fuse 5 ABS warning light 6 Front wheel sensor rotor 7 Front wheel sensor 8 Hydraulic unit assembly 9 Rear wheel sensor...

Page 11: ...ip ratio is the value that shows the rate of wheel slippage and is defined by the following formula Slip ratio Chassis speed Wheel speed Chassis speed 100 0 There is no slipping between the wheel and the road surface The chassis speed is equal to the wheel speed 100 The wheel speed is 0 but the chassis is moving i e wheel lock Brake force and vehicle stability When the brake pressure is increased ...

Page 12: ...s the hydraulic pressure in the brake caliper Once the ABS ECU determines that the tendency of the wheel to lock has diminished after the hydraulic pressure is reduced it increases the hydraulic pressure point B in the following figure The hydraulic pressure is initially increased quickly and then it is increased gradually ABS operation and vehicle control If the ABS starts operating there is a te...

Page 13: ... engine braking the ABS may not be able to prevent the wheel from locking WARNING EWA13870 The ABS controls only the tendency of the wheel to lock caused by applying the brakes The ABS cannot prevent wheel lock on slippery surfaces such as ice when it is caused by engine braking even if the ABS is operating Electronic ABS features The Yamaha ABS anti lock brake system has been developed with the m...

Page 14: ... installed in the wheel sensor generates pulses The pulse frequency which is proportional to the wheel speed is converted into a wave in the hall IC so that it can be output The ABS ECU calculates the wheel rotation speed by detecting the pulse frequency 1 2 3 4 4 7 7 5 6 6 8 9 9 10 11 12 13 14 1 Rear brake master cylinder 2 Hydraulic unit assembly 3 Front brake master cylinder 4 Inlet solenoid va...

Page 15: ...ight will go off when the vehicle is ridden or pushed at a speed of 10 km h 6 3 mi h or faster NOTICE ECA20950 If the rear wheel is raced with the vehicle on a maintenance stand the ABS warning light may flash or come on If this occurs turn the main switch to OFF then back to ON The ABS op eration is normal if the ABS warning light goes off after the vehicle starts off If the fault codes are not d...

Page 16: ...enerated in the inlet solenoid valve varies proportionally with the duty cycle control voltage that is supplied to it Since this voltage is continuously variable the solenoid valve moves smoothly and the hydraulic pressure is adjusted linearly 1 When the brakes are operated normally the inlet solenoid valve 1 is open and the outlet solenoid valve 2 is closed The brake line between the brake master...

Page 17: ... caliper side Buffer chamber The buffer chamber accumulates the brake fluid that is depressurized while the ABS is operating ABS ECU The ABS ECU is integrated with the hydraulic unit to achieve a compact and lightweight design As shown in the following block diagram the ABS ECU receives wheel sensor signals from the front and rear wheels and also receives signals from other monitor circuits 3 Brak...

Page 18: ...ion and troubleshooting 1 Battery 2 AC magneto 3 Rectifier regulator 4 Main fuse 5 ABS motor fuse 6 ABS solenoid fuse 7 Main switch 8 ABS control unit fuse 9 Rear brake light switch 10 Front brake light switch 11 Tail brake light 12 ABS test coupler 13 Hydraulic unit assembly 14 ABS ECU 15 ABS motor relay 16 Solenoid relay 17 Front brake outlet solenoid 18 Front brake inlet solenoid 19 Rear brake ...

Page 19: ...hen the ABS is not activated the inlet solenoid valve is open and the outlet solenoid valve is closed because a control signal has not been transmitted from the ABS ECU Therefore when the brake lever is squeezed the hydraulic pressure in the brake master cylinder increases and the brake fluid is sent to the brake caliper At this time the inlet and outlet check valves of the hydraulic pump are clos...

Page 20: ...s 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 Outlet solenoid valve 7 I...

Page 21: ...let solenoid valve opens the brake line from the brake master cylinder opens allowing the brake fluid to be sent to the brake caliper 1 Brake master cylinder 2 Brake light switch 3 ABS motor 4 Hydraulic pump 5 Buffer chamber 6 Outlet solenoid valve 7 Inlet solenoid valve 8 Brake caliper 9 Wheel sensor 10 ABS ECU 11 ABS warning light 12 Brake fluid pressure 13 Time B9X F8197 E0 book Page 12 Thursda...

Page 22: ...in switch to OFF then back to ON The ABS operation is normal if the ABS warning light goes off after the vehicle starts off The ABS operation is normal if the ABS warning light flashes Even if the ABS warning light remains on and does not go off or if it comes on after riding conven tional braking performance of the vehicle is maintained 1 Brake master cylinder 2 Brake light switch 3 ABS motor 4 H...

Page 23: ...he cornering perfor mance Depending on the road conditions the braking distance may be longer compared to that of vehicles not equipped with ABS Therefore ride at a safe speed and keep a safe distance be tween yourself and other vehicles The braking of the vehicle even in the worst case is principally executed when the vehicle is advancing straight ahead During a turn sudden braking is liable to c...

Page 24: ...rake system may not work correctly WARNING If the ABS warning light does not turn off af ter reaching 10 km h 6 mi h or if the warn ing light comes on while riding Use extra caution to avoid possible wheel lock during emergency braking Have a Yamaha dealer check the vehicle as soon as possible EAU79723 MULTI FUNCTION DISPLAY EWA12313 WARNING Be sure to stop the vehicle before making any setting ch...

Page 25: ...consump tion AVE_ _ _ Km L and clock CLOCK in the following order ODO TRIP 1 TRIP 2 Km L AVE_ _ _ Km L CLOCK ODO Odometer The odometer shows the total distance trav eled by the vehicle Tripmeters The tripmeter shows the total distance traveled since it was last reset To reset a tripmeter select it by pushing the SELECT button for one second TIP The odometer will lock at 999999 and cannot be reset ...

Page 26: ... start flashing 4 Use the SELECT button to set the hours 5 Push the SELECT button for two seconds and the minute digits will start flashing 6 Use the SELECT button to set the minutes 7 Push the SELECT button for two seconds to confirm settings and start the clock Self diagnosis mode This model is equipped with a self diagnosis function for various electrical circuits If a problem is detected in an...

Page 27: ...switch to run before starting the engine Set this switch to stop to stop the engine in case of an emergency such as in the event of an overturn or if the throttle is stuck EAU12713 Start switch Push this switch to crank the engine with the starter EAU15306 SIDESTAND The sidestand is located on the left side of the frame Raise the sidestand or lower it with your foot while holding the vehicle uprig...

Page 28: ...o remove the crankshaft from the crankcase Crankshaft installing tool with spacer YSST 266 YSST 267 90890 01284 90890 04081 Crankshaft installing Extension YSST 1266 These tools are used for installing the crankshaft TFF oil seal remover YSST 270 This tool is used to remove Oil seal New magneto holder YSST 601 B 90890 01701 90890 01481 This tool is used to hold the magneto Valve spring compressor ...

Page 29: ...rew Main switch steering lock YSST 611 A This tool is used to loosen or tighten the main switch steering lock Scraper YSST 612 This tool is used to scrap the sealant from crankcase surface Cup B YSST 620 B This tool is used to remove the bearings of rear wheel LH RH front wheel LH RH and main axle Cup C YSST 620 C This tool is used to remove the bearing of drive axle balancer shaft and cam shaft b...

Page 30: ...rew from magneto cover Upper and lower race installer YSST 626 Upper race installer attachment YSST 1226 This tool is used to install upper and lower races New magneto puller YSST 628 90890 04169 This tool is used to remove the AC Magneto rotor with the help of magneto holder Fixing tool bearing steering lower YSST 670 This tool is used to install under bracket bearing steering lower Tappet screw ...

Page 31: ... tubeless tires Tappet adjusting socket YSST 806 A 90890 04150 This tool is used to adjust valve clearance T handle YSST 813 This tool is used to hold the TFF cylinder 28 mm hexagon nut socket wrench when removing or installing the damper rod Rear shock absorber adjuster YSST 821 90890 01519 This tool is used to adjust the rear shock absorber Bearing puller YSST 824 This tool is used to remove the...

Page 32: ...e the wheel Disc brake face out YSST 890 This tool is used to check the disc runout Bush YSST 893 This tool is used as an attachment with crankcase separator YSST 265 Bearing punch with pilot driver YSST 951 This tool is used to install the bearings Rotor holder tool S 1113 90890 01235 This tool is used to hold the drive sprocket Funnel with long tail S 1119 This funnel is used to fill engine oil ...

Page 33: ...eter INS 003 90890 03189 This instrument is used to check the electrical system Fuel pressure gauge INS 006 90890 03181 90890 03176 90890 03186 This tool is used to measure the fuel pressure Ignition checker INS 007 90890 06754 This tool is used to check efficiency of ignition at spark plug Compression gauge INS 009 90890 03081 This instrument is used to measure engine compression Tool name Tool n...

Page 34: ... electrical fault in advance fuel injection system Yamaha diagnostic tool Ver 3 INS 019 90890 03264 This tool is used to diagnose electrical fault in advance fuel injection system Sub harness 3 90890 03266 This tool is used to connect FI YDT coupler to adapter interface BS VI models Yamaha bond No 1215B TB 1215B 90890 85505 This bond is used to seal two mating surfaces e g crankcase mating surface...

Page 35: ...1 26 GEN INFO B9X F8197 E0 book Page 26 Thursday July 16 2020 2 28 PM ...

Page 36: ... 2 2 MAINTENANCE SPECIFICATION CHASSIS 2 6 MAINTENANCE SPECIFICATION ELECTRICAL 2 8 TIGHTENING TORQUES 2 10 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 10 ENGINE TIGHTENING TORQUES 2 11 CHASSIS TIGHTENING TORQUES 2 18 CABLE ROUTING 2 19 B9X F8197 E0 book Page 1 Thursday July 16 2020 2 28 PM ...

Page 37: ...SPEC B9X F8197 E0 book Page 2 Thursday July 16 2020 2 28 PM ...

Page 38: ...20 mm 32 3 in FZN250D A Overall height 1075 mm 42 3 in FZN250 A 1105 mm 43 5 in FZN250D A Wheelbase 1360 mm 53 5 in Ground clearance 160 mm 6 30 in Minimum turning radius 2 5 m 8 20 ft Weight Curb weight 153 kg 337 lb FZN250 A 154 kg 340 lb FZN250D A Loading Maximum load 165 kg 364 lb Riding capacity 2 persons GENERAL SPECIFICATIONS B9X F8197 E0 book Page 1 Thursday July 16 2020 2 28 PM ...

Page 39: ...4 L 3 7 US gal 3 1 Imp gal Fuel reserve amount 2 1 L 0 55 US gal 0 46 Imp gal Engine oil Recommended brand YAMALUBE SAE viscosity grades 10W 40 Recommended engine oil API service SL type JASO standard MA Lubrication system Wet sump Engine oil quantity Oil change 1 35 L 1 43 US qt 1 19 Imp qt With oil filter removal 1 45 L 1 53 US qt 1 28 Imp qt Quantity disassembled 1 55 L 1 64 US qt 1 36 Imp qt O...

Page 40: ...h exhaust 0 90 1 20 mm 0 0354 0 0472 in Limit 1 7 mm 0 07 in Valve stem diameter intake 5 975 5 990 mm 0 2352 0 2358 in Limit 5 950 mm 0 2343 in Valve stem diameter exhaust 5 960 5 975 mm 0 2346 0 2352 in Limit 5 930 mm 0 2335 in Valve guide inside diameter intake 6 000 6 012 mm 0 2362 0 2367 in Valve guide inside diameter exhaust 6 000 6 012 mm 0 2362 0 2367 in Valve stem to valve guide clearance...

Page 41: ...g End gap limit 0 80 mm 0 0314 in Ring side clearance 0 020 0 055 mm 0 0008 0 0022 in Side clearance limit 0 115 mm 0 0045 in Crankshaft Crank assembly width 69 25 69 30 mm 2 726 2 728 in Runout limit 0 030 mm 0 0012 in Clutch Clutch type Wet multiple disc Clutch lever free play 10 0 15 0 mm 0 39 0 59 in Friction plate thickness 2 92 3 08 mm 0 115 0 121 in Wear limit 2 82 mm 0 111 in Plate quantit...

Page 42: ...atio 3 067 46 15 Final drive Chain Air filter Air filter element Oil coated paper element Fuel pump Pump type Electrical Maximum consumption amperage 1 7 A Fuel injector Resistance 12 2 Throttle body ID mark B971 01 Idling condition Engine idling speed 1300 1500 r min AI system Inactive O2 feedback control Active Exhaust gas sampling point Muffler tail pipe Engine temperature 115 125 C 239 257 F C...

Page 43: ...M C 52P Manufacturer model MRF NYLOGRIP ZAPPER FX1 Rear tire Type Tubeless Size 140 70 17M C 66S Manufacturer model MRF NYLOGRIP ZAPPER S2 Tire air pressure measured on cold tires Front 175 kPa 1 75 kgf cm2 25 psi 1 75 bar Rear 200 kPa 2 00 kgf cm2 29 psi 2 00 bar Front brake Type Hydraulic single disc brake Disc outside diameter thickness 282 0 4 0 mm 11 10 0 16 in Brake disc thickness limit 3 5 ...

Page 44: ... 9 25 in Limit 230 3 mm 9 07 in Inner tube bending limit 0 2 mm 0 01 in Quantity left 469 0 cm3 15 86 US oz 16 54 Imp oz Quantity right 469 0 cm3 15 86 US oz 16 54 Imp oz Level left 75 mm 3 0 in Level right 75 mm 3 0 in Recommended oil Yamaha Suspension Oil G10 Rear suspension Type Swingarm Spring Coil spring Shock absorber Hydraulic damper Spring preload Adjusting system Mechanical adjustable typ...

Page 45: ...1 4 V Output voltage over operating angle 3 7 4 4 V Charging system Charging system AC magneto Standard output 14 0 V 11 5 A at 5000 r min Stator coil resistance 0 456 0 684 Rectifier regulator Regulator type Single phase Regulated voltage DC 14 14 8 V Battery Model ETZ 7 Voltage capacity 12 V 6 0 Ah 10 HR Bulb wattage Headlight LED Brake tail light LED Front turn signal light 10 0 W Rear turn sig...

Page 46: ...tion sensor Crankshaft position sensor resistance 192 288 Intake air temperature sensor resistance 5700 6300 at 0 C 5700 6300 at 32 F Atmospheric pressure sensor output voltage 3 88 4 12 V at 101 3 kPa 3 88 4 12 V at 1 01 kgf cm2 3 88 4 12 V at 14 7 psi Engine temperature sensor resistance 28500 31500 at 0 C 28500 31500 at 32 F 1819 2223 at 75 C 1819 2223 at 167 F Fuse s Main fuse 15 0 A ABS contr...

Page 47: ...emblies 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 N m kgf m lb ft 10 mm 6 mm 6 0 6 4 4 12 mm 8 mm 15 1 5 11 14 mm 10 mm 30 3 0...

Page 48: ...0 N m 6 0 kgf m 44 lb ft Camshaft sprocket cover bolt M6 1 10 N m 1 0 kgf m 7 4 lb ft Timing chain tensioner plug M6 1 8 N m 0 8 kgf m 5 9 lb ft Timing chain tensioner bolt M6 2 10 N m 1 0 kgf m 7 4 lb ft Apply Yamaha bond No 1215B to screw thread Oil pump assembly bolt M6 3 7 N m 0 7 kgf m 5 2 lb ft Engine oil drain plug M12 1 20 N m 2 0 kgf m 15 lb ft Oil filter element cover bolt M6 3 10 N m 1 ...

Page 49: ...rew M6 1 12 N m 1 2 kgf m 8 9 lb ft Stopper lever bolt M6 1 10 N m 1 0 kgf m 7 4 lb ft Push lever assembly bolt M8 1 12 N m 1 2 kgf m 8 9 lb ft Oil pipe union bolt On Crank case M10 1 20 N m 2 0 kgf m 15 lb ft Oil pipe union bolt On Cylinder M8 1 17 N m 1 7 kgf m 13 lb ft Oil cooler mounting bolt M6 2 10 N m 1 0 kgf m 7 4 lb ft Oil cooler hoses bolts Oil cooler side M6 4 7 N m 0 7 kgf m 5 2 lb ft ...

Page 50: ...tening sequence Clutch cover tightening sequence 2 2 3 3 1 1 5 5 6 6 4 4 5 5 11 2 11 2 6 6 10 10 8 8 7 1 7 1 9 9 5 3 4 4 1 9 1 9 8 8 7 7 6 6 5 5 4 3 3 4 2 15 2 15 14 14 15 13 12 12 11 11 10 10 TIGHTENING TORQUES B9X F8197 E0 book Page 13 Thursday July 16 2020 2 28 PM ...

Page 51: ...2 14 SPEC Crankcase tightening sequence 6 6 5 5 8 8 9 9 10 10 11 11 12 12 13 13 14 2 14 2 3 3 4 4 1 7 1 7 TIGHTENING TORQUES B9X F8197 E0 book Page 14 Thursday July 16 2020 2 28 PM ...

Page 52: ...ft Brush guard bolt upper and lower for B0Y1 M6 4 9 N m 0 9 kgf m 6 6 lb ft Clutch lever nut M6 1 6 N m 0 6 kgf m 4 4 lb ft Front fender bolt hexagon bolt M6 2 7 N m 0 7 kgf m 5 2 lb ft Front fender bolt button head bolt M6 2 6 N m 0 6 kgf m 4 4 lb ft Main switch steering lock screw M6 2 7 N m 0 7 kgf m 5 2 lb ft Meter assembly screw 3 3 N m 0 3 kgf m 2 2 lb ft License plate bracket and windshield...

Page 53: ... kgf m 0 5 lb ft Rear reflector and rear fender cover nut M5 1 1 5 N m 0 15 kgf m 1 1 lb ft Seat lock and frame bolt M6 2 7 N m 0 7 kgf m 5 2 lb ft Battery box and frame bolt M6 2 8 N m 0 8 kgf m 5 9 lb ft Front wheel axle nut M14 1 38 N m 3 8 kgf m 28 lb ft Rear wheel axle nut M14 1 59 N m 5 9 kgf m 44 lb ft Drive chain puller locknut M8 2 14 N m 1 4 kgf m 10 lb ft Rear wheel sprocket nut M8 6 43...

Page 54: ... 0 8 kgf m 5 9 lb ft Rear brake switch stay bolt M6 1 10 N m 1 0 kgf m 7 4 lb ft Front brake lever nut M7 1 6 N m 0 6 kgf m 4 4 lb ft Rear brake disc bolt M8 3 23 N m 2 3 kgf m 17 lb ft Rear brake caliper sliding pin bolt small 1 12 N m 1 2 kgf m 8 7 lb ft Rear brake pad pin bolt 2 17 N m 1 7 kgf m 13 lb ft Rear brake caliper sliding pin bolt long 1 22 N m 2 2 kgf m 16 lb ft Rear brake caliper ble...

Page 55: ...nit to brake caliper M10 2 29 N m 2 9 kgf m 21 lb ft Hydraulic unit bracket bolt M6 3 7 N m 0 7 kgf m 5 2 lb ft Rear brake hose holder bracket and rear arm bolt RH side M6 2 8 N m 0 8 kgf m 5 9 lb ft Rear brake hose holder bolt Hydraulic unit to caliper M6 1 8 N m 0 8 kgf m 5 9 lb ft Rear brake hose bracket and rear arm comp bolt RH rear arm comp pivot shaft side M6 1 8 N m 0 8 kgf m 5 9 lb ft Rea...

Page 56: ...LE ROUTING Chassis Front view M L K J 17 I H 18 6 C B 3 4 5 7 8 F 11 7 8 E 9 10 11 12 2 1 A 13 D 6 14 15 16 G F 11 7 8 11 12 20 21 19 10 20 12 11 F F 10 19 8 20 21 7 20 8 7 B9X F8197 E0 book Page 19 Thursday July 16 2020 2 28 PM ...

Page 57: ...andlebar Ê Keep the auxiliary light leads outside as shown and then assemble the headlight assembly Ë Insert the clamp in the hole of headlight stay Ì Pass the wire harness through guide of headlight stay Í Layout of leads in band shall be in random order Î Pass the headlight upper cover to guide of headlight assembly Ï Keep the headlight lead outside as shown and then assemble the headlight assem...

Page 58: ...2 21 SPEC CABLE ROUTING CABLE ROUTING Meter assembly 1 D 9 8 7 6 5 4 3 1 10 E F A B 2 1 C 1 H G B9X F8197 E0 book Page 21 Thursday July 16 2020 2 28 PM ...

Page 59: ...er cover É Insert the hang shape into hole of upper cover left right Ê Edge of rubber cover shall be at outside edge of upper cover Ë Layout of leads under rubber cover shall be in random order Ì Insert part of rubber cover Í Insert part of rubber cover shall be inserted into hole of rubber cover position of insert part of rubber cover shall be towards rear side left right Î Slit shall be on right...

Page 60: ...2 23 SPEC CABLE ROUTING CABLE ROUTING Handlebar Top view 1 2 3 A B 5 6 7 4 C 13 12 11 9 10 8 8 5 2 4 6 D 8 E 2 14 14 B9X F8197 E0 book Page 23 Thursday July 16 2020 2 28 PM ...

Page 61: ...rn C Throttle cable Pull D Guide stay È Right handlebar switch lead shall not be pinched between meter assembly and headlight stay É Pass the leads to upper side of clutch cable Ê Pass the throttle cables both to guide of stay Ë Pass the clutch switch lead left handlebar switch lead main switch lead to intended shape of headlight stay in random order Ì Pass the right handlebar switch lead to inten...

Page 62: ...nder È Pass the wire harness OBD from lower side of turn signal relay É Pass the wire harness OBD and turn signal relay lead from upper side of couplers cover Ê Ensure PVC tube should properly cover all naked wires Ë Set the OBD coupler onto the knob and push till it get fixed properly Ì Ensure couplers cover shall not pinched between fender and seat B9X F8197 E0 book Page 25 Thursday July 16 2020...

Page 63: ...2 26 SPEC CABLE ROUTING CABLE ROUTING Sidestand switch Left view G 2 4 2 H I J 2 E C 2 D B A 3 1 5 F 5 5 B9X F8197 E0 book Page 26 Thursday July 16 2020 2 28 PM ...

Page 64: ...side Ì After clamp sidestand switch lead shall be adjusted without slack Í Layout of leads in clamp shall be in random order Î Set the tip of the clamp to the inner side tip of the clamp shall not be cut Ï Set the tip of the clamp to the upper side tip of the clamp shall not be cut clamp threading direction is not required Ð Pass the clamp from the lower side of bracket Ñ Set the tip of the clamp ...

Page 65: ...on system pipe 2 Air induction system solenoid 3 Air induction system hose Air induction system solenoid to air filter case 4 Main switch lead 5 Main switch steering lock È Insert the wire harness clamp in the hole of bracket É Pass the switch lead from the right side of the main switch steering lock B9X F8197 E0 book Page 28 Thursday July 16 2020 2 28 PM ...

Page 66: ...filter case 5 Air induction system pipe 6 Air induction system hose Air induction system solenoid to air induction system pipe È Knob of the clip shall be upper side of the vehi cle É Knob of the clip shall be lower side of the vehi cle Ê Mark of white paint shall be towards right side of the vehicle Ë Knob of the clip shall be right side of the vehicle B9X F8197 E0 book Page 29 Thursday July 16 2...

Page 67: ...tion system solenoid 3 Bracket È Fix the air induction system solenoid assembly onto the bracket knobs and push till it get fixed properly É Ensure mark of white paint shall be upper side of the vehicle Ê Insert the hose on up to the mark B9X F8197 E0 book Page 30 Thursday July 16 2020 2 28 PM ...

Page 68: ...LE ROUTING Chassis Rear right view L B C D F E G H I J K A R 2 3 4 6 8 9 10 11 12 13 14 1 N 15 16 17 18 19 20 17 1 21 O 22 21 23 17 7 21 24 25 23 P Q 23 26 8 Q 26 23 8 4 5 M B9X F8197 E0 book Page 31 Thursday July 16 2020 2 28 PM ...

Page 69: ...in the hole of frame Î Set large diameter open mouth of clamp to inside and assemble bend tube to clutch cable Set small diameter of open mouth of the clamp to downward and assemble non protector part of starting motor lead Ï Fit the band to the end of rear arm frame bracket Ð Rear brake light switch lead shall be clamped at the yellow tape Ñ Rear brake light switch lead shall be adjusted without ...

Page 70: ...p view CABLE ROUTING Engine Front left view 90 10 O 18 18 19 Q 16 T 2 S 3 10 16 3 L P 10 F E D C 8 H 5 3 I L 10 A 1 K J 2 3 4 B 5 6 7 G 9 R 15 14 M 16 14 N 9 O 17 11 12 13 P 17 3 U V B9X F8197 E0 book Page 33 Thursday July 16 2020 2 28 PM ...

Page 71: ... end of horn bracket frame using plastic band and lead shall be adjusted from upper side of the band without slack Ð Spark plug lead shall be screwed and tighten with spark plug cap Pull off strength of spark plug lead shall be minimum 30 N Ñ Brake hose O2 sensor lead front wheel sensor lead and horn lead shall be properly arranged with frame from outside of the vehicle in mention order Ò Coupler ...

Page 72: ...UTING CABLE ROUTING ABS Hydraulic unit 1 Battery box 2 ABS hydraulic unit 3 ABS hydraulic unit lead 4 Air filter assembly È Clamp shall be inserted in the hole of frame B9X F8197 E0 book Page 35 Thursday July 16 2020 2 28 PM ...

Page 73: ...2 36 SPEC CABLE ROUTING CABLE ROUTING ABS Rear brake B9X F8197 E0 book Page 36 Thursday July 16 2020 2 28 PM ...

Page 74: ...the brake light switch stay Ë Wheel sensor shall be clamped at white tape Ì Clamp shall be inserted in the hole of battery box Í Set the tip of the clamp as shown cut the tip of the band maximum length of band tip 5mm Î Adjust the brake light switch until brake light turn on before brake starts to be working Ï Install the spring hook into the brake pedal spring stay as shown Ð Pin shall be inserte...

Page 75: ...2 38 SPEC CABLE ROUTING CABLE ROUTING ABS front brake Right view D B C E A 4 10 12 10 13 3 10 11 7 6 5 2 9 8 9 1 9 F 12 14 15 B9X F8197 E0 book Page 38 Thursday July 16 2020 2 28 PM ...

Page 76: ...ion bolt È Clamp shall be attached on paint mark of front brake hose É Pin of front brake hose ABS hydraulic unit to brake caliper shall touch the brake hose bracket Ê End fitting of front brake hose ABS hydraulic unit to master cylinder shall touch brake hose bracket Ë Band upper edge shall fit to lower edge of paint mark of front brake hose ABS hydraulic unit to master cylinder both direction of...

Page 77: ...e master cylinder 2 Front brake hose bracket 3 Frame 4 Engine stay 5 Brake hose bracket 6 Front brake hose ABS hydraulic unit to front brake caliper 7 Clamp 8 Front wheel speed sensor lead È Clamp shall be inserted in the hole of engine stay É Both front brake hoses should properly set to clamp B9X F8197 E0 book Page 40 Thursday July 16 2020 2 28 PM ...

Page 78: ...ear brake master cyl inder shall touch to end fitting of rear brake hose to rear brake caliper É Pin of rear brake hose to rear brake caliper shall touch to end fitting of rear brake hose to rear brake master cylinder Ê Pin of front brake hose to front brake master cylinder shall touch to end fitting of front brake hose to front brake caliper Ë Pin of front brake hose to front brake caliper shall ...

Page 79: ...HART FOR THE EMISSION CONTROL SYSTEM 3 1 GENERAL MAINTENANCE AND LUBRICATION CHART 3 1 ENGINE 3 4 ADJUSTING THE VALVE CLEARANCE 3 4 ELECTRICAL SYSTEM 3 6 ADJUSTING THE HEADLIGHT BEAM 3 6 CHASSIS 3 7 BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS 3 7 B9X F8197 E0 book Page 0 Thursday July 16 2020 2 28 PM ...

Page 80: ... and regap Replace Every 15000 km 9000 mi 4 Valves Check valve clearance Adjust if necessary 5 Fuel injection Adjust engine idling speed 6 Exhaust sys tem Check for leakage Tighten if necessary Replace gasket s if neces sary Every 10000 km 6000 mi 7 Evaporative emission con trol system Check control system for dam age Replace if necessary 8 Air induction system Check the air induction sys tem sole...

Page 81: ...k chain slack alignment and condition Adjust and lubricate chain with a special O ring chain lu bricant thoroughly Every 500 km 300 mi and after washing the motorcycle rid ing in the rain or riding in wet areas 15 Steering bearings Check bearing play and steer ing for roughness Lubricate with lithium soap based grease Every 10000 km 6200 mi 16 Chassis fas teners Make sure that all nuts bolts and s...

Page 82: ...y four years and if cracked or damaged 23 Front fork Check operation and for oil leakage Repair if necessary Replace oil Every 10000 km 6000 mi 24 Shock ab sorber as sembly Check operation and shock absorber for oil leakage 25 Engine oil Change Check vehicle for oil leakage 26 Engine oil fil ter element Replace 27 Engine oil strainer Clean Every 15000 km 9000 mi 28 Front and rear brake switch es C...

Page 83: ...L COOLER on page 5 48 of base service manual B97 F8197 E0 Cylinder head valve covers along with O rings Refer to CYLINDER HEAD on page 5 6 of base service manual B97 F8197 E0 4 Remove Timing mark accessing screw 1 Crankshaft end accessing screw 2 5 Measure Valve clearance Out of specification Adjust a Turn the crankshaft counterclockwise b Align the I mark a on the AC Magneto rotor with the statio...

Page 84: ...the valve clearance adjustment steps until the specified clear ance is obtained 7 Install Crankshaft end accessing screw along with the O ring Timing mark accessing screw along with the O ring 8 Install Cylinder head valve cover along with O ring Oil cooler Refer to OIL COOLER on page 5 49 of base service manual B97 F8197 E0 Fuel tank breather hose Canister hose Spark plug cap 9 Install Fuel tank ...

Page 85: ...e help of philip screwdriver 1 in direction a or b from right side of headlight TIP o Valve clearance adjustment should be made on a cold engine at room temperature Height at low beam line a 67 6 cm Height at low beam line b 47 6 cm Direction a Headlight beam is raised Direction b Headlight beam is lowered a b At Low Beam 67 6 cm height 10 meter 75 kg Single rider Weight a b B9X F8197 E0 book Page...

Page 86: ...ary to let the brake fluid settle for a few hours Repeat the bleeding procedure when the tiny bubbles in the hose have disappeared 1 Bleed ABS a Fill the brake fluid reservoir to the proper level with the specified brake fluid b Install the diaphragm brake master cylin der reservoir or brake fluid reservoir c Connect a clear plastic hose 1 tightly to the bleed screw 2 d Place the other end of the ...

Page 87: ...evel with the specified brake fluid l Tighten the bleed screw to specification m Fill the brake master cylinder or brake fluid reservoir to the proper level with the spec ified brake fluid WARNING EWA13110 After bleeding the hydraulic brake system check the brake operation T R Front brake caliper bleed screw 14 N m 1 4 kgf m 10 lb ft Rear brake caliper bleed screw 6 N m 0 6 kgf m 4 4 lb ft Specifi...

Page 88: ...G THE REAR WHEEL 4 13 FRONT BRAKE 4 16 REMOVING THE FRONT BRAKE CALIPER 4 17 INSTALLING THE FRONT BRAKE CALIPER 4 17 REAR BRAKE 4 19 REMOVING THE REAR BRAKE CALIPER 4 20 INSTALLING THE REAR BRAKE CALIPER 4 20 ABS ANTI LOCK BRAKE SYSTEM 4 22 REMOVING THE HYDRAULIC UNIT ASSEMBLY 4 24 CHECKING THE HYDRAULIC UNIT ASSEMBLY 4 24 INSTALLING THE HYDRAULIC UNIT ASSEMBLY 4 25 HYDRAULIC UNIT OPERATION TESTS ...

Page 89: ...CHAS B9X F8197 E0 book Page 1 Thursday July 16 2020 2 28 PM ...

Page 90: ... cover 1 5 Left seat handle 1 6 Right seat handle 1 7 Tail cover 1 8 Left rear side cover 1 9 Right rear side cover 1 10 Mud protector 1 11 Left side panel assembly 1 12 Right side panel assembly 1 13 Under cowling assembly 1 For installation reverse the removal proce dure 2 2 1 4 13 21 2 1 15 5 5 3 7 GENERAL CHASSIS B9X F8197 E0 book Page 1 Thursday July 16 2020 2 28 PM ...

Page 91: ...5 Auxiliary light coupler 1 Disconnect 6 Headlight assembly bolt lower 2 7 Head light assembly 1 8 Meter coupler 1 Disconnect 9 Meter assembly 1 TIP Disconnect wire harness holders from guide stay Disconnect all leads couplers and con nectors Refer cable routing 10 Meter pad 1 11 Guide stay 1 12 Turn signal light LH RH 1 1 12 12 9 8 5 10 11 7 6 6 3 4 2 1 GENERAL CHASSIS B9X F8197 E0 book Page 2 Th...

Page 92: ...s 13 Headlight stay with indicators 1 14 lgnition switch connectors 1 15 Main switch steering lock 1 For installation reverse the removal proce dure Removing and installing the main switch steering lock screw by using special tool Main switch steering lock T 30 YSST 611A 13 14 15 B9X F8197 E0 book Page 3 Thursday July 16 2020 2 28 PM ...

Page 93: ...oving the windshield for B0Y1 Order Job Parts to remove Q ty Remarks 1 Licence plate stay 1 2 Windshield 1 3 Meter cover 1 For installation reverse the removal proce dure 2 3 B9X F8197 E0 book Page 4 Thursday July 16 2020 2 28 PM ...

Page 94: ...1 Rear view mirror assy 1 Disconnect 2 End grip 1 3 Brush guard assembly 1 4 Brush guard bracket bolts 2 Loosen 5 Brush guard bracket 1 For installation reverse the removal proce dure 9 N m 0 9 kgf m 6 6 lb ft 9 N m 0 9 kgf m 6 6 lb ft 2 3 4 4 5 B9X F8197 E0 book Page 5 Thursday July 16 2020 2 28 PM ...

Page 95: ...stem solenoid to air filter case 1 Disconnect 3 Air filter case Throttle body joint clamp screw 1 Loosen 4 Rectifier regulator unit 1 5 Air filter case cover 1 6 Air filter seal 1 7 Air filter element 1 8 Air filter case 1 9 Air filter case Throttle body joint clamp 1 10 Resonator 1 11 Air filter hose 1 12 Duct 1 For installation reverse the removal proce dure 12 A Engine breather pipe B Air induc...

Page 96: ...ont brake caliper 1 4 Front wheel sensor 1 5 Front wheel axle nut 1 6 Washer 1 7 Front wheel axle 1 8 Front wheel 1 9 Collar 2 10 Front brake disc 1 11 Front wheel sensor rotor 1 Use Torx bit T 25 for wheel sensor rotor bolt For installation reverse the removal proce dure 38 N m 3 8 kgf m 28 lb ft FRONT WHEEL B9X F8197 E0 book Page 7 Thursday July 16 2020 2 28 PM ...

Page 97: ...EL SENSOR AND SENSOR ROTOR ECA21070 NOTICE Handle the ABS components with care since they have been accurately adjusted Keep them away from dirt and do not sub ject them to shocks The wheel sensor cannot be disassembled Do not attempt to disassemble it If faulty replace with a new one Keep any type of magnets including mag netic pick up tools magnetic screwdrivers etc away from the wheel sensor or...

Page 98: ...g outward Use Torx bit T 25 for opening tightening wheel sensor rotor bolt EAS30932 INSTALLING THE FRONT WHEEL 1 Lubricate Oil seal lips 2 Install Collars Front wheel Front wheel axle Front wheel axle nut TIP Install the tire and wheel with the mark 1 pointing in the direction of wheel rotation Align the DOT mark 2 with the tire air valve in stallation point Apply lithium soap based grease to the ...

Page 99: ...ions war page caused by overtorque wrong installa tion direction rotor decentering LOCTITE on the mounting surface of the rotor defor mation caused by an impact during service and caught foreign materials If there is any defective part repair or replace the defective part TIP Measure the distance between the front wheel sensor rotor and front wheel sensor in several places in one rotation of the f...

Page 100: ... B97 F8197 E0 on page 4 1 Rear wheel speed sensor 1 Axle nut 1 2 Washer 1 3 Drive chain adjusting locknut 2 Loosen 4 Drive chain adjusting nut 2 Loosen 5 Rear wheel axle 1 6 Washer 1 7 Rear wheel 1 8 Collar sprocket axle 1 9 Collar wheel 1 10 Drive chain puller 2 For installation reverse the removal proce dure B9X F8197 E0 book Page 11 Thursday July 16 2020 2 28 PM ...

Page 101: ... drive hub 1 3 Rear wheel drive hub damper 6 4 Rear brake disc 1 5 Rear wheel sensor rotor 1 6 Oil seal 1 7 Bearing 1 8 Spacer 1 9 Oil seal 1 10 Bearing 1 11 Collar 1 For installation reverse the removal proce dure 43 N m 4 3 kgf m 32 lb ft 8 0 N m 0 8 kgf m 5 9 lb ft 23 N m 2 3 kgf m 17 lb ft B9X F8197 E0 book Page 12 Thursday July 16 2020 2 28 PM ...

Page 102: ...r wheel sprocket MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR NOTICE Handle the ABS components with care since they have been accurately adjusted Keep them away from dirt and do not sub ject them to shocks The wheel sensor cannot be disassembled Do not attempt to disassemble it If faulty replace with a new one Keep any type of magnets including mag netic pick up tools magnetic screwdriver...

Page 103: ...n the projection a in the swingarm with the slot b of the brake caliper bracket Apply lithium soap based grease to the con tact surface and threads of the rear wheel axle nut 5 Lubricate Rear brake caliper bolt 6 Install Rear brake caliper 7 Adjust Drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK in base service manual B97 F8197 E0 on page 3 17 8 Tighten Rear wheel axle nut Rear brake ca...

Page 104: ...que wrong installa tion direction rotor decentering LOCTITE on the mounting surface of the rotor defor mation caused by an impact during service and caught foreign materials If there is any defective part repair or replace the defective part TIP Measure the distance between the rear wheel sensor rotor and rear wheel sensor in several places in one rotation of the rear wheel Do not turn the rear wh...

Page 105: ... Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS on page 3 7 1 Front brake hose union bolt brake caliper side 1 2 Brake hose gasket 2 3 Front brake hose brake hose joint to brake cali per 1 4 Front brake caliper bolt 2 5 Sensor lead holder 1 6 Front brake caliper 1 B9X F8197 E0 book Page 16 Thursday July 16 2020 2 28 PM ...

Page 106: ...older Brake hose gaskets 2 Front brake hose brake hose joint to brake caliper 3 Brake hose union bolt 4 EWA13531 WARNING Proper brake hose routing is essential to in sure safe vehicle operation ECA18220 NOTICE When installing the brake hose 3 onto the brake caliper 1 make sure the brake hose a passes between the projection b on the brake caliper Refer to REPLACING THE FRONT BRAKE PADS in base serv...

Page 107: ... plastic parts Therefore always clean up any spilt brake fluid immediately 3 Bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS on page 3 7 4 Check Brake fluid level Below the minimum level mark a Add the specified brake fluid to the proper level 5 Check Brake lever operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS on page 3 7...

Page 108: ...R WHEEL on page 4 11 Brake fluid Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS on page 3 7 Rear wheel Refer to REAR WHEEL on page 4 11 1 Rear brake hose union bolt 1 2 Brake hose gasket 2 3 Rear brake hose 1 4 Rear brake caliper 1 For installation reverse the removal proce dure B9X F8197 E0 book Page 19 Thursday July 16 2020 2 28 PM ...

Page 109: ... TIP Put the end of the brake hose into a container and pump out the brake fluid carefully EAS30190 INSTALLING THE REAR BRAKE CALIPER 1 Lubricate Rear brake caliper bolt 2 Install Brake pad shims onto the brake pads Brake pads Rear brake caliper 1 along with rear wheel Rear wheel sensor Refer to REPLACING THE REAR BRAKE PADS in base service manual B97 F8197 E0 on page 4 35 Brake hose gaskets 2 Rea...

Page 110: ...r the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock ECA13540 NOTICE 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 7 5 Check Brake fluid level Below the minimum level mark a Add ...

Page 111: ...e manual B97 F8197 E0 on page 4 1 Rear left side cover Refer to GENERAL CHASSIS in base ser vice manual B97 F8197 E0 on page 4 1 Side panel assembly LH RH Fuel tank Refer to GENERAL CHASSIS in base ser vice manual B97 F8197 E0 on page 4 1 Air filter assembly Refer to GENERAL CHASSIS in base ser vice manual B97 F8197 E0 on page 4 3 Battery and Battery box Refer to CHECKING AND CHARGING THE BATTERY ...

Page 112: ... Rear brake hose hydraulic unit to rear brake master cylinder 1 6 Front brake hose hydraulic unit to front brake master cylinder 1 7 Front brake hose hydraulic unit to front brake caliper 1 8 Rubber band 1 9 Front brake hose to brake caliper 1 10 Front brake hose to brake master cylinder 1 11 Brake hose holder 1 12 Hydraulic unit assembly 1 13 Hydraulic unit bracket 1 14 Hydraulic unit 1 B9X F8197...

Page 113: ...en removed be sure to tighten them to the specified torque and bleed the brake system 1 Disconnect ABS ECU coupler 1 TIP Push the lock a and pull the lever b of the ABS ECU coupler in the direction of the arrow shown and then dis connect the coupler 2 Remove Brake hoses TIP Do not operate the brake lever and brake pedal while removing the brake hoses ECA14530 NOTICE When removing the brake hoses c...

Page 114: ...bolt for the brake hose 2 c Position the front brake hose hydraulic unit to front brake master cylinder 1 so that pin shall contact b of front brake hose hydraulic unit to front brake caliper 2 and then temporarily tighten the union bolt for the brake hose 1 d Position the rear brake hose hydraulic unit to rear brake master cylinder 3 so that pin shall contact d of front brake hose hydraulic unit ...

Page 115: ...n page 6 102 9 Perform a trial run Refer to CHECKING THE ABS WARNING LIGHT on page 4 30 EAS30930 HYDRAULIC UNIT OPERATION TESTS The reaction force pulsating action generated in the brake lever and brake pedal when the ABS is activated can be tested when the vehicle is stopped The hydraulic unit operation can be tested using the following two methods Brake line routing confirmation this test checks...

Page 116: ...simul taneously TIP The hydraulic unit operates 1 second after the brake lever and brake pedal are operated si multaneously and continues for approximately 5 seconds The operation of the hydraulic unit can be con firmed using the indicator On The hydraulic unit is operating Flashing The conditions for operating the hy draulic unit have not been met Off The brake lever and brake pedal are not being...

Page 117: ...over TIP For the ABS reaction force confirmation use the diagnosis mode of the Yamaha diagnostic tool For more information refer to the opera tion manual of the Yamaha diagnostic tool Before performing the ABS reaction force con firmation make sure that no malfunctions have been detected in the ABS ECU and that the wheels are not rotating 1 Stand the vehicle on a level surface by using maintenance...

Page 118: ...on consists of quick pulses Be sure to continue operating the brake lever and brake pedal even after the pulsating action has stopped ON and OFF on the tool screen indicate when the brakes are being applied and re leased respectively 10 After the pulsating action has stopped in the brake lever it is generated in the brake pedal 1 and continues for a few seconds TIP The reaction force pulsating act...

Page 119: ...the main switch to OFF 13 Remove the Yamaha diagnostic tool from the Yamaha diagnostic tool coupler and then in stall the protective cap 14 Turn the main switch to ON 15 Set the start engine stop switch to 16 Check for brake fluid leakage around the hy draulic unit Brake fluid leakage Replace the hydraulic unit brake hoses and related parts as a set 17 If the operation of the hydraulic unit is nor...

Page 120: ...ENG CHAPTER 5 ENGINE ENGINE REMOVAL 5 1 CRANKCASE 5 5 B9X F8197 E0 book Page 0 Thursday July 16 2020 2 28 PM ...

Page 121: ...ENG B9X F8197 E0 book Page 1 Thursday July 16 2020 2 28 PM ...

Page 122: ...ve Now tighten remaining bolts as per specified torque value Removing the muffler Order Job Parts to remove Q ty Remarks Under cowling Refer to GENERAL CHASSIS on page 4 1 1 O2 sensor coupler 1 Disconnect 2 Muffler 1 3 Exhaust pipe gasket 1 For installation reverse the removal proce dure ENGINE REMOVAL B9X F8197 E0 book Page 1 Thursday July 16 2020 2 28 PM ...

Page 123: ...anual B97 F8197 E0 on page 7 62 Engine oil Drain Refer to CHANGING THE ENGINE OIL in base manual B97 F8197 E0 on page 3 9 Throttle body clamp 1 Loosen 1 Cylinder head breather hose 1 Disconnect 2 Air induction system hose Air induction system solenoid to air induction system pipe 1 Disconnect 3 Engine ground cable clutch cable holder 1 4 Clutch cable 1 Disconnect 5 Oil cooler pipe collar with O ri...

Page 124: ...er 1 1 Disconnect 10 Sidestand switch coupler 1 Disconnect 11 Sidestand switch 1 12 Shift arm 1 13 Drive chain sprocket cover 1 14 Drive chain 1 15 Horn leads 2 Disconnect 16 Starting motor lead 1 Disconnect For installation reverse the removal proce dure 6 5 3 7 N m 0 37 kgf m 2 7 lb ft 10 B9X F8197 E0 book Page 3 Thursday July 16 2020 2 28 PM ...

Page 125: ...lower side 1 1 4 Engine mounting bolt nut rear upper side 1 1 5 Engine mounting bolt nut upper side 1 1 6 Engine 1 7 Air induction system pipe 1 For installation reverse the removal proce dure 43 N m 4 3 kgf m 32 lb ft 43 N m 4 3 kgf m 32 lb ft 43 N m 4 3 kgf m 32 lb ft 43 N m 4 3 kgf m 32 lb ft 10 1 0 7 4 N m kgf m lb ft 13 1 3 9 6 N m kgf m lb ft 27 2 7 20 N m kgf m lb ft 1st 2nd 7 B9X F8197 E0 ...

Page 126: ... base manual B97 F8197 E0 on page 5 38 Oil pump assembly Refer to OIL PUMP in base manual B97 F8197 E0 on page 5 46 Shift shaft Refer to SHIFT SHAFT in base manual B97 F8197 E0 on page 5 50 Starter motor Refer to ELECTRIC STARTER in base manual B97 F8197 E0 on page 5 34 Balancer gears Refer to BALANCER GEAR in base manu al B97 F8197 E0 on page 5 52 Magneto rotor Refer to MAGNETO AND STARTER CLUTCH...

Page 127: ...Timing chain guide intake side 1 3 Circlip 1 4 Rotor 1 5 Circlip 1 6 Drive sprocket nut 1 7 Lock washer 1 8 Drive sprocket 1 9 Neutral switch 1 10 Right crankcase 1 11 Dowel pin 2 12 Left crankcase 1 For installation reverse the removal proce dure B9X F8197 E0 book Page 6 Thursday July 16 2020 2 28 PM ...

Page 128: ...5 7 ENG B9X F8197 E0 book Page 7 Thursday July 16 2020 2 28 PM ...

Page 129: ...RAM 6 16 TROUBLESHOOTING 6 18 FUEL INJECTION SYSTEM 6 22 CIRCUIT DIAGRAM 6 22 ECU SELF DIAGNOSTIC FUNCTION 6 24 TROUBLESHOOTING METHOD 6 25 YAMAHA DIAGNOSTIC TOOL 6 26 TROUBLESHOOTING DETAILS FAULT CODE 6 28 TROUBLESHOOTING DETAILS 6 29 SELF DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE 6 30 SELF DIAGNOSTIC FUNCTION TABLE 6 30 COMMUNICATION ERROR WITH THE YAMAHA DIAGNOSTIC TOOL 6 36 DIAGNOSTIC COD...

Page 130: ...FAIL TO COME ON 6 77 A 3 THE ABS WARNING LIGHT COMES ON 6 77 A 4 ONLY THE ABS ECU FAILS TO COMMUNICATE The select unit screen does not appear 6 78 A 5 ABS ECU AND FI ECU FAIL TO COMMUNICATE Cannot connect due to a tool error 6 78 B 1 MALFUNCTION ARE CURRENTLY DETECTED 6 78 B 2 DIAGNOSIS USING THE FAULT CODES 6 78 B 3 DELETING THE FAULT CODES 6 102 C 1 FINAL CHECK 6 102 ELECTRICAL COMPONENTS 6 103 ...

Page 131: ...6 1 ELEC ELECTRICAL SYSTEM IGNITION SYSTEM CIRCUIT DIAGRAM B WIRE MINUS LEAD B B B A B B W B B W B MAIN HARNESS IGNITION SYSTEM B9X F8197 E0 book Page 1 Thursday July 16 2020 2 28 PM ...

Page 132: ...16 Engine ground 17 Main switch 18 Fuse 23 Right handlebar switch 25 Engine stop switch 33 Lean angle sensor 35 ECU Engine control unit 36 Ignition coil 37 Spark plug 42 Sidestand switch 44 Joint connection 1 45 Joint connection 2 IGNITION SYSTEM B9X F8197 E0 book Page 2 Thursday July 16 2020 2 28 PM ...

Page 133: ...ck the spark plug Refer to CHECKING THE SPARK PLUG in base service manual B97 F8197 E0 on page 3 8 Re gap or replace the spark plug 4 Check the spark gap Refer to CHECKING THE IGNITION SPARK GAP in base service manual B97 F8197 E0 on page 7 67 Ignition system is OK 5 Check the ignition coil Refer to CHECKING THE IGNITION COIL in base service manual B97 F8197 E0 on page 7 66 Replace the ignition co...

Page 134: ...ce the lean angle sensor 9 Check the engine stop switch Refer to CHECKING THE SWITCHES on page 6 105 The engine stop switch is faulty Replace the right handlebar switch 10 Check the entire ignition system wiring Properly connect or repair the ignition system wiring Replace the ECU IGNITION SYSTEM B9X F8197 E0 book Page 4 Thursday July 16 2020 2 28 PM ...

Page 135: ...6 5 ELEC ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM B WIRE MINUS LEAD B B B A B B W B B W B MAIN HARNESS ELECTRIC STARTING SYSTEM B9X F8197 E0 book Page 5 Thursday July 16 2020 2 28 PM ...

Page 136: ...witch 18 Fuse 19 Starter relay 20 Starter motor 21 Starting circuit cut off relay 22 Clutch switch 23 Right handlebar switch 24 Start switch 25 Engine stop switch 27 Diode 42 Sidestand switch 44 Joint connection 1 45 Joint connection 2 ELECTRIC STARTING SYSTEM B9X F8197 E0 book Page 6 Thursday July 16 2020 2 28 PM ...

Page 137: ... is closed The starting circuit cut off relay prevents the starter motor from operating when neither of these condi tions has been met In this instance the starting circuit cut off relay is open so current cannot reach the starter motor When at least one of the above conditions has been met the starting circuit cut off relay is closed and the engine can be started by pressing the start switch 11 1...

Page 138: ...R OPERATION in base service manual B97 F8197 E0 on page 7 68 Starter motor is OK Perform the electric starting system troubleshooting starting with step 5 4 Check the starter motor Refer to CHECKING THE STARTER MOTOR in base service manual B97 F8197 E0 on page 5 36 Repair or replace the starter motor 5 Check the starting circuit cut off relay Refer to CHECKING THE RELAYS in base service manual B97...

Page 139: ...HECKING THE SWITCHES on page 6 105 Replace the sidestand switch 11 Check the clutch switch Refer to CHECKING THE SWITCHES on page 6 105 Replace the clutch switch 12 Check the start switch Refer to CHECKING THE SWITCHES on page 6 105 The start switch is faulty Replace the right handlebar switch 13 Check the entire starting system wiring Refer to CIRCUIT DIAGRAM Properly connect or repair the starti...

Page 140: ...6 10 ELEC CHARGING SYSTEM CIRCUIT DIAGRAM B WIRE MINUS LEAD B B B A B B W B B W B MAIN HARNESS CHARGING SYSTEM B9X F8197 E0 book Page 10 Thursday July 16 2020 2 28 PM ...

Page 141: ... 11 ELEC 3 Stator coil 4 Rectifier Regulator 13 Battery positive lead 14 Battery 15 Battery negative lead 16 Engine ground 18 Fuse CHARGING SYSTEM B9X F8197 E0 book Page 11 Thursday July 16 2020 2 28 PM ...

Page 142: ...rminals Recharge or replace the battery 3 Check the stator coil Refer to CHECKING THE STATOR COIL in base service manual B97 F8197 E0 on page 7 68 Replace the crankshaft position sensor stator assembly 4 Check the rectifier regulator Refer to CHECKING THE RECTIFIER REGULATOR in base service manual B97 F8197 E0 on page 7 69 Replace the rectifier regulator 5 Check the entire charging system wiring R...

Page 143: ...6 13 ELEC LIGHTING SYSTEM LIGHTING SYSTEM CIRCUIT DIAGRAM B WIRE MINUS LEAD B B B A B B W B B W B MAIN HARNESS B9X F8197 E0 book Page 13 Thursday July 16 2020 2 28 PM ...

Page 144: ...int connection 2 46 Meter assembly 51 Meter light 53 High beam indicator light 58 Auxiliary light with DRL 59 Joint 1 60 Left handlebar switch 61 Headlight switch 62 Pass switch 63 Dimmer switch 66 Joint 2 67 Joint 3 68 Headlight assembly 69 Headlight High beam 70 Headlight Low beam 74 Licence plate light 75 Brake tail light B9X F8197 E0 book Page 14 Thursday July 16 2020 2 28 PM ...

Page 145: ...e 7 60 Replace the bulb s and bulb socket s 2 Check the fuse Refer to CHECKING THE FUSES on page 6 106 Replace the fuse 3 Check the battery Refer to CHECKING AND CHARGING THE BATTERY in base service manual B97 F8197 E0 on page 7 62 Clean the battery terminals Recharge or replace the battery 4 Check the main switch Refer to CHECKING THE SWITCHES on page 6 105 Replace the main switch 5 Check the dim...

Page 146: ...6 16 ELEC SIGNALING SYSTEM SIGNALING SYSTEM CIRCUIT DIAGRAM B9X F8197 E0 book Page 16 Thursday July 16 2020 2 28 PM ...

Page 147: ...ht switch 44 Joint connection 1 45 Joint connection 2 46 Meter assembly 48 Multi function display 49 Neutral indicator light 52 Turn signal indicator light 54 Fuel sender 56 Turn signal relay 57 Horn 60 Left handlebar switch 64 Horn switch 65 Turn signal light switch 71 Front turn signal light right left 72 Rear turn signal light left 73 Rear turn signal light right 75 Brake tail light B9X F8197 E...

Page 148: ...n base service manual B97 F8197 E0 on page 7 62 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 6 105 Replace the main switch 4 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM in base service manual B97 F8197 E0 on page 7 17 Properly connect or repair the signaling system wiring Check the condition of each...

Page 149: ...SES on page 6 106 Replace the front brake light switch 3 Check the rear brake light switch Refer to CHECKING THE SWITCHES on page 6 105 Replace the rear brake light switch 4 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM in base service manual B97 F8197 E0 on page 7 17 Properly connect or repair the signaling system wiring This circuit is OK 1 Check the turn signal light bulb an...

Page 150: ...system wiring Replace the meter assembly 1 Check the neutral switch Refer to CHECKING THE SWITCHES on page 6 105 Replace the neutral switch 2 Check the entire signaling system wiring Properly connect or repair the signaling system wiring Replace the meter assembly 1 Check the fuel sender Refer to CHECKING THE FUEL SENDER in base service manual B97 F8197 E0 on page 7 65 Replace the fuel pump 2 Chec...

Page 151: ...nsor Refer to CHECKING THE FUEL SENDER in base service manual B97 F8197 E0 on page 7 70 Replace the speed sensor 2 Check the entire signaling system wiring Properly connect or repair the signaling system wiring Replace the meter assembly B9X F8197 E0 book Page 21 Thursday July 16 2020 2 28 PM ...

Page 152: ...6 22 ELEC FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM CIRCUIT DIAGRAM 1 2 4 3 2 1 3 4 B9X F8197 E0 book Page 22 Thursday July 16 2020 2 28 PM ...

Page 153: ...r temperature sensor 31 Throttle position sensor 32 Engine temperature sensor 33 Lean angle sensor 34 FID Fast idle device 35 ECU Engine control unit 36 Ignition coil 37 Spark plug 38 Air induction system solenoid 39 Fuel injection 40 O2 sensor 41 Yamaha diagnostic tool coupler 42 Sidestand switch 44 Joint connection 1 45 Joint connection 2 46 Meter assembly 47 Engine trouble warning light 48 Mult...

Page 154: ...ng light comes on for around 2 seconds after the main switch has been set to ON and it comes on while the start switch is being pushed If the warning light does not come on under these conditions the warning light LED may be defective ECU detects an abnormal signal from a sensor If the ECU detects an abnormal signal from a sensor while the vehicle is being driven the ECU illumi nates the engine tr...

Page 155: ...tors Refer to SENSOR AND ACTUATOR OP ERATION TABLE For ECU reinstallation refer to recovering initial status in TROUBLESHOOTING DETAILS Turn the main switch to OFF and then back to ON Check if an error code is displayed Repair complete Erase the malfunction history Turning the main switch to OFF will not erase the malfunction history Erase the malfunction history in the diagnostic mode Refer to SE...

Page 156: ...the engine EAS30951 YAMAHA DIAGNOSTIC TOOL This model uses the Yamaha diagnostic tool to identify malfunctions For information about using the Yamaha diagnostic tool refer to the operation manual that is included with the tool Connecting the Yamaha diagnostic tool Disconnect the Yamaha diagnostic tool coupler 1 and then connect the Yamaha diagnostic tool 2 to the coupler 3 Note To connect FI ECU n...

Page 157: ...e is detected the symptoms are displayed along with the item name 7 Trouble list The item list of the detected malfunction or recover malfunction are displayed 8 Trouble Information This appears to click on detected malfunction 1 for the details of the diagnosis are displayed Click Service Manual F10 to open the service manual and check the details of the fault Select function Trouble List YAMAHA ...

Page 158: ...se of the malfunction following the order given After the check and service of the malfunctioning part have been completed delete the fault codes dis played on the Yamaha diagnostic tool according to the reinstatement method Fault code No Fault code number displayed on the Yamaha diagnostic tool when the engine failed to work normally Diagnostic code No Diagnostic code number to be used when the d...

Page 159: ...SOR OPERATION TABLE on page 6 37 NOTICE This model is equipped with OBD1 On Board Diagnostic due to OBD1 system adoption en gine trouble warning light will glow continuously even the fault has been rectified To off engine trouble warning light use YDT Yamaha diagnostic tool to erase all fault codes For erase the fault codes follow below steps Select function Trouble List YAMAHA DIAGNOSTIC TOOL ME1...

Page 160: ...t P0107 open circuit ground fault P0108 sky fault Able Able Coupler malfunc tion between sensor module and ECU Open or short circuit in harness between sensor module and ECU Sensor malfunc tion ECU malfunction No normal sig nals are received from the intake air pressure sensor P0107 Signal is 0 23V or less P0108 Signal is 4 86V or more High idling Instable idling Poor engine response Insufficient ...

Page 161: ...e Coupler malfunc tion between sensor module and ECU Open or short circuit in harness between sensor module and ECU Incorrect installa tion of the sen sor module Sensor malfunc tion ECU malfunction No normal sig nals are received from the throttle position sensor P0122 Signal is 0 2 V or less P0123 Signal is 4 8 V or more High idling Instable idling Poor engine response Insufficient power Decelera...

Page 162: ...53 V or less Exhaust gas deterioration O2 feedback is prohibited O2 feedback feedback learning is prohibited Remove the O2 sensor coupler and leave Idle for more than 10 minutes then ride for more than 60 seconds at fully open Lean an gle sen sor Judged as turn over P1E30 Unable Unable Vehicle has over turned Improperly in stalled sensor Defective sensor ECU malfunc tion Overturn signal detected E...

Page 163: ...areful P1605 Remove the lean angle sensor cou pler or dis connect it at the switch box Vehicle speed sensor P0500 Able Able Open or short circuit in be tween vehicle speed sensor and ECU Vehicle speed sensor malfunc tion ECU malfunc tion No normal sig nals are received from the vehicle speed sensor to ECU Unable to display the speed on the meter Exhaust gas deterioration O2 feedback is prohibited ...

Page 164: ...d ECU Open or short circuit in harness between FID and ECU Defective FID so lenoid ECU malfunc tion FID solenoid does not drive Startability deterioration Instable idling High engine idle speed FID solenoid energization is prohibited Disconnect one of the output signal leads to the FID solenoid or discon nect it at the switch box and start the engine O2 sensor heater Doesnot work P0030 Able Able C...

Page 165: ...5 V or more Startability deterioration Exhaust gas deterioration Engine tem perature When key is ON 30 C When trav eling 100 C Remove the engine tem perature sen sor coupler or disconnect it at the switch box Side stand switch Open or short circuit in the wire harness to ECU P1601 Unable Unable Coupler malfunc tion between switch and ECU Open or short circuit in harness between switch and ECU Swit...

Page 166: ...he ECU Defective coupler between service tool and ECU Open or short circuit in wire harness between service tool and ECU Malfunction in service tool Malfunction in ECU Er 2 No signals are received from the ECU within the specified duration Defective coupler between service tool and ECU Open or short circuit in wire harness between service tool and ECU Malfunction in service tool Malfunction in ECU...

Page 167: ...7 Vehicle speed puls es Indication Displays vehicle speed pulses integrated value 0 999 pulses Rear whee stops Check that the dis played value is constant Turn the rear whee several times by hand and input the vehicle speed pulse The displayed value is added D08 Lean angle sensor Indication Displays the output val ue of the lean angle sensor 0 5 0 V Upright position 0 4 1 4 V Overturned 3 7 4 4 V ...

Page 168: ...stic tool screen will come on D54 FID Operation Determine whether the FID solenoid is mal functioning by confirm ing the operating sound of the FID solenoid The AI solenoid turns ON OFF five times every second During which the CHECK indicator and the indicator on the Yamaha diag nostic tool screen will come on D60 EEPROM fault code No display Indication Displays the EEPROM data error location de t...

Page 169: ...t or broken terminals and locking condition of the pins Defective connections Re connect or replace the harness Crank the engine and check the condition of the fault code in the diagnostic mode of the Yamaha diagnostic tool Condition is Recovered Go to item 7 and finish the service Condition is Detected Go to item 3 3 Harness continuity Open or short circuit Replace the harness Crank the engine an...

Page 170: ...he intake air pressure sensorr detected P0107 open circuit ground fault P0108 sky fault Diagnostic code No D03 Intake air pressure sensor NOTICE Do not remove the sensor module If fault code numbers P0107 P0108 and P0106 are indicated at the same time check and repair P0107 P0108 first Item Item and components and probable cause Actions Confirmation procedure after actions 1 Connection of sensor c...

Page 171: ...to ON and then check the condition of the fault code in diagnostic mode of the Yamaha diagnostic tool Condition is Recovered Go to item 8 and finish the service Condition is Detected Go to item 4 4 Installed condition of the sensor module Check the installation part for looseness stuck places Check if the mounting position is OK Turn the main switch to ON and then check the condition of the fault ...

Page 172: ...agnostic mode of the Yamaha diagnostic tool Condition is Recovered Go to item 8 and finish the service Condition is Detected Go to item 6 6 ECU malfunction Replace the ECU Finish the service 7 EG warning light delete the fault code Delete this fault code with the status Recovered in the Yamaha diagnostic tool Fault code No P0107 P0108 Symptoms Open or short circuit in the intake air pressure senso...

Page 173: ...ttle fully closed After the above work is finished check the condition of the fault code in diagnostic mode of the Yamaha diagnostic tool Condition is Recovered Go to item 3 and finish the service Condition is Detected Go to item 2 2 Defective intake air pressure sensor Check in diagnostic mode code No D03 When engine is stopped Atmo spheric pressure at the current altitude and weather conditions ...

Page 174: ...ndition of the pins Defective connections Re connect or replace the harness Turn the main switch to ON and then check the condition of the fault code in diagnostic mode of the Yamaha diagnostic tool Condition is Recovered Go to item 7 and finish the service Condition is Detected Go to item 3 3 Harness continuity Open or short circuit Replace the harness ECU TPS sensor output Note In the case of P0...

Page 175: ...cedure after actions 1 Connection of the sensor mod ule coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Defective connections Re connect or replace the harness Turn the main switch to ON and then check the condition of the fault code in diagnostic mode of the Yamaha diagnostic tool Condition is ...

Page 176: ...ective intake air tempera ture sensor Check in diagnostic mode code No D05 When engine is cold Displays the temperature close to the ambient temperature An indicated value is incorrect Replace the throttle body Turn the main switch to ON and then check the condition of the fault code in diagnostic mode of the Yamaha diagnostic tool Condition is Recovered Go to item 7 and finish the service Conditi...

Page 177: ...aha diagnostic tool Condition is Recovered Go to item 8 and finish the service Condition is Detected Go to item 3 Alternatively delete the fault code with the status Detected 3 Connection of main harness ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Defective connections Re connect or repl...

Page 178: ...d finish the service Condition is Detected Go to item 7 Alternatively delete the fault code with the status Detected 7 ECU malfunction Replace the ECU Finish the service 8 EG warning light delete the fault code Delete this fault code with thestatus Recovered in the Yamaha diagnostic tool Fault code No P1E30 Symptoms Turnover of vehicle Diagnostic code No D08 Lean angle sensor Item Item and compone...

Page 179: ...n Replace the ECU Finish the service 5 EG warning light delete the fault code Delete this fault code with the status Recovered in the Yamaha diagnostic tool Fault code No P0351 Symptoms Defective ignition coil primary lead Diagnostic code No D30 Ignition coil Item Item and components and probable cause Actions Confirmation procedure after actions 1 Connection of ignition coil cou pler Check the lo...

Page 180: ...r the above work is finished check the condition of the fault code in diagnostic mode of the Yamaha diagnostic tool Condition is Recovered Go to item 7 and finish the service Condition is Detected Go to item 5 5 Ignition coil malfunction Prima ry coil continuity check Refer to Ignition system Ignition coil checking method 1 Connect the multi meter 100 to the ignition coil coupler 2 Measure the ign...

Page 181: ... the pins Defective connections Re connect or replace the harness Check the operating noise of the applicable injector in the diag nostic mode code No D36 There is operation noise Per form the procedure in item 7 No operation noise Perform the procedure in item 4 4 Connection of the sub harness Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken term...

Page 182: ...in switch to ON OFF ON After the above work is finished check the condition of the fault code in diagnostic mode of the Yamaha diagnostic tool Condition is Recovered Go to item 6 and finish the service Condition is Detected Go to item 3 3 Harness continuity Open or short circuit Replace the harness Turn the main switch to ON OFF ON After the above work is finished check the condition of the fault ...

Page 183: ...onnection of ABS unit coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Defective connections Re connect or replace the harness Turn the main switch to ON and turn the rear wheel several times and input the vehicle speed pulses After the above work is finished check the condition of the fault code...

Page 184: ...e condition of the fault code in diagnostic mode of the Yamaha diagnostic tool Condition is Recovered Go to item 8 and finish the service Condition is Detected Go to item 6 6 ECU malfunction Replace the ECU Turn the main switch to ON and turn the rear wheel several times and input the vehicle speed pulses After the above work is finished check the condition of the fault code in diagnostic mode of ...

Page 185: ...on is Detected Go to item 2 2 Continuity of wire harness be tween the battery and ECU cou pler Open or short circuit Replace the harness After starting the engine let it idle and leave it for about 5 sec onds And then check the condition of the fault code in diagnostic mode of the Yamaha diagnostic tool Condition is Recovered Go to item 4 and finish the service Condition is Detected Go to item 3 3...

Page 186: ...s Detected Return to item 1 and check again If there is no change in the situ ation perform the procedure in item 4 4 ECU malfunction Replace the ECU Finish the service 5 EG warning light delete the fault code Delete this fault code with the status Recovered in the Yamaha diagnostic tool Fault code No P0560 Symptoms Charging voltage is abnormal Diagnostic code No Item Item and components and proba...

Page 187: ...g condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Defective connections Re connect or replace the harness Turn the main switch to ON and then check the condition of the fault code in diagnostic mode of the Yamaha diagnostic tool Condition is Recovered Go to item 6 and finish the service Condition is Detected Go to item 3...

Page 188: ...pler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Defective connections Re connect or replace the harness Turn the main switch to ON and then check the condition of the fault code in diagnostic mode of the Yamaha diagnostic tool Condition is Recovered Go to item 6 and finish the service Condition is Detected Start EG and check the condition o...

Page 189: ...ble cause Actions Confirmation procedure after actions 1 Installed condition of O2 sensor Check the installation part for looseness and stuck places Turn the main switch to ON and then check the condition of the fault code in diagnostic mode of the Yamaha diagnostic tool Condition is Recovered Go to item 7 and finish the service Condition is Detected Go to item 2 2 Connection of O2 sensor cou pler...

Page 190: ...m 7 and finish the service Condition is Detected Go to item 6 6 ECU malfunction Replace the ECU Finish the service 7 EG warning light delete the fault code Delete this fault code with the status Recovered in the Yamaha diagnostic tool Fault code No P0197 P0198 Symptoms Open or short circuit in the engine temperature sensor P0197 ground fault P0198 open circuit sky fault Diagnostic code No D11 Engi...

Page 191: ... mounting position is OK Turn the main switch to ON and then check the condition of the fault code in diagnostic mode of the Yamaha diagnostic tool Condition is Recovered Go to item 7 and finish the service Condition is Detected Go to item 5 5 Faulty engine temperature sen sor Check in diagnostic mode code No D11 When engine is cold Displays the temperature close to the ambient temperature An indi...

Page 192: ...nd retract and extend the sidestand After the above work is finished check the condition of the fault code in diagnostic mode of the Yamaha diagnostic tool Condition is Recovered Go to item 6 and finish the service Condition is Detected Go to item 3 3 Harness continuity Open or short circuit Replace the harness Between side standswitch and ECU Between side standswitch and EG ground Turn the main s...

Page 193: ...ns Re connect or replace the harness Turn the main switch to ON and then check the condition of the fault code in diagnostic mode of the Yamaha diagnostic tool Condition is Recovered Go to item 6 and finish the service Condition is Detected Go to item 3 3 Harness continuity Open or short circuit Recon nect or replace the harness ECU AIS AIS Main switch Turn the main switch to ON and then check the...

Page 194: ...in item 3 If you can start with a self start er check the condition of the fault code in diagnostic mode of the Yamaha diagnostic tool Condition is Recovered Go to item 7 and finish the service Condition is Detected Go to item 6 3 Check the connection of the battery terminals and lead Connect the battery terminals to the lead so that the screws are not loose and the terminals do not come off Repea...

Page 195: ...f the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item 7 and finish the service Condition is Detected Go to item 6 6 ECU malfunction Replace the ECU Finish the service 7 EG warning light delete the fault code Delete this fault code with the status Recovered in the Yamaha diagnostic tool Fault code No P1602 Symptoms The ECU cannot record vehicle ...

Page 196: ...type sensor or sensor module 197 Intake air temperature sensor Instantaneous abnormality of the intake air temperature sensor detected Same as fault code No P0112 P0113 Perform the inspection points listed for fault code P0112 P0113 in the service manual Note Refer to the service manual to check whether the vehicle under inspection uses a separate type sensor or sensor module 201 Engine temperatur...

Page 197: ...sensor feedback Open or short circuit in the harness between the sensor and ECU Sensor malfunction ECU malfunction Defective fuel injection system If a fault code is indicated address this first Note In rare cases CODE241 may be indicated even when the system is normal 244 Poor starting and inability to start Poor starting and inability to start detected No gasoline Defective fuel injection system...

Page 198: ...6 68 ELEC FUEL PUMP SYSTEM FUEL PUMP SYSTEM CIRCUIT DIAGRAM B9X F8197 E0 book Page 68 Thursday July 16 2020 2 28 PM ...

Page 199: ... lead 14 Battery 15 Battery negative lead 16 Engine ground 17 Main switch 18 Fuse 23 Right handlebar switch 25 Engine stop switch 35 ECU Engine control unit 44 Joint connection 1 55 Fuel pump B9X F8197 E0 book Page 69 Thursday July 16 2020 2 28 PM ...

Page 200: ...97 E0 on page 7 62 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 6 105 Replace the main switch 4 Check the engine stop switch Refer to CHECKING THE SWITCHES on page 6 105 The engine stop switch is faulty Replace the right handlebar switch 5 Check the fuel pump Refer to CHECKING THE FUEL PUMP BODY in base service manual B9...

Page 201: ...6 71 ELEC ABS ANTI LOCK BRAKE SYSTEM EAS20085 ABS ANTI LOCK BRAKE SYSTEM EAS30843 CIRCUIT DIAGRAM 2A 30A 15A B9X F8197 E0 book Page 71 Thursday July 16 2020 2 28 PM ...

Page 202: ...ground 17 Main switch 18 Fuse 23 Right handlebar switch 26 Front brake light switch 35 ECU Engine control unit 43 Rear brake light switch 44 Joint connection 1 45 Joint connection 2 46 Meter assembly 50 ABS warning light 51 Meter light 76 ABS ECU Electric control unit 77 Front wheel sensor 78 Rear wheel sensor 79 Joint 4 80 ABS test coupler B9X F8197 E0 book Page 72 Thursday July 16 2020 2 28 PM ...

Page 203: ... BRAKE SYSTEM EAS30844 ABS COUPLER LOCATION CHART 1 Meter assembly coupler 2 Rear wheel sensor coupler 3 ABS test coupler 4 ABS ECU coupler 5 Front wheel sensor coupler B9X F8197 E0 book Page 73 Thursday July 16 2020 2 28 PM ...

Page 204: ...mation about using the Yamaha diagnostic tool refer to B 2 DIAG NOSIS USING THE FAULT CODES on page 6 78 For troubleshooting items other than the following items follow the normal service method EWA16710 WARNING When maintenance or checks have been performed on components related to the ABS be sure to perform a final check before delivering the vehicle to the customer TIP To final check refer to C...

Page 205: ...r pulling on them with too much force since the ABS components are precisely adjusted The ABS ECU and hydraulic unit are united assemblies and cannot be disassembled The malfunction history is stored in the memory of the ABS ECU Delete the fault codes when the ser vice is finished This is because the past fault codes will be displayed again if another malfunction occurs EAS30529 BASIC INSTRUCTIONS...

Page 206: ...he light is checked The malfunction is not corrected There is a break in the wire harness between the ABS ECU and the meter assembly The meter assembly circuit is defective The ABS warning light circuit in the hydraulic unit assembly is defective The ABS warning light LED is defective The wire harness is grounded between the ABS ECU and the meter assembly The meter assembly circuit is defective Th...

Page 207: ...ED is defective Replace the meter assembly If the ABS warning light comes on the ABS ECU is defective Replace the hydraulic unit assembly EAS30964 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 6 105 If there is no continuity replace the main switch 2 Battery Check the condition of the battery Refer to CHECKING AND...

Page 208: ... test coupler Check for continuity between blue red terminal of the ABS ECU coupler and blue red terminal of the ABS test coupler Check for continuity between white black terminal of the ABS ECU coupler and white black terminal of the ABS test coupler 4 ABS ECU malfunction Replace the hydraulic unit assembly EAS31164 A 5 ABS ECU AND FI ECU FAIL TO COMMUNICATE Cannot connect due to a tool error 1 Y...

Page 209: ...e following chart Refer to this chart and check the vehicle Once all the work is complete delete the fault codes B 3 TIP Check the inspection points after terminating the connection with the Yamaha diagnostic tool and turn ing the main switch off Operation of the Yamaha diagnostic tool Fault diagnosis mode Malfunction results are displayed in the top part of the window area Yamaha diagnostic tool ...

Page 210: ... detected malfunction 1 for the details of the diagnosis are displayed Click Service Manual F10 to open the service manual and check the details of the fault 9 Save To save the result of diagnosis of malfunction click Save F12 Note Must save the result for future reference 10 Update To run the diagnosis of malfunction again click Update F11 11 Service Manual To view the service manual click Servic...

Page 211: ...he rear wheel sen sor Incorrect installation of the rear wheel Defective sensor rotor or incorrect installation of the rotor Defective rear wheel sen sor or incorrect installation of the sensor 13 26 Front wheel sensor abnor mal pulse period Front wheel sensor signal is not received properly The pulse period is abnormal while the vehicle is traveling Foreign material adhered around the front wheel...

Page 212: ...gnal is not received properly Miss ing pulses are detected in the signal while the vehicle is traveling Foreign material adhered around the front wheel sen sor Incorrect installation of the front wheel Defective sensor rotor or incorrect installation of the rotor Defective front wheel sen sor or incorrect installation of the sensor 18 46 Rear wheel sensor missing pulses Rear wheel sensor signal is...

Page 213: ...cuit is detected in the solenoid power supply circuit in the hydraulic unit assembly Defective hydraulic unit as sembly 33 Hydraulic unit assembly ab normal ABS motor power supply Power is not supplied to the motor circuit in the hydraulic unit assembly Blown ABS motor fuse Defective coupler between the battery and the hydrau lic unit assembly Open or short circuit in the wire harness between the ...

Page 214: ...properly Miss ing pulses are detected in the signal while the vehicle is traveling Foreign material adhered around the rear wheel sen sor Incorrect installation of the rear wheel Defective sensor rotor or incorrect installation of the rotor Defective rear wheel sen sor or incorrect installation of the sensor 51 52 Vehicle system power sup ply voltage of ABS ECU power supply is high for fault code ...

Page 215: ...ydraulic unit assembly ab normal internal power sup ply Abnormality is detected in the power supply circuit in the hydraulic unit assembly Defective hydraulic unit as sembly 63 Front wheel sensor power supply voltage of power supply is low Power voltage supplied from the ABS ECU to the front wheel sensor is too low Short circuit in the wire har ness between the front wheel sensor and the hy drauli...

Page 216: ... Check the wheel sensor for damage and the installed condition of the sensor Repair or replace the wheel sensor if necessary Refer to MAINTENANCE OF THE WHEEL SENSOR AND SENSOR ROTOR on page 4 8 Fault code No 12 Item Rear wheel sensor intermittent pulses or no pulses Symptom Rear wheel sensor signal is not received properly Pulses are not re ceived or are received intermittently while the vehicle ...

Page 217: ...sensor if necessary 2 Incorrect installation of the front wheel Check the components for looseness distortion and bends Refer to CHECKING THE FRONT WHEEL in base ser vice manual B97 F8197 E0 on page 4 7 3 Defective sensor rotor or incorrect instal lation of the rotor Check the surface of the sensor rotor for damage Re place the sensor rotor if there is visible damage Refer to MAINTENANCE OF THE WH...

Page 218: ...he sensor Repair or replace the wheel sensor if necessary Refer to MAINTENANCE OF THE WHEEL SENSOR AND SENSOR ROTOR on page 4 8 Fault code No 15 Item Front wheel sensor open or short circuit Symptom Open or short circuit is detected in the front wheel sensor Order Item components and probable cause Check or maintenance job 1 Defective coupler between the front wheel sensor and the hydraulic unit a...

Page 219: ...e terminal 3 and the green terminal 4 and between the black white terminal 3 and the red termi nal 5 If there is short circuit the wire harness is defective Replace the wire harness 6 ABS ECU 7 Front wheel sensor 3 Defective front wheel sensor or hydraulic unit assembly If the above items were performed and no malfunctions were found the wheel sensor or hydraulic unit assembly is defective Replace...

Page 220: ...terminal 5 If there is no continuity the wire harness is defective Replace the wire harness Check that there is no short circuit between the yellow terminal 1 and the brown terminal 2 and between the yellow terminal 4 and the brown terminal 5 If there is short circuit the wire harness is defective Replace the wire harness Check that there is no short circuit between the black terminal 3 and the ye...

Page 221: ...allation of the front wheel Check the components for looseness distortion and bends Refer to CHECKING THE FRONT WHEEL in base ser vice manual B97 F8197 E0 on page 4 7 3 Defective sensor rotor or incorrect instal lation of the rotor Check the surface of the sensor rotor for damage Replace the sensor rotor if there is visible damage Refer to MAINTENANCE OF THE WHEEL SENSOR AND SENSOR ROTOR on page 4...

Page 222: ...ceived properly while the vehicle is travel ing Brake light circuit or front or rear brake light switch circuit Order Item components and probable cause Check or maintenance job 1 Defective signaling system tail brake light or brake light switch Check the brake light switches Refer to CHECKING THE SWITCHES on page 6 105 2 Defective coupler between the signaling system tail brake light or brake lig...

Page 223: ...er securely See TIP 3 Open or short circuit in the wire harness between the battery and the hydraulic unit assembly Replace if there is an open or short circuit Between ABS ECU coupler and ABS solenoid fuse red red 4 Defective hydraulic unit assembly If the above items were performed and no malfunctions were found replace the hydraulic unit assembly Refer to ABS ANTI LOCK BRAKE SYSTEM on page 6 71...

Page 224: ...ction repair it and connect the cou pler securely See TIP 3 Open or short circuit in the wire harness between the battery and the hydraulic unit assembly Replace if there is an open or short circuit Between ABS ECU coupler and ABS motor fuse red blue red blue Between ABS ECU coupler and ground black black 4 Defective hydraulic unit assembly If the above items were performed and no malfunctions wer...

Page 225: ...iper when the brake lever is operated and that the pressure decreases when the lever is re leased Refer to CHECKING THE FRONT BRAKE DISC in base service manual B97 F8197 E0 on page 4 23 4 Defective hydraulic unit assembly If the above items were performed and no malfunctions were found replace the hydraulic unit assembly Refer to ABS ANTI LOCK BRAKE SYSTEM on page 6 71 Fault code No 42 47 Item Rea...

Page 226: ...ecessary 2 Incorrect installation of the front wheel Check the components for looseness distortion and bends Refer to CHECKING THE FRONT WHEEL in base ser vice manual B97 F8197 E0 on page 4 7 3 Defective sensor rotor or incorrect instal lation of the rotor Check the surface of the sensor rotor for damage Re place the sensor rotor if there is visible damage Refer to MAINTENANCE OF THE WHEEL SENSOR ...

Page 227: ... ROTOR on page 4 8 4 Defective rear wheel sensor or incorrect installation of the sensor Check the wheel sensor for damage and the installed condition of the sensor Repair or replace the wheel sensor if necessary Refer to MAINTENANCE OF THE WHEEL SENSOR AND SENSOR ROTOR on page 4 8 Fault code No 51 52 Item Vehicle system power supply voltage of ABS ECU power supply is high for fault code No 51 Veh...

Page 228: ...re is an open or short circuit Between ABS ECU coupler and ABS control unit fuse brown brown 4 Defective charging system Check the charging system Refer to CHARGING SYSTEM on page 6 10 Fault code No 54 Item Hydraulic unit assembly defective ABS solenoid and ABS motor power supply circuits Symptom Abnormality is detected in the solenoid or motor power supply circuit in the hydraulic unit assembly O...

Page 229: ...ly Replace the hydraulic unit assembly Refer to ABS ANTI LOCK BRAKE SYSTEM on page 6 71 Fault code No 56 Item Hydraulic unit assembly abnormal internal power supply Symptom Abnormality is detected in the power supply circuit in the hydraulic unit assembly Order Item components and probable cause Check or maintenance job 1 Defective hydraulic unit assembly Replace the hydraulic unit assembly Refer ...

Page 230: ...t between the black terminal 3 and the green terminal 1 If there is a short circuit the wire harness is defective Replace the wire harness 4 ABS ECU 5 Front wheel sensor 2 Defective front wheel sensor Check that there is no short circuit between the black terminal 1 and the white terminal 2 If there is a short circuit the wheel sensor is defective Repair or replace the wheel sensor 3 ABS ECU 4 Fro...

Page 231: ...t between the black terminal 3 and the yellow terminal 1 If there is a short circuit the wire harness is defective Replace the wire harness 4 ABS ECU 5 Rear wheel sensor 2 Defective rear wheel sensor Check that there is no short circuit between the black terminal 1 and the white terminal 2 If there is a short circuit the wheel sensor is defective Repair or replace the wheel sensor 3 ABS ECU 4 Rear...

Page 232: ...ONT WHEEL on page 4 9 and REMOVING THE REAR WHEEL on page 4 13 3 Perform brake line routing confirmation Refer to HYDRAULIC UNIT OPERATION TESTS on page 4 26 If it does not have reaction force properly the brake hose is not properly routed or connected 4 Delete the fault codes Refer to B 3 DELETING THE FAULT CODES on page 6 102 5 Checking the ABS warning light Check that the ABS warning light goes...

Page 233: ...lock 2 Clutch switch 3 Front brake light switch 4 Ignition coil 5 Fuel sender 6 Fuel pump 7 Fuel injector 8 Fuse box 9 Battery 10 Rear brake light switch 11 AC magneto 12 Crankshaft position sensor 13 Starter motor 14 Throttle body sensor assembly 15 Air cut off valve B9X F8197 E0 book Page 103 Thursday July 16 2020 2 28 PM ...

Page 234: ...ier regulator 18 ECU Engine Control Unit 19 Turn signal relay 20 Rear wheel sensor 21 Hydraulic unit assembly 22 Sidestand switch 23 Neutral switch 24 Engine temperature sensor 25 Horn 26 Front wheel sensor 27 O2 sensor 28 Lean angle sensor B9X F8197 E0 book Page 104 Thursday July 16 2020 2 28 PM ...

Page 235: ...ary replace the switch 12 13 R Dg Ch Br W L NR NL Ch Dg B W B Y L P Y R Br W 11 L Y Sb G Y B 1 Main switch 2 Front brake light switch 3 Starter switch 4 Engine stop switch 5 Rear brake light switch 6 Clutch switch 7 Horn switch 8 Pass switch 9 Dimmer switch 10 Headlight switch 11 Turn signal light switch 12 Neutral switch 13 Sidestand switch B9X F8197 E0 book Page 105 Thursday July 16 2020 2 28 PM...

Page 236: ...ng amperage rating may cause extensive damage to the electri cal system cause the lighting and ignition systems to malfunction and could possibly cause a fire 4 Install Rider seat and passenger seat Refer to GENERAL CHASSIS in base ser vice manual B97 F8197 E0 on page 4 1 EAS00587 CHECKING THE AIR INDUCTION SYSTEM SOLENOID 1 1 Check Air induction system solenoid resistance Out of specification Rep...

Page 237: ...OR MEDIUM AND HIGH SPEED PERFORMANCE 7 2 FAULTY GEAR SHIFTING 7 2 SHIFT PEDAL DOES NOT MOVE 7 2 JUMPS OUT OF GEAR 7 2 FAULTY CLUTCH 7 2 OVERHEATING 7 2 OVERCOOLING 7 3 POOR BRAKING PERFORMANCE 7 3 FAULTY FRONT FORK LEGS 7 3 UNSTABLE HANDLING 7 3 FAULTY LIGHTING OR SIGNALING SYSTEM 7 4 B9X F8197 E0 book Page 1 Thursday July 16 2020 2 28 PM ...

Page 238: ...TRBL SHTG B9X F8197 E0 book Page 2 Thursday July 16 2020 2 28 PM ...

Page 239: ...eriorated or contaminated fuel Sucked in air 4 Canister Hose clogged Hose band twisted Electrical system 1 Battery Discharged battery Faulty battery 2 Fuse s Blown damaged or incorrect fuse Improperly installed fuse 3 Spark plug Incorrect spark plug gap Incorrect spark plug heat range Fouled spark plug Worn or damaged electrode Worn or damaged insulator Faulty spark plug cap 4 Ignition coil Cracke...

Page 240: ...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 EAS28560 FAULTY CLUTCH Clutch slips 1 Clutch Improperly assembled clutch Improperly adjusted clutch cable...

Page 241: ...inner tube Cracked or damaged outer tube Improperly installed oil seal Damaged oil seal lip Incorrect oil level high Loose damper rod assembly bolt Damaged damper rod assembly bolt copper washer Cracked or damaged front fork cap O ring Malfunction Bent or damaged inner tube Bent or damaged outer tube Damaged fork spring Worn or damaged outer tube bushing Bent or damaged damper rod Incorrect oil vi...

Page 242: ...me on Wrong tail brake light LED Too many electrical accessories Incorrect connection Burnt out tail brake light Turn signal does not come on Faulty turn signal switch Faulty turn signal relay Burnt out turn signal bulb Incorrect connection Damaged or faulty wire harness Improperly grounded circuit Faulty battery Blown damaged or incorrect fuse Turn signal blinks slowly Faulty turn signal relay Fa...

Page 243: ...7 5 TRBL SHTG TROUBLESHOOTING B9X F8197 E0 book Page 5 Thursday July 16 2020 2 28 PM ...

Page 244: ...l indicator light 50 ABS warning light 51 Meter light 52 Turn signal indicator light 53 High beam indicator light 54 Fuel sender 55 Fuel pump 56 Turn signal relay 57 Horn 58 Auxiliary light with DRL 59 Joint 1 60 Left handlebar switch 61 Headlight switch 62 Pass switch 63 Dimmer switch 64 Horn switch 65 Turn signal light switch 66 Joint 2 67 Joint 3 68 Headlight assembly 69 Headlight High beam 70 ...

Page 245: ...B9X F8197 E0 book Page 1 Thursday July 16 2020 2 28 PM ...

Page 246: ...1 2 4 3 15A 2A 2A 30A 30A 15A B WIRE MINUS LEAD B B B A B B W B MAIN HARNESS 2 1 3 4 B W B FZN250 A 2020 B9X1 FZN250D A 2020 B0Y1 WIRING DIAGRAM ...

Page 247: ...B9X F8197 E0 87 7 B9X F8197 E0 book Page 2 Thursday July 16 2020 2 28 PM ...

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