Yamaha MBK X-MAX 300 2017 Page 20 Service Manual Download

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SPECIAL TOOLS

1-11

Sheave fixed block
90890-04135
Sheave fixed bracket
YM-04135

5-40, 5-43

Oil seal guide (40mm)
90890-01590
Sliding sheave guide 40mm
YM-01590

5-43

Flywheel puller
90890-01404
Flywheel puller
YM-01404

5-49

Rotor puller bolt M14 X L80
90890-04183
Rotor puller bolt M14 X L80
YM-04183

5-49

Digital circuit tester (CD732)
90890-03243
Model 88 Multimeter with tachometer
YU-A1927

5-54, 8-128,
8-129, 8-130,
8-131, 8-131,
8-132, 8-133,
8-133, 8-133,
8-134, 8-134,
8-135, 8-135,
8-136, 8-137,
8-137, 8-138

Crankshaft metal installation base set
90890-04181
Crankshaft metal installation base set
YM-04181

5-67, 5-72

Tool name/Tool No.

Illustration

Reference

pages

ø40

L80

M14×P1.5

Summary of Contents for MBK X-MAX 300 2017

Page 1: ...2017 SERVICE MANUAL X MAX 300 EVOLIS 300 CZD300 A CZD300 AH B74 F8197 E0 ...

Page 2: ......

Page 3: ...pear in future editions of this manual where applicable TIP If the contents of the manual are revised the last digit of the manual number will be increased by one Designs and specifications are subject to change without notice EAS30001 IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following notations This is the safety alert symbol It is use...

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

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

Page 6: ......

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

Page 8: ......

Page 9: ...1 GENERAL INFORMATION IDENTIFICATION 1 1 VEHICLE IDENTIFICATION NUMBER 1 1 MODEL LABEL 1 1 FEATURES 1 2 MULTI FUNCTION DISPLAY 1 2 SPECIAL TOOLS 1 8 ...

Page 10: ... 1 1 EAS20007 IDENTIFICATION EAS30002 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the frame EAS30003 MODEL LABEL The model label 1 is affixed to the inside of the storage box 1 1 ...

Page 11: ...e UK To switch the displays between kilo meters and miles turn the main switch to ON while pushing the INFO switch and then con tinue to push the INFO switch for eight sec onds Clock The clock uses a 24 hour time system To set the clock 1 Turn the main switch to OFF 2 Push and hold the TRIP switch 3 Turn the main switch to ON while pushing the TRIP switch and then continue to push the TRIP switch ...

Page 12: ...check the electrical circuit Refer to COOLING SYSTEM on page 8 27 The coolant temperature varies with changes in the weather and engine load Tripmeter display The tripmeter display is equipped with the fol lowing odometer tripmeter time tripmeter fuel reserve tripmeter oil change tripmeter V belt replacement tripmeter Push the TRIP switch to change the display between the odometer Odo tripmeter Tr...

Page 13: ...Oil change tripmeter Oil Trip The oil change tripmeter shows the distance traveled since the oil was last changed The oil change indicator OIL flashes at the ini tial 1000 km 600 mi then at 4000 km 2400 mi and every 5000 km 3000 mi thereafter to indi cate that the engine oil should be changed After changing the engine oil reset the oil change indicator and the oil change tripmeter To reset them bo...

Page 14: ... aver age fuel consumption display Consumption Av erage_ _ _ km L or Consumption Average_ _ _ L 100 km instantaneous fuel consumption display Consumption_ _ _ km L or Consump tion_ _ _ L 100 km and average speed display Average in the following order Air temp Battery TCS ON or TCSOFF Consumption Average_ _ _ km L Consump tion Average_ _ _ L 100 km Consumption_ _ _ km L Consumption_ _ _ L 100 km Av...

Page 15: ...trol system TCS ON the system is on TCSOFF the system is off TIP If only TCS is displayed there is a communica tion error within the vehicle Check the electrical circuit Refer to SIGNALING SYSTEM on page 8 19 Average fuel consumption display This function calculates the average fuel con sumption since it was last reset The average fuel consumption can be displayed as either Consumption Average_ _ ...

Page 16: ...isplay shows the average speed since it was last reset To reset the average speed display select it by pushing the INFO switch and then push the INFO switch for three seconds Warning message function This function displays a warning message corre sponding to the current warning L FUEL Appears when the last segment of the fuel meter starts flashing If L FUEL is dis played refuel as soon as possible...

Page 17: ... ACC For others use part numbers starting with 90890 Tool name Tool No Illustration Reference pages Yamaha diagnostic tool USB 90890 03256 3 4 3 7 3 8 4 68 4 69 7 17 7 17 7 18 7 18 8 34 8 88 8 110 8 128 Yamaha diagnostic tool A I 90890 03254 3 4 3 7 3 8 4 68 4 69 7 17 7 17 7 18 7 18 8 34 8 88 8 110 8 128 Steering nut wrench 90890 01403 Exhaust flange nut wrench YU A9472 3 16 4 89 Thickness gauge 9...

Page 18: ...3 Valve spring compressor 90890 04019 Valve spring compressor YM 04019 5 27 5 31 Valve spring compressor attachment 90890 06320 5 27 5 31 Valve guide remover ø5 90890 04097 Valve guide remover 5 0 mm YM 04097 5 28 Valve guide installer ø5 90890 04098 Valve guide installer 5 0 mm YM 04098 5 28 Valve guide reamer ø5 90890 04099 Valve guide reamer 5 0 mm YM 04099 5 28 Tool name Tool No Illustration R...

Page 19: ...o and rotor holder YU 01235 5 40 5 45 Rotor holding tool 90890 04166 Rotor holding tool YM 04166 5 40 5 40 5 44 5 45 5 49 5 49 5 50 5 51 Locknut wrench 90890 01348 Locknut wrench YM 01348 5 40 5 44 Sheave spring compressor 90890 04134 Sheave spring compressor YM 04134 5 40 5 43 Tool name Tool No Illustration Reference pages YU 01304 ...

Page 20: ...bolt M14 X L80 90890 04183 Rotor puller bolt M14 X L80 YM 04183 5 49 Digital circuit tester CD732 90890 03243 Model 88 Multimeter with tachometer YU A1927 5 54 8 128 8 129 8 130 8 131 8 131 8 132 8 133 8 133 8 133 8 134 8 134 8 135 8 135 8 136 8 137 8 137 8 138 Crankshaft metal installation base set 90890 04181 Crankshaft metal installation base set YM 04181 5 67 5 72 Tool name Tool No Illustratio...

Page 21: ...ler 90890 04145 6 10 Middle driven shaft bearing driver 90890 04058 Middle drive bearing installer 40 50 mm YM 04058 6 10 Pressure gauge 90890 03153 Pressure gauge YU 03153 7 7 Fuel pressure adapter 90890 03186 Fuel pressure adapter YM 03186 7 7 OBD GST Leadwire kit 90890 03249 8 34 Ignition checker 90890 06754 Oppama pet 4000 spark checker YM 34487 8 132 Tool name Tool No Illustration Reference p...

Page 22: ...SPECIAL TOOLS 1 13 ...

Page 23: ...S GENERAL SPECIFICATIONS 2 1 ENGINE SPECIFICATIONS 2 2 CHASSIS SPECIFICATIONS 2 7 ELECTRICAL SPECIFICATIONS 2 9 TIGHTENING TORQUES 2 11 ENGINE TIGHTENING TORQUES 2 11 CHASSIS TIGHTENING TORQUES 2 11 CABLE ROUTING 2 13 ...

Page 24: ... in Wheelbase 1540 mm 60 6 in Ground clearance 135 mm 5 31 in Minimum turning radius 2 6 m 8 53 ft Weight Curb weight 179 kg 395 lb Loading Maximum load 161 kg 355 lb Riding capacity 2 person Storage compartment_1 location Left leg shield Storage compartment_1 maximum load 1 0 kg 2 lb Storage compartment_2 location Right leg shield Storage compartment_2 maximum load 0 5 kg 1 lb Storage compartment...

Page 25: ...igher JASO standard MA or MB Lubrication system Wet sump Engine oil quantity Oil change 1 50 L 1 59 US qt 1 32 Imp qt With oil filter removal 1 60 L 1 69 US qt 1 41 Imp qt Quantity disassembled 1 70 L 1 80 US qt 1 50 Imp qt Final transmission oil Type Motor oil SAE 10W 30 type SE or higher or Gear oil SAE 85W GL 3 Quantity disassembled 0 23 L 0 24 US qt 0 20 Imp qt Quantity 0 20 L 0 21 US qt 0 18 ...

Page 26: ...ameter 11 985 12 000 mm 0 4719 0 4724 in Limit 12 015 mm 0 4730 in Rocker arm shaft outside diameter 11 966 11 976 mm 0 4711 0 4715 in Limit 11 935 mm 0 4699 in Rocker arm to rocker arm shaft clearance 0 009 0 034 mm 0 0004 0 0013 in Limit 0 080 mm 0 0032 in Valve valve seat valve guide Valve clearance cold Intake 0 06 0 12 mm 0 0024 0 0047 in Exhaust 0 20 0 26 mm 0 0079 0 0102 in Valve dimensions...

Page 27: ...e diameter 15 995 16 000 mm 0 6297 0 6299 in Limit 15 975 mm 0 6289 in Piston pin to piston pin bore clearance 0 002 0 018 mm 0 0001 0 0007 in Piston ring Top ring Ring type Barrel End gap limit 0 50 mm 0 0197 in Ring side clearance 0 030 0 065 mm 0 0012 0 0026 in Side clearance limit 0 115 mm 0 0045 in 2nd ring Ring type Taper End gap limit 1 15 mm 0 0453 in Ring side clearance 0 020 0 055 mm 0 0...

Page 28: ...n Drivetrain Primary reduction ratio 1 000 Transmission type V belt automatic Transmission ratio 2 386 0 746 1 Weight outside diameter 23 0 mm 0 91 in Limit 22 5 mm 0 89 in Compression spring free length 111 0 mm 4 37 in Limit 99 9 mm 3 93 in Main axle runout limit 0 08 mm 0 0032 in Drive axle runout limit 0 08 mm 0 0032 in Secondary reduction ratio 7 590 48 18 37 13 Final drive Gear Air filter Ai...

Page 29: ...ENGINE SPECIFICATIONS 2 6 Exhaust gas sampling point Muffler tail pipe CO 0 0 1 0 Fuel line pressure at idle 220 300 kPa 2 2 3 0 kgf cm 31 9 43 5 psi Throttle grip free play 3 0 5 0 mm 0 12 0 20 in ...

Page 30: ... tire Type Tubeless Size 140 70 14 M C 62P Manufacturer model DUNLOP SCOOTSMART Tire air pressure measured on cold tires 1 person Front 200 kPa 2 00 kgf cm 29 psi Rear 225 kPa 2 25 kgf cm 33 psi 2 persons Front 200 kPa 2 00 kgf cm 29 psi Rear 225 kPa 2 25 kgf cm 33 psi Front brake Type Hydraulic single disc brake Disc outside diameter thickness 267 0 4 5 mm 10 51 0 18 in Brake disc thickness limit...

Page 31: ...nt suspension Type Telescopic fork Spring Coil spring Shock absorber Hydraulic damper Fork spring free length 348 3 mm 13 71 in Limit 341 3 mm 13 44 in Recommended oil Yamaha Suspension Oil G10 Quantity left 235 0 cm 7 95 US oz 8 29 Imp oz Quantity right 235 0 cm 7 95 US oz 8 29 Imp oz Level left 155 mm 6 1 in Level right 155 mm 6 1 in Rear suspension Type Unit swing Spring Coil spring Shock absor...

Page 32: ...Operating angle 50 Output voltage up to operating angle 0 4 1 4 V Output voltage over operating angle 3 7 4 4 V Charging system Charging system AC magneto Standard output 14 0 V 12 5 A at 5000 r min Standard output 14 0 V 175 W at 5000 r min Stator coil resistance 0 360 0 540 Ω Rectifier regulator Regulator type Single phase Regulated voltage DC 14 0 15 0 V Rectifier capacity DC 20 0 A Battery Mod...

Page 33: ...resistance full 10 0 14 0 Ω Sender unit resistance empty 267 0 273 0 Ω Fuel injection sensor Crankshaft position sensor resistance 228 342 Ω Intake air temperature sensor resistance 5700 6300 Ω at 0 C 5700 6300 Ω at 32 F Coolant temperature sensor resistance 2513 2777 Ω at 20 C 2513 2777 Ω at 68 F Coolant temperature sensor resistance 210 221 Ω at 100 C 210 221 Ω at 212 F Fuse s Main fuse 20 0 A M...

Page 34: ... ft Muffler cap bolt M6 1 8 N m 0 8 kgf m 5 9 lb ft Coolant drain bolt water pump side M6 1 10 N m 1 0 kgf m 7 4 lb ft Coolant drain bolt radiator side M10 1 1 6 N m 0 16 kgf m 1 2 lb ft Engine oil drain bolt M12 1 20 N m 2 0 kgf m 15 lb ft Final transmission oil drain bolt M8 1 20 N m 2 0 kgf m 15 lb ft Oil filter element cover bolt M6 3 10 N m 1 0 kgf m 7 4 lb ft Clutch housing nut M14 1 75 N m ...

Page 35: ...que Remarks Upper handlebar holder bolt M8 4 21 N m 2 1 kgf m 15 lb ft Front brake caliper bolt M10 2 35 N m 3 5 kgf m 26 lb ft Brake caliper bleed screw M7 2 6 N m 0 6 kgf m 4 4 lb ft Front wheel axle nut M14 1 52 N m 5 2 kgf m 38 lb ft Rear brake caliper bolt M10 2 35 N m 3 5 kgf m 26 lb ft Rear wheel axle nut M16 1 125 N m 12 5 kgf m 92 lb ft Upper bracket pinch bolt M8 2 23 N m 2 3 kgf m 17 lb...

Page 36: ...CABLE ROUTING 2 13 EAS20021 CABLE ROUTING Handlebar front view 1 2 B A C D 3 4 4 5 5 6 7 ...

Page 37: ...dlebar switch 7 Lower handlebar cover A Face the paint mark on the front brake hose front brake master cylinder to hydraulic unit to the front B Position the front brake hose front brake master cylinder to hydraulic unit so that its projection contacts the front brake master cylinder C Position the rear brake hose rear brake master cylinder to hydraulic unit so that its projection contacts the rea...

Page 38: ...CABLE ROUTING 2 15 Handlebar left side view 1 2 1 2 3 4 3 4 3 4 3 4 6 2 5 5 1 2 3 4 5 6 1 2 3 4 5 6 1 5 6 ...

Page 39: ... cylinder to hydraulic unit 2 Handlebar switch lead left handlebar switch 3 Throttle cable decelerator cable 4 Throttle cable accelerator cable 5 Front brake hose front brake master cylinder to hydraulic unit 6 Handlebar switch lead right handlebar switch ...

Page 40: ...CABLE ROUTING 2 17 Steering left side view 5 1 6 2 3 4 7 8 7 4 3 9 2 2 2 12 10 12 11 11 11 13 13 8 14 14 15 16 17 18 19 15 19 12 3 4 8 20 21 22 23 23 24 A B B D C E ...

Page 41: ...ine Control Unit 16 Radiator fan motor relay 17 Rollover valve 18 Starting circuit cut off relay 19 Rectifier regulator 20 Main switch 21 Rear brake hose hydraulic unit to rear brake caliper 22 Front storage compartment lock cable 23 Rectifier regulator coupler 24 Horn A Position the tapes on the right handlebar switch lead and left handlebar switch lead to the rear of the guide on the frame B Pos...

Page 42: ...CABLE ROUTING 2 19 Frame left side view A A D E B C B F 1 1 2 2 3 3 1 2 3 3 1 2 3 4 3 4 4 4 5 5 5 5 5 6 7 9 8 8 11 10 10 10 12 4 ...

Page 43: ...neto lead A Route the wire harness through the guide on the frame B Route the seat lock cable to the inside of the frame C Make sure that the frame ground terminal contact the frame D Fasten the wire harness with the plastic band Route the plastic band through the upper hole of the stay on the flame E Point the end of plastic band downward Make sure that the end does not contact the fuel tank F Co...

Page 44: ...CABLE ROUTING 2 21 Frame top view A C B H I D E F G J 1 2 3 4 5 5 7 6 5 6 7 6 7 8 9 12 10 11 13 14 14 14 ...

Page 45: ... under the engine ground lead and over the AC magneto lead C Make sure that the engine ground lead terminal contacts the stopper on the crankcase D Route the wire harness and rear wheel sensor lead through the guide E Route the seat lock cable through the guide F Route the rear wheel sensor lead to the rear of wire harness G When routing the spark plug lead make sure that the distance between the ...

Page 46: ...CABLE ROUTING 2 23 Radiator front and left view A C B A F E D 2 1 5 4 3 2 6 I G 7 J H 2 ...

Page 47: ...r hose to the rear of the projection on the radiator rear cover D Install the coolant reservoir hose with its paint mark facing forward E Point the ends of the hose clamp forward F Face the paint mark on the radiator filler hose forward G Fasten the coolant reservoir breather hose with the clamp on the radiator rear cover H Install the coolant reservoir hose with its paint mark facing upward I Fas...

Page 48: ...CABLE ROUTING 2 25 Radiator right side view E 2 2 2 2 2 3 I 1 A B 4 4 4 4 H K 3 D 5 C F 6 H G G I J 7 8 7 8 7 8 9 9 9 ...

Page 49: ...paint mark facing to the right D Install the cooling system air bleed hose with its paint mark facing to the right Point the end of clamp to the right E Install the radiator filler hose with its paint mark facing forward Point the end of clamp forward F Install the radiator filler hose with its paint mark facing to the right Point the end of clamp to the right G Make sure that the end of the hoses...

Page 50: ...CABLE ROUTING 2 27 Tail brake light left side view 4 B A C D E F 1 2 2 2 3 3 4 4 5 3 ...

Page 51: ...hrough the hole in the rear lower cowling assembly Align the tapes on the leads with the hole C Route the license plate light lead to the hole on the frame D Route the tail brake light lead left tail brake light to the rear of the turn signal light lead and the front of the rear lower cowling assembly E Route the tail brake light lead right tail brake light and license plate light lead through the...

Page 52: ...CABLE ROUTING 2 29 Air filter case top view 1 1 2 1 2 3 3 4 A B D C E F G H I I J C ...

Page 53: ...d C 1 5 mm 0 04 0 20 in D Point the ends of hose clamp to the rearward E Fasten the hose with the clamp with its end facing downward F Install the cylinder head breather hose with its paint mark facing to the right and completely onto the hose fitting G 1 3 mm 0 04 0 12 in H Route the cylinder head breather hose through the guide on the air filter case joint I Install the cylinder head breather ho...

Page 54: ...CABLE ROUTING 2 31 Hydraulic unit top and left right side view 1 2 2 2 3 3 4 1 2 3 4 5 6 1 6 ...

Page 55: ...o front brake caliper 2 Rear brake hose hydraulic unit to rear brake caliper 3 Rear brake hose rear brake master cylinder to hydraulic unit 4 Front brake hose front brake master cylinder to hydraulic unit 5 Hydraulic unit assembly 6 Front wheel sensor lead ...

Page 56: ...CABLE ROUTING 2 33 Battery front side view B A 2 1 8 7 3 4 4 3 5 6 9 10 ...

Page 57: ...Positive battery lead 4 Battery 5 Yamaha diagnostic tool coupler 6 Starter relay 7 Fuse box 2 8 Fuse box 1 9 Battery band 10 ABS test coupler lead A Route the positive battery leads through the battery band B Route the ABS test coupler lead through the battery band ...

Page 58: ...CABLE ROUTING 2 35 Battery rear view 1 2 3 4 2 2 2 3 A 3 2 3 2 ...

Page 59: ...CABLE ROUTING 2 36 1 Headlight lead 2 Wire harness 3 Starter relay lead 4 Meter assembly coupler A Route the wire harness through the guide ...

Page 60: ...CABLE ROUTING 2 37 Front fork right side view 1 1 2 2 2 1 1 2 1 2 A A B C 1 2 ...

Page 61: ...ke hose hydraulic unit to front brake caliper 2 Front wheel sensor A Fasten the front brake hose hydraulic unit to front brake caliper and front wheel sensor with the clamp in the area shown in the illustration B Rearward C Forward ...

Page 62: ...CABLE ROUTING 2 39 Fuel tank right side view D C H B 1 1 1 2 3 6 6 6 4 6 5 7 8 8 2 9 7 7 6 7 4 B A G F E I 10 10 10 10 ...

Page 63: ...ark on the fuel tank breather hose rollover valve to canister to the right C Face the paint mark on the fuel tank breather hose fuel tank to rollover valve to the right D Face the paint mark on the canister breather hose to the right E Rearward F Forward G Fasten the canister purge hose and cooling system air bleed hose with the holder Align the holder with the paint mark on the canister purge hos...

Page 64: ...CABLE ROUTING 2 41 Fuel tank top view 4 4 1 2 3 A D C B B E F ...

Page 65: ...rflow hose upward B Fasten the canister purge hose with the holder Align the holder with the paint mark on the canister purge hose C Forward D Rearward E Face the paint mark on the canister purge hose forward Point the end of hose clamp forward F Install the canister purge hose up to the bend in the hose fitting on the throttle body ...

Page 66: ...CABLE ROUTING 2 43 Rear brake right side view A A 1 1 1 1 1 1 1 B C D E 2 2 ...

Page 67: ...et on the rear wheel sensor lead to the holder on the V belt case air filter element cover C Route the rear wheel sensor lead to the upward of the V belt case air filter element cover rib D Route the rear wheel sensor lead through the guide on the V belt case air filter element cover Position the inside edge of the tape on the lead in the area shown in the illustration E Position the rear brake ho...

Page 68: ...CABLE ROUTING 2 45 ...

Page 69: ...REAR BRAKE HOSES 3 12 BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS 3 12 CHECKING THE WHEELS 3 13 CHECKING THE TIRES 3 14 CHECKING THE WHEEL BEARINGS 3 15 CHECKING AND ADJUSTING THE STEERING HEAD 3 15 LUBRICATING THE STEERING HEAD 3 16 CHECKING THE CHASSIS FASTENERS 3 16 LUBRICATING THE LEVERS 3 17 CHECKING THE SIDESTAND 3 17 LUBRICATING THE SIDESTAND 3 17 CHECKING THE CENTERSTAND 3 17 LUBRICATING THE C...

Page 70: ...ADJUSTING THE HEADLIGHT BEAM 3 25 ...

Page 71: ......

Page 72: ...RAL MAINTENANCE AND LUBRICATION CHART TIP The annual checks must be performed every year except if a kilometerbased maintenance or for the UK a mileage based maintenance is performed instead From 50000 km 30000 mi repeat the maintenance intervals starting from 10000 km 6000 mi Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools data and technical skil...

Page 73: ...earing assemblies for looseness Moderately repack with lithi um soap based grease 15 Chassis fasteners Make sure that all nuts bolts and screws are properly tight ened 16 Front and rear brake lever pivot shaft Lubricate with silicone grease 17 Sidestand center stand Check operation Lubricate with lithium soap based grease 18 Sidestand switch Check operation and replace if necessary 19 Front fork C...

Page 74: ...ed Every two years replace the internal components of the brake master cylinders and calipers and change the brake fluid Replace the brake hoses every four years and if cracked or damaged 24 Cooling system Check coolant level and vehi cle for coolant leakage Change Every 3 years 25 V belt Replace When the V belt replacement indicator flashes every 20000 km 12000 mi 26 Front and rear brake switches...

Page 75: ...rsion 3 0 and after to perform the dynamic inspection For information about using the Yamaha diagnostic tool refer to the operation manual that is included with the tool 5 Install Battery cover assembly Refer to GENERAL CHASSIS 1 on page 4 1 EAS30619 CHECKING THE FUEL LINE 1 Remove Battery cover assembly Refer to GENERAL CHASSIS 1 on page 4 1 Front cowling assemblies Refer to GENERAL CHASSIS 2 on ...

Page 76: ...tightening the spark plug make sure that the inside a of the spark plug wrench 2 does not the contact the portion b of the spark plug 8 Install Storage box Refer to GENERAL CHASSIS 4 on page 4 10 EAS30622 ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves TIP Valve clearance adjustment should be made on a cold engine at room temperature When the valve clearance is t...

Page 77: ... the piston is at TDC on the compression stroke align the I mark c on the camshaft sprocket with the match mark d on the cylinder head c Measure the valve clearance with a thick ness gauge 1 Out of specification Adjust 4 Adjust Valve clearance a Remove the collars 1 b Slide the rocker arms 2 toward the timing chain and then remove the valve pads 3 TIP Before removing the valve pads cover the crank...

Page 78: ...ricate the valve pad with molybdenum di sulfide oil Install the valve pad in the correct place h Measure the valve clearance again i If the valve clearance is still out of specifi cation repeat all of the valve clearance adjustment steps until the specified clear ance is obtained 5 Install All removed parts TIP For installation reverse the removal procedure EAS31017 CHECKING THE ENGINE IDLING SPEE...

Page 79: ... on page 8 34 EAS31922 CHECKING THE CANISTER 1 Remove Battery Refer to GENERAL CHASSIS 1 on page 4 1 Front cowling assemblies Refer to GENERAL CHASSIS 2 on page 4 4 Meter assembly Refer to GENERAL CHASSIS 3 on page 4 7 Lower side covers Refer to GENERAL CHASSIS 4 on page 4 10 Footrest board assembly Refer to GENERAL CHASSIS 5 on page 4 13 Leg shield assembly Refer to GENERAL CHASSIS 6 on page 4 16...

Page 80: ...r element 1 Remove Air filter case cover Pre air filter element 1 Refer to AIR FILTER CASE on page 7 11 2 Clean Pre air filter element Blow the compressed air to the outer surface of the pre air filter element 3 Install Pre air filter element Refer to INSTALLING THE AIR FILTER CASE on page 7 12 4 Remove Sub air filter element 1 Air filter element 2 Refer to AIR FILTER CASE on page 7 11 5 Check Sub...

Page 81: ...er cover bolts 1 V belt case air filter element cover 2 TIP Lift up the air filter case slightly remove the rear wheel sensor lead 3 from the holders a on the V belt case air filter element cover and then re move the V belt case air filter element cover 2 Remove V belt case air duct 1 3 Remove V belt case air filter element 1 4 Clean V belt case air filter element Blow the compressed air to the ou...

Page 82: ... to FRONT BRAKE on page 4 38 EAS30634 CHECKING THE REAR BRAKE PADS The following procedure applies to all of the brake pads 1 Operate the brake 2 Check Rear brake pad Wear indicators a almost touch the brake disc Replace the brake pads and brake pad shims as a set Refer to REAR BRAKE on page 4 51 EAS30632 CHECKING THE BRAKE FLUID LEVEL 1 Stand the vehicle on a level surface TIP Place the vehicle o...

Page 83: ...hose lead guide Front brake hose holder Loose Tighten the holder and guide bolt 3 Hold the vehicle upright and apply the front brake several times 4 Check Brake hoses Brake fluid leakage Replace the damaged hose Refer to FRONT BRAKE on page 4 38 and ABS ANTI LOCK BRAKE SYSTEM on page 4 63 EAS30636 CHECKING THE REAR BRAKE HOSES 1 Check Brake hoses 1 Cracks damage Replace 2 Check Rear brake hose hol...

Page 84: ...screw TIP Loosening the bleed screw will release the pres sure and cause the brake lever to contact the throttle grip or handlebar grip h Tighten the bleed screw and then release the brake lever i Repeat steps e to h until all of the air bubbles have disappeared from the brake fluid in the plastic hose j Check the operation of the hydraulic unit Refer to HYDRAULIC UNIT OPERA TION TESTS on page 4 6...

Page 85: ...re surfaces Damage wear Replace the tire WARNING EWA14080 Do not use a tubeless tire on a wheel de signed only for tube tires to avoid tire fail ure and personal injury from sudden deflation When using a tube tire be sure to install the correct tube Always replace a new tube tire and a new tube as a set To avoid pinching the tube make sure the wheel rim band and tube are centered in the wheel groo...

Page 86: ...lies to all of the wheel bearings 1 Check Wheel bearings Refer to CHECKING THE FRONT WHEEL on page 4 29 EAS30645 CHECKING AND ADJUSTING THE STEERING HEAD 1 Stand the vehicle on a level surface WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over TIP Place the vehicle on a suitable stand so that the front wheel elevated 2 Check Steering head Grasp the handleba...

Page 87: ...s If neces sary hold the lower ring nut and tighten the upper ring nut until their slots are aligned h Install the lock washer 1 TIP Make sure the lock washer tabs a sit correctly in the ring nut slots b 5 Install Handlebar Refer to HANDLEBAR on page 4 71 Meter panel assembly Refer to GENERAL CHASSIS 3 on page 4 7 Front cowling assemblies Refer to GENERAL CHASSIS 2 on page 4 4 Battery Refer to GEN...

Page 88: ...right and apply the front brake 4 Check Front fork operation Push down hard on the handlebar several times and check if the front fork rebounds smoothly Rough movement Repair Refer to FRONT FORK on page 4 78 EAS30808 CHECKING THE REAR SHOCK ABSORBER ASSEMBLIES The following procedure applies to both of the rear shock absorber assemblies 1 Stand the vehicle on a level surface WARNING EWA13120 Secur...

Page 89: ...several min utes and then turn it off 3 Check Engine oil level The engine oil level should be between the minimum level mark a and maximum level mark b Below the minimum level mark Add the recommended engine oil to the proper level TIP Before checking the engine oil level wait a few minutes until the oil has settled NOTICE ECA13370 Do not allow foreign materials to enter the crankcase 4 Start the ...

Page 90: ...cover 6 Install Engine oil drain bolt along with the gasket 7 Fill Crankcase with the specified amount of the recom mended engine oil 8 Install Engine oil filler cap along with the O ring 9 Start the engine warm it up for several min utes and then turn it off 10 Check Engine for engine oil leaks 11 Check Engine oil level Refer to CHECKING THE ENGINE OIL LEVEL on page 3 18 12 Remove Storage box Ref...

Page 91: ...the final transmission oil 5 Install Final transmission oil drain bolt along with the copper washer 6 Fill Final transmission oil with the specified amount of the recom mended final transmission oil 7 Install Final transmission oil filler cap along with the O ring TIP Lubricate the O ring with lithium soap based grease 8 Start the engine warm it up for several min utes and then turn it off 9 Check...

Page 92: ...10 Radiator cover Refer to GENERAL CHASSIS 5 on page 4 13 Exhaust pipe Refer to ENGINE REMOVAL on page 5 7 2 Check Radiator 1 Cooling system air bleed hose 2 Coolant reservoir hose 3 Radiator filler pipe 4 Radiator filler hose 5 Radiator outlet hose 6 Radiator inlet hose 7 Thermostat assembly 8 Water pump inlet hose 9 Water pump outlet pipe 10 Cracks tears Replace Refer to RADIATOR on page 6 2 THE...

Page 93: ...n the hissing sound has stopped press down on the radi ator cap and turn it counterclockwise to re move TIP When removing the radiator cap hold the radia tor filler pipe 2 5 Remove Coolant drain bolt radiator side 1 along with the O ring Coolant drain bolt water pump side 2 along with the copper washer 6 Drain Coolant from the engine and radiator 7 Install Coolant drain bolt water pump side along ...

Page 94: ...ter Do not mix different types of antifreeze 9 Install Radiator cap 1 TIP Make sure that the projection a on the radiator cap contacts the projection b on the radiator fill er pipe 10 Connect Coolant reservoir hose Coolant reservoir breather hose 11 Remove Coolant reservoir cap 12 Fill Coolant reservoir with the recommended coolant to the maxi mum level mark a 13 Install Coolant reservoir cap 1 TI...

Page 95: ...f the in ner and outer cables WARNING EWA13270 Damaged outer cable may cause the cable to corrode and interfere with its movement Re place damaged outer cable and inner cables as soon as possible 1 Check Outer cable Damage Replace 2 Check Cable operation Rough movement Lubricate TIP Hold the cable end upright and pour a few drops of lubricant into the cable sheath or use a suit able lubricating de...

Page 96: ...t the engine and turn the handlebars to the right and to the left to ensure that this does not cause the engine idling speed to change EAS30663 CHECKING THE SWITCHES LIGHTS AND SIGNALS 1 Check that all switches operate and that all lights come on Refer to Instrument and control functions in OWNER S MANUAL Faulty Refer to CHECKING THE SWITCHES on page 8 127 and CHECK ING THE BULBS AND BULB SOCKETS ...

Page 97: ...S 4 4 10 REMOVING THE UPPER SIDE COVERS 4 11 INSTALLING THE UPPER SIDE COVERS 4 11 REMOVING THE LOWER CENTER COVER 4 11 INSTALLING THE LOWER CENTER COVER 4 11 REMOVING THE LOWER SIDE COVERS 4 12 INSTALLING THE LOWER SIDE COVERS 4 12 GENERAL CHASSIS 5 4 13 DISASSEMBLING THE FOOTREST BOARD ASSEMBLIES 4 15 ASSEMBLING THE FOOTREST BOARD ASSEMBLIES 4 15 INSTALLING THE RADIATOR COVER 4 15 GENERAL CHASSI...

Page 98: ... 45 REMOVING THE FRONT BRAKE CALIPER 4 46 DISASSEMBLING THE FRONT BRAKE CALIPER 4 46 CHECKING THE FRONT BRAKE CALIPER 4 47 ASSEMBLING THE FRONT BRAKE CALIPER 4 47 INSTALLING THE FRONT BRAKE CALIPER 4 47 REMOVING THE FRONT BRAKE MASTER CYLINDER 4 48 CHECKING THE FRONT BRAKE MASTER CYLINDER 4 49 ASSEMBLING THE FRONT BRAKE MASTER CYLINDER 4 49 INSTALLING THE FRONT BRAKE MASTER CYLINDER 4 49 REAR BRAK...

Page 99: ... HANDLEBAR 4 75 INSTALLING THE UPPER HANDLEBAR COVER 4 77 FRONT FORK 4 78 REMOVING THE FRONT FORK LEGS 4 82 DISASSEMBLING THE FRONT FORK LEGS 4 82 CHECKING THE FRONT FORK LEGS 4 83 ASSEMBLING THE FRONT FORK LEGS 4 83 INSTALLING THE FRONT FORK LEGS 4 86 STEERING HEAD 4 87 REMOVING THE LOWER BRACKET 4 89 CHECKING THE STEERING HEAD 4 89 INSTALLING THE STEERING HEAD 4 89 REAR SHOCK ABSORBER ASSEMBLIES...

Page 100: ... Battery rear cover 1 4 Windshield cover 2 5 Windshield 1 6 Windshield bracket 2 7 Negative battery lead 1 Disconnect 8 Positive battery lead 1 Disconnect 9 ABS test coupler 1 10 Battery 1 11 Battery band 1 1 5 N m 0 15 kgf m 1 1 lb ft T R 1 8 N m 0 18 kgf m 1 3 lb ft T R 1 8 N m 0 18 kgf m 1 3 lb ft T R 0 5 N m 0 05 kgf m 0 37 lb ft T R 8 N m 0 8 kgf m 5 9 lb ft T R 1 5 4 6 3 2 11 9 7 10 8 ...

Page 101: ...gs c Pull the battery cover assembly forward to remove the projections c on the battery cover assembly from the grommets EAS32307 INSTALLING THE BATTERY COVER ASSEMBLY 1 Install Battery cover assembly 1 a Fit the projections a on the battery cover assembly into the grommets b Fit the projections b on the battery cover assembly into the holes c in the front up per cowlings c Install the battery cov...

Page 102: ...v er 1 into the holes b in the battery rear cov er 2 2 Install the battery cover screws and quick fas tener and then tighten the screws to specifi cation EAS31397 ADJUSTING THE WINDSHIELD HEIGHT 1 Remove Windshield covers Windshield 2 Adjust Windshield height position TIP Remove the bolts and then install the bolts 1 in the desired position 3 Install Windshield Windshield covers T R Battery cover ...

Page 103: ...ly right 1 6 Front turn signal light coupler right 1 Disconnect 7 Front upper cowling left 1 8 Front turn signal light left 1 9 Front lower cowling left 1 10 Front upper cowling right 1 11 Front turn signal light right 1 12 Front lower cowling right 1 1 8 N m 0 18 kgf m 1 3 lb ft T R 1 8 N m 0 18 kgf m 1 3 lb ft T R 1 8 N m 0 18 kgf m 1 3 lb ft T R 1 8 N m 0 18 kgf m 1 3 lb ft T R 1 8 N m 0 18 kgf...

Page 104: ...jections a on the front cowling assembly into the holes b in the leg shield assembly and headlight unit cover b Install the front cowling assembly bolt screws and quick fasteners and then tighten the bolt and screws to specifica tion EAS32312 DISASSEMBLING THE FRONT COWLING ASSEMBLIES The following procedure applies to both of the front cowling assemblies 1 Remove the front cowling screws and clam...

Page 105: ...nt cowling screws and clamp and then tighten the screws to specification 3 Route the front turn signal light lead through the guides a on the front upper cowling and front lower cowling 4 Fit the front turn signal light coupler into the slot b in the front upper cowling T R Front cowling screw 1 8 N m 0 18 kgf m 1 3 lb ft a a b b 1 2 b a b ...

Page 106: ...ight unit coupler 1 Disconnect 3 Headlight unit cover 1 4 Headlight unit 1 5 Meter assembly panel molding 1 6 Starter relay 1 7 Fuse box 1 1 8 Fuse box 2 1 9 Yamaha diagnostic tool coupler 1 10 Battery box 1 1 8 N m 0 18 kgf m 1 3 lb ft T R 1 8 N m 0 18 kgf m 1 3 lb ft T R 1 8 N m 0 18 kgf m 1 3 lb ft T R 8 N m 0 8 kgf m 5 9 lb ft T R 7 N m 0 7 kgf m 5 2 lb ft T R 8 N m 0 8 kgf m 5 9 lb ft T R 7 N...

Page 107: ...pler 1 Disconnect 13 Meter panel assembly 1 14 Meter assembly panel 1 15 Meter assembly 1 1 8 N m 0 18 kgf m 1 3 lb ft T R 1 8 N m 0 18 kgf m 1 3 lb ft T R 1 8 N m 0 18 kgf m 1 3 lb ft T R 8 N m 0 8 kgf m 5 9 lb ft T R 7 N m 0 7 kgf m 5 2 lb ft T R 8 N m 0 8 kgf m 5 9 lb ft T R 7 N m 0 7 kgf m 5 2 lb ft T R 7 N m 0 7 kgf m 5 2 lb ft T R 11 13 14 15 12 ...

Page 108: ...emove the projections a on the meter assem bly panel molding from the holes b in the meter assembly panel EAS32315 INSTALLING THE METER ASSEMBLY PANEL MOLDING 1 Install Meter assembly panel molding 1 TIP Fit the projections a on the meter assembly panel molding into the holes b in the meter as sembly panel b a 1 b a 1 ...

Page 109: ...age box light 1 4 Flap 1 5 Upper side cover left 1 6 Upper side cover right 1 7 Lower center cover 1 8 Lower side cover left 1 9 Lower side cover right 1 1 8 N m 0 18 kgf m 1 3 lb ft T R 1 8 N m 0 18 kgf m 1 3 lb ft T R 1 8 N m 0 18 kgf m 1 3 lb ft T R 9 N m 0 9 kgf m 6 6 lb ft T R 9 N m 0 9 kgf m 6 6 lb ft T R 4 0 N m 0 40 kgf m 3 0 lb ft T R 4 0 N m 0 40 kgf m 3 0 lb ft T R 6 8 5 7 9 3 1 2 4 ...

Page 110: ...following procedure applies to both of the upper side covers 1 Install Upper side cover 1 a Fit the projections a on the upper side cover into the holes b in the lower side covers b Install the quick fasteners EAS32318 REMOVING THE LOWER CENTER COVER 1 Remove Lower center cover 1 a Remove the lower center cover screws b Pull the lower center cover outward to re move the projections a on the cover ...

Page 111: ...b Pull the lower side cover outward to re move the projections a on the cover from the grommets b EAS32321 INSTALLING THE LOWER SIDE COVERS The following procedure applies to both of the lower side covers 1 Install Lower side cover 1 a Fit the projections a on the lower side cover into the grommets b b Install the lower side cover bolt and screws and then tighten the bolt to speci fication T R Low...

Page 112: ...est board mat right 1 3 Footrest board assembly left 1 4 Footrest board assembly right 1 5 Radiator cover 1 6 Bottom cover assembly 1 7 Footrest board molding left 1 8 Footrest board left 1 1 8 N m 0 18 kgf m 1 3 lb ft T R 1 8 N m 0 18 kgf m 1 3 lb ft T R 1 8 N m 0 18 kgf m 1 3 lb ft T R 1 8 N m 0 18 kgf m 1 3 lb ft T R 2 5 N m 0 25 kgf m 1 8 lb ft T R 3 8 N m 0 38 kgf m 2 8 lb ft T R 3 8 N m 0 38...

Page 113: ...2 Bottom cover 1 1 13 Bottom cover 2 1 1 8 N m 0 18 kgf m 1 3 lb ft T R 1 8 N m 0 18 kgf m 1 3 lb ft T R 1 8 N m 0 18 kgf m 1 3 lb ft T R 1 8 N m 0 18 kgf m 1 3 lb ft T R 2 5 N m 0 25 kgf m 1 8 lb ft T R 3 8 N m 0 38 kgf m 2 8 lb ft T R 3 8 N m 0 38 kgf m 2 8 lb ft T R 9 N m 0 9 kgf m 6 6 lb ft T R 9 N m 0 9 kgf m 6 6 lb ft T R 9 N m 0 9 kgf m 6 6 lb ft T R 9 N m 0 9 kgf m 6 6 lb ft T R 11 10 13 1...

Page 114: ...RD ASSEMBLIES The following procedure applies to both of the footrest board assemblies 1 Fit the projections a on the footrest board molding 1 into the holes b in the footrest board 2 2 Install the footrest board screws and clamps and then tighten the screws to specification EAS32348 INSTALLING THE RADIATOR COVER 1 Install Radiator cover 1 TIP Fit the hole a in the radiator cover the hook b on the...

Page 115: ...fer to GENERAL CHASSIS 3 on page 4 7 Lower side covers Refer to GENERAL CHASSIS 4 on page 4 10 Footrest board assemblies Refer to GENERAL CHASSIS 5 on page 4 13 1 Fuel tank cap lid assembly 1 2 Fuel tank cap lid lock cable 1 Disconnect 3 Fuel tank cap lid cover 1 4 Fuel tank cap lid 1 3 8 N m 0 38 kgf m 2 8 lb ft T R 3 8 N m 0 38 kgf m 2 8 lb ft T R 1 8 N m 0 18 kgf m 1 3 lb ft T R 9 N m 0 9 kgf m...

Page 116: ...t 1 Open 7 Upper center cover 1 8 Auxiliary DC jack coupler 1 Disconnect 9 Buzzer coupler 1 Disconnect 10 Front storage compartment lock cable assembly 1 11 Leg shield assembly 1 3 8 N m 0 38 kgf m 2 8 lb ft T R 3 8 N m 0 38 kgf m 2 8 lb ft T R 1 8 N m 0 18 kgf m 1 3 lb ft T R 9 N m 0 9 kgf m 6 6 lb ft T R 9 N m 0 9 kgf m 6 6 lb ft T R 5 10 9 7 11 6 8 ...

Page 117: ... ty Remarks 1 Front storage box left 1 2 Auxiliary DC jack 1 3 Front storage box right 1 4 Buzzer 1 5 Leg shield 1 1 8 N m 0 18 kgf m 1 3 lb ft T R 1 8 N m 0 18 kgf m 1 3 lb ft T R 1 8 N m 0 18 kgf m 1 3 lb ft T R 2 8 N m 0 28 kgf m 2 1 lb ft T R 1 0 N m 0 10 kgf m 0 73 lb ft T R 5 2 3 4 1 ...

Page 118: ... the fuel tank cap lid cover into the holes b in the fuel tank cap lid b Install the fuel tank cap lid cover screw and then tighten the screw to specification EAS32329 REMOVING THE UPPER CENTER COVER 1 Remove Upper center cover 1 a Remove the quick fasteners b Pull the upper center cover outward to re move the projections a on the cover from the holes b in the leg shield EAS32330 INSTALLING THE UP...

Page 119: ...GENERAL CHASSIS 6 4 20 a Fit the projections a on the upper center cover into the holes b in the leg shield b Install the quick fasteners 1 a 1 b ...

Page 120: ...blies Refer to GENERAL CHASSIS 2 on page 4 4 Lower side cover Refer to GENERAL CHASSIS 4 on page 4 10 Footrest board assemblies Refer to GENERAL CHASSIS 5 on page 4 13 1 Seat 1 2 Seat damper pivot 1 3 Seat hinge pin 1 4 Seat hinge 1 5 Seat hinge molding 2 6 Seat damper 1 7 Seat damper bracket 1 7 N m 0 7 kgf m 5 2 lb ft T R 12 N m 1 2 kgf m 8 9 lb ft T R 1 6 7 2 4 5 3 New 25 N m 2 5 kgf m 18 lb ft...

Page 121: ...GENERAL CHASSIS 7 4 22 EAS32331 INSTALLING THE SEAT DAMPER 1 Install Seat damper 1 TIP Install the seat damper so that the rod a is pointing downward as shown in the illustration 1 a ...

Page 122: ...light 1 Disconnect 7 Tail brake light connector left tail brake light 1 Disconnect 8 Tail brake light coupler right tail brake light 1 Disconnect 9 Tail brake light connector right tail brake light 1 Disconnect 10 Rear lower cowling assembly 1 23 N m 2 3 kgf m 17 lb ft T R 23 N m 2 3 kgf m 17 lb ft T R 1 8 N m 0 18 kgf m 1 3 lb ft T R 1 8 N m 0 18 kgf m 1 3 lb ft T R 1 8 N m 0 18 kgf m 1 3 lb ft T...

Page 123: ...ob Parts to remove Q ty Remarks 1 Tail brake light cover 1 2 Rear lower cowling left 1 3 Tail brake light left 1 4 Rear lower cowling right 1 5 Tail brake light right 1 1 8 N m 0 18 kgf m 1 3 lb ft T R 1 8 N m 0 18 kgf m 1 3 lb ft T R 1 8 N m 0 18 kgf m 1 3 lb ft T R 4 5 3 1 2 ...

Page 124: ...er cover 1 a Fit the projections a on the rear center cover into the holes b in the rear upper cowling b Fit the projections c on the rear center cover into the holes d in the tail brake light cover c Fit the holes e in the rear center cover to the projection f on the tail brake light cov er d Tighten the rear center cover screws to specification EAS32354 REMOVING THE REAR UPPER COWLINGS The follo...

Page 125: ...ar upper cowlings 1 Install Rear upper cowling 1 a Fit the projection a on the rear upper cowling into the hole b in the rear lower cowling b Tighten the rear upper cowling bolt and screw to specification T R Rear upper cowling bolt 7 N m 0 7 kgf m 5 2 lb ft Rear upper cowling screw 1 8 N m 0 18 kgf m 1 3 lb ft 1 a b ...

Page 126: ...1 3 Front wheel sensor 1 4 Front wheel axle nut 1 5 Front wheel axle 1 6 Collar 2 7 Front wheel 1 8 Front wheel sensor rotor 1 9 Front brake disc 1 23 N m 2 3 kgf m 17 lb ft T R 52 N m 5 2 kgf m 38 lb ft T R 7 N m 0 7 kgf m 5 2 lb ft T R 7 N m 0 7 kgf m 5 2 lb ft T R 8 N m 0 8 kgf m 5 9 lb ft T R 35 N m 3 5 kgf m 26 lb ft T R LT LT LT LT LS LS New 4 7 9 5 3 6 6 2 1 8 5 3 ...

Page 127: ...FRONT WHEEL 4 28 Disassembling the front wheel Order Job Parts to remove Q ty Remarks 1 Oil seal 2 2 Wheel bearing left 1 3 Spacer 1 4 Wheel bearing right 1 2 3 1 4 1 LS New New New New LS ...

Page 128: ...ke lever when removing the brake caliper 3 Elevate Front wheel TIP Place the vehicle on a suitable stand so that the front wheel is elevated EAS30146 DISASSEMBLING THE FRONT WHEEL 1 Remove Oil seals Wheel bearings a Clean the surface of the front wheel hub b Remove the oil seals 1 with a flat head screwdriver TIP To prevent damaging the wheel place a rag 2 between the screwdriver and the wheel sur...

Page 129: ...he wheel sensor or the wheel sensor rotor 1 Check Front wheel sensor 1 Cracks bends distortion Replace Iron powder dust Clean 2 Check Front wheel sensor rotor 1 Cracks damage scratches Replace the front wheel sensor rotor Iron powder dust solvent Clean TIP When cleaning the wheel sensor rotor be care ful not to damage the surface of the sensor rotor EAS30151 ASSEMBLING THE FRONT WHEEL 1 Lubricate ...

Page 130: ...static balance EAS30154 INSTALLING THE FRONT WHEEL FRONT BRAKE DISC 1 Install Front brake disc 1 Front wheel sensor rotor 2 NOTICE ECA21011 Do not drop the wheel sensor rotor or sub ject it to shocks If any solvent gets on the wheel sensor ro tor wipe it off immediately Replace the brake disc bolts and wheel sensor rotor bolts with new ones TIP Install the brake disc with its chamfered side a faci...

Page 131: ...ar ing for looseness and the front wheel sensor and sensor rotor installation conditions warpage caused by overtorque wrong in stallation direction rotor decentering LOC TITE on the mounting surface of the rotor deformation caused by an impact during ser vice and caught foreign materials If there is any defective part repair or replace the de fective part TIP Measure the distance between the front...

Page 132: ...FRONT WHEEL 4 33 WARNING EWA13500 Make sure the brake hose is routed properly ...

Page 133: ...e 5 7 Swingarm assembly Refer to REAR SHOCK ABSORBER AS SEMBLIES AND SWINGARM on page 4 91 1 Rear wheel 1 2 Rear brake disc 1 3 Rear wheel sensor rotor 1 4 Rear wheel sensor bracket 1 5 Rear wheel sensor 1 New New LT LT 3 23 N m 2 3 kgf m 17 lb ft T R 7 N m 0 7 kgf m 5 2 lb ft T R 8 N m 0 8 kgf m 5 9 lb ft T R 10 N m 1 0 kgf m 7 4 lb ft T R 5 4 3 1 2 3 ...

Page 134: ...m away from dirt and do not sub ject them to shocks The rear wheel sensor cannot be disassem bled Do not attempt to disassemble it If faulty replace with a new one Keep any type of magnets including mag netic pick up tools magnetic screwdrivers etc away from the rear wheel sensor or rear wheel sensor rotor Do not drop or shock the wheel sensor or the wheel sensor rotor 1 Check Rear wheel sensor Re...

Page 135: ...t of specification Check the wheel bear ing for looseness and the rear wheel sensor and sensor rotor installation conditions warpage caused by overtorque wrong in stallation direction rotor decentering LOC TITE on the mounting surface of the rotor deformation caused by an impact during ser vice and caught foreign materials If there is any defective part repair or replace the de fective part TIP Me...

Page 136: ...REAR WHEEL 4 37 2 1 2 1 a ...

Page 137: ...rake hose lead guide 1 2 Front brake caliper 1 3 Brake pad clip 2 4 Brake pad pin 1 5 Brake pad inner 1 6 Brake pad outer 1 7 Brake pad spring 1 8 Brake caliper bleed screw 1 Loosen 5 7 2 8 4 3 1 6 7 N m 0 7 kgf m 5 2 lb ft T R 35 N m 3 5 kgf m 26 lb ft T R 6 N m 0 6 kgf m 4 4 lb ft T R 35 N m 3 5 kgf m 26 lb ft T R ...

Page 138: ...inder reservoir diaphragm hold er 1 3 Brake master cylinder reservoir diaphragm 1 4 Front brake light switch connector 2 Disconnect 5 Front brake light switch 1 6 Front brake lever pivot bolt nut 1 1 7 Front brake lever 1 8 Front brake hose union bolt master cylinder side 1 8 4 5 6 7 6 3 2 1 S New New 1 5 N m 0 15 kgf m 1 1 lb ft T R 29 N m 2 9 kgf m 21 lb ft T R 11 N m 1 1 kgf m 8 1 lb ft T R 6 N...

Page 139: ... brake master cylinder to hydraulic unit 1 Disconnect 11 Front brake master cylinder holder 1 12 Front brake master cylinder assembly 1 9 10 9 12 11 S New New 1 5 N m 0 15 kgf m 1 1 lb ft T R 29 N m 2 9 kgf m 21 lb ft T R 11 N m 1 1 kgf m 8 1 lb ft T R 6 N m 0 6 kgf m 4 4 lb ft T R 6 N m 0 6 kgf m 4 4 lb ft T R 1 1 N m 0 11 kgf m 0 81 lb ft T R ...

Page 140: ...FRONT BRAKE 4 41 Disassembling the front brake master cylinder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder kit 1 2 Brake master cylinder body 1 2 1 S BF New ...

Page 141: ...M ABS on page 3 12 1 Front brake hose union bolt brake caliper side 1 2 Brake hose gasket 2 3 Front brake hose hydraulic unit to front brake caliper 1 Disconnect 4 Front brake hose lead guide 1 5 Front brake caliper 1 5 3 1 2 4 New 29 N m 2 9 kgf m 21 lb ft T R 7 N m 0 7 kgf m 5 2 lb ft T R 35 N m 3 5 kgf m 26 lb ft T R 35 N m 3 5 kgf m 26 lb ft T R ...

Page 142: ...1 3 Brake pad inner 1 4 Brake pad outer 1 5 Brake pad spring 1 6 Front brake caliper bracket 1 7 Brake caliper piston 2 8 Brake caliper piston dust seal 2 9 Brake caliper piston seal 2 10 Brake caliper bleed screw 1 11 Brake caliper body 1 3 4 5 2 1 10 11 9 8 9 8 7 7 6 S S New New BF BF S S S New New 6 N m 0 6 kgf m 4 4 lb ft T R ...

Page 143: ...age 4 27 2 Check Brake disc Damage galling Replace 3 Measure Brake disc runout Out of specification Correct the brake disc runout or replace the brake disc a Place the vehicle on a suitable stand so that the front wheel is elevated b Before measuring the front brake disc runout turn the handlebar to the left or right to ensure that the front wheel is sta tionary c Remove the brake caliper d Hold t...

Page 144: ...rake caliper 1 Measure Brake pad wear limit a Out of specification Replace the brake pads as a set 2 Install Brake pad spring Brake pads TIP Always install new brake pads and new brake pad spring as a set a Connect a clear plastic hose 1 tightly to the bleed screw 2 Put the other end of the hose into an open container b Loosen the bleed screw and push the brake caliper piston into the brake calipe...

Page 145: ...emoving the brake caliper drain the brake fluid from the entire brake system 1 Remove Front brake hose union bolt 1 Brake hose gaskets 2 Front brake hose 3 TIP Put the end of the brake hose into a container and pump out the brake fluid carefully EAS30172 DISASSEMBLING THE FRONT BRAKE CALIPER 1 Remove Brake caliper pistons 1 Brake caliper piston dust seals 2 Brake caliper piston seals 3 a Blow comp...

Page 146: ...on internal brake com ponents as they will cause the brake caliper piston dust seals and brake caliper piston seals to swell and distort Whenever a brake caliper is disassembled replace the brake caliper piston dust seals and brake caliper piston seals EAS30934 INSTALLING THE FRONT BRAKE CALIPER 1 Install Front brake caliper 1 temporarily Front brake hose lead guide 2 Brake hose gaskets 3 Front br...

Page 147: ...ould cause vapor lock NOTICE ECA13540 Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 5 Bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS on page 3 12 6 Check Brake fluid level Below the minimum level mark a Add the specified brake fluid to the proper level Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS on pa...

Page 148: ...nents EAS30182 INSTALLING THE FRONT BRAKE MASTER CYLINDER 1 Install Front brake master cylinder assembly Front brake master cylinder holder 1 TIP Install the brake master cylinder holder with the UP mark a facing up Align the end of the front brake master cylinder holder with the punch mark b on the handle bar First tighten the upper bolt then the lower bolt 2 Install Brake hose gaskets 1 Front br...

Page 149: ...r brake performance When refilling be careful that water does not enter the brake master cylinder reser voir Water will significantly lower the boil ing point of the brake fluid and could cause vapor lock NOTICE ECA13540 Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 4 Bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SY...

Page 150: ...y Remarks 1 Rear brake caliper 1 2 Brake pad clip 2 3 Brake pad pin 1 4 Brake pad inner 1 5 Brake pad outer 1 6 Brake pad shim inner 1 7 Brake pad shim outer 1 8 Brake pad spring 1 9 Brake caliper bleed screw 1 Loosen 5 7 1 9 2 4 3 8 6 6 N m 0 6 kgf m 4 4 lb ft T R 35 N m 3 5 kgf m 26 lb ft T R ...

Page 151: ...ervoir cap 1 2 Brake master cylinder reservoir diaphragm hold er 1 3 Brake master cylinder reservoir diaphragm 1 4 Rear brake light switch connector 2 Disconnect 5 Rear brake light switch 1 6 Rear brake lever pivot bolt nut 1 1 7 Rear brake lever 1 4 5 6 7 6 3 2 1 S New 1 5 N m 0 15 kgf m 1 1 lb ft T R 29 N m 2 9 kgf m 21 lb ft T R 11 N m 1 1 kgf m 8 1 lb ft T R 6 N m 0 6 kgf m 4 4 lb ft T R 6 N m...

Page 152: ...t 2 10 Rear brake hose rear brake master cylinder to hydraulic unit 1 Disconnect 11 Rear brake master cylinder holder 1 12 Rear brake master cylinder assembly 1 8 9 10 12 11 S New 1 5 N m 0 15 kgf m 1 1 lb ft T R 29 N m 2 9 kgf m 21 lb ft T R 11 N m 1 1 kgf m 8 1 lb ft T R 6 N m 0 6 kgf m 4 4 lb ft T R 6 N m 0 6 kgf m 4 4 lb ft T R 1 1 N m 0 11 kgf m 0 81 lb ft T R ...

Page 153: ...REAR BRAKE 4 54 Disassembling the rear brake master cylinder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder kit 1 2 Brake master cylinder body 1 2 1 S BF New ...

Page 154: ...rain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS on page 3 12 1 Rear brake hose union bolt brake caliper side 1 2 Brake hose gasket 2 3 Rear brake hose hydraulic unit to rear brake caliper 1 Disconnect 4 Rear brake caliper 1 New 2 1 3 4 29 N m 2 9 kgf m 21 lb ft T R 35 N m 3 5 kgf m 26 lb ft T R ...

Page 155: ...him inner 1 6 Brake pad shim outer 1 7 Brake pad spring 1 8 Brake caliper bracket 1 9 Collar 1 10 Brake caliper piston 1 11 Brake caliper piston dust seal 1 12 Brake caliper piston seal 1 13 Brake caliper bleed screw 1 14 Brake caliper body 1 S S S New New BF S 23 N m 2 3 kgf m 17 lb ft T R 31 N m 3 1 kgf m 23 lb ft T R 6 N m 0 6 kgf m 4 4 lb ft T R 8 10 11 12 13 14 2 1 7 9 5 3 4 6 ...

Page 156: ... 1 Remove Rear wheel Refer to REAR WHEEL on page 4 34 2 Check Brake disc Damage galling Replace 3 Measure Brake disc runout Out of specification Correct the brake disc runout or replace the brake disc Refer to CHECKING THE FRONT BRAKE DISC on page 4 44 4 Measure Brake disc thickness Measure the brake disc thickness at a few dif ferent locations Out of specification Replace Refer to CHECKING THE FR...

Page 157: ...nstall Brake pad pin Brake pad clips Rear brake caliper Rear brake caliper bolts 4 Check Brake fluid level Below the minimum level mark a Add the specified brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 11 5 Check Brake lever operation Soft or spongy feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS on page 3 12 EAS30186 REMOVING TH...

Page 158: ...bly Brake fluid delivery passages brake caliper body Obstruction Blow out with compressed air WARNING EWA17070 Whenever a brake caliper is disassembled replace the brake caliper piston dust seal and brake caliper piston seal 2 Check Brake caliper bracket Cracks damage Replace EAS30189 ASSEMBLING THE REAR BRAKE CALIPER WARNING EWA17080 Before installation all internal brake com ponents should be cl...

Page 159: ... Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake performance When refilling be careful that water does not enter the brake master cylinder reser voir Water will significantly lower the boil ing point of the brake fluid and could cause vapor lock NOTICE ECA13540 Brake fluid may damage painted ...

Page 160: ...linder reservoir cap 2 Brake master cylinder reservoir diaphragm holder 3 Brake master cylinder reservoir diaphragm 4 Damage wear Replace 4 Check Brake hose Cracks damage wear Replace EAS30195 ASSEMBLING THE REAR BRAKE MASTER CYLINDER WARNING EWA13520 Before installation all internal brake com ponents should be cleaned and lubricated with clean or new brake fluid Never use solvents on internal bra...

Page 161: ... fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake performance When refilling be careful that water does not enter the brake master cylinder reser voir Water will significantly lower the boil ing point of the brake fluid and could cause vapor lock NOTICE ECA13540 Brake fluid may damage painted surfaces and plastic parts Therefor...

Page 162: ...Refer to GENERAL CHASSIS 2 on page 4 4 Battery box Refer to GENERAL CHASSIS 3 on page 4 7 1 ABS ECU coupler 1 Disconnect 2 Front brake hose union bolt hydraulic unit as sembly side 2 3 Rear brake hose union bolt hydraulic unit as sembly side 2 4 Brake hose gasket 8 5 Rear brake hose rear brake master cylinder to hydraulic unit 1 Disconnect 4 3 3 2 2 4 5 4 4 1 29 N m 2 9 kgf m 21 lb ft T R 29 N m 2...

Page 163: ...r brake caliper 1 Disconnect 7 Front brake hose hydraulic unit to front brake caliper 1 Disconnect 8 Front brake hose front brake master cylinder to hydraulic unit 1 Disconnect 9 Hydraulic unit assembly 1 New New New 8 7 6 9 29 N m 2 9 kgf m 21 lb ft T R 29 N m 2 9 kgf m 21 lb ft T R 7 N m 0 7 kgf m 5 2 lb ft T R 7 N m 0 7 kgf m 5 2 lb ft T R New ...

Page 164: ...ecified torque and bleed the brake system 1 Disconnect ABS ECU coupler 1 TIP While pushing the portion a of the ABS ECU coupler move the lock lever b in the direction of the arrow shown to disconnect the coupler 2 Remove Brake hoses TIP Do not operate the brake levers while removing the brake hoses NOTICE ECA14530 When removing the brake hoses cover the area around the hydraulic unit to catch any ...

Page 165: ... hose front brake master cylinder to hydraulic unit c Position the front brake hose hydraulic unit to front brake caliper 2 so that its projection b contacts the front brake hose front brake master cylinder to hy draulic unit 1 and then temporarily tight en the union bolt for the front brake hose hydraulic unit to front brake caliper d Position the rear brake hose hydraulic unit to rear brake cali...

Page 166: ...T OPERATION TESTS The reaction force pulsating action generated in the brake levers 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 the function of the ABS after the sys tem was disassembled adjusted or serviced ABS reaction force confirmation this test ge...

Page 167: ...e lever and rear brake lever are not being operated 9 Check Hydraulic unit operation Click Actuator Check a single pulse will be generated in the front brake lever 1 rear brake lever 2 and again in the front brake lever 1 in this order TIP ON and OFF on the tool screen indicate when the brakes are being applied and released respectively NOTICE ECA22080 Check that the pulse is felt in the front bra...

Page 168: ...y TIP If the battery voltage is lower than 12 8 V charge the battery and then perform ABS reaction force confirmation 5 Removing the protective cap 1 and then connect the Yamaha diagnostic tool to the ABS test coupler 4P 6 Start the Yamaha diagnostic tool and display the diagnosis mode screen 7 Select code No 1 ABS reaction force con firmation 8 Click Actuator Check and then operate the front brak...

Page 169: ...sts of quick pulses ON and OFF on the tool screen indicate when the brakes are being applied and re leased respectively NOTICE ECA22080 Check that the pulse is felt in the front brake lever rear brake lever and again in the front brake lever in this order If the pulse is felt in the rear brake lever be fore it is felt in the front brake lever check that the brake hoses and brake pipes are connecte...

Page 170: ...ts to remove Q ty Remarks 1 Rearview mirror 2 2 Upper handlebar panel 1 3 Upper handlebar cover 1 22 N m 2 2 kgf m 16 lb ft T R 22 N m 2 2 kgf m 16 lb ft T R 1 8 N m 0 18 kgf m 1 3 lb ft T R 1 8 N m 0 18 kgf m 1 3 lb ft T R 1 8 N m 0 18 kgf m 1 3 lb ft T R 4 0 N m 0 40 kgf m 3 0 lb ft T R 1 1 2 3 ...

Page 171: ... light switch connector 2 Disconnect 9 Front brake master cylinder holder 1 10 Front brake master cylinder 1 11 Handlebar switch right 1 12 Throttle cable 2 Disconnect LS LS LS 1 8 N m 0 18 kgf m 1 3 lb ft T R 2 3 N m 0 23 kgf m 1 7 lb ft T R 2 5 N m 0 25 kgf m 1 8 lb ft T R 21 N m 2 1 kgf m 15 lb ft T R 2 3 N m 0 23 kgf m 1 7 lb ft T R 7 N m 0 7 kgf m 5 2 lb ft T R 7 N m 0 7 kgf m 5 2 lb ft T R 1...

Page 172: ...ebar holder 2 17 Lower handlebar cover 1 LS LS LS 1 8 N m 0 18 kgf m 1 3 lb ft T R 2 3 N m 0 23 kgf m 1 7 lb ft T R 2 5 N m 0 25 kgf m 1 8 lb ft T R 21 N m 2 1 kgf m 15 lb ft T R 2 3 N m 0 23 kgf m 1 7 lb ft T R 7 N m 0 7 kgf m 5 2 lb ft T R 7 N m 0 7 kgf m 5 2 lb ft T R 11 N m 1 1 kgf m 8 1 lb ft T R 11 N m 1 1 kgf m 8 1 lb ft T R 17 16 16 15 14 14 13 ...

Page 173: ... front side of the handlebar holder and then on the rear side TIP The upper handlebar holders should be in stalled with the punch mark a facing forward Align the punch mark b on the handlebar with the inner edge of the upper surface of the right lower handlebar holder 4 Install Upper handlebar cover Refer to INSTALLING THE UPPER HAN DLEBAR COVER on page 4 77 EAS32355 REMOVING THE UPPER HANDLEBAR C...

Page 174: ...r handlebar holders are installed in the same position The upper handlebar holders should be in stalled with the punch mark d facing forward Align the punch mark e on the handlebar with the inner edge of the upper surface of the right lower handlebar holder 3 Install Handlebar switch right 1 Throttle cables 2 Throttle grip 3 Grip end right 4 TIP Lubricate the end of the throttle cables and the ins...

Page 175: ... screw then the rear screw 7 Install Rear brake master cylinder Rear brake master cylinder holder 1 TIP Install the brake master cylinder holder with the UP mark a facing up Align the end of the front brake master cylinder holder with the punch mark b on the handle bar First tighten the front bolt then the rear bolt 8 Install Handlebar grip 1 Grip end left 2 a Apply a thin coat of a rubber adhesiv...

Page 176: ...in of clearance a between the handlebar grip and the grip end EAS32356 INSTALLING THE UPPER HANDLEBAR COVER 1 Install Upper handlebar cover 1 Upper handlebar panel 2 a Fit the projections a on the upper handle bar cover into the holes b in the lower handlebar cover TIP There should be 0 5 4 0 mm 0 02 0 16 in of clearance c between the upper handlebar cov er and handlebar switch b Install the quick...

Page 177: ...RAL CHASSIS 2 on page 4 4 Meter panel assembly Refer to GENERAL CHASSIS 3 on page 4 7 Front wheel Refer to FRONT WHEEL on page 4 27 1 Front fender assembly 1 2 Front fender side cover left 1 3 Front fender side cover right 1 4 Front fender 1 5 Front fork cap 1 1 8 N m 0 18 kgf m 1 3 lb ft T R 23 N m 2 3 kgf m 17 lb ft T R 30 N m 3 0 kgf m 22 lb ft T R 9 N m 0 9 kgf m 6 6 lb ft T R 9 N m 0 9 kgf m ...

Page 178: ...cap bolt 1 Loosen 7 Upper bracket pinch bolt 1 Loosen 8 Lower bracket pinch bolt 1 Loosen 9 Front fork leg 1 1 8 N m 0 18 kgf m 1 3 lb ft T R 23 N m 2 3 kgf m 17 lb ft T R 30 N m 3 0 kgf m 22 lb ft T R 9 N m 0 9 kgf m 6 6 lb ft T R 9 N m 0 9 kgf m 6 6 lb ft T R 7 N m 0 7 kgf m 5 2 lb ft T R 8 9 6 7 ...

Page 179: ...ure applies to both of the front fork legs 1 Front fork cap bolt 1 2 O ring 1 3 Spacer 1 4 Spring seat 1 5 Fork spring 1 6 Dust seal 1 7 Oil seal clip 1 8 Front fork damper rod bolt 1 9 Copper washer 1 10 Damper rod 1 LT LT LT LS LS New New New New 9 8 New New New 7 6 4 5 3 2 1 10 30 N m 3 0 kgf m 22 lb ft T R ...

Page 180: ...mper rod ring 1 12 Rebound spring 1 13 Inner tube 1 14 Oil flow stopper 1 15 Oil flow stopper spring 1 16 Inner tube bushing 1 17 Oil seal 1 18 Washer 1 19 Outer tube bushing 1 20 Outer tube 1 LT LT LT LS LS New New New New 13 14 15 16 19 20 New New 18 17 11 New 12 30 N m 3 0 kgf m 22 lb ft T R ...

Page 181: ...d lower brack et pinch bolts support the front fork leg EAS30207 DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Drain Fork oil TIP Stroke the outer tube several times while drain ing the fork oil 2 Remove Dust seal 1 Oil seal clip 2 with a flathead screwdriver NOTICE ECA14180 Do not scratch the inner tube 3 Remove Front fork damper rod bolt 1 Cop...

Page 182: ...n Blow out all of the oil passag es with compressed air Oil flow stopper Damage Replace NOTICE ECA14200 The front fork leg has a built in damper ad justing rod and a very sophisticated inter nal construction which are particularly sensitive to foreign material When disassembling and assembling the front fork leg do not allow any foreign ma terial to enter the front fork EAS30209 ASSEMBLING THE FRO...

Page 183: ...g to the inner tube TIP Allow the damper rod to slide slowly down the in ner tube until it protrudes from the bottom of the inner tube Be careful not to damage the inner tube d Install the oil flow stopper onto the inner tube 5 3 Lubricate Inner tube s outer surface 4 Install Inner tube in the outer tube 5 Install Copper washer Front fork damper rod bolt 6 Tighten Front fork damper rod bolt 1 TIP ...

Page 184: ...l seal cover the top of the front fork leg with a plastic bag to protect the oil seal during installation 9 Install Oil seal clip 1 TIP Adjust the oil seal clip so that it fits into the outer tube s groove 10 Install Dust seal 1 with the fork seal driver weight 2 Fork seal driver weight 90890 01184 Replacement hammer YM A9409 7 Fork seal driver attachment ø33 90890 01368 Replacement 33 mm YM A9409...

Page 185: ...arily tighten the front fork cap bolt Tighten the front fork cap bolt specified torque when installing the front fork with upper brack et EAS30210 INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Install Front fork leg Temporarily tighten the lower bracket pinch bolt TIP Make sure the inner tube end is flush with the top of the upper bracket 2 Tighten...

Page 186: ...L CHASSIS 2 on page 4 4 Meter panel assembly Refer to GENERAL CHASSIS 3 on page 4 7 Front wheel Refer to FRONT WHEEL on page 4 27 Handlebar Refer to HANDLEBAR on page 4 71 Front fork legs Refer to FRONT FORK on page 4 78 1 Front brake hose guide 1 2 Front brake hose holder 1 3 Steering stem nut 1 New LS LS LS 1st 48 N m 4 8 kgf m 35 lb ft 2nd 14 N m 1 4 kgf m 10 lb ft T R 91 N m 9 1 kgf m 67 lb ft...

Page 187: ...5 Lock washer 1 6 Upper ring nut 1 7 Rubber washer 1 8 Lower ring nut 1 9 Lower bracket 1 10 Lower bracket cap 1 11 Bearing cover 1 12 Upper bearing 1 13 Lower bearing 1 14 Dust seal 1 LS LS LS New 1st 48 N m 4 8 kgf m 35 lb ft 2nd 14 N m 1 4 kgf m 10 lb ft T R 91 N m 9 1 kgf m 67 lb ft T R 7 N m 0 7 kgf m 5 2 lb ft T R 7 N m 0 7 kgf m 5 2 lb ft T R 10 9 14 13 12 11 8 7 6 5 4 ...

Page 188: ...rings Bearing races a Remove the bearing races from the steer ing head pipe 1 with a long rod 2 and hammer b Remove the bearing race 3 from the low er bracket with a floor chisel 4 and ham mer c Install a new dust seal and new bearing races NOTICE ECA14270 If the bearing race is not installed properly the steering head pipe could be damaged TIP Always replace the bearings and bearing races as a se...

Page 189: ...CKING AND ADJUSTING THE STEERING HEAD on page 3 15 3 Install Front brake hose holder 1 TIP While holding the front brake hose holder so that the portion a of the holder contacts the lower bracket tighten the bolt to specification T R Front brake hose holder bolt 7 N m 0 7 kgf m 5 2 lb ft 2 1 a 4 1 2 3 1 a ...

Page 190: ...brake caliper 1 3 Rear shock absorber assembly 2 4 Rear wheel axle nut 1 5 Spacer 1 6 Swingarm assembly 1 7 Collar 1 8 Oil seal 1 9 Circlip 1 10 Bearing 1 11 Oil seal 1 12 Swingarm 1 New LS New New LS LS LS 23 N m 2 3 kgf m 17 lb ft T R 30 N m 3 0 kgf m 22 lb ft T R 23 N m 2 3 kgf m 17 lb ft T R 30 N m 3 0 kgf m 22 lb ft T R 7 N m 0 7 kgf m 5 2 lb ft T R 35 N m 3 5 kgf m 26 lb ft T R 57 N m 5 7 kg...

Page 191: ...BLY 1 Check Rear shock absorber rod Bends damage Replace the rear shock absorber assembly Rear shock absorber assembly Oil leaks Replace the rear shock absorber assembly Spring Damage wear Replace the rear shock ab sorber assembly Bushings Damage wear Replace the rear shock ab sorber assembly Bolts Bends damage wear Replace EAS31230 CHECKING THE SWINGARM 1 Check Swingarm Bends cracks damage Replac...

Page 192: ...bolts 3 4 5 Install Rear shock absorber assemblies TIP Tighten the rear shock absorber assembly bolts temporarily and then tighten them to specifica tion 6 Install Rear brake hose holder 1 TIP Fit the projection a on the rear brake hose hold er into the hole b in the swingarm T R Rear wheel axle nut 125 N m 12 5 kgf m 92 lb ft Swingarm mounting bolt 57 N m 5 7 kgf m 42 lb ft T R Rear shock absorbe...

Page 193: ... THE TIMING CHAIN TENSIONER 5 18 INSTALLING THE CYLINDER HEAD 5 18 CAMSHAFT 5 22 REMOVING THE CAMSHAFT 5 23 CHECKING THE CAMSHAFT ASSEMBLY 5 23 CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS 5 23 INSTALLING THE CAMSHAFT 5 24 VALVES AND VALVE SPRINGS 5 26 REMOVING THE VALVES 5 27 CHECKING THE VALVES AND VALVE GUIDES 5 27 CHECKING THE VALVE SEATS 5 29 CHECKING THE VALVE SPRINGS 5 30 INSTALLING THE V...

Page 194: ... SHEAVE 5 44 GENERATOR AND STARTER CLUTCH 5 46 REMOVING THE GENERATOR 5 49 REMOVING THE STARTER CLUTCH 5 49 CHECKING THE STARTER CLUTCH 5 49 INSTALLING THE STARTER CLUTCH 5 50 INSTALLING THE GENERATOR 5 50 ELECTRIC STARTER 5 52 CHECKING THE STARTER MOTOR 5 54 ASSEMBLING THE STARTER MOTOR 5 55 INSTALLING THE STARTER MOTOR 5 55 OIL PUMP 5 56 CHECKING THE OIL STRAINER 5 59 CHECKING THE OIL PUMP 5 59 ...

Page 195: ...ONNECTING ROD 5 67 CHECKING THE BALANCER SHAFT ASSEMBLY 5 70 INSTALLING THE CONNECTING ROD 5 70 INSTALLING THE CRANKSHAFT JOURNAL BEARINGS 5 71 INSTALLING THE CRANKSHAFT ASSEMBLY AND BALANCER SHAFT ASSEMBLY 5 72 TRANSMISSION 5 73 CHECKING THE TRANSMISSION 5 75 INSTALLING THE TRANSMISSION 5 75 ...

Page 196: ...RAMS EAS32362 ENGINE OIL LUBRICATION CHART 13 12 8 6 5 9 2 4 10 11 3 1 7 1 Oil strainer 2 Oil pump feed 3 Oil filter element 4 Relief valve assembly 5 Main gallery 6 Crankshaft 7 To piston 8 Camshaft 9 Oil pump scavenge 10 Crankcase left 11 Crankcase right 12 Cylinder 13 Cylinder head ...

Page 197: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 5 2 EAS32363 LUBRICATION DIAGRAMS 1 1 2 1 Oil filter element 2 Engine oil check bolt ...

Page 198: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 5 3 4 5 1 3 1 2 1 Oil strainer feed 2 Oil strainer scavenge 3 Crankshaft 4 Oil pump scavenge 5 Oil pump feed ...

Page 199: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 5 4 1 2 3 4 5 6 1 Camshaft 2 Crankshaft 3 Oil pump scavenge 4 Oil pump feed 5 Relief valve assembly 6 Oil filter element ...

Page 200: ...ge stabilizes WARNING EWA12960 To prevent sparking ground the spark plug lead before cranking the engine c If the compression pressure is above the maximum specification check the cylinder head valve surfaces and piston crown for carbon deposits Carbon deposits Eliminate d If the compression pressure is below the minimum specification pour a teaspoonful of engine oil into the spark plug bore and m...

Page 201: ...orage box Refer to GENERAL CHASSIS 4 on page 4 10 2 Check Cylinder head breather hose 1 Transmission case breather hose 2 Cracks damage Replace Loose connections Connect properly NOTICE ECA21600 Make sure the cylinder head breather hose and transmission case breather hose are routed correctly 3 Install Storage box Refer to GENERAL CHASSIS 4 on page 4 10 1 2 ...

Page 202: ...p bolt 1 Loosen 2 Muffler assembly 1 3 Clamp 1 4 Gasket 1 5 Exhaust pipe 1 6 Exhaust gasket 1 7 Muffler protector 1 8 Muffler cap 1 9 Muffler 1 LT LT LT New New 4 5 8 1 3 9 2 7 6 8 N m 0 8 kgf m 5 9 lb ft T R 8 N m 0 8 kgf m 5 9 lb ft T R 20 N m 2 0 kgf m 15 lb ft T R 15 N m 1 5 kgf m 11 lb ft T R 53 N m 5 3 kgf m 39 lb ft T R ...

Page 203: ...ly Refer to GENERAL CHASSIS 1 on page 4 1 Front cowling assemblies Refer to GENERAL CHASSIS 2 on page 4 4 Lower side covers Refer to GENERAL CHASSIS 4 on page 4 10 Bottom cover assembly Refer to GENERAL CHASSIS 5 on page 4 13 Rear lower cowling assembly Refer to GENERAL CHASSIS 8 on page 4 23 Rear brake caliper Refer to REAR BRAKE on page 4 51 Exhaust pipe Refer to ENGINE REMOVAL on page 5 7 7 N m...

Page 204: ...Refer to AIR FILTER CASE on page 7 11 Intake manifold Refer to THROTTLE BODY on page 7 13 1 Crankshaft position sensor coupler 1 Disconnect 2 Stator coil coupler 1 Disconnect 3 Coolant temperature sensor coupler 1 Disconnect 4 O2 sensor coupler 1 Disconnect 5 Spark plug cap 1 Disconnect 6 Engine ground lead 1 Disconnect 7 Rear wheel sensor coupler 1 Disconnect 1 2 7 6 3 4 5 7 N m 0 7 kgf m 5 2 lb ...

Page 205: ... 2 2 3 Engine mounting nut bolt rear side 2 2 4 Engine 1 5 Starter motor lead 1 Disconnect 6 Engine bracket nut bolt 1 1 7 Engine bracket 1 LS 23 N m 2 3 kgf m 17 lb ft T R 30 N m 3 0 kgf m 22 lb ft T R 45 N m 4 5 kgf m 33 lb ft T R 60 N m 6 0 kgf m 44 lb ft T R 45 N m 4 5 kgf m 33 lb ft T R 3 5 N m 0 35 kgf m 2 6 lb ft T R 2 2 2 1 1 7 3 3 3 6 5 4 6 ...

Page 206: ...ront side 7 Install Rear shock absorber assemblies 7 TIP Tighten the rear shock absorber assembly bolts temporarily and then tighten them to specifica tion EAS31717 CONNECTING THE LEADS 1 Connect Engine ground lead 1 TIP Make sure that the engine ground lead terminal a contacts the stopper b on the crankcase Recommended lubricant Lithium soap based grease T R Engine bracket nut 60 N m 6 0 kgf m 44...

Page 207: ...OVAL 5 12 EAS30252 INSTALLING THE EXHAUST PIPE AND MUFFLER 1 Install Exhaust gasket 1 to the cylinder head TIP Install the exhaust gasket with its projections a facing toward the cylinder head b 1 a New 1 a a New ...

Page 208: ...er to GENERAL CHASSIS 5 on page 4 13 Exhaust pipe Refer to ENGINE REMOVAL on page 5 7 Coolant Drain Refer to CHANGING THE COOLANT on page 3 21 Thermostat assembly Refer to THERMOSTAT on page 6 6 1st 16 N m 1 6 kgf m 12 lb ft 2nd 16 N m 1 6 kgf m 12 lb ft T R 15 N m 1 5 kgf m 11 lb ft T R 25 N m 2 5 kgf m 18 lb ft T R Specified angle 180 10 N m 1 0 kgf m 7 4 lb ft T R 10 N m 1 0 kgf m 7 4 lb ft T R...

Page 209: ...cessing bolt 1 3 O2 sensor coupler 1 Disconnect 4 O2 sensor 1 TIP Remove the O2 sensor only when neces sary 5 Spark plug cap 1 Disconnect 6 Spark plug 1 1st 16 N m 1 6 kgf m 12 lb ft 2nd 16 N m 1 6 kgf m 12 lb ft T R 15 N m 1 5 kgf m 11 lb ft T R 25 N m 2 5 kgf m 18 lb ft T R Specified angle 180 10 N m 1 0 kgf m 7 4 lb ft T R 10 N m 1 0 kgf m 7 4 lb ft T R 10 N m 1 0 kgf m 7 4 lb ft T R 10 N m 1 0...

Page 210: ...13 Cylinder head cover gasket 1 14 Cylinder head breather cover 1 15 Cylinder head breather cover gasket 1 1st 16 N m 1 6 kgf m 12 lb ft 2nd 16 N m 1 6 kgf m 12 lb ft T R 15 N m 1 5 kgf m 11 lb ft T R 25 N m 2 5 kgf m 18 lb ft T R Specified angle 180 10 N m 1 0 kgf m 7 4 lb ft T R 10 N m 1 0 kgf m 7 4 lb ft T R 10 N m 1 0 kgf m 7 4 lb ft T R 10 N m 1 0 kgf m 7 4 lb ft T R 10 N m 1 0 kgf m 7 4 lb f...

Page 211: ...Cylinder head 1 22 Cylinder head gasket 1 23 Dowel pin 2 24 Engine oil check bolt 1 1st 16 N m 1 6 kgf m 12 lb ft 2nd 16 N m 1 6 kgf m 12 lb ft T R 15 N m 1 5 kgf m 11 lb ft T R 25 N m 2 5 kgf m 18 lb ft T R Specified angle 180 10 N m 1 0 kgf m 7 4 lb ft T R 10 N m 1 0 kgf m 7 4 lb ft T R 10 N m 1 0 kgf m 7 4 lb ft T R 10 N m 1 0 kgf m 7 4 lb ft T R 10 N m 1 0 kgf m 7 4 lb ft T R 24 N m 2 4 kgf m ...

Page 212: ...rocket TIP Use the camshaft sprocket stopper 2 and loosen the camshaft sprocket bolts To prevent the timing chain from falling into the crankcase fasten it with a wire 4 Remove Cylinder head TIP Loosen the bolts and nuts in the proper se quence as shown Loosen each bolt and nuts 1 2 of a turn at a time After all of the bolts and nuts are fully loosened remove them EAS30277 CHECKING THE CYLINDER HE...

Page 213: ...G THE CAMSHAFT SPROCKET 1 Check Camshaft sprocket More than 1 4 tooth wear a Replace the camshaft sprocket timing chain and crank shaft as a set EAS30279 CHECKING THE TIMING CHAIN TENSIONER 1 Check Timing chain tensioner Cracks damage Replace 2 Check One way cam operation Rough movement Replace the timing chain tensioner assembly 3 Check Timing chain tensioner cap bolt 1 Washer 2 Timing chain tens...

Page 214: ...et onto the camshaft and then finger tighten the camshaft sprocket bolts NOTICE ECA20600 Do not turn the crankshaft when installing the camshaft sprocket to avoid damage or improper valve timing TIP Align the I mark a on the camshaft sprocket with the match mark b on the cylinder head b While holding the camshaft temporarily tighten the camshaft sprocket bolts 4 Install Timing chain tensioner gask...

Page 215: ...tor rotor cover I mark c Make sure the I mark c on the camshaft sprocket is aligned with the match mark d on the cylinder head Out of alignment Correct Refer to the installation steps above 7 Tighten Camshaft sprocket bolts 1 TIP Tighten the camshaft sprocket bolts with the camshaft sprocket stopper 2 8 Measure Valve clearance Out of specification Adjust Refer to ADJUSTING THE VALVE CLEAR ANCE on ...

Page 216: ...CYLINDER HEAD 5 21 TIP While holding the bracket 1 so that the bracket 1 the portion a of the cylinder head tighten the bolt to specification T R Bracket bolt 10 N m 1 0 kgf m 7 4 lb ft 1 a ...

Page 217: ...to CYLINDER HEAD on page 5 13 1 Camshaft stopper plate 1 2 Collar 2 3 Rocker arm shaft retainer 1 4 Rocker arm shaft 2 5 Exhaust rocker arm 1 6 Intake rocker arm 1 7 Camshaft assembly 1 8 Bearing 1 10 N m 1 0 kgf m 7 4 lb ft T R 12 N m 1 2 kgf m 8 9 lb ft T R 8 N m 0 8 kgf m 5 9 lb ft T R LT E E M New M M M M 1 3 2 2 4 4 7 8 6 5 ...

Page 218: ...shaft oil passage Obstruction Blow out with compressed air 5 Check Decompression system TIP Check that the decompression lever moves smoothly Check that the operating range a of the de compression lever is the same as the range shown in the illustration EAS30259 CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS The following procedure applies to all of the rocker arms and rocker arm shafts 1 Check Ro...

Page 219: ...efective part s EAS30269 INSTALLING THE CAMSHAFT 1 Lubricate Camshaft assembly 2 Lubricate Rocker arms Rocker arm shafts 3 Install Rocker arm shaft retainer 1 Rocker arm inside diameter 11 985 12 000 mm 0 4719 0 4724 in Limit 12 015 mm 0 4730 in Rocker arm shaft outside diame ter 11 966 11 976 mm 0 4711 0 4715 in Limit 11 935 mm 0 4699 in 1 1 a Rocker arm to rocker arm shaft clearance 0 009 0 034 ...

Page 220: ... rocker arm shaft retainer make sure that the notches a in the rocker arm shafts face inward While holding the rocker arm shaft retainer so that the portion b of the retainer contact the cylinder head tighten the bolt to specification a b 1 ...

Page 221: ...arks Cylinder head Refer to CYLINDER HEAD on page 5 13 Camshaft Rocker arms Refer to CAMSHAFT on page 5 22 1 Valve pad 4 2 Valve cotter 8 3 Valve spring retainer 4 4 Valve spring 4 5 Intake valve 2 6 Exhaust valve 2 7 Valve stem seal 4 8 Valve spring seat 4 9 Valve guide 4 E M M New New New New M M M M E 2 1 3 4 2 1 3 4 7 9 9 5 8 7 8 6 ...

Page 222: ...s Valve cotters 1 TIP Remove the valve cotters by compressing the valve spring with the valve spring compressor and the valve spring compressor attachment 2 3 Remove Valve spring retainer 1 Valve spring 2 Valve 3 Valve stem seal 4 Valve spring seat 5 TIP Identify the position of each part very carefully so that it can be reinstalled in its original place EAS30284 CHECKING THE VALVES AND VALVE GUID...

Page 223: ...m to valve guide clearance TIP After replacing the valve guide reface the valve seat 3 Eliminate Carbon deposits from the valve face and valve seat Valve stem to valve guide clear ance intake 0 010 0 037 mm 0 0004 0 0015 in Limit 0 080 mm 0 0032 in Valve stem to valve guide clear ance exhaust 0 025 0 052 mm 0 0010 0 0020 in Limit 0 100 mm 0 0039 in New Valve guide position 11 98 12 02 mm 0 471 0 4...

Page 224: ...place the cylinder head a Apply Blue layout fluid b onto the valve face b Install the valve into the cylinder head c Press the valve through the valve guide and onto the valve seat to make a clear impression d Measure the valve seat width TIP Where the valve seat and valve face contacted one another the blue layout fluid will have been removed 4 Lap Valve face Valve seat TIP After replacing the cy...

Page 225: ...nto the valve face h Install the valve into the cylinder head i Press the valve through the valve guide and onto the valve seat to make a clear impression j Measure the valve seat width again If the valve seat width is out of specification re face and lap the valve seat EAS30286 CHECKING THE VALVE SPRINGS The following procedure applies to all of the valve springs 1 Measure Valve spring free lengt...

Page 226: ...ers 1 TIP Install the valve cotters by compressing the valve spring with the valve spring compressor and the valve spring compressor attachment 2 5 To secure the valve cotters onto the valve stem lightly tap the valve tip with a soft face hammer NOTICE ECA13800 Hitting the valve tip with excessive force could damage the valve 6 Install Valve pads Recommended lubricant Engine oil b Smaller pitch E ...

Page 227: ...arks Cylinder head Refer to CYLINDER HEAD on page 5 13 Water pump outlet pipe Refer to WATER PUMP on page 6 8 1 Timing chain guide exhaust side 1 2 Cylinder 1 3 Cylinder gasket 1 4 Dowel pin 2 5 Piston pin clip 2 6 Piston pin 1 7 Piston 1 8 Top ring 1 9 2nd ring 1 10 Oil ring 1 New New New E E E E 5 5 8 10 9 7 6 1 2 4 4 3 ...

Page 228: ...emoving a piston ring open the end gap with your fingers and lift the other side of the ring over the piston crown EAS30291 CHECKING THE CYLINDER AND PISTON 1 Check Piston wall Cylinder wall Vertical scratches Replace the cylinder piston and piston rings as a set 2 Measure Piston to cylinder clearance a Measure cylinder bore D with the cylin der bore gauge TIP Measure cylinder bore D between the i...

Page 229: ...iston crown to level the position ring near the bottom of the cylinder a where the cyl inder wear is lowest 3 Measure Piston ring end gap Out of specification Replace the piston ring TIP The oil ring expander spacer end gap cannot be measured If the oil ring rail gap is excessive re place all three piston rings b 8 0 mm 0 31 in from the bottom edge of the piston Piston Diameter 69 962 69 985 mm 2 ...

Page 230: ... 4 Top ring 5 TIP Be sure to install the piston rings so that the manufacturer marks face up 2 Install Piston 1 Piston pin 2 Piston pin clips 3 TIP Apply engine oil to the piston pin and connect ing rod Make sure the punch mark a on the piston points towards the exhaust side of the cylinder Before installing the piston pin clips cover the crankcase opening with a clean rag to prevent the clips fro...

Page 231: ...Offset Piston ring end gaps 5 Install Dowel pins Cylinder gasket Cylinder 1 TIP While holding the piston 2 with one hand in stall the cylinder with the other hand Pass the timing chain and timing chain guide intake side through the timing chain cavity Recommended lubricant Engine oil a Top ring b 2nd ring c Upper oil ring rail d Oil ring expander e Lower oil ring rail A Exhaust side 1 2 a 3 New 1 ...

Page 232: ...NERAL CHASSIS 4 on page 4 10 Air filter case Refer to AIR FILTER CASE on page 7 11 1 V belt case air filter element cover 1 2 V belt case air duct 1 3 V belt case air filter element 1 4 V belt case 1 5 V belt case gasket 1 6 Dowel pin 1 7 Circlip 1 8 Bearing 1 12 4 4 4 8 7 6 5 3 2 4 1 10 N m 1 0 kgf m 7 4 lb ft T R 7 N m 0 7 kgf m 5 2 lb ft T R New New New New ...

Page 233: ...ks 1 Primary fixed sheave bolt 1 2 Washer 1 3 Primary fixed sheave 1 4 Primary sliding sheave assembly 1 5 Collar 1 6 Cam 1 7 Primary sheave weight 6 8 Slider 3 9 Primary sliding sheave 1 10 Oil seal 1 11 Washer 1 12 Clutch housing nut 1 13 Clutch housing 1 14 Secondary sheave nut 1 Loosen 15 Secondary sheave assembly 1 16 V belt 1 11 6 8 15 14 13 12 8 8 7 9 5 16 3 2 1 4 10 85 N m 8 5 kgf m 63 lb ...

Page 234: ...der Job Parts to remove Q ty Remarks 1 Secondary sheave nut 1 2 Clutch carrier assembly 1 3 Compression spring 1 4 Spring seat 1 1 5 Spring seat 2 1 6 Guide pin 4 7 Collar 4 8 Secondary sliding sheave 1 9 O ring 2 10 Oil seal 2 11 Bearing 1 12 Secondary fixed sheave 1 4 12 6 7 8 11 5 3 2 1 10 10 9 New New New ...

Page 235: ... the secondary sheave with the ro tor holding tool 2 loosen the secondary sheave nut one full turn with the locknut wrench 3 EAS30312 DISASSEMBLING THE SECONDARY SHEAVE 1 Remove Secondary sheave nut 1 TIP Install the sheave spring compressor 2 and sheave fixed block 3 onto the secondary sheave as shown Then compress the spring and remove the secondary sheave nut Rotor holding tool 90890 01235 Univ...

Page 236: ...tch with a cloth 2 Measure Clutch shoe thickness a Out of specification Replace the clutch shoes and springs as a set EAS30315 CHECKING THE V BELT 1 Check V belt 1 Cracks damage wear Replace Grease oil Clean the primary and second ary sheave 2 Measure V belt width a Out of specification Replace TIP Measure the V belt width as illustration EAS30316 CHECKING THE PRIMARY SHEAVE 1 Check Primary slidin...

Page 237: ...ry fixed sheave Secondary sliding sheave Cracks damage wear Replace the sec ondary fixed and sliding sheaves as a set 2 Check Torque cam groove a Damage wear Replace the secondary fixed and sliding sheaves as a set 3 Check Guide pins 1 Damage wear Replace the secondary fixed and sliding sheaves as a set 4 Check Spring free length Out of specification Replace the spring EAS30321 ASSEMBLING THE SECO...

Page 238: ...sion spring Clutch carrier assembly Secondary sheave nut 1 TIP Install the sheave spring compressor 2 and sheave fixed block 3 onto the secondary sheave as shown Then compress the spring and install the secondary sheave nut Install the secondary sheave nut with its ta pered side facing the clutch carrier EAS32361 ASSEMBLING THE PRIMARY FIXED SHEAVE 1 Clean Primary fixed sheave Primary sliding shea...

Page 239: ... V belt with the printed arrow mark on the V belt facing in the direction shown in the il lustration Install the V belt onto the primary sheave side 2 Tighten Secondary sheave nut 1 TIP While holding the secondary sheave with the ro tor holding tool 2 tighten the secondary sheave nut with the locknut wrench 3 3 Install Clutch housing 1 Clutch housing nut 2 TIP While holding the clutch housing with...

Page 240: ...osition and in the second ary sheave when the pulley is at its narrowest position and make sure the V belt is tight 7 Tighten Primary fixed sheave bolt 1 Tightening torque when reusing the primary fixed sheave bolt and washer Tightening torque when installing a new primary fixed sheave bolt and washer TIP While holding the primary fixed sheave with the rotor holding tool 2 tighten the primary fixe...

Page 241: ... 4 on page 4 10 Radiator cover Refer to GENERAL CHASSIS 5 on page 4 13 Exhaust pipe Refer to ENGINE REMOVAL on page 5 7 Coolant Drain Refer to CHANGING THE COOLANT on page 3 21 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 19 Water pump inlet hose water pump outlet pipe Refer to WATER PUMP on page 6 8 10 N m 1 0 kgf m 7 4 lb ft T R 10 N m 1 0 kgf m 7 4 lb ft T R 1 5 N m 0 15 kgf m 1 ...

Page 242: ...4 Timing mark accessing bolt 1 5 Engine oil filler cap 1 6 Generator cover 1 7 Generator cover gasket 1 8 Dowel pin 2 9 Plate 1 10 Stator coil assembly Stator coil Crankshaft po sition sensor 1 10 N m 1 0 kgf m 7 4 lb ft T R 10 N m 1 0 kgf m 7 4 lb ft T R 1 5 N m 0 15 kgf m 1 1 lb ft T R 13 N m 1 3 kgf m 9 6 lb ft T R 13 N m 1 3 kgf m 9 6 lb ft T R 2 0 N m 0 20 kgf m 1 5 lb ft T R 75 N m 7 5 kgf m...

Page 243: ...clutch idle gear 1 13 Generator rotor assembly 1 14 Woodruff key 1 15 Starter clutch gear 1 16 Starter clutch 1 17 Generator rotor 1 10 N m 1 0 kgf m 7 4 lb ft T R 10 N m 1 0 kgf m 7 4 lb ft T R 1 5 N m 0 15 kgf m 1 1 lb ft T R 13 N m 1 3 kgf m 9 6 lb ft T R 13 N m 1 3 kgf m 9 6 lb ft T R 2 0 N m 0 20 kgf m 1 5 lb ft T R 75 N m 7 5 kgf m 55 lb ft T R M New New New LT LT LT E E LS LS FW FWD 15 14 1...

Page 244: ...olt and the crank shaft EAS30868 REMOVING THE STARTER CLUTCH 1 Remove Starter clutch bolts 1 Generator rotor 2 Starter clutch TIP While holding the generator rotor with the rotor holding tool 3 loosen the starter clutch bolts EAS30869 CHECKING THE STARTER CLUTCH 1 Check Starter clutch rollers 1 Damage wear Replace the starter clutch 2 Check Starter clutch idle gear Rotor holding tool 90890 04166 R...

Page 245: ...d EAS30871 INSTALLING THE STARTER CLUTCH 1 Install Starter clutch 1 to the generator rotor 2 TIP Starter clutch with the arrow mark a is toward the generator rotor While holding the generator rotor with the rotor holding tool 3 tighten the starter clutch bolts 4 EAS30872 INSTALLING THE GENERATOR 1 Install Starter clutch gear Woodruff key Generator rotor assembly Washer Generator rotor bolt TIP Cle...

Page 246: ... and b on the oil pump Align the slit c on the impeller shaft with the projection d on the oil pump shaft Tighten the generator cover bolts in stages and in a crisscross pattern 5 Connect Stator coil coupler Crankshaft position sensor coupler TIP To route the stator coil crankshaft position sen sor lead refer to CABLE ROUTING on page 2 13 Rotor holding tool 90890 04166 Rotor holding tool YM 04166 ...

Page 247: ...arts to remove Q ty Remarks Storage box Refer to GENERAL CHASSIS 4 on page 4 10 Air filter case Refer to AIR FILTER CASE on page 7 11 1 Starter motor bracket 1 2 Starter motor 1 3 Starter motor lead 1 Disconnect 10 N m 1 0 kgf m 7 4 lb ft T R 3 5 N m 0 35 kgf m 2 6 lb ft T R LS New 2 1 3 ...

Page 248: ... 1 2 Gasket 1 3 Oil seal 1 4 Bearing 1 5 Armature assembly 1 6 Circlip 1 7 Stator 1 8 Gasket 1 9 Brush holder 1 10 Brush spring 4 11 Brush 2 12 Brush and holder set 1 13 Starter motor rear cover 1 1 5 N m 0 15 kgf m 1 1 lb ft T R 3 5 N m 0 35 kgf m 2 6 lb ft T R New New New New New New 13 11 5 4 8 3 1 6 2 11 12 10 9 10 7 ...

Page 249: ...Replace the starter motor a Measure the armature assembly resis tance with the digital circuit tester b If the resistance is out of specification re place the starter motor 5 Measure Brush length a Out of specification Replace the brushes as a set 6 Measure Brush spring force Out of specification Replace the brush springs as a set Commutator diameter 24 5 mm 0 96 in Limit 23 5 mm 0 93 in Mica unde...

Page 250: ...IP Align the match marks a on the starter motor front cover and rear cover with the match marks b on the stator EAS30327 INSTALLING THE STARTER MOTOR 1 Connect Starter motor lead 1 to the starter motor 2 TIP Connect the starter motor lead to the starter mo tor so that the lead is parallel to the starter motor axis a T R Starter motor cover bolt 3 5 N m 0 35 kgf m 2 6 lb ft T R Starter motor lead s...

Page 251: ...ng assemblies Refer to GENERAL CHASSIS 2 on page 4 4 Lower side cover left Refer to GENERAL CHASSIS 4 on page 4 10 Radiator cover Refer to GENERAL CHASSIS 5 on page 4 13 Exhaust pipe Refer to ENGINE REMOVAL on page 5 7 Coolant Drain Refer to CHANGING THE COOLANT on page 3 21 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 19 10 N m 1 0 kgf m 7 4 lb ft T R FWD FWD ...

Page 252: ...Water pump inlet hose water pump outlet pipe Refer to WATER PUMP on page 6 8 Generator rotor assembly Starter clutch gear Refer to GENERATOR AND STARTER CLUTCH on page 5 46 1 Oil pump assembly 1 2 Oil pump drive chain 1 3 Oil strainer feed 1 3 2 1 10 N m 1 0 kgf m 7 4 lb ft T R FWD FWD ...

Page 253: ...in 2 3 Oil pump outer rotor scavenge 1 4 Oil pump inner rotor scavenge 1 5 Pin 1 6 Oil pump housing scavenge 1 7 Washer 1 8 Dowel pin 2 9 Oil pump outer rotor feed 1 10 Oil pump inner rotor feed 1 11 Pin 1 12 Oil pump driven gear 1 13 Oil pump housing feed 1 3 4 7 6 9 10 12 13 11 8 8 5 2 1 7 N m 0 7 kgf m 5 2 lb ft T R E E E ...

Page 254: ...place the oil pump EAS30785 CHECKING THE OIL PUMP DRIVE CHAIN 1 Check Oil pump drive chain Cracks stiffness Replace the oil pump chain and oil pump assembly as a set EAS30342 ASSEMBLING THE OIL PUMP 1 Lubricate Inner rotors Outer rotors Oil pump shaft with the recommended lubricant 2 Install Inner rotors TIP When installing the inner rotor align the pins 1 in the oil pump shaft with the grooves a ...

Page 255: ...CHECKING THE OIL PUMP on page 5 59 EAS30343 INSTALLING THE OIL PUMP 1 Install Oil pump assembly NOTICE ECA13890 After tightening the bolts make sure the oil pump turns smoothly A Scavenge B Feed T R Oil pump bolt 10 N m 1 0 kgf m 7 4 lb ft A B a a 1 1 ...

Page 256: ...sembly Refer to GENERATOR AND STARTER CLUTCH on page 5 46 Oil pump assembly Refer to OIL PUMP on page 5 56 Secondary sheave assembly Refer to V BELT AUTOMATIC TRANSMIS SION on page 5 37 Swingarm assembly Refer to REAR SHOCK ABSORBER AS SEMBLIES AND SWINGARM on page 4 91 Rear wheel Rear wheel sensor Refer to REAR WHEEL on page 4 34 LT LT LS LS LS New New New New 10 N m 1 0 kgf m 7 4 lb ft T R 10 N ...

Page 257: ...cover 1 5 Oil filter element 1 6 Engine oil drain bolt 1 7 Final transmission oil filler cap 1 8 Crankcase left 1 9 Dowel pin 2 10 Oil nozzle 1 11 Relief valve assembly 1 12 Oil strainer scavenge 1 13 Crankcase right 1 LT LT LS LS LS New New New New 10 N m 1 0 kgf m 7 4 lb ft T R 10 N m 1 0 kgf m 7 4 lb ft T R 10 N m 1 0 kgf m 7 4 lb ft T R 10 N m 1 0 kgf m 7 4 lb ft T R 20 N m 2 0 kgf m 15 lb ft ...

Page 258: ...with compressed air EAS30391 CHECKING THE TIMING CHAIN AND TIMING CHAIN GUIDE 1 Check Timing chain Damage stiffness Replace the timing chain camshaft and crankshaft sprocket as a set 2 Check Timing chain guide intake side Damage wear Replace EAS30338 CHECKING THE RELIEF VALVE 1 Check Relief valve body Damage wear Replace EAS31069 CHECKING THE OIL STRAINER 1 Check Oil strainer scavenge Damage Repla...

Page 259: ...oughly wipe off any sealant that protrudes from between the left crankcase and the right crankcase Tighten each bolt 1 4 of a turn at a time in stag es and in a crisscross pattern 5 Check Crankshaft operation Rough movement Repair T R Crankcase bolt 10 N m 1 0 kgf m 7 4 lb ft ...

Page 260: ... Job Parts to remove Q ty Remarks Crankcase Separate Refer to CRANKCASE on page 5 61 1 Crankshaft assembly 1 2 Balancer shaft assembly 1 3 Crankshaft journal bearing left crankcase side 2 4 Crankshaft journal bearing right crankcase side 2 5 Oil seal 1 6 Bearing 2 E E New E E E E E E LS 1 2 4 5 6 6 4 3 ...

Page 261: ...ecting rod Order Job Parts to remove Q ty Remarks 1 Connecting rod cap 1 2 Big end lower bearing 1 3 Connecting rod 1 4 Big end upper bearing 1 2 3 4 1 E E M M M New New New New 1st 18 N m 1 8 kgf m 13 lb ft 2nd Specified angle 180 T R ...

Page 262: ...rfaces Crankshaft pin surfaces Bearing surfaces Scratches wear Replace the crankshaft 3 Measure Crankshaft pin to big end bearing clearance Out of specification Replace the big end bearings a Clean the big end bearings crankshaft pins and the inside of the connecting rod halves b Install the big end upper bearing into the connecting rod and the big end lower bearing into the connecting rod cap TIP...

Page 263: ... on the connecting rod e Tighten the connecting rod nuts Refer to INSTALLING THE CONNECT ING ROD on page 5 70 f Remove the connecting rod and big end bearings g Measure the compressed Plastigauge width f on the crankshaft pin If the crankshaft pin to big end bearing clearance is out of specification select re placement big end bearings 4 Select Big end bearings P1 TIP The numbers A stamped into th...

Page 264: ... set c Measure the crankshaft journal diameter a of each crankshaft journal If it is out of specification replace the crankshaft d Measure the crankshaft journal bearing in side diameter b of each crankshaft jour nal bearing TIP Measure the crankshaft journal bearing inside diameter at the distance a shown in the illustra tion e If crankshaft journal bearing inside diame ter is 40 03 and crankshaf...

Page 265: ...icate Crankshaft pins Big end bearings inner surface Balancer big end bearings inner surface with the recommended lubricant 3 Install Big end bearings Connecting rods Connecting rod caps onto the crankshaft pins TIP Be sure to reinstall each big end bearing in its original place Align the projections a on the big end bear ings with the notches b in the connecting rods and connecting rod caps J1 cr...

Page 266: ...d nut 2 and the connecting rod cap 3 c Tighten the connecting rod nuts further to reach the specified angle 180 WARNING EWA13400 If the connecting rod nut is tightened more than the specified angle do not loosen the nut and then retighten it Instead replace the connecting rod bolt and nut with a new one and perform the procedure again NOTICE ECA19930 Do not use a torque wrench to tighten the conne...

Page 267: ...crankshaft journal bearings into the crankcase using the pressure tool 3 and a press 2 Measure Install depth of crankshaft journal bearings Install depth of oil seal EAS32341 INSTALLING THE CRANKSHAFT ASSEMBLY AND BALANCER SHAFT ASSEMBLY 1 Install Balancer shaft assembly 1 Crankshaft assembly 2 to the right crankcase TIP Align the punch mark a on the crankshaft as sembly with the punch mark b on t...

Page 268: ...n page 5 7 Storage box Refer to GENERAL CHASSIS 4 on page 4 10 Air filter case Refer to AIR FILTER CASE on page 7 11 Swingarm Refer to REAR SHOCK ABSORBER AS SEMBLIES AND SWINGARM on page 4 91 Rear wheel Refer to REAR WHEEL on page 4 34 Secondary sheave assembly Refer to V BELT AUTOMATIC TRANSMIS SION on page 5 37 E LS LS New New New New New New New E E E E E E LS 20 N m 2 0 kgf m 15 lb ft T R 20 ...

Page 269: ...case cover 1 4 Transmission case cover gasket 1 5 Dowel pin 2 6 Primary drive gear 1 7 1st wheel gear 1 8 Circlip 1 9 Drive axle 1 10 Main axle 1 11 Primary driven gear 1 12 Oil seal 2 13 Circlip 1 14 Bearing 6 E LS LS New New New New New New New E E E E E E LS 20 N m 2 0 kgf m 15 lb ft T R 20 N m 2 0 kgf m 15 lb ft T R 5 5 12 14 13 8 4 3 12 9 1 7 14 6 14 14 10 11 14 14 6 2 ...

Page 270: ...ive part s EAS30438 INSTALLING THE TRANSMISSION 1 Install Oil seal 1 to the transmission case cover 2 Oil seal 3 to the left crankcase 4 TIP Lubricate the oil seal with lithium soap based grease 2 Install Circlips 1 TIP Install the circlip with its chamfered side facing as shown 3 Install Transmission case cover 1 TIP Tighten the transmission case cover bolts in the proper tightening sequence as s...

Page 271: ...DIATOR 6 4 INSTALLING THE RADIATOR 6 4 THERMOSTAT 6 6 CHECKING THE THERMOSTAT ASSEMBLY 6 7 INSTALLING THE THERMOSTAT ASSEMBLY 6 7 WATER PUMP 6 8 DISASSEMBLING THE WATER PUMP 6 10 CHECKING THE WATER PUMP 6 10 ASSEMBLING THE WATER PUMP 6 10 INSTALLING THE GENERATOR COVER 6 10 ...

Page 272: ...S 6 1 EAS20299 COOLING SYSTEM DIAGRAMS 6 3 2 1 5 6 7 4 1 Water pump inlet hose 2 Thermostat assembly 3 Radiator inlet hose 4 Cooling system air bleed hose 5 Radiator outlet hose 6 Water pump outlet pipe 7 Water pump assembly ...

Page 273: ...SSIS 4 on page 4 10 Radiator cover Refer to GENERAL CHASSIS 5 on page 4 13 Coolant Drain Refer to CHANGING THE COOLANT on page 3 21 1 Coolant reservoir hose 1 2 Coolant reservoir 1 3 Coolant reservoir cap 1 4 Coolant reservoir breather hose 1 5 Radiator cap 1 TIP Remove Install it with the radiator filler pipe held 1 2 3 4 5 New New 1 6 N m 0 16 kgf m 1 2 lb ft T R 8 N m 0 8 kgf m 5 9 lb ft T R 7 ...

Page 274: ... filler hose 1 9 Radiator inlet hose 1 10 Radiator outlet hose 1 11 Radiator fan motor coupler 1 Disconnect 12 Radiator 1 13 Coolant drain bolt 1 14 Radiator fan 1 15 Radiator rear cover 1 6 7 8 9 10 11 12 13 14 15 New New 1 6 N m 0 16 kgf m 1 2 lb ft T R 8 N m 0 8 kgf m 5 9 lb ft T R 7 N m 0 7 kgf m 5 2 lb ft T R 7 N m 0 7 kgf m 5 2 lb ft T R ...

Page 275: ...r ten sec onds and make sure there is no drop in pressure 4 Check Radiator fan Damage Replace Malfunction Check and repair Refer to COOLING SYSTEM on page 8 27 EAS30440 INSTALLING THE RADIATOR 1 Install Radiator cap 1 TIP Make sure that the projection a on the radiator cap contacts the projection b on the radiator fill er pipe 2 Install Coolant reservoir cap 1 TIP Point the tab a on the coolant re...

Page 276: ...eplace any faulty part a Attach the radiator cap tester 1 and radi ator cap tester adapter 2 to the radiator b Apply 196 kPa 1 96 kgf cm 27 9 psi of pressure c Measure the indicated pressure with the gauge Radiator cap tester 90890 01325 Mityvac cooling system tester kit YU 24460 A Radiator cap tester adapter 31mm 90890 05375 Radiator cap tester adapter 31mm YM 05375 2 1 ...

Page 277: ...HASSIS 2 on page 4 4 Lower side covers Refer to GENERAL CHASSIS 4 on page 4 10 Radiator cover Refer to GENERAL CHASSIS 5 on page 4 13 Coolant Drain Refer to CHANGING THE COOLANT on page 3 21 1 Water pump inlet hose 1 Disconnect 2 Cooling system air bleed hose 1 Disconnect 3 Radiator inlet hose 1 Disconnect 4 Radiator outlet hose 1 Disconnect 5 Thermostat assembly 1 1 2 4 3 5 New S 9 N m 0 9 kgf m ...

Page 278: ...ne b at 90 C 194 F TIP If the accuracy of the thermostat is in doubt re place it A faulty thermostat could cause serious overheating or overcooling EAS30445 INSTALLING THE THERMOSTAT ASSEMBLY 1 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 21 2 Check Cooling system Leaks Repair or replace any faulty part Refer to INSTALLING THE RA...

Page 279: ...0 Radiator cover Refer to GENERAL CHASSIS 5 on page 4 13 Exhaust pipe Refer to ENGINE REMOVAL on page 5 7 Coolant Drain Refer to CHANGING THE COOLANT on page 3 21 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 19 1 Water pump inlet hose 1 Disconnect 2 Water pump outlet pipe 1 3 Crankshaft position sensor coupler 1 Disconnect 10 2 3 1 New LS LS LS New New New New New FWD FWD 10 N m 1 0...

Page 280: ...ect 5 Generator cover 1 6 Generator cover gasket 1 7 Dowel pin 2 8 Water pump housing 1 9 Circlip 1 10 Impeller shaft 1 11 Water pump seal 1 12 Bearing 1 5 10 9 6 7 4 12 11 10 8 LS LS LS New New New New New New FWD FWD 10 N m 1 0 kgf m 7 4 lb ft T R 10 N m 1 0 kgf m 7 4 lb ft T R 10 N m 1 0 kgf m 7 4 lb ft T R ...

Page 281: ...as shown in the illustra tion 2 Lubricate Water pump seal 3 Install Impeller shaft 1 Circlip TIP After installation check that the impeller shaft ro tates smoothly EAS32358 INSTALLING THE GENERATOR COVER 1 Install Dowel pins Generator cover gasket Installed depth of water pump seal 0 2 0 7 mm 0 01 0 03 in Mechanical seal installer 90890 04145 Middle driven shaft bearing driv er 90890 04058 Middle ...

Page 282: ...on sensor coupler TIP To route the stator coil crankshaft position sen sor lead refer to CABLE ROUTING on page 2 13 3 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 21 4 Check Cooling system Leaks Repair or replace any faulty part Refer to INSTALLING THE RADIATOR on page 6 4 5 Measure Radiator cap opening pressure Below the specifi...

Page 283: ...NSTALLING THE FUEL TANK 7 6 CHECKING THE FUEL PRESSURE 7 7 FUEL INJECTOR 7 8 REMOVING THE FUEL HOSE 7 9 CHECKING THE FUEL INJECTOR 7 9 INSTALLING THE FUEL INJECTOR 7 9 INSTALLING THE FUEL HOSE 7 9 AIR FILTER CASE 7 11 INSTALLING THE AIR FILTER CASE 7 12 THROTTLE BODY 7 13 REMOVING THE THROTTLE BODY 7 15 CHECKING THE THROTTLE BODY 7 15 CLEANING THE ISC IDLE SPEED CONTROL UNIT AND THROTTLE BODY 7 15...

Page 284: ...assembly Refer to GENERAL CHASSIS 3 on page 4 7 Lower side covers Refer to GENERAL CHASSIS 4 on page 4 10 Bottom cover assembly Refer to GENERAL CHASSIS 5 on page 4 13 Leg shield assembly Refer to GENERAL CHASSIS 6 on page 4 16 Seat damper Seat damper bracket Refer to GENERAL CHASSIS 7 on page 4 21 Canister Refer to FUEL TANK on page 7 1 16 N m 1 6 kgf m 12 lb ft T R 4 0 N m 0 40 kgf m 3 0 lb ft T...

Page 285: ...p 1 2 Fuel tank overflow tray 1 3 Fuel tank breather hose fuel tank to rollover valve 1 Disconnect 4 Fuel pump coupler 1 Disconnect 5 Fuel hose 1 Disconnect 6 Fuel tank 1 7 Fuel pump bracket 1 8 Fuel pump assembly 1 9 Fuel pump gasket 1 10 Fuel filter holder 1 11 Fuel filter 1 12 Fuel pump 1 16 N m 1 6 kgf m 12 lb ft T R 4 0 N m 0 40 kgf m 3 0 lb ft T R 6 4 6 2 3 4 5 1 8 12 9 10 11 7 New New ...

Page 286: ...to GENERAL CHASSIS 3 on page 4 7 Lower side covers Refer to GENERAL CHASSIS 4 on page 4 10 Footrest board assembly Refer to GENERAL CHASSIS 5 on page 4 13 Leg shield assembly Refer to GENERAL CHASSIS 6 on page 4 16 1 Fuel tank breather hose rollover valve to canis ter 1 2 Rollover valve holder 1 3 Rollover valve 1 4 Fuel tank breather hose fuel tank to rollover valve 1 7 N m 0 7 kgf m 5 2 lb ft T ...

Page 287: ...FUEL TANK 7 4 Removing the canister Order Job Parts to remove Q ty Remarks 5 Canister purge hose 1 6 Canister bracket 2 7 Canister 1 8 Canister breather hose 1 7 N m 0 7 kgf m 5 2 lb ft T R 7 5 6 8 6 ...

Page 288: ...here it will be removed EAS30451 REMOVING THE FUEL PUMP 1 Remove Fuel pump NOTICE ECA14721 Do not drop the fuel pump or give it a strong shock Do not touch the base section of the fuel sender EAS31376 REMOVING THE FUEL FILTER 1 Remove Fuel filter holder 1 Fuel filter 2 O ring 3 a Unhook the projections a on fuel filter holder from the fuel pump and then slide the holder sideways to remove it b Rem...

Page 289: ... the fuel pump Align the projections b three locations on the fuel pump gasket with the slots c in the fuel pump Align the projection d on the fuel pump with the slot in the fuel pump bracket Align the projection d on the fuel pump with the projection e on the fuel tank Tighten the fuel pump bolts in the proper tight ening sequence as shown EAS30457 INSTALLING THE FUEL TANK 1 Install Fuel hose NOT...

Page 290: ... cause fuel to spurt out when removing the hose NOTICE ECA20020 Although the fuel has been removed from the fuel tank be careful when removing the fuel hose since there may be fuel remaining in it TIP Before removing the hose place a few rags in the area under where it will be removed b Connect the pressure gauge 1 and fuel pressure adapter 2 to the fuel hose 3 c Start the engine d Measure the fue...

Page 291: ...n page 4 1 Front cowling assemblies Refer to GENERAL CHASSIS 2 on page 4 4 Lower side covers Refer to GENERAL CHASSIS 4 on page 4 10 Bottom cover assembly Refer to GENERAL CHASSIS 5 on page 4 13 1 Fuel hose holder 1 2 Fuel hose 1 3 Fuel injector coupler 1 Disconnect 4 Fuel injector 1 12 N m 1 2 kgf m 8 9 lb ft T R 7 N m 0 7 kgf m 5 2 lb ft T R New E 1 4 3 2 ...

Page 292: ...OR 1 Check Injector Obstruction Replace and check the fuel pump fuel supply system Deposit Replace Damage Replace 2 Check Injector resistance Refer to CHECKING THE FUEL INJEC TOR on page 8 137 EAS31617 INSTALLING THE FUEL INJECTOR 1 Install O ring 1 to the fuel injector Fuel injector 2 TIP Lubricate the O ring with engine oil Align the projection a on the fuel injector with the hole b in the intak...

Page 293: ...7 10 2 Install Fuel hose holder 1 TIP While holding the fuel hose holder so that the portion a of the holder contacts the portion b of the cylinder head cover T R Fuel hose holder bolt 7 N m 0 7 kgf m 5 2 lb ft 1 b a ...

Page 294: ...lter case duct cover 1 5 Air filter case duct 1 6 Air filter element 1 7 Transmission case breather hose 1 8 Cylinder head breather hose 1 Disconnect 9 Air filter case joint clamp screw 1 Loosen 10 Air filter case 1 11 Air filter check hose 1 12 Air filter case joint 1 6 4 2 1 5 3 3 10 11 7 8 9 12 5 3 5 New New 3 0 N m 0 30 kgf m 2 2 lb ft T R 10 N m 1 0 kgf m 7 4 lb ft T R 1 2 N m 0 12 kgf m 0 88...

Page 295: ...he air filter case joint 2 TIP Align the projection a on the air filter case joint with the slot b in the air filter case joint clamp 3 Install Air filter case duct 1 to the air filter case cover 2 TIP Fit the projection a on the air filter case duct be tween the projections b on the air filter case cover 4 Install Pre air filter element 1 TIP Fit pre air filter element into the slot a in the air ...

Page 296: ... Idle Speed Control unit coupler 1 Disconnect 2 Throttle body sensor assembly coupler 1 Disconnect 3 Throttle cable 2 Disconnect 4 Throttle cable holder 1 5 Canister purge hose 1 Disconnect 6 Intake manifold clamp screw 1 Loosen 7 Throttle body 1 8 Intake manifold 1 9 Intake manifold joint 1 12 N m 1 2 kgf m 8 9 lb ft T R 12 N m 1 2 kgf m 8 9 lb ft T R 5 N m 0 5 kgf m 3 7 lb ft T R 7 N m 0 7 kgf m...

Page 297: ... Q ty Remarks 10 ISC Idle Speed Control unit holder 1 11 ISC Idle Speed Control unit 1 12 Spring 1 12 N m 1 2 kgf m 8 9 lb ft T R 12 N m 1 2 kgf m 8 9 lb ft T R 5 N m 0 5 kgf m 3 7 lb ft T R 7 N m 0 7 kgf m 5 2 lb ft T R 10 11 12 New New LS 3 0 N m 0 30 kgf m 2 2 lb ft T R ...

Page 298: ...e body 2 Check Butterfly valve Damage scratches wear Replace the throttle body NOTICE ECA21770 Do not adjust the stop screw 1 EAS31254 CLEANING THE ISC IDLE SPEED CONTROL UNIT AND THROTTLE BODY 1 Remove the throttle body from the vehicle TIP Before removing the throttle body disconnect the throttle cables canister purge hose and couplers 2 Remove Screw 1 ISC Idle Speed Control unit holder 2 ISC Id...

Page 299: ...or for eign materials to adhere to the sealing sur faces of the O ring Do not scratch or deform the ISC valve or air passage otherwise poor starting per formance an unstable engine idling speed or uncontrollable engine speed could re sult Do not clean any areas other than the areas a b and c If the cleaning agent en ters the ISC unit or throttle body thorough ly wipe it off 7 Adjust the ISC unit p...

Page 300: ... DIAGNOSTIC CODE TABLE on page 9 1 ISC valve position Use the diagnostic code number 54 Refer to SELF DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE on page 9 1 12 Reset A F control learning values Use the diagnostic code number 87 Refer to SELF DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE on page 9 1 13 Place the vehicle on the centerstand so that the rear wheel is elevated 14 Check Engine idling...

Page 301: ...hat the rear wheel is elevated 6 Check Engine idling speed Start the engine warm it up and then mea sure the engine idling speed EAS30980 INSTALLING THE THROTTLE BODY 1 Install Intake manifold joint 1 Intake manifold 2 Throttle body TIP Make sure that the groove a in the intake manifold joint is facing toward the cylinder head Align the projection b on the intake manifold with slot c in the intake...

Page 302: ...THROTTLE BODY 7 19 ...

Page 303: ...ROUBLESHOOTING 8 13 LIGHTING SYSTEM 8 15 CIRCUIT DIAGRAM 8 15 TROUBLESHOOTING 8 17 SIGNALING SYSTEM 8 19 CIRCUIT DIAGRAM 8 19 TROUBLESHOOTING 8 21 COOLING SYSTEM 8 27 CIRCUIT DIAGRAM 8 27 TROUBLESHOOTING 8 29 FUEL INJECTION SYSTEM 8 31 CIRCUIT DIAGRAM 8 31 ECU SELF DIAGNOSTIC FUNCTION 8 33 TROUBLESHOOTING METHOD 8 33 YAMAHA DIAGNOSTIC TOOL 8 34 TROUBLESHOOTING DETAILS 8 34 FUEL PUMP SYSTEM 8 77 CI...

Page 304: ...BLING A SMART KEY 8 122 DISABLING THE POWER ON ALARM 8 123 REPLACEMENT PARTS LIST 8 124 ELECTRICAL COMPONENTS 8 125 CHECKING THE SWITCHES 8 127 CHECKING THE FUSES 8 128 REPLACING THE ECU Engine Control Unit 8 128 CHECKING AND CHARGING THE BATTERY 8 128 CHECKING THE RELAYS 8 129 CHECKING THE TURN SIGNAL HAZARD RELAY 8 130 CHECKING THE DIODES 8 131 CHECKING THE IGNITION SPARK GAP 8 132 CHECKING THE ...

Page 305: ......

Page 306: ...G B B B B B B B L Y B B W G Y P O B R W W Br R B L L L W Y Sb Gy B L Y Y G L R G R L Y W R B W B O L B Br WGy R R B B L P W Y L B W W R Br R Br R R B R B Br R B L R W R R R B W B W B W B W B B B B B R W R W R W R W R W R W R W Br R W R B L R B O O R B Br R Br R L G L Y L G B B L Y L Y R R B R R R R W R W L L Y B 1 6 10 11 22 24 30 44 45 46 54 67 67 ...

Page 307: ...EM 8 2 1 Crankshaft position sensor 6 Main switch 10 Backup fuse 11 Main fuse 22 Battery 24 Main fuse 2 30 Sidestand switch 44 ECU Engine Control Unit 45 Ignition coil 46 Spark plug 54 Engine ground 67 Frame ground ...

Page 308: ... BATTERY on page 8 128 Clean the battery terminals Recharge or replace the battery 3 Check the spark plug Refer to CHECKING THE SPARK PLUG on page 3 4 Re gap or replace the spark plug 4 Check the ignition spark gap Refer to CHECKING THE IGNI TION SPARK GAP on page 8 132 Ignition system is OK 5 Check the spark plug cap Refer to CHECKING THE SPARK PLUG CAP on page 8 132 Replace the spark plug cap 6 ...

Page 309: ... main switch 9 Check the sidestand switch Refer to CHECKING THE SWITCHES on page 8 127 Replace the sidestand switch 10 Check the entire ignition system wiring Refer to CIRCUIT DIAGRAM on page 8 1 Properly connect or replace the wire har ness Replace the ECU Refer to REPLAC ING THE ECU Engine Control Unit on page 8 128 ...

Page 310: ... B B B B B Dg B L W Ch G Y L W Ch G Y Dg B Y Dg B R Ch G Y Ch G Y R Y Dg B Br W Br B P R W P R W B Br W Br R R Br W P Y W R W R B B Y W R W R B Br R Br W P W B R W Br R W G Y R W R W R W Br R Br R Br R L R R R B B B B B B G Y G Y G Y R W L W G Y G Y G Y Br W R W R B R W L W L W L W Br W Br R Br R Br R Br R R W L G L G B B P R B B R B R R R B Br R G Y 6 11 13 22 24 25 26 28 29 30 31 32 35 67 67 70 ...

Page 311: ...use 22 Battery 24 Main fuse 2 25 Starter relay 26 Starter motor 28 Diode 3 29 Starting circuit cut off relay 30 Sidestand switch 31 Handlebar switch right 32 Start engine stop switch 35 Front brake light switch 67 Frame ground 70 Handlebar switch left 74 Rear brake light switch ...

Page 312: ...ont brake light switch is closed and the side stand is up the sidestand switch is closed The rear brake lever is pulled to the handlebar the rear brake light switch is closed and the sidestand is up the sidestand switch is closed 10 M 1 9 4 13 2 3 5 11 8 6 7 12 1 Battery 2 Main fuse 3 Main switch 4 Main fuse 2 5 Start engine stop switch 6 Diode 3 7 Starting circuit cut off relay 8 Sidestand switch...

Page 313: ...n the battery terminals Recharge or replace the battery 3 Check the starter motor operation Refer to CHECKING THE START ER MOTOR OPERATION on page 8 134 Starter motor is OK Perform the electric starting system troubleshooting starting with step 5 4 Check the starter motor Refer to CHECKING THE START ER MOTOR on page 5 54 Repair or replace the starter motor 5 Check the starting circuit cut off re l...

Page 314: ...witch 10 Check the start engine stop switch Refer to CHECKING THE SWITCHES on page 8 127 The start engine stop switch is faulty Re place the right handlebar switch 11 Check the brake light switches Front and rear Refer to CHECKING THE SWITCHES on page 8 127 Replace the brake light switch es 12 Check the entire starting system wiring Refer to CIRCUIT DIAGRAM on page 8 5 Properly connect or replace ...

Page 315: ...ELECTRIC STARTING SYSTEM 8 10 ...

Page 316: ...CHARGING SYSTEM 8 11 EAS20074 CHARGING SYSTEM EAS30496 CIRCUIT DIAGRAM W W W W B W R W R R L W G Y R W R W W W W B R B B R B R R 2 3 22 24 67 ...

Page 317: ...CHARGING SYSTEM 8 12 2 AC magneto 3 Rectifier regulator 22 Battery 24 Main fuse 2 67 Frame ground ...

Page 318: ...use 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 128 Clean the battery terminals Recharge or replace the battery 3 Check the stator coil Refer to CHECKING THE STATOR COIL on page 8 134 Replace the stator coil assembly 4 Check the rectifier regulator Refer to CHECKING THE RECTI FIER REGULATOR on page 8 135 Replace the rectifier regulator 5 Check the entire charging syste...

Page 319: ...CHARGING SYSTEM 8 14 ...

Page 320: ...B W Br R B L B Y Dg B R Ch G Y Ch G Y R Y Dg B Br W Br B P R W P R W B Br W Br R Y Br R B Y B G B G BBr R B B R B W LG B L R B L Ch G Y W P W Dg Gy R W R Y B L R G B G B Br R Y Y Br Br R Br R Br R Br R Br R Br R Br R R B R B Br R B L R L R R Y Br R L R R R B W B W B W B W B B B B B Br R L R L R B B B B B B B B B B Br R Br R Br R Br R Br R Br R B L Br R L R Y B R B R Y R Y R B Br R Br R Br R R R B ...

Page 321: ...ght 61 Tail brake light assembly right 63 Tail brake light right 64 Tail brake light assembly left 66 Tail brake light left 67 Frame ground 70 Handlebar switch left 71 Dimmer switch 77 Headlight assembly 78 Headlight low beam 79 Headlight high beam 80 Auxiliary light 81 Meter assembly 83 Multi function meter 87 Meter light 90 High beam indicator light 92 Storage box light ...

Page 322: ...k the condition of each bulb and bulb socket Refer to CHECKING THE BULBS AND BULB SOCKETS in BASIC INFORMATION separate volume Replace the bulb s and bulb socket s 2 Check the fuses Main main 2 backup and answer back Refer to CHECKING THE FUS ES on page 8 128 Replace the fuse s 3 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 128 Clean the battery terminals Recharge or repl...

Page 323: ...system wiring Refer to CIRCUIT DIAGRAM on page 8 15 Properly connect or replace the wire har ness Replace the ECU meter assembly tail brake light assembly storage box light or headlight assembly Refer to REPLACING THE ECU Engine Con trol Unit on page 8 128 ...

Page 324: ... L Ch G Y W P W Dg Gy L G B W R Br W P Y W R W R B B Y W R W R B Br R Br W P W B B G B Br W B Y Br B W W R R W B L G B B B B B L L R Dg Ch Br R P P B Ch Br Dg Br W Br W Br R Br W Br W Br W R W G Y R W R W R W R W R W Br R Br R Br R Br R Br R R B R B L R L R Br R L B L R W R R R Br W G L G B W L B W B W B W B W W B B W B W B W B W B W B B B Ch Ch Ch Ch Ch Ch Ch Ch Ch Br R L R L R B B B B B B B B B ...

Page 325: ...el sensor 56 Rear wheel sensor 57 Joint connector 59 ABS ECU 61 Tail brake light assembly right 62 Rear turn signal light right 63 Tail brake light right 64 Tail brake light assembly left 65 Rear turn signal light left 66 Tail brake light left 67 Frame ground 68 Turn signal hazard relay 69 Horn 70 Handlebar switch left 72 Horn switch 73 Turn signal switch 74 Rear brake light switch 75 Front turn s...

Page 326: ... Battery cover assembly 2 Front cowling assemblies 3 Meter panel assembly 4 Lower side covers 5 Footrest board assemblies 6 Leg shield assembly NG OK NG OK NG OK NG OK 1 Check the fuses Main main 2 backup turn signal light and hazard signaling system and ABS control unit Refer to CHECKING THE FUS ES on page 8 128 Replace the fuse s 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on ...

Page 327: ...e front brake light switch Refer to CHECKING THE SWITCHES on page 8 127 Replace the front brake light switch 2 Check the rear brake light switch Refer to CHECKING THE SWITCHES on page 8 127 Replace the rear brake light switch 3 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 8 19 Properly connect or replace the wire har ness Replace the tail brake light assembly 1 Check t...

Page 328: ...ing system wiring Refer to CIRCUIT DIAGRAM on page 8 19 Properly connect or replace the wire har ness Replace the meter assembly 1 Check the coolant temperature sen sor Refer to CHECKING THE COOL ANT TEMPERATURE SENSOR on page 8 136 Replace the coolant temperature sensor 2 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 8 19 Properly connect or replace the wire har ness R...

Page 329: ...place the hydraulic unit assembly ECU or meter assembly 1 Check the crankshaft position sen sor Refer to CHECKING THE CRANK SHAFT POSITION SENSOR on page 8 134 Replace the stator coil assembly 2 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 8 19 Properly connect or replace the wire har ness Replace the meter assembly or ECU Refer to REPLACING THE ECU En gine Control Uni...

Page 330: ... operate NG OK 1 Check the fuel sender Refer to CHECKING THE FUEL SENDER on page 8 135 Replace the fuel pump 2 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 8 19 Properly connect or replace the wire har ness Replace the meter assembly 1 Check the rear wheel sensor Refer to MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR on page 4 35 Replace the rear wheel sensor 2...

Page 331: ...SIGNALING SYSTEM 8 26 ...

Page 332: ... B L Y B B W G Y P O B R W W Br R B L L L W Y Sb Gy B L Y Y G L R G R L Y W R B W B O L B Br WGy R R B B L P W Y L B W B L B B L B R L L R W W Y R W R W R W Br R L R R R B W B W B W B W B B B B B B G R B L G R B L W Y W Y R W R L L L B R L R B Br R Br R Br R R W R R B R R R Br R Br R R B Br R Br R R B R B 6 9 10 11 13 22 24 36 44 52 53 54 67 67 ...

Page 333: ...diator fan motor fuse 10 Backup fuse 11 Main fuse 13 Signaling system fuse 22 Battery 24 Main fuse 2 36 Coolant temperature sensor 44 ECU Engine Control Unit 52 Radiator fan motor relay 53 Radiator fan motor 54 Engine ground 67 Frame ground ...

Page 334: ...efer to CHECKING AND CHARGING THE BATTERY on page 8 128 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 127 Replace the main switch 4 Check the radiator fan motor Refer to CHECKING THE RADIA TOR FAN MOTOR on page 8 136 Replace the radiator fan motor 5 Check the radiator fan motor relay Refer to CHECKING THE RE LAYS on pag...

Page 335: ... 8 30 NG OK 7 Check the entire cooling system s wiring Refer to CIRCUIT DIAGRAM on page 8 27 Properly connect or replace the wire har ness Replace the ECU Refer to REPLACING THE ECU En gine Control Unit on page 8 128 ...

Page 336: ... W LG B L R B L Ch G Y W P W Dg Gy Y L B R B Y Br B W L G B W R Br W P Y W R W R B B Y W R W R B Br R Br W P W B W R R W B W L L R G B G B Br R Y Y Br Br R R W R W Br R Br R Br R Br R Br R R B R B R B Br R L R L R Br R L B L R W R R R Br W G L Br Y G B W B W L Br Y B W B W B W B W W B W B B W B W B W B W B W B B B B B B B B B B B R W R W R W R W R W Br W R W R B R W R W R W Br W Br R Gy R W R G R ...

Page 337: ...sure sensor 40 Intake air temperature sensor 41 O2 sensor 42 Lean angle sensor 43 Yamaha diagnostic tool coupler 44 ECU Engine Control Unit 45 Ignition coil 46 Spark plug 47 Fuel injector 51 ISC Idle Speed Control unit 52 Radiator fan motor relay 53 Radiator fan motor 54 Engine ground 55 Front wheel sensor 56 Rear wheel sensor 57 Joint connector 59 ABS ECU 67 Frame ground 70 Handlebar switch left ...

Page 338: ...hat enable the engine to continue operating or stop operating depending on the conditions EAS30506 TROUBLESHOOTING METHOD The engine operation is not normal and the engine trouble warning light comes on 1 Check Fault code number a Check the fault code numbers that have a condition of Malfunction using the Yamaha diagnostic tool b Identify the faulty system with the fault code number c Identify the...

Page 339: ...LS This section describes the measures per fault code number displayed on the Yamaha diagnostic tool Check and service the items or components that are the probable cause 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 c...

Page 340: ...angle sensor Fuel pump relay Radiator fan motor relay Fault code No P0106 Item Intake air pressure sensor system malfunction clogged or de tached Fail safe system Able to start engine Able to drive vehicle Diagnostic code No 03 Tool display Displays the intake air pressure Procedure Operate the throttle while pulling the brake lever and pushing the side of the start engine stop switch If the displ...

Page 341: ... mmHg 20 7 inHg When engine is cranking Make sure that the indication value changes The value does not change when engine is cranking Re place the throttle body Refer to REPLACING THE THROTTLE BODY on page 7 18 Service is finished 3 Delete the fault code and check that the engine trouble warning light goes off Confirm that the fault code has a condition of Recover using the Yamaha diagnostic tool ...

Page 342: ...he pins Improperly connected Con nect the coupler securely or re place the wire harness Turn the main switch to ON and then check the condition of the fault code using the mal function mode of the Yamaha di agnostic tool Condition is Recover Go to item 7 and finish the service Condition is Malfunction Go to item 3 3 Wire harness continuity Open or short circuit Replace the wire harness Turn the ma...

Page 343: ... ECU coupler pink white pink white If there is no continuity replace the wire harness Fault code No P0107 P0108 Item No normal signals are received from the intake air pressure sensor P0107 Intake air pressure sensor open or ground short circuit de tected P0108 Intake air pressure sensor open or power short circuit de tected B L Y L P WBr W B L Y L P WBr W B L Y B B W G Y P O B R W W Br R B L L L ...

Page 344: ... installed sensor Reinstall the throttle body Refer to THROTTLE BODY on page 7 13 Turn the main switch to ON and then check the condition of the fault code using the mal function mode of the Yamaha di agnostic tool Condition is Recover Go to item 7 and finish the service Condition is Malfunction Go to item 5 Fault code No P0107 P0108 Item No normal signals are received from the intake air pressure...

Page 345: ...function mode of the Yamaha di agnostic tool Condition is Recover Go to item 7 and finish the service Condition is Malfunction Go to item 6 6 Malfunction in ECU Replace the ECU Refer to REPLACING THE ECU Engine Control Unit on page 8 128 Service is finished 7 Delete the fault code and check that the engine trouble warning light goes off Confirm that the fault code has a condition of Recover using ...

Page 346: ...terminals and locking condition of the pins Improperly connected Con nect the coupler securely or re place the wire harness Turn the main switch to ON and then check the condition of the fault code using the mal function mode of the Yamaha di agnostic tool Condition is Recover Go to item 7 and finish the service Condition is Malfunction Go to item 3 3 Wire harness continuity Open or short circuit ...

Page 347: ...tinuity replace the wire harness 3 6 Disconnect the couplers from the parts that are connected to the ECU Refer to Parts connected to the ECU on page 8 35 Fault code No P0112 P0113 Item No normal signals are received from the intake air temperature sen sor P0112 Intake air temperature sensor ground short circuit detected P0113 Intake air temperature sensor open or power short circuit detected B L ...

Page 348: ...s not close to the ambient tem perature Replace the throttle body Refer to REPLACING THE THROTTLE BODY on page 7 18 Turn the main switch to ON and then check the condition of the fault code using the mal function mode of the Yamaha di agnostic tool Condition is Recover Go to item 7 and finish the service Condition is Malfunction Go to item 6 6 Malfunction in ECU Replace the ECU Refer to REPLACING ...

Page 349: ...ng condition of the pins Improperly connected Con nect the coupler securely or re place the wire harness Turn the main switch to ON and then check the condition of the fault code using the mal function mode of the Yamaha di agnostic tool Condition is Recover Go to item 7 and finish the service Condition is Malfunction Go to item 2 2 Connection of ECU coupler Check the locking condition of the coup...

Page 350: ...lace the wire harness 3 4 For P0118 Open circuit Between coolant temperature sensor coupler and ECU coupler green red green red If there is no continuity replace the wire harness Fault code No P0117 P0118 Item No normal signals are received from the coolant temperature sensor P0117 Coolant temperature sensor ground short circuit detected P0118 Coolant temperature sensor open or power short circuit...

Page 351: ...ish the service Condition is Malfunction Go to item 5 5 Defective coolant temperature sensor Execute the diagnostic mode Code No 06 When engine is cold Displayed temperature is close to the ambient temperature The displayed temperature is not close to the ambient tem perature Replace the cool ant temperature sensor Refer to CYLINDER HEAD on page 5 13 Turn the main switch to ON and then check the c...

Page 352: ...ensor signal 13 21 fully closed position 97 107 fully open position Procedure Check with throttle valves fully closed Check with throttle valves fully open Item Probable cause of malfunc tion and check Maintenance job Confirmation of service com pletion 1 Connection of throttle body sen sor assembly coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent o...

Page 353: ...5 Sensor output lead 6 Sensor ground lead 3 2 Disconnect the ECU coupler from the ECU Disconnect the throttle body sensor assembly coupler from the throttle body 3 3 For P0122 Ground short circuit Between throttle body sensor assembly coupler and ground yellow ground If there is continuity replace the wire harness Fault code No P0122 P0123 Item No normal signals are received from the throttle posi...

Page 354: ...the parts that are connected to the ECU Refer to Parts connected to the ECU on page 8 35 Fault code No P0122 P0123 Item No normal signals are received from the throttle position sensor P0122 Throttle position sensor open or ground short circuit de tected P0123 Throttle position sensor open or power short circuit detect ed B L Y L P WBr W B L Y B B W G Y P O B R W W Br R B L L L W Y Sb Gy B L Y Y G...

Page 355: ...alue of 97 107 is indicated An indicated value is out of the specified range Replace the throttle body Refer to REPLACING THE THROTTLE BODY on page 7 18 Turn the main switch to ON and then check the condition of the fault code using the mal function mode of the Yamaha di agnostic tool Condition is Recover Go to item 7 and finish the service Condition is Malfunction Go to item 6 6 Malfunction in EC...

Page 356: ... nect the coupler securely or re place the wire harness Turn the main switch to ON and then check the condition of the fault code using the mal function mode of the Yamaha di agnostic tool Condition is Recover Go to item 7 and finish the service Condition is Malfunction Go to item 3 3 Connection of wire harness ECU coupler Check the locking condition of the coupler Disconnect the coupler and check...

Page 357: ...it Fail safe system Unable to start engine Unable to drive vehicle Diagnostic code No 36 Actuation Actuates fuel injector five times at one second intervals The check indicator on the Yamaha diagnostic tool screen comes on each time the fuel injector is actuated Procedure Disconnect the fuel pump coupler Check that fuel injector is actuated five times by listening for the operating sound Item Prob...

Page 358: ...le warning light goes off Start the engine and let it idle for approximately 5 seconds Confirm that the fault code has a condition of Recover using the malfunction mode of the Yamaha diagnostic tool and then delete the fault code Fault code No P0201 Item Fuel injector no normal signals are received from the fuel injector circuit Fault code No P0335 Item Crankshaft position sensor no normal signals...

Page 359: ...r to GENERATOR AND STARTER CLUTCH on page 5 46 Crank the engine and then check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recover Go to item 7 and finish the service Condition is Malfunction Go to item 5 5 Defective crankshaft position sensor Check the crankshaft position sensor Refer to CHECKING THE CRANKSHAFT POSITION SENSOR on page 8 13...

Page 360: ... securely or re place the wire harness Start the engine and let it idle for approximately 5 seconds Check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recover Go to item 7 and finish the service Condition is Malfunction Go to item 3 3 Wire harness continuity Open or short circuit Replace the wire harness Between ignition coil coupler and ECU...

Page 361: ...ator fan motor relay open circuit detected Fail safe system Able to start engine Able to drive vehicle Diagnostic code No Tool display Procedure Item Probable cause of malfunc tion and check Maintenance job Confirmation of service com pletion 1 Connection of radiator fan motor relay coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminal...

Page 362: ... Service is finished 6 Delete the fault code and check that the engine trouble warning light goes off Confirm that the fault code has a condition of Recover using the Yamaha diagnostic tool and then delete the fault code Fault code No P0480 Item No normal signals are received from the radiator fan motor relay Radiator fan motor relay open circuit detected Fault code No P0500 Item Front wheel senso...

Page 363: ...or Open or short circuit or defec tive sensor Replace the front wheel sensor Between front wheel sensor coupler and ABS ECU coupler green green blue blue Between ABS ECU coupler and ECU coupler white white Execute the diagnostic mode Code No 07 Rotate the front wheel by hand and check that the indicated val ue increases Value increases Go to item 7 Value does not increase Go to item 5 5 Malfunctio...

Page 364: ...on Execute the diagnostic mode Code No 54 Fully closes the ISC Idle Speed Control valve and then fully opens the valve This operation takes approximately 3 seconds ISC operating sound is heard Go to item A 2 ISC operating sound is not heard Go to item B 2 for the defective ISC Idle Speed Con trol unit A 2 Incorrect front wheel sensor sig nal Check the front wheel sensor Execute the diagnostic mode...

Page 365: ...et it idle for approximately 10 seconds Check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recover Go to item A 9 and finish the service Condition is Malfunction Go to item A 7 A 7 ISC Idle Speed Control unit is not moving correctly Replace the ISC Idle Speed Control unit Refer to CLEANING THE ISC IDLE SPEED CONTROL UNIT AND THROTTLE BODY on...

Page 366: ...e pins Improperly connected Con nect the coupler securely or re place the wire harness Execute the diagnostic mode Code No 54 ISC operating sound is heard Go to item B 9 and delete the fault code ISC operating sound is not heard Go to item B 3 B 3 Connection of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking cond...

Page 367: ...s off Start the engine and let it idle for approximately 10 seconds Confirm that the fault code has a condition of Recover using the Yamaha diagnostic tool and then delete the fault code Fault code No P0507 Item A Component other than ISC Idle Speed Control unit is defec tive ISC operating sound is heard B Defective ISC Idle Speed Control unit ISC operating sound is not heard Fault code No P0511 I...

Page 368: ...n is Malfunction Go to item 4 4 Faulty ISC unit operation Execute the diagnostic mode Code No D54 ISC unit operation sound is not heard Replace the ISC unit Refer to CLEANING THE ISC IDLE SPEED CONTROL UNIT AND THROTTLE BODY on page 7 15 Turn the main switch to ON and then check the condition of the fault code using the mal function mode of the Yamaha diagnostic tool Condition is Recover Go to ite...

Page 369: ...ng voltage is abnormal Fault code No P0601 Item Faulty ECU memory Fail safe system Unable to start engine Unable to drive vehicle Diagnostic code No Tool display Procedure Item Probable cause of malfunc tion and check Maintenance job Confirmation of service com pletion 1 Malfunction in ECU Replace the ECU Refer to REPLACING THE ECU Engine Control Unit on page 8 128 Turn the main switch to ON Check...

Page 370: ...tem 7 and finish the service Condition is Malfunction Ex ecute the diagnostic mode Code No 67 and then repeat item 1 If the same number is indicated go to item 6 4 12 is indicated in the diagnos tic mode Code No 60 EE PROM data error for A F control learning values Turn the main switch to OFF Turn the main switch to ON and then check the condition of the fault code using the mal function mode of t...

Page 371: ... of service com pletion 1 Connection of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the coupler securely or re place the wire harness Start the engine and let it idle for approximately 5 seconds Check the condition of the fault code using the malfunction mod...

Page 372: ...ch to ON and then extend and retract the sidestand Check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recover Go to item 7 and finish the service Condition is Malfunction Go to item 2 2 Connection of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition...

Page 373: ...maha diagnostic tool Condition is Recover Go to item 7 and finish the service Condition is Malfunction Go to item 6 6 Malfunction in ECU Replace the ECU Refer to REPLACING THE ECU Engine Control Unit on page 8 128 Service is finished 7 Delete the fault code and check that the engine trouble warning light goes off Confirm that the fault code has a condition of Recover using the Yamaha diagnostic to...

Page 374: ...ace the wire harness Turn the main switch to ON then to OFF and then back to ON Check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recover Go to item 6 and finish the service Condition is Malfunction Go to item 3 3 Wire harness continuity Open or short circuit Replace the wire harness Turn the main switch to ON then to OFF and then back to O...

Page 375: ... Between lean angle sensor coupler and ECU coupler yellow green yellow green If there is no continuity replace the wire harness Fault code No P1604 P1605 Item P1604 Lean angle sensor ground short circuit detected P1605 Lean angle sensor open or power short circuit detected B L Y G L B L Y B B W G Y P O B R W W Br R B L L L W Y Sb Gy B L Y Y G L R G R L Y W R B W B O L B Br W Gy R R B B L P W Y L B...

Page 376: ... then back to ON Check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recover Go to item 6 and finish the service Condition is Malfunction Go to item 5 5 Malfunction in ECU Replace the ECU Refer to REPLACING THE ECU Engine Control Unit on page 8 128 Service is finished 6 Delete the fault code and check that the engine trouble warning light goe...

Page 377: ... rear wheel speed pulse is 0 km h Go to item 2 2 Connection of rear wheel sen sor coupler Check the locking condition of the coupler Discon nect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the coupler securely or re place the wire harness Rotate the rear wheel by hand and check the display value for the rear wheel speed pu...

Page 378: ...km h Go to item 6 6 Defective rear wheel sensor Improperly installed sensor Reinstall or replace the sensor Refer to INSTALLING THE REAR WHEEL REAR BRAKE DISC on page 4 36 Rotate the rear wheel by hand and check the display value for the rear wheel speed pulse us ing the monitoring function Display value for the rear wheel speed pulse is greater than 0 km h Go to item 9 and de lete the fault code ...

Page 379: ...ocking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the coupler securely or re place the wire harness Start the engine warm it up and then race it Check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recover Go to item 8 and finish th...

Page 380: ... Condition is Malfunction Go to item 6 Also delete this fault code which has a condition of Mal function 6 Defective O2 sensor Check the O2 sensor Replace if defective Refer to CYLINDER HEAD on page 5 13 Start the engine warm it up and then race it Check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recover Go to item 8 and finish the service...

Page 381: ...FUEL INJECTION SYSTEM 8 76 ...

Page 382: ... G Y P O B R W W Br R B L L L W Y Sb Gy B L Y Y G L R G R L Y W R B W B O L B Br WGy R R B B L P W Y L B W Br W R B L B R W B G B Br W B R Br W P Y W R W R B B Y W R W R B Br R Br W P W B R W Br R Br R Br R Br R R B R B R B R B Br R L R R R B W B W B W B W B B R W R B Br R R B B L B L B Br W Br W R W R B R B Br R Br R Br R R B P R R B B R B R R R R B Br R 6 10 11 22 24 31 32 44 49 50 54 67 67 ...

Page 383: ...8 78 6 Main switch 10 Backup fuse 11 Main fuse 22 Battery 24 Main fuse 2 31 Handlebar switch right 32 Start engine stop switch 44 ECU Engine Control Unit 49 Fuel pump 50 Fuel pump relay 54 Engine ground 67 Frame ground ...

Page 384: ...ry terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 127 Replace the main switch 4 Check the start engine stop switch Refer to CHECKING THE SWITCHES on page 8 127 The start engine stop switch is faulty Re place the right handlebar switch 5 Check the fuel pump relay Refer to CHECKING THE RE LAYS on page 8 129 Replace the fuel pump relay 6 Che...

Page 385: ...FUEL PUMP SYSTEM 8 80 ...

Page 386: ... G Y Ch G Y R Y Dg B Br W Br B P R W P R W B Br W Br R G BBr R B B R B W LG B L R B L Ch G Y W P W Dg Gy Y Br B W L G B W R Br W P Y W R W R B B Y W R W R B Br R Br W P W B R W B W L L R Br R Br R W G Y R W R W Br R Br R Br R Br R R B R B R B L R L R R Y Br L Br R L R R R Y B R L Br W R G L Br Y G B W B W L Br Y L B L R L B B W B W B W L R R B B B W W B W W L B B W B W B W B W B W B B L R L R B B ...

Page 387: ... 35 Front brake light switch 44 ECU Engine Control Unit 54 Engine ground 55 Front wheel sensor 56 Rear wheel sensor 57 Joint connector 58 ABS test coupler 59 ABS ECU 61 Tail brake light assembly right 63 Tail brake light right 64 Tail brake light assembly left 66 Tail brake light left 67 Frame ground 70 Handlebar switch left 74 Rear brake light switch 81 Meter assembly 83 Multi function meter 85 A...

Page 388: ... 5 3 4 2 L B L R B R B B R L R B B W G L Br Y W W L W B G Y Y B Y B Br W L R L B B W G BBr R B B R B W LG B L R B L Ch G Y W P W Dg Gy Y Br B W L G B W 1 ABS test coupler 2 ABS ECU coupler 3 Rear wheel sensor coupler 4 Meter assembly coupler 5 Front wheel sensor coupler ...

Page 389: ...c tool For information about using the Yamaha diagnostic tool refer to B 2 DIAG NOSIS USING THE FAULT CODES on page 8 88 For troubleshooting items other than the following items follow the normal service method WARNING EWA16710 When maintenance or checks have been performed on components related to the ABS be sure to perform a final check before delivering the vehicle to the customer TIP To final ...

Page 390: ... them to shocks or pulling on them with too much force since the ABS components are precisely adjusted The ABS ECU and hydraulic unit are united assemblies and cannot be disassembled The malfunction history is stored in the memory of the ABS ECU Delete the fault codes when the ser vice is finished This is because the past fault codes will be displayed again if another malfunction occurs EAS30529 B...

Page 391: ...d normally Finished Yes No A Turn the main switch to ON and check the ABS warning light Fails to come on Comes on The ABS ECU coupler is disconnected The wire harness is defective The hydraulic unit assembly is defective Can communicate B 1 Check for ABS fault codes in the screen for the Execute fault diagnosis Yamaha diagnostic tool Are fault codes displayed on the screen No Yes The reaction forc...

Page 392: ...uit including the ABS warning light LED is defective Replace the meter assembly If the ABS warning light comes on the ABS ECU is defective Replace the hydraulic unit assembly 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 8 127 If there is no continuity replace the main switch 2 Battery Check the condition...

Page 393: ...ween the ABS ECU coupler and the ABS test coupler Check for continuity between blue red terminal of the ABS ECU coupler and blue red terminal of the ABS test coupler CANH Check for continuity between blue black terminal of the ABS ECU coupler and blue black terminal of the ABS test coupler CANL 5 ABS ECU malfunction Replace the hydraulic unit assembly EAS31165 B 1 MALFUNCTION ARE CURRENTLY DETECTE...

Page 394: ...lses Rear wheel sensor signal is not received properly Puls es are not received or are re ceived intermittently while the vehicle is traveling Foreign material adhered around the 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...

Page 395: ...ses Front wheel sensor signal is not received properly Miss ing pulses are detected in the signal while the vehicle is traveling Foreign material adhered around the front wheel sen sor Incorrect installation of the front wheel Defective sensor rotor or incorrect installation of the rotor Defective front wheel sen sor or incorrect installation of the sensor 18 46 Rear wheel sensor missing pulses Re...

Page 396: ...ircuit Short circuit 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 harn...

Page 397: ...or signal is not received 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 supp...

Page 398: ...ly 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 draulic unit assembly Defective front wheel sen sor Defective hydraulic unit as sembly 64 Rear wheel sensor power supply voltage of power supply is low Power voltage supplied from the ABS ECU to the rear wheel se...

Page 399: ...ttent 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 is traveling Order Item components and probable cause Check or maintenance job 1 Foreign material adhered around the rear wheel sensor Check the surface of the sensor rotor and wheel sensor for foreign material such as metal particles Clean t...

Page 400: ...allation of the front wheel Check the components for looseness distortion and bends Refer to CHECKING THE FRONT WHEEL on page 4 29 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 FRONT WHEEL SENSOR AND SENSOR ROTOR on page 4 30 4 Defective front wheel s...

Page 401: ... MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR on page 4 35 Fault code No 14 27 Item Rear wheel sensor abnormal pulse period Symptom Rear wheel sensor signal is not received properly The pulse period is abnormal while the vehicle is traveling Order Item components and probable cause Check or maintenance job Fault code No 15 Item Front wheel sensor open or short circuit Symptom Open or shor...

Page 402: ...place 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 the wheel sensor or hydraulic unit assembly Refer to FRONT WHEEL on page 4 27 and ABS AN TI LOCK BRAKE SYSTEM on page 4 63 Fault code No 15 Item Front wheel s...

Page 403: ... between the black white terminal 3 and the brown terminal 4 and be tween the black white terminal 3 and the yellow ter minal 5 If there is short circuit the wire harness is defective Replace the wire harness 6 ABS ECU 7 Rear wheel sensor 3 Defective rear wheel sensor or hydraulic unit assembly If the above items were performed and no malfunctions were found the wheel sensor or hydraulic unit asse...

Page 404: ...or rotor and wheel sensor if necessary 2 Incorrect installation of the front wheel Check the components for looseness distortion and bends Refer to CHECKING THE FRONT WHEEL on page 4 29 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 FRONT WHEEL SENSOR A...

Page 405: ...ce the hydraulic unit assembly Refer to ABS ANTI LOCK BRAKE SYSTEM on page 4 63 Fault code No 24 Item Brake light switch or brake light Symptom Brake light signal is not received 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 brake light or brake ...

Page 406: ...ery 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 4 63 Fault code No 32 Item Hydraulic unit assembly short circuit in ABS solenoid pow...

Page 407: ...he motor circuit in the hydraulic unit assem bly Order Item components and probable cause Check or maintenance job Fault code No 34 Item Hydraulic unit assembly short circuit in ABS motor power supply cir cuit Symptom Short circuit is detected in the motor power supply circuit in the hy draulic unit assembly Order Item components and probable cause Check or maintenance job 1 Defective hydraulic un...

Page 408: ...en though the signal is transmitted from the ABS ECU to reduce the hydraulic pressure Order Item components and probable cause Check or maintenance job Fault code No 42 47 Item Rear wheel ABS intermittent wheel speed pulses or incorrect depres surization Symptom Pulses from the rear wheel sensor are received intermittently while the vehicle is traveling for fault code No 42 Rear wheel will not rec...

Page 409: ...nd wheel sensor for foreign material such as metal particles Clean the sensor rotor and wheel sensor if necessary 2 Incorrect installation of the front wheel Check the components for looseness distortion and bends Refer to CHECKING THE FRONT WHEEL on page 4 29 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...

Page 410: ...ses Symptom Rear wheel sensor signal is not received properly Missing pulses are detected in the signal while the vehicle is traveling Order Item components and probable cause Check or maintenance job Fault code No 51 52 Item Vehicle system power supply voltage of ABS ECU power supply is high for fault code No 51 Vehicle system power supply voltage of wheel sensor power supply is high for fault co...

Page 411: ...ircuit Between ABS ECU coupler and ABS control unit fuse brown white brown white 4 Defective charging system Check the charging system Refer to CIRCUIT DIAGRAM on page 8 11 Fault code No 54 Item Hydraulic unit assembly defective ABS solenoid and ABS motor power supply circuits Symptom Abnormality is detected in the solenoid or motor power supply circuit in the hydraulic unit assembly Order Item co...

Page 412: ... cause Check or maintenance job Fault code No 55 Item Hydraulic unit assembly defective ABS ECU Symptom Abnormal data is detected 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 to ABS ANTI LOCK BRAKE SYSTEM on page 4 63 Fault code No 56 Item Hydraulic unit assembly abnorm...

Page 413: ...t circuit between the black white 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...

Page 414: ... circuit between the black white 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 A...

Page 415: ...HEEL FRONT BRAKE DISC on page 4 31 and INSTALL ING THE REAR WHEEL REAR BRAKE DISC on page 4 36 3 Perform brake line routing confirmation Refer to HYDRAULIC UNIT OPERATION TESTS on page 4 67 If it does not have reaction force properly the brake hose is not properly routed or connected 4 Delete the fault codes Refer to B 3 DELETING THE FAULT CODES on page 8 110 5 Checking the ABS warning light Check...

Page 416: ...B L Ch G Y W P W Dg Gy B B R W G W B B Ch B L Y R G L R R Y Dg G R W G B G W R B R Br W P Y W R W R B B Y W R W R B Br R Br W P W B G W R W G W R B R W L Y R Y R G L R G B B B R G B B L R Br R Br W Br R Br W Br W Br R Br R Br R Br R R B R B R B B B R G R B R B L R L R L R Dg Ch R Y Br L Br R B G L G B R R R B B W B W B W B W B B B Ch Ch Ch Ch Ch Ch Ch Ch L R L R B B B B B B B B B B B B B B B Dg Dg...

Page 417: ...ght and hazard fuse 22 Battery 24 Main fuse 2 30 Sidestand switch 31 Handlebar switch right 33 Hazard switch 44 ECU Engine Control Unit 54 Engine ground 62 Rear turn signal light right 65 Rear turn signal light left 67 Frame ground 68 Turn signal hazard relay 75 Front turn signal light right 76 Front turn signal light left 81 Meter assembly 82 Smart key indicator light 83 Multi function meter ...

Page 418: ...OK 1 Check the smart key The smart key indicator light comes on when the smart key but ton is pushed Check the button cell battery Refer to CHECKING THE SMART KEY BATTERY on page 8 137 Replace the button cell battery of the smart key Standard battery CR2032 2 Check the fuses Main main 2 backup signaling system turn signal and hazard and answer back Refer to CHECKING THE FUS ES on page 8 128 Replac...

Page 419: ...urned on NO YES NG OK 6 Check the entire smart key sys tem s wiring Refer to CIRCUIT DIAGRAM on page 8 111 Properly connect or replace the wire har ness Replace the smart key unit 1 Check the vehicle power Refer to Checking the vehicle pow er on page 8 113 Repair or replace any defective parts There are sources of strong electro magnetic waves in the vicinity Move the vehicle Smart key malfunction...

Page 420: ... 113 Repair or replace any defective parts Check the mechanical components of the lock for malfunctions Repair or replace any defective parts Adjust or replace the seat lock cable 1 Check the vehicle power Refer to Checking the vehicle pow er on page 8 113 Repair or replace any defective parts Check the mechanical components of the lock for malfunctions Repair or replace any defective parts Adjust...

Page 421: ...page 8 113 Repair or replace any defective parts 2 Check the buzzer operation Refer to CHECKING THE BUZZ ER on page 8 137 Replace the buzzer 3 Check the turn signal light bulbs and sockets Refer to CHECKING THE BULBS AND BULB SOCKETS in BASIC INFORMATION separate volume Replace the turn signal light bulb socket or both Replace the smart key unit ...

Page 422: ...shing in 0 15 second intervals the vehicle power cannot be turned back on Item Flash pattern Flashing time number of flashes Malfunction and check point Low voltage of smart key button cell battery a LED on b LED off 20 seconds Replace the button cell battery of the smart key Refer to SMART KEY SYSTEM on page 8 111 Vehicle power off verifi cation error a LED on b LED off 30 seconds The smart key c...

Page 423: ...the smart key unit Radio wave noise inter ference or disconnect ed lead Obstruction due to ra dio wave noise Disconnection in the wire harness Defective ECU Defective smart key unit Perform the checks and maintenance job for Engine does not start even though vehicle power is turned on 54 Smart key unit Codes transmitted be tween the ECU and the smart key unit do not match Radio wave noise inter fe...

Page 424: ...The smart key indicator light 1 will come on for 3 seconds to indicate the transition to emergency mode 3 After the smart key indicator light goes off use the main switch to enter the smart key identifica tion number 1 located inside the smart key case open the smart key case as shown or the iden tification number 2 located on the identification number card Refer to the following procedure on how ...

Page 425: ...e start over again from step 2 When there are no main switch operations for 10 seconds during the identification number input pro cess When the smart key indicator light is allowed to flash nine or more times The identification number is not entered correctly 6 While the smart key indicator light is on push the main switch once more to complete emergency mode access The smart key indicator light w...

Page 426: ... smart keys For example if 5 smart keys are registered the indicator light flashes 5 times 5 While the smart key indicator light is on for 10 seconds push the button on the smart key to transmit a signal from the smart key to the smart key unit 6 If the smart key is registered successfully the smart key indicator light will come on for 3 sec onds and then the smart key system will turn off If the ...

Page 427: ...the smart keys that you want to enable and place them within 80 cm 31 5 in of the smart key unit 6 Push the main switch for 5 seconds or more to start the communication between the smart key unit and the smart keys that are located within 80 cm 31 5 in of the unit TIP The number of smart keys that currently can be used will be indicated Number of flashes Number of verified smart keys 1 cycle of on...

Page 428: ...or light will come on for approximately 4 seconds 3 While the smart key indicator light is on turn the main switch to ON 4 Extend and retract the sidestand by hand for 10 times or more within 15 seconds from vehicle power on 5 When the buzzer sounds the setting is complete If the buzzer sounds 2 times The power on alarm is turned off If the buzzer sounds 1 times The power on alarm is turned on a 1...

Page 429: ...rt key iden tification number Smart key Smart key Smart key unit ECU Smart key Register the smart key identifi cation number in the emergency mode Smart key unit Replace the smart key smart key unit and ECU as a set ECU When the vehicle system is turned on the smart key identifi cation number is automatically registered to the ECU Smart key unit ECU Replace the smart key smart key unit and ECU as ...

Page 430: ...re sensor 3 Main switch 4 Front brake light switch 5 Rear brake light switch 6 ABS ECU 7 Turn signal hazard relay 8 Battery 9 Lean angle sensor 10 Buzzer 11 ECU Engine Control Unit 12 Front wheel sensor 13 Rectifier regulator 14 Fuel pump 15 Fuel sender 16 O2 sensor 17 Ignition coil 18 AC magneto 19 Crankshaft position sensor 20 Rear wheel sensor ...

Page 431: ...Intake air pressure sensor 4 Intake air temperature sensor 5 ISC Idle Speed Control unit 6 Fuel injector 7 Spark plug 8 Starting circuit cut off relay 9 Diode 1 10 Fuel pump relay 11 Fuse box 1 12 Starter relay 13 Fuse box 2 14 Diode 2 15 Diode 3 16 Radiator fan motor relay 17 Horn 18 Radiator fan motor 19 Sidestand switch 20 Starter motor ...

Page 432: ...K P TRIP INFO PASS L B B B R W G Y R W G Y R Br R Br L R Y B L B B B L W Ch G Y Dg B Ch G Y Y Dg B Br W Br P R W R Br W P B Y W R W R B R R Y Br L Br R R R BL W Dg Br W Ch Y W B P B Y Br Y Ch Br W Dg P B 1 2 8 9 10 11 3 4 5 6 7 1 Main switch 2 Request switch 3 Start engine stop switch 4 Hazard switch 5 TRIP INFO switch 6 Front brake light switch 7 Sidestand switch 8 Dimmer switch 9 Horn switch 10 ...

Page 433: ...bly Refer to GENERAL CHASSIS 1 on page 4 1 EAS31006 REPLACING THE ECU Engine Control Unit 1 Turn the main switch to OFF 2 Replace the ECU Engine Control Unit 3 Clean the throttle body Refer to CLEANING THE ISC IDLE SPEED CONTROL UNIT AND THROTTLE BODY on page 7 15 4 Reset A F control learning value Use the diagnostic code number 87 Refer to SELF DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE on pag...

Page 434: ...minals 10 Install Battery cover assembly Refer to GENERAL CHASSIS 1 on page 4 1 EAS30553 CHECKING THE RELAYS Check each switch for continuity with the digital circuit tester If the continuity reading is incor rect replace the relay 1 Disconnect the relay from the wire harness 2 Connect the digital circuit tester and battery 12 V to the relay terminals as shown Check the relay operation Out of spec...

Page 435: ...voltage Out of specification Replace 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 1 Positive battery terminal R B 3 4 R R L W G Y 1 2 Br W R B R W L B 2 1 4 3 R L L R W ...

Page 436: ...robe Ground Digital circuit tester CD732 90890 03243 Model 88 Multimeter with ta chometer YU A1927 Br R Br W 1 Diode 1 Continuity Positive tester probe brown red 1 Negative tester probe brown blue 2 No continuity Positive tester probe brown blue 2 Negative tester probe brown red 1 Diode 2 Continuity Positive tester probe blue white 3 Negative tester probe green yellow 4 No continuity Positive test...

Page 437: ...ch to ON d Measure the ignition spark gap a e Crank the engine by side of the start engine stop switch is pushed and gradual ly increase the spark gap until a misfire oc curs EAS30557 CHECKING THE SPARK PLUG CAP 1 Check Spark plug cap resistance Out of specification Replace a Remove the spark plug cap from the spark plug lead b Connect the digital circuit tester to the spark plug cap as shown c Me...

Page 438: ...ital circuit tester to the lean angle sensor coupler as shown c Turn the main switch to ON d Tilt the lean angle sensor to 50 e Measure the lean angle sensor output voltage Primary coil resistance 2 16 2 64 Ω Digital circuit tester CD732 90890 03243 Model 88 Multimeter with ta chometer YU A1927 Positive tester probe red white 1 Negative tester probe orange 2 Secondary coil resistance 8 64 12 96 kΩ...

Page 439: ...10 A wire that is used as a jumper lead must have at least the same capacity of the bat tery lead otherwise the jumper lead may burn This check is likely to produce sparks therefore make sure no flammable gas or fluid is in the vicinity b Check the starter motor operation EAS30566 CHECKING THE STATOR COIL 1 Disconnect Stator coil coupler from the wire harness 2 Check Stator coil resistance Out of ...

Page 440: ...wn b Move the fuel sender float to minimum 3 and maximum 4 level position c Measure the fuel sender resistance EAS31372 CHECKING THE FUEL METER This model is equipped with a self diagnosis de vice for the fuel level detection circuit 1 Check Fuel meter 1 Turn the main switch to ON Charging voltage 14 15 V at 5000 r min Digital circuit tester CD732 90890 03243 Model 88 Multimeter with ta chometer Y...

Page 441: ...tem perature sensor is dropped replace it 2 Check Coolant temperature sensor resistance Out of specification Replace a Connect the digital circuit tester to the coolant temperature sensor terminals as shown b Immerse the coolant temperature sensor 1 in a container filled with coolant 2 TIP Make sure that the coolant temperature sensor terminals do not get wet c Place a thermometer 3 in the coolant...

Page 442: ...UZZER 1 Check Buzzer operation Buzzer does not sound Replace a Disconnect the buzzer coupler from the wire harness b Connect the battery 12 V to the buzzer coupler as shown c Check that the buzzer sounds EAS31257 CHECKING THE MAIN SWITCH SOLENOID 1 Check Main switch solenoid a Disconnect the main switch solenoid cou pler from the wire harness Resistance 12 2 Ω Digital circuit tester CD732 90890 03...

Page 443: ... solenoid as shown c Check the main switch solenoid continuity d If there is no continuity replace the main switch assembly Digital circuit tester CD732 90890 03243 Model 88 Multimeter with ta chometer YU A1927 Positive tester probe red white 1 Negative tester probe black 2 B R W 1 2 ...

Page 444: ...ELECTRICAL COMPONENTS 8 139 ...

Page 445: ...ESHOOTING SELF DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE 9 1 SELF DIAGNOSTIC FUNCTION TABLE 9 1 DIAGNOSTIC CODE SENSOR OPERATION TABLE 9 8 DIAGNOSTIC CODE ACTUATOR OPERATION TABLE 9 9 EVENT CODE TABLE 9 11 ...

Page 446: ...ir pressure is fixed to 101 3 kPa O2 feedback is not carried out P0107 P0108 P0107 Intake air pressure sensor open or ground short circuit detected P0108 Intake air pressure sensor power short circuit detected no normal signals are received from the in take air pressure sen sor P0107 Low voltage of the intake air pres sure sensor circuit 0 2 V or less P0108 High voltage of the intake air pres sure...

Page 447: ...2 feedback is not carried out ISC learning is not carried out P0117 P0118 P0117 Coolant tem perature sensor ground short circuit detected P0118 Coolant tem perature sensor open or power short circuit detected no normal signals are received from the coolant temperature sensor P0117 Low voltage of the coolant tem perature sensor circuit 0 1 V or less P0118 High voltage of the coolant tem perature se...

Page 448: ...is fixed to 15 Intake air pressure is fixed to 101 3 kPa Fuel is not cut off due to the throttle open ing O2 feedback is not carried out P0132 O2 sensor power short circuit detected no normal signals are received from the O2 sensor High voltage of the O2 sensor circuit 4 8 V or more Improperly installed O2 sensor Defective coupler between O2 sensor and ECU Power short circuit in wire harness be tw...

Page 449: ...d Injection is not car ried out P0480 Radiator fan motor re lay open circuit detect ed no normal signals are received from the ra diator fan motor relay Open circuit in wire harness between ra diator fan motor re lay and ECU Defective coupler between radiator fan motor relay and ECU Defective driver Open circuit in radi ator fan motor relay Malfunction in ECU Engine is difficult to start Loss of e...

Page 450: ...C and front wheel sensor Disconnected hose or air leak from in take air passage Defective throttle valve or throttle ca ble Defective ISC unit ISC valve stuck ful ly open Malfunction in ECU Engine idling speed is high Idle speed control is not carried out P0511 ISC Idle Speed Con trol unit ISC unit does not op erate Defective coupler between ISC and ECU Open or short cir cuit in wire harness betwe...

Page 451: ...diameter learn ing values are not properly written Increased exhaust emissions Engine cannot be started or is difficult to start Engine idling speed is unstable OBD memory value is not correct Traction control sys tem does not operate properly ISC learning values Default values O2 feedback learning value is initialized CO adjustment value is initialized OBD memory value is initialized Tire diamete...

Page 452: ...heel sensor Open or short cir cuit in wire harness between rear wheel sensor and ABS unit Open or short cir cuit in wire harness between ABS unit and ECU Defective rear wheel sensor Defective ABS unit Malfunction in ECU Traction control sys tem does not operate Traction control sys tem indicator light on the multi function me ter comes on TCS indicator light on the multi function meter cannot be u...

Page 453: ...temperature with the tool display value 06 Coolant temperature When engine is cold Dis plays temperature closer to air temperature When engine is hot Displays current coolant temperature Compare the actually mea sured coolant temperature with the tool display value 07 Front wheel speed pulse Front wheel speed pulse 0 999 Check that the number in creases when the front wheel is rotated The number i...

Page 454: ...ed Control learning data To erase the ISC Idle Speed Control learning data click the Yamaha diagnostic tool Actuator Check button three times in 5 seconds 70 Control number 0 254 87 A F control learning data era sure 00 ECU learning data has been erased 01 ECU learning data has not been erased To erase the ECU learning data click the Yamaha diag nostic tool Actuator Check button three times in 5 s...

Page 455: ...d 52 Headlight Actuates the headlight five times at five second inter vals The check indicator on the Yamaha diagnostic tool screen come on each time the relay is actuated Check that the headlight is on five times 54 ISC Idle Speed Control unit Actuates and fully closes the ISC valve then opens it to the standby opening position This operation takes approxi mately 3 seconds until it is completed T...

Page 456: ...mber P1604 and P1605 Perform the checks and maintenance jobs for fault code number P1604 and P1605 218 Crankshaft position sensor Brief abnormality de tected in crankshaft po sition sensor Same as for fault code number P0335 Perform the checks and maintenance jobs for fault code number P0335 240 O2 sensor Correction value re mains at upper limit Correction value re mains at upper limit during O2 f...

Page 457: ...ective fuel injec tion system Dirty or worn spark plug Defective battery Defective ECU If a fault code is indi cated perform the checks and mainte nance jobs for the fault code first Event code number 243 may be indicated even if the system is normal 244 Difficult unable to start engine Engine starting difficult unable condition detect ed Empty fuel tank Defective fuel injec tion system Dirty or w...

Page 458: ...coupler 59 ABS ECU 60 License plate light 61 Tail brake light assembly right 62 Rear turn signal light right 63 Tail brake light right 64 Tail brake light assembly left 65 Rear turn signal light left 66 Tail brake light left 67 Frame ground 68 Turn signal hazard relay 69 Horn 70 Handlebar switch left 71 Dimmer switch 72 Horn switch 73 Turn signal switch 74 Rear brake light switch 75 Front turn sig...

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Page 461: ...L R Dg Ch G B G B Br R P P Y Y B Ch Br Dg Br R Br W Br W Br R Br W Br W Br W R W G Y R W R W R W R W R W R W Br R Br R Br R Br R Br R Br R Br R R B R B R B R B R B Br R B B B R G R B R B R B L R L R L R R B Dg Ch R Y Br L Br R B G L G B B L W R W W W W B R R R B R B Br Br L Y B R L Br W R G L Br Y G B W B W L Br Y L B L R L B B W B W B W L R R B B B W W B W W L B B B W B W B W B W B W B B B B B B ...

Page 462: ...LÉCTRICO ON OPEN OFF LOCK P TRIP INFO PASS B B B B R B B B B B B B B B B B B B B R R B B G G B B Gy B B B B 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 54 54 55 56 57 58 59 60 61 64 65 62 63 66 67 67 67 67 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 ...

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Yamaha MBK X-MAX 300 2017, Service Manual

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