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Yamaha MT-09 2021, Service Manual

The Yamaha MT-09 2021 Service Manual is a comprehensive guide packed with detailed instructions and diagrams to assist users in maintaining and repairing their MT-09 motorcycles. Available for free download at manualshive.com, this manual is a must-have for all MT-09 owners seeking reliable DIY solutions.

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4-2

GENERAL CHASSIS (1)

Removing the rear cover

Order

Job/Parts to remove

Q’ty

Remarks

Rider seat

Refer to “GENERAL CHASSIS (1)” on 
page 4-1.

Battery

Refer to “GENERAL CHASSIS (1)” on 
page 4-1.

1

Seat bracket

1

2

Rear side cover (left)

1

3

Rear side cover (right)

1

4

Rear turn signal light coupler

2

Disconnect.

5

License plate light coupler

1

Disconnect.

6

Mudguard assembly

1

7

Lower fender cover

1

8

Tail/brake light coupler

1

Disconnect.

9

Tail/brake light

1

10

Cover

1

11

IMU (Inertial Measurement Unit)

1

12

IMU coupler

1

Disconnect.

13

Rectifier/regulator cover

1

14

Rectifier/regulator coupler

1

Disconnect.

15

Rectifier/regulator

1

13

3

1

8

5

15

9

10

2

6

(4)

7

14

4

11

(4)

(4)

(4)

(4)

12

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

.

7 N

•

m (0.7 kgf

•

m, 5.2 lb

•

ft)

T.

R

.

2.0 N

•

m (0.20 kgf

•

m, 1.5 lb

•

ft)

T.

R

.

7 N

•

m (0.7 kgf

•

m, 5.2 lb

•

ft)

T.

R

.

1.5 N

•

m (0.15 kgf

•

m, 1.1 lb

•

ft)

T.

R

.

4.0 N

•

m (0.40 kgf

•

m, 3.0 lb

•

ft)

T.

R

.

1.0 N

•

m (0.10 kgf

•

m, 0.73 lb

•

ft)

T.

R

.

Summary of Contents for MT-09 2021

Page 1: ...2021 SERVICE MANUAL MT 09 MT 09SP B7N 28197 E0 MTN890 MTN890D ...

Page 2: ......

Page 3: ...will appear 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 EAS20002 This is the safety alert ...

Page 4: ...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 of...

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

Page 6: ......

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

Page 8: ......

Page 9: ...1 GENERAL INFORMATION IDENTIFICATION 1 1 VEHICLE IDENTIFICATION NUMBER 1 1 MODEL LABEL 1 1 FEATURES 1 2 GLOSSARY 1 2 DISPLAY 1 2 BASIC SERVICE INFORMATION 1 9 ELECTRICAL SYSTEM 1 9 SPECIAL TOOLS 1 10 ...

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

Page 11: ... switched between kilometers and miles Tachometer The tachometer shows the engine speed as measured by the rotational velocity of the crank shaft in revolutions per minute r min NOTICE ECA19660 Do not operate the engine in the tachometer red zone Vehicle information displays The two vehicle information displays can be indi vidually set to show the following items ODO odometer F TRIP fuel reserve t...

Page 12: ...wo vehicle information displays 2 Press the wheel switch inward to highlight the information display 3 Rotate the wheel switch to select the desired information display item 4 Press and hold the wheel switch inward until the highlighted display item is reset Transmission gear display This shows which gear the transmission is in This model has 6 gears and a neutral position The neutral position is ...

Page 13: ...rsor In this mode the temperature levels can be in stantly adjusted by rotating the wheel switch up down To exit this mode and return the wheel switch to its normal functionality press and hold the wheel switch inward TIP The current grip warmer setting is saved when the vehicle is turned off Lap timer This stopwatch function can be activated through the setting MENU Once activated the vehicle inf...

Page 14: ...gs MENU Rotate the wheel switch up or down to highlight items or increase decrease values and then short push the wheel switch briefly press the wheel switch inward to confirm the selection Press and hold the wheel switch to exit the MENU and return to the main display any time TIP Certain settings menu screens have an up ward pointing triangle mark item Select the tri angle mark to save settings ...

Page 15: ...turned off independently of TCS for TCSMODE M When TCS MODE has been set to OFF on the main screen TCS SCS and LIF are all turned off together SCS SCS can be set to OFF 1 2 and 3 OFF turns the slide control system off setting level 1 provides the least amount of system in tervention and setting level 3 provides the greatest amount of system intervention LIF LIF can be set to OFF 1 2 and 3 Setting ...

Page 16: ...he indicator stops flashing can be chosen Once selected rotate the wheel switch up down to increase or decrease the r min value by incre ments of 200 r min IND Stop is settable between 6200 13000 r min Maintenance This module allows you to record the distance traveled between engine oil changes use the OIL item and for two other items of your choice use INTERVAL 1 and INTERVAL 2 To reset a mainten...

Page 17: ...odule is selected the hours will be highlighted Set the hours by rotating the wheel switch Push the switch to confirm and highlight the minutes After confirming the minutes you will be re turned to the top MENU screen All Reset This module resets all settings items except the odometer and clock to their default or factory presets Select YES to reset all items After selecting YES all items will be ...

Page 18: ...nto the washer where con tacting the IMU grommet When installing the IMU use only a genuine bolt and washer and tighten the bolt to the specified torque Pay attention not to expose the IMU to strong shocks such as striking or drop ping it Do not place any foreign objects in and around the battery box Do not obstruct breather opening a of the IMU Do not clean the breather opening and do not blow it...

Page 19: ... list provided below to avoid any mistakes TIP For U S A and Canada use part number starting with YM YU or ACC For others use part number starting with 90890 Tool name Tool No Illustration Reference pages Yamaha diagnostic tool USB 90890 03267 3 4 3 11 4 54 4 55 7 11 9 3 9 46 9 47 Yamaha diagnostic tool A I 90890 03264 3 4 3 11 4 54 4 55 7 11 9 3 9 46 9 47 Thickness gauge 90890 03268 Feeler gauge ...

Page 20: ...mm 90890 04176 YU 04176 3 30 Oil pressure gauge set 90890 03120 3 30 Fork spring compressor 90890 01441 Fork spring compressor YM 01441 4 66 4 71 Rod holder 90890 01434 Damper rod holder double ended YM 01434 4 66 4 71 Damper rod holder ø27 90890 01582 Damper rod holder YM 01582 4 67 4 68 Fork seal driver 90890 01442 Adjustable fork seal driver 36 46 mm YM 01442 4 69 4 69 4 70 Tool name Tool No Il...

Page 21: ...1 Ring nut wrench 90890 01268 Spanner wrench YU 01268 4 76 Drive chain cut rivet tool 90890 01550 Drive chain cut rivet tool YM 01550 4 87 4 89 Compression gauge 90890 03081 Engine compression tester YU 33223 5 7 Compression gauge extension 122mm 90890 04136 Compression gauge extension 122mm YM 04136 5 7 Tool name Tool No Illustration Reference pages YM A8703 90890 01578 YM A8703 90890 03081 YU 33...

Page 22: ... 5 31 5 35 Valve spring compressor attachment ø23 90890 04179 Valve spring compressor adapter ø23 YM 04179 5 31 5 35 Valve guide remover ø4 5 90890 04116 Valve guide remover 4 5 mm YM 04116 5 32 Valve guide installer ø4 5 90890 04117 Valve guide installer 4 5 mm YM 04117 5 32 Valve guide reamer ø4 5 90890 04118 Valve guide reamer 4 5 mm YM 04118 5 32 Sheave holder 90890 01903 Primary clutch holder...

Page 23: ...59 8 59 8 60 8 61 8 61 8 62 8 62 8 63 8 64 8 65 8 65 8 65 8 66 Clutch holder 90890 04199 Universal clutch holder YM 91042 5 49 5 53 Piston pin puller set 90890 01304 Piston pin puller YU 01304 5 70 Connecting rod big end bearing installer 90890 04193 Connecting rod big end bearing installer YM 04193 5 72 5 75 Piston installing tool 90890 04161 Piston installing tool YM 04161 5 77 Tool name Tool No...

Page 24: ...ter pump seal installer YM 33221 A 6 14 Middle driven shaft bearing driver 90890 04058 Middle drive bearing installer 40 50 mm YM 04058 6 14 Pressure gauge 90890 03153 Pressure gauge YU 03153 7 10 7 11 Fuel injector pressure adapter 90890 03210 Fuel injector pressure adapter YU 03210 7 10 Fuel pressure adapter 90890 03176 Fuel pressure adapter YM 03176 7 11 Tool name Tool No Illustration Reference...

Page 25: ...1 16 SPECIAL TOOLS Ignition checker 90890 06754 Oppama pet 4000 spark checker YM 34487 8 59 Tool name Tool No Illustration Reference pages ...

Page 26: ...1 17 SPECIAL TOOLS ...

Page 27: ... GENERAL SPECIFICATIONS 2 1 ENGINE SPECIFICATIONS 2 2 CHASSIS SPECIFICATIONS 2 6 ELECTRICAL SPECIFICATIONS 2 10 TIGHTENING TORQUES 2 12 ENGINE TIGHTENING TORQUES 2 12 CHASSIS TIGHTENING TORQUES 2 12 CABLE ROUTING 2 15 ...

Page 28: ...Overall length 2090 mm 82 3 in Overall width 795 mm 31 3 in Overall height 1190 mm 46 9 in Wheelbase 1430 mm 56 3 in Ground clearance 140 mm 5 51 in Minimum turning radius 3 4 m 11 16 ft Weight Curb weight 189 kg 417 lb MTN890 190 kg 419 lb MTN890D Loading Maximum load 166 kg 366 lb Riding capacity 2 person ...

Page 29: ...mended engine oil grade API service SG type or higher JASO standard MA Lubrication system Wet sump Engine oil quantity Oil change 2 80 L 2 96 US qt 2 46 Imp qt With oil filter removal 3 20 L 3 38 US qt 2 82 Imp qt Quantity disassembled 3 50 L 3 70 US qt 3 08 Imp qt Oil filter Oil filter type Cartridge Oil pump Oil pressure 300 0 kPa 5000 r min at 100 C 43 5 psi 5000 r min at 212 F Cooling system C...

Page 30: ...seat contact width limit exhaust 1 8 mm 0 07 in Valve stem diameter limit intake 4 445 mm 0 1750 in Valve stem diameter limit exhaust 4 430 mm 0 1744 in Valve guide inside diameter intake 4 500 4 512 mm 0 1772 0 1776 in Valve guide inside diameter exhaust 4 500 4 512 mm 0 1772 0 1776 in Valve stem to valve guide clearance limit intake 0 080 mm 0 0032 in Valve stem to valve guide clearance limit ex...

Page 31: ...of the same color Code 0 White Code 1 Blue Code 2 Black Code 3 Brown Code 4 Green Balancer Balancer shaft runout limit 0 030 mm 0 0012 in Bearing color code Code 1 Blue Code 2 Black Code 3 Brown Code 4 Green Code 5 Yellow Balancer shaft journal to balancer shaft bearing clearance 0 023 0 047 mm 0 0009 0 0019 in Clutch Clutch type Wet multiple disc Clutch lever free play 10 0 15 0 mm 0 39 0 59 in M...

Page 32: ... 21 4th 1 381 29 21 5th 1 190 25 21 6th 1 037 28 27 Main axle runout limit 0 08 mm 0 0032 in Drive axle runout limit 0 08 mm 0 0032 in Secondary reduction ratio 2 813 45 16 Shifting mechanism Installed shift rod length 236 4 238 4 mm 9 31 9 39 in Air filter Air filter element Oil coated paper element Fuel injector Resistance 12 0 Ω Idling condition Engine idling speed 1200 1400 r min O2 feedback c...

Page 33: ...GESTONE BATTLAX HYPERSPORT S22F Rear tire Type Tubeless Size 180 55ZR17M C 73W Manufacturer model BRIDGESTONE BATTLAX HYPERSPORT S22R Tire air pressure measured on cold tires 1 person Front 250 kPa 2 50 kgf cm 36 psi Rear 290 kPa 2 90 kgf cm 42 psi 2 persons Front 250 kPa 2 50 kgf cm 36 psi Rear 290 kPa 2 90 kgf cm 42 psi Front brake Type Hydraulic dual disc brake Brake disc thickness limit 4 0 mm...

Page 34: ...8 Imp oz MTN890D Quantity right 472 0 cm 15 96 US oz 16 65 Imp oz MTN890 473 0 cm 15 99 US oz 16 68 Imp oz MTN890D Level left 107 mm 4 2 in MTN890 110 mm 4 3 in MTN890D Level right 107 mm 4 2 in MTN890 110 mm 4 3 in MTN890D Spring preload Adjustment value Soft 19 0 mm 0 75 in Adjustment value STD 15 0 mm 0 59 in Adjustment value Hard 4 0 mm 0 16 in Rebound damping Unit for adjustment Click Adjustm...

Page 35: ... preload Unit for adjustment Cam position MTN890 Adjustment value Soft 1 MTN890 Adjustment value STD 4 MTN890 Adjustment value Hard 7 MTN890 Adjustment value Soft 154 0 mm 6 06 in MTN890D Adjustment value STD 154 0 mm 6 06 in MTN890D Adjustment value Hard 146 0 mm 5 75 in MTN890D Rebound damping Unit for adjustment Click MTN890D Turn MTN890 Adjustment value from the start position Soft 2 1 2 MTN89...

Page 36: ...5 Chain type Sealed type Number of links 110 Drive chain slack Sidestand 36 0 41 0 mm 1 42 1 61 in Drive chain slack Maintenance stand 36 0 41 0 mm 1 42 1 61 in Drive chain slack limit Sidestand 46 0 mm 1 81 in 15 link length limit 239 3 mm 9 42 in ...

Page 37: ...V Battery Model YTZ10S Voltage capacity 12 V 8 6 Ah 10 HR Bulb wattage Headlight LED Brake tail light LED Front turn signal light LED Rear turn signal light LED Auxiliary light LED License plate light 5 0 W Meter lighting LED Indicator light Neutral indicator light LED Stability control indicator light LED Oil pressure and Coolant temperature warning light LED High beam indicator light LED Turn si...

Page 38: ...ssure sensor output voltage 3 59 3 67 V at 101 3 kPa 3 59 3 67 V at 1 01 kgf cm 3 59 3 67 V at 14 7 psi 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 50 0 A Headlight fuse 7 5 A Brake light fuse 2 0 A MTN890D Signaling system fuse 7 5 A Ignition fuse 10 0 A Radiator fan moto...

Page 39: ...1 10 N m 1 0 kgf m 7 4 lb ft Engine oil drain bolt M14 1 43 N m 4 3 kgf m 32 lb ft Item Thread size Q ty Tightening torque Remarks Front wheel axle M18 1 72 N m 7 2 kgf m 53 lb ft Front wheel axle pinch bolt M8 1 23 N m 2 3 kgf m 17 lb ft Rear wheel sprocket nut M10 5 80 N m 8 0 kgf m 59 lb ft Rear wheel axle nut M24 1 105 N m 10 5 kgf m 77 lb ft Rear brake caliper bolt front M12 1 27 N m 2 7 kgf ...

Page 40: ...G TORQUES TIP Lower ring nut 1 Tighten the ring nut to approximately 52 N m 5 2 kgf m 38 lb ft with a torque wrench then loosen the lower ring nut completely 2 Tighten the lower ring nut to 14 N m 1 4 kgf m 10 lb ft ...

Page 41: ...2 14 TIGHTENING TORQUES ...

Page 42: ...OUTING EAS20021 CABLE ROUTING Handlebar front view for MTN890 J 17 I H 16 7 4 11 Q B C 15 16 A 23 13 16 L 24 25 M 7 11 N O 16 P 21 20 19 15 14 13 12 10 22 K 18 15 26 27 7 F 26 R 27 S F 1 2 3 4 5 6 7 8 9 D 11 E G F ...

Page 43: ...ebar switch coupler right into the hole of the meter assembly bracket E Route the handlebar switch lead left to horn on the rear side of the wire harness F Insert the clamp into the hole of the meter assembly bracket G Face the terminal of the horn inside H Insert the clamp into the hole of the headlight bracket I Route the handlebar switch lead right on the rear side of the wire harness to accele...

Page 44: ...CABLE ROUTING Handlebar front view for MTN890D R 18 31 32 18 32 G L K J I G Q P 22 A 29 28 16 27 26 25 23 24 21 22 18 17 16 15 10 13 20 19 M 22 30 31 N 7 O 14 1 2 3 4 5 6 8 9 7 5 9 9 B 7 C 11 D 12 E 14 F G H ...

Page 45: ...ch switch lead to the rounded part of the handlebar Face the locking part of the plastic band forward Face the end of the plastic band downward No specific order for routing C Route the clutch switch lead on the rear side of the wire harness to handlebar switch cou pler right D Insert an auxiliary light coupler into the hole of the meter assembly bracket E Insert the clutch switch coupler into the...

Page 46: ...2 19 CABLE ROUTING Steering head left and right view 5 2 6 4 5 5 7 2 6 7 8 6 9 B A B 1 2 3 B ...

Page 47: ... left 3 Handlebar switch lead left to horn 4 Clamp 5 Meter assembly bracket 6 Upper bracket 7 Clutch cable 8 Brake hose 9 Wire harness to meter A Insert the clamp into the hole of the coupler cover B Insert the clamp into the hole of the meter assembly bracket ...

Page 48: ...6 17 10 18 19 20 21 24 25 26 23 23 22 22 F E 1 1 2 3 38 14 15 15 B 13 D 12 11 K 13 S 35 Q R G P M K G I J H G G 38 T G N O 30 30 31 31 32 32 33 33 34 L 35 5 8 8 8 9 36 36 37 7 6 C 6 6 29 28 24 27 25 18 19 20 21 H G 34 4 A 23 4 U 22 V 39 K 38 9 K ...

Page 49: ...e H Left side of the vehicle I Set the neutral switch coupler installation direction within the range as shown in the fig ure J Route the clutch cable on the front side of the starter motor lead K Front side of the vehicle L Pass each lead through the hole in the front side panel right and secure it with a plastic locking tie Face the locking part of the plastic locking tie rearward Face the end o...

Page 50: ...2 23 CABLE ROUTING Frame front left side view 17 11 10 18 19 12 13 3 9 6 7 C G 14 C 15 16 C 1 2 9 8 7 6 5 4 3 A B I 23 21 24 25 22 25 16 24 20 22 22 21 21 D 20 26 22 21 H 8 7 E F 3 18 J ...

Page 51: ...lead through the notch section of the front side panel left Route each lead wire as shown in the figure C Pass the wire harness to ECU coupler through the recess of the air filter assembly D Fix the wire harness to O2 sensor and wire harness to front turn signal light left by passing the plastic locking tie through the holes 2 places in the front side panel left Face the locking part of the plasti...

Page 52: ...ABLE ROUTING Frame rear left side view 13 16 17 12 C 10 C B 10 13 12 18 M Q C 9 A 4 1 7 3 J H I 3 19 T P O 20 N 13 12 12 C 10 C 9 C 9 K 10 L 15 14 3 1 E G F D 2 7 3 1 1 2 3 4 5 6 7 8 9 10 11 9 12 R 21 S 18 4 ...

Page 53: ...o the front side F Left side of the vehicle G Front of the vehicle H Pass the shift sensor lead in front of the shift rod joint and shift arm I Bend the shift sensor lead upward at the bot tom of the sensor side J Fix the shift sensor and its lead to the top part of the locknut on the shift sensor with the clamp K Arrange the sidestand switch lead to the inside of the vehicle L Face the paint mark...

Page 54: ...2 27 CABLE ROUTING Canister left side view D C 6 2 3 A 10 1 4 5 B E P 5 14 O 12 13 Q 9 11 I 8 H 3 G 6 M J N F K 7 L 6 11 3 7 8 9 15 16 1 7 8 3 8 ...

Page 55: ...ister F Face the end of the plastic locking tie leftward and cut off the excess G Insert the plastic locking tie into the hole of the bracket H Arrange the sidestand switch lead to the right side of the vehicle I Arrange the shift sensor lead to the left side of the vehicle J Left side of the vehicle K Route the stator coil lead to the front of the vehicle and fix the gray tape part with a plas ti...

Page 56: ...2 29 CABLE ROUTING Main switch rear view for MTN890 17 F 16 15 18 2 1 18 J 24 I 19 H G 23 22 21 20 6 A 7 13 12 11 C 10 9 B 8 3 4 5 2 D E 4 14 7 ...

Page 57: ...onge protector 23 Hook and loop fastener hook side black 24 Main switch coupler A Route the radiator fan motor lead between the brake hoses and frame B Route the wire harness to front turn signal light right and oil pressure switch between the brake hoses and frame C Route the handlebar switch lead left on the rear side of the wire harness D Insert the clamp into the hole of the coupler cover E In...

Page 58: ...2 31 CABLE ROUTING Main switch rear view for MTN890D 5 15 8 E D 18 F 16 19 17 20 H 24 G 23 22 21 25 I 2 19 J 6 5 4 3 2 12 13 14 11 C 10 9 B 7 8 A 1 ...

Page 59: ...23 End portion of sponge protector 24 Hook and loop fastener hook side black 25 Main switch coupler A Route the radiator fan motor lead between the brake hoses and frame B Route the wire harness to front turn signal light right and oil pressure switch between the brake hoses and frame C Route the handlebar switch lead left on the rear side of the wire harness D Insert the clamp into the hole of th...

Page 60: ...2 33 CABLE ROUTING Main switch left side view A C B 6 1 D 6 1 6 1 2 3 4 5 5 6 1 ...

Page 61: ...wheel sensor lead 4 Wire harness to O2 sensor 5 Bracket 6 Frame A Insert the clamp into the hole of the bracket B Insert the clamp into the rib of the frame C Insert the clamp with touched the protrusion on the frame D Insert the clamp between the protrusions on the frame ...

Page 62: ...BLE ROUTING Frame top view 19 17 18 J I Q O P A R M N H G F E K L L O C S 1 1 2 4 B 3 5 6 7 D 8 9 10 22 31 30 29 28 27 26 25 24 23 22 21 20 16 15 13 12 11 14 38 37 36 34 12 11 35 22 9 9 9 39 22 33 14 16 32 32 ...

Page 63: ...ess to shift sensor wire harness to sidestand switch and stator coil lead C Insert the relay unit until it touches the rib on the battery box D Insert the rear wheel sensor coupler into the hole of the battery box E Pass the wire harness to radiator fan motor relay into the coupler cover and push it between the wire harness to ABS ECU and wire harness main line F Insert the joint coupler into the ...

Page 64: ...2 37 CABLE ROUTING Rear fender top view 3 21 L 19 M 17 M 18 17 18 21 3 B 5 4 3 E 6 F 7 A 2 1 D 8 G 9 H 10 11 C O N 22 K 20 I 12 J 17 16 J 18 J 19 14 13 15 Q 23 P 19 ...

Page 65: ...cking tie E Insert the rear turn signal light coupler left into the hole of the box F Insert the rear turn signal light coupler right into the hole of the box G Insert the YDT coupler until it stops the rib stopper on the box H Insert the starter relay until it stops the rib stopper on the battery box I Route the tail brake light lead to the wire guide beneath the cover J Do not bite the lead with...

Page 66: ...2 39 CABLE ROUTING ABS ECU top view 1 8 9 10 11 6 11 5 12 A 2 B D 7 G 7 H 3 C 4 5 6 7 E F I ...

Page 67: ...itch lead on the rear side of the wire harness to rectifier reg ulator C Route the rear wheel sensor lead on the rear side of the wire harness to rectifier regula tor D Route the rear wheel sensor lead on the top side of the wire harness E Route the wire harness to radiator fan motor relay on the rear side of the wire harness to ABS ECU and wire harness to joint cou pler F Route the rear brake lig...

Page 68: ...2 41 CABLE ROUTING IMU top view 7 7 2 3 4 5 8 1 1 7 9 A B 6 D 6 C 9 10 ...

Page 69: ...y lead A Do not contact the starter motor lead with the bracket B Route the starter motor lead on the lower side of the bracket C Insert the clamp into the hole of the battery box D When inserting the clamp into the battery box pass the starter motor lead through the left side of the rib on the battery box After inserting the clamp into the battery box the starter motor lead may come off the rib o...

Page 70: ...2 43 CABLE ROUTING Front brake hose left side view 7 5 4 2 3 2 8 B 1 A H 2 6 4 2 F F G G E E I D 4 2 6 J C ...

Page 71: ...the brake hose hydraulic unit to front brake caliper left without slacking D Route the front wheel sensor lead on the front side of the brake hose and clamp the white tape portion The opening of the clamp should face the front Make sure the clamp is engaged by 3 or more notches E 45 F Left side of the vehicle G Front side of the vehicle H Insert the grommet of the front wheel sensor lead I Route t...

Page 72: ...2 45 CABLE ROUTING Front brake hose right side view 2 1 2 1 8 8 3 3 2 C D 7 G 7 E H 7 6 3 5 4 9 1 6 6 2 8 11 A B 2 1 9 10 G 7 H F 6 1 7 I 12 ...

Page 73: ...ake hose between the stoppers on the brake hose joint C Insert the clamp into the hole of the bracket of meter assembly D Make sure the clamp is engaged by 2 or more notches Engage the claws so that they face toward the right of the vehicle E Insert the grommet of the front wheel sensor lead F Fit the clamp between the ribs on the front fender G Make sure the clamp is engaged by 2 or more notches ...

Page 74: ...2 47 CABLE ROUTING Rear brake hose right side view 10 10 2 2 2 2 2 3 3 3 3 H B E E G G 10 2 3 B E F G I 3 10 J 10 J 5 J K 6 7 L 3 3 L 4 4 8 M N 10 J O 2 9 1 A D 3 C 3 A P O 4 3 7 ...

Page 75: ... of the vehicle H Fasten the protector of the rear brake hose with the clamp I The opening of the clamp should face the top Make sure the clamp is engaged by 3 or more notches J Route the rear wheel sensor lead on the out side of the rear brake hose hydraulic unit to rear brake caliper K The opening of the clamp should face the down L The opening of the clamp should face the outside Make sure the ...

Page 76: ...2 49 CABLE ROUTING ABS ECU Electronic Control Unit top and left side view E 6 C D A B 3 5 4 6 7 8 4 5 9 10 10 11 9 2 1 ...

Page 77: ...inder to hydraulic unit 5 Hydraulic unit brake pipe hydraulic unit to front brake calipers 6 Battery box 7 Hydraulic unit brake pipe hydraulic unit to rear brake caliper 8 Hydraulic unit brake pipe rear brake master cylinder to hydraulic unit 9 Rear brake hose hydraulic unit to rear brake caliper 10 Rear brake hose rear brake master cylinder to hydraulic unit 11 Bracket A 79 B 89 C 77 D 78 E Front...

Page 78: ...2 51 CABLE ROUTING Fuel tank left side view 1 2 3 4 5 6 A 1 7 C 4 5 B 4 D E F 8 1 9 4 5 G H 5 ...

Page 79: ...tall the hose clip on the raised portion of the hose fitting D Face the tip of the clip backward from the central axis of the fuel tank breather hose E Face the tip of the clip forward from the cen tral axis of the fuel tank drain hose F Install the fuel tank drain hose on the projec tion side of the fuel tank G Insert the fuel tank breather hose up to the section where the fuel tank pipe increase...

Page 80: ...2 53 CABLE ROUTING Canister 1 2 5 3 4 6 A B C D D E F G H I J ...

Page 81: ...e purge cut valve solenoid to can ister upward D Install the clip with its end facing the down E Insert each hose until it stops each part F Install the clip with its end facing the rear G Fit the fuel tank drain hose into the canister holder as shown in the illustration H Face the blue paint mark on the canister purge hose purge cut valve solenoid to can ister upward I Install the clip with its e...

Page 82: ...2 55 CABLE ROUTING Air filter case and throttle bodies left side view 3 4 A A O C A H L B G 2 3 E D K I J 1 F M N 2 1 3 5 6 ...

Page 83: ...uld face the forward I The end of the clip should face the left J The end of the clip should face the right K Hose until it butts against the throttle body L 5 7 mm 0 20 0 28 in 3 places M Insert the cylinder head breather hose until it reaches the rounded end of the pipe Install the cylinder head breather hose with the yel low paint mark facing the left Install the clip with its end facing the le...

Page 84: ...2 57 CABLE ROUTING Radiator front side view R H G S Q C B A N D E F M K L J I L P O R R W V 1 5 2 7 6 2 3 3 4 8 9 U T ...

Page 85: ...the clip with its end facing inward Fit the clip in the center between the spools never ride on the spool I Insert the radiator inlet hose until it touches the rib of the water jacket joint J Align the yellow paint mark on the radiator inlet hose with the rib on the water jacket joint K Install the hose clamp screw to face it top side L Install the hose clamp with the screw head facing the inward ...

Page 86: ...2 59 CABLE ROUTING Radiator right side view 3 2 1 B A D C 4 ...

Page 87: ...tor fan cover A Direction of the hose tip does not matter B Pass the coolant reservoir hose through the front side panel right guide C Pass the radiator hose cylinder head to radi ator through the notch of the radiator fan cover D Pass the radiator fan motor lead through the notch of the radiator fan cover ...

Page 88: ...2 61 CABLE ROUTING Radiator right side view C B A D E 1 F G I H ...

Page 89: ...he root of the radiator properly B 0 2 mm 0 0 08 in C Front side of the vehicle D Right side of the vehicle E Install the clip with its end facing the rear F 3 mm 0 12 in or more G Make sure not to install the hose clip on the raised portion of the hose fitting H Hose plug in section I Hose clip fixed position details ...

Page 90: ...2 63 CABLE ROUTING Oil cooler and thermostat front side view F G A F G 4 6 1 5 A E 2 C D B A 7 I H K L J K P O N 3 M M ...

Page 91: ...s end the screw head facing the down F Fit the clip at a position more than 1 mm 0 04 in from the end of the hose and do not ride on the spool G Face the yellow paint mark on the hoses for ward insert them up to the step where the thick part of pipe H Install the clip with its end facing the right I Align the white paint mark on the oil cooler inlet hose with the rib on the water jacket joint and ...

Page 92: ...2 65 CABLE ROUTING Water pump left side view 3 4 A 2 C D B F 1 E ...

Page 93: ...Align the white paint mark on the water pump inlet hose with the rib on the water pump and insert until the hose stops B Hose clamp fixed position details C 3 mm 0 12 in or more D 0 1 mm 0 0 04 in E Hose plug in section F Make sure not to install the hose clamp on the raised portion of the hose fitting ...

Page 94: ...2 67 CABLE ROUTING ...

Page 95: ...ING THE BRAKE FLUID LEVEL 3 13 ADJUSTING THE FRONT DISC BRAKE 3 13 CHECKING THE FRONT BRAKE PADS 3 14 ADJUSTING THE REAR DISC BRAKE 3 14 CHECKING THE REAR BRAKE PADS 3 15 CHECKING THE FRONT BRAKE HOSES 3 15 CHECKING THE REAR BRAKE HOSE 3 15 BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS 3 15 CHECKING THE WHEELS 3 16 CHECKING THE TIRES 3 16 CHECKING THE WHEEL BEARINGS 3 18 CHECKING THE SWINGARM OPERATION ...

Page 96: ...NE OIL LEVEL 3 28 CHANGING THE ENGINE OIL 3 28 MEASURING THE ENGINE OIL PRESSURE 3 29 CHECKING THE COOLANT LEVEL 3 31 CHECKING THE COOLING SYSTEM 3 31 CHANGING THE COOLANT 3 31 CHECKING THE FRONT BRAKE LIGHT SWITCH 3 33 ADJUSTING THE REAR BRAKE LIGHT SWITCH 3 33 CHECKING AND LUBRICATING THE CABLES 3 33 CHECKING THE THROTTLE GRIP 3 34 CHECKING AND CHARGING THE BATTERY 3 34 CHECKING THE FUSES 3 34 A...

Page 97: ...RAL MAINTENANCE AND LUBRICATION CHART No ITEM CHECK OR MAINTENANCE JOB ODOMETER READING ANNUAL CHECK 1000 km 600 mi 10000 km 6000 mi 20000 km 12000 mi 30000 km 18000 mi 40000 km 24000 mi 1 Fuel line Check fuel hoses for cracks or damage Replace if necessary 2 Spark plugs Check condition Adjust gap and clean Replace 3 Valve clearance Check and adjust Every 40000 km 24000 mi 4 Fuel injection Check e...

Page 98: ...re properly tight ened 15 Brake lever pivot shaft Lubricate with silicone grease 16 Brake pedal pivot shaft Lubricate with lithium soap based grease 17 Clutch lever pivot shaft Lubricate with lithium soap based grease 18 Shift pedal pivot shaft Lubricate with lithium soap based grease 19 Sidestand Check operation Lubricate with molybdenum disulfide grease 20 Sidestand switch Check operation and re...

Page 99: ...correct the brake fluid level Every two years replace the internal components of the brake master cylinders and calipers and change the brake fluid Replace the brake hoses every four years and if cracked or damaged 28 Moving parts and cables Lubricate 29 Throttle grip Check operation Lubricate the throttle grip housing tube guides 30 Lights signals and switches Check operation Adjust headlight bea...

Page 100: ... Use the Dynamic inspection function of the YDT version 3 0 and after to perform the dynam ic inspection For information about using the YDT refer to the operation manual that is includ ed with the tool 5 Install Rider seat Refer to GENERAL CHASSIS 1 on page 4 1 EAS30619 CHECKING THE FUEL LINE The following procedure applies to all of the fuel drain and breather hoses 1 Remove Rider seat Refer to ...

Page 101: ...lug cleaner or wire brush 6 Measure Spark plug gap a with a wire thickness gauge Out of specification Regap 7 Install Spark plug Ignition coil TIP Before installing the spark plug clean the spark plug and gasket surface 8 Install Air filter case Refer to GENERAL CHASSIS 2 on page 4 10 Fuel tank Refer to FUEL TANK on page 7 1 Fuel tank center cover Refer to GENERAL CHASSIS 1 on page 4 1 Rider seat ...

Page 102: ...ession stroke can be found when the camshaft lobes are turned away from each other c Measure the valve clearance with a thick ness gauge TIP If the valve clearance is incorrect record the measured reading Measure the valve clearance in the following sequence d To measure the valve clearances of the other cylinders starting with cylinder 1 at TDC turn the crankshaft counterclockwise as specified in...

Page 103: ...valve pad TIP The thickness a of each valve pad is marked in hundredths of millimeters on the side that touch es the valve lifter Example If the valve pad is marked 158 the pad thickness is 1 58 mm 0 062 in d Calculate the sum of the values obtained in steps b and c to determine the required valve pad thickness and the valve pad num ber Example 1 58 mm 0 062 in 0 05 mm 0 002 in 1 63 mm 0 064 in Th...

Page 104: ...onization should be adjusted properly the air filter element should be clean and the engine should have adequate compres sion 1 Start the engine and let it warm up for several minutes 2 Check Engine idling speed Out of specification Go to next step 3 Check ISC idle speed control learning value 00 or 01 Check the intake system 02 Clean the throttle bodies Refer to CHECKING AND CLEANING THE THROTTLE...

Page 105: ... ECA21300 Do not turn the bypass air screw white paint mark of the throttle body that is the stan dard Otherwise the engine may run roughly at idle and the throttle bodies may not oper ate properly TIP Turn the bypass air screw using the carburetor angle driver After each step rev the engine two or three times each time for less than a second and check the synchronization again If a bypass air scr...

Page 106: ...enter cover Refer to GENERAL CHASSIS 1 on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 Air filter case Refer to GENERAL CHASSIS 2 on page 4 10 2 Check Cylinder head breather hose 1 Cracks damage Replace Loose connection Connect properly NOTICE ECA14920 Make sure the cylinder head breather hose is routed correctly 3 Install Air filter case Refer to GENERAL CHASSIS 2 on page 4 10 Fuel tank Refe...

Page 107: ... TIP Be sure to set the CO density level to standard and then adjust the exhaust gas volume To adjust the exhaust gas volume use the CO adjustment mode of the YDT For more infor mation refer to the operation manual of the YDT 1 Remove the protective cap and then connect the YDT to coupler Refer to YDT on page 9 3 TIP Yamaha diagnostic tool A I 90890 03264 in cludes YDT sub harness 6P 90890 03266 I...

Page 108: ... to poor engine per formance and possible overheating TIP When installing the air filter element into the air filter case cover make sure that the sealing sur faces are aligned to prevent any air leaks 5 Install Fuel tank Refer to FUEL TANK on page 7 1 Fuel tank center cover Refer to GENERAL CHASSIS 1 on page 4 1 Rider seat Refer to GENERAL CHASSIS 1 on page 4 1 EAS30629 ADJUSTING THE CLUTCH LEVER...

Page 109: ...rmance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake performance When refilling be careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock NOTICE ECA13540 Brake fluid may damage painted surfac...

Page 110: ...cators 1 almost touch the brake disc Replace the brake pads as a set Refer to FRONT BRAKE on page 4 25 EAS30631 ADJUSTING THE REAR DISC BRAKE 1 Adjust Brake pedal position a Loosen the locknut 1 b Turn the adjusting bolt 2 until the specified brake pedal position is obtained WARNING EWA18830 After adjusting the brake pedal position check that the end of the adjusting bolt a is visible through the ...

Page 111: ...on page 4 37 EAS30893 BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS WARNING EWA14000 Always bleed the brake system when the brake related parts are removed NOTICE ECA22640 Bleed the brake system in the following or der 1st step Front brake master cylinder 2nd step Front brake calipers 3rd step Rear brake caliper WARNING EWA16530 Bleed the ABS whenever the system is disassembled a brake hose is loosened ...

Page 112: ...peat steps e to i and then fill the brake fluid reservoir to the proper level with the specified brake flu id l Tighten the bleed screw to specification m Fill the brake fluid reservoir to the proper level with the specified brake fluid Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 13 WARNING EWA13110 After bleeding the hydraulic brake system check the brake operation EAS30638 CHECKING THE WHE...

Page 113: ...rning handling characteristics can be giv en if a tire combination other than one approved by Yamaha is used on this vehicle WARNING EWA13210 New tires have a relatively low grip on the road surface until they have been slightly worn Therefore approximately 100 km should be traveled at normal speed before any high speed riding is done TIP For tires with a direction of rotation mark 1 Install the t...

Page 114: ... loose can skip and damage the swing arm or cause an accident Therefore keep the drive chain slack within the specified lim its 1 Shift the transmission into the neutral posi tion 2 Check Drive chain slack Out of specification Adjust TIP Measure the distance a between the rib end on the drive chain guide 1 and the center point of the drive chain 2 The center point b of the drive chain is ap prox 3...

Page 115: ...te Steam clean ing high pressure washing certain solvents and the use of a coarse brush can damage these O rings Therefore use only kerosene to clean the drive chain Wipe the drive chain dry and thoroughly lubricate it with engine oil or chain lubricant that is suitable for O ring chains Do not use any other lubricants on the drive chain since they may contain solvents that could damage the O ring...

Page 116: ...e slots of both ring nuts If necessary hold the lower ring nut and tighten the upper ring nut until their slots are aligned h Install the lock washer 1 TIP Make sure the lock washer tabs a sit correctly in the ring nut slots b 5 Install Upper bracket Refer to HANDLEBAR on page 4 57 EAS30646 LUBRICATING THE STEERING HEAD 1 Lubricate Upper bearing Lower bearing Bearing race EAS31186 CHECKING THE CHA...

Page 117: ...e Front fork leg Oil leaks between inner tube and outer tube Replace the oil seal 3 Hold the vehicle upright and apply the front brake 4 Check Front fork operation Push down hard on the handlebar several times and check if the front fork rebounds smoothly Rough movement Repair Refer to FRONT FORK on page 4 63 EAS30806 ADJUSTING THE FRONT FORK LEGS for MTN890 The following procedure applies to both...

Page 118: ...mber of clicks of each damping force adjusting mechanism and to modify the specifications as necessary Compression damping left side only NOTICE ECA13590 Never go beyond the maximum or minimum adjustment positions 1 Adjust Compression damping a Turn the adjusting screw 1 in direction a or b Spring preload Adjustment value Soft 19 0 mm 0 75 in Adjustment value STD 15 0 mm 0 59 in Adjustment value H...

Page 119: ...nt can result in poor han dling and loss of stability NOTICE ECA13590 Never go beyond the maximum or minimum adjustment positions 1 Adjust Spring preload a Turn the adjusting bolt 1 in direction a or b TIP The spring preload setting is determined by measuring the distance c shown in the illustra tion The shorter distance c is the higher the spring preload the longer distance c is the lower the spr...

Page 120: ...ove specifications due to small dif ferences in production the actual number of clicks always represents the entire adjusting range To obtain a precise adjustment it would be advisable to check the number of clicks of each damping force adjusting mechanism and to modify the specifications as necessary Direction a Rebound damping is increased sus pension is harder Direction b Rebound damping is dec...

Page 121: ...g over Spring preload NOTICE ECA13590 Never go beyond the maximum or minimum adjustment positions 1 Adjust Spring preload a Adjust the spring preload with the special wrench 1 and extension bar 2 included in the owner s tool kit b Turn the adjusting ring 3 in direction a or b c Align the desired position on the adjusting ring with the stopper 4 Direction a Compression damping is increased suspensi...

Page 122: ...there is no danger of it falling over Spring preload NOTICE ECA13590 Never go beyond the maximum or minimum adjustment positions 1 Adjust Spring preload a Turn the adjusting knob 1 in direction a or b TIP The spring preload setting is determined by measuring the distance c shown in the illustra tion The shorter distance c is the higher the spring preload the longer distance c is the lower the spri...

Page 123: ...number of clicks always represents the entire adjusting range To obtain a precise adjustment it would be advisable to check the number of clicks of each damping force adjusting mechanism and to modify the specifications as necessary Spring preload Adjustment value Soft 154 0 mm 6 06 in MTN890D Adjustment value STD 154 0 mm 6 06 in MTN890D Adjustment value Hard 146 0 mm 5 75 in MTN890D Direction a ...

Page 124: ...use clutch slippage Therefore do not add any chemical additives or use engine oils with a grade of CD or higher and do not use oils labeled ENERGY CONSERVING II Do not allow foreign materials to enter the crankcase TIP Before checking the engine oil level wait a few minutes until the oil has settled 4 Start the engine warm it up for several min utes and then turn it off 5 Check the engine oil leve...

Page 125: ...for engine oil leaks 11 Check Engine oil level Refer to CHECKING THE ENGINE OIL LEVEL on page 3 28 EAS30810 MEASURING THE ENGINE OIL PRESSURE 1 Check Engine oil level Below the minimum level mark a Add the recommended engine oil to the proper level 2 Start the engine warm it up for several min utes and then turn it off NOTICE ECA13410 When the engine is cold the engine oil will have a higher visco...

Page 126: ...cification Check 8 Remove Oil pressure gauge Adapter C Oil pressure switch joint bolt Oil pressure switch joint with the O ring 9 Install O ring 1 Oil pressure switch joint with the oil pressure switch 2 Oil pressure switch joint bolt 3 Oil pressure gauge joint 18 mm 90890 04176 YU 04176 Oil pressure switch joint bolt 10 N m 1 0 kgf m 7 4 lb ft Oil pressure gauge set 90890 03120 1 2 T R 1 2 1 2 Oi...

Page 127: ...E COOLING SYSTEM 1 Check Radiator 1 Water pump inlet hose 2 Thermostat housing 3 Thermostat 4 Thermostat cover 5 Radiator outlet hose 6 Water pump 7 Radiator inlet hose 8 Oil cooler outlet hose 9 Water jacket joint 10 Oil cooler inlet hose 11 Oil cooler 12 Cracks damage Replace Refer to RADIATOR on page 6 3 OIL COOLER on page 6 7 THERMOSTAT on page 6 9 and WATER PUMP on page 6 11 EAS30813 CHANGING...

Page 128: ...mful and should be handled with special care WARNING EWA13040 If coolant splashes in your eyes thorough ly wash them with water and consult a doc tor If coolant splashes on your clothes quickly wash it away with water and then with soap and water If coolant is swallowed induce vomiting and get immediate medical attention 1 1 2 1 1 2 Water pump drain bolt 10 N m 1 0 kgf m 7 4 lb ft Coolant reservoi...

Page 129: ...EAS30814 CHECKING THE FRONT BRAKE LIGHT SWITCH Refer to ELECTRICAL COMPONENTS on page 8 51 EAS30659 ADJUSTING THE REAR BRAKE LIGHT SWITCH TIP The rear brake light switch is operated by move ment of the brake pedal The rear brake light switch is properly adjusted when the brake light comes on just before the braking effect starts 1 Check Rear brake light operation timing Incorrect Adjust 2 Adjust R...

Page 130: ...ly and returns properly when released Repeat this check with the handlebar turned all the way to the left and right EAS30816 CHECKING AND CHARGING THE BATTERY Refer to CHECKING AND CHARGING THE BATTERY on page 8 56 EAS30662 CHECKING THE FUSES Refer to CHECKING THE FUSES on page 8 55 EAS30664 ADJUSTING THE HEADLIGHT BEAM 1 Adjust Headlight beam vertically TIP To adjust the headlight beam vertically...

Page 131: ...ASSEMBLING THE REAR WHEEL 4 21 CHECKING THE REAR WHEEL 4 21 CHECKING THE REAR WHEEL DRIVE HUB 4 21 CHECKING AND REPLACING THE REAR WHEEL SPROCKET 4 21 ASSEMBLING THE REAR WHEEL 4 22 MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR 4 22 ADJUSTING THE REAR WHEEL STATIC BALANCE 4 22 INSTALLING THE REAR WHEEL REAR BRAKE DISC 4 23 FRONT BRAKE 4 25 INTRODUCTION 4 31 CHECKING THE FRONT BRAKE DISCS 4...

Page 132: ... 47 ABS ANTI LOCK BRAKE SYSTEM 4 49 REMOVING THE HYDRAULIC UNIT ASSEMBLY 4 51 CHECKING THE HYDRAULIC UNIT ASSEMBLY 4 51 CHECKING THE BRAKE PIPES 4 52 INSTALLING THE HYDRAULIC UNIT ASSEMBLY 4 52 HYDRAULIC UNIT OPERATION TESTS 4 53 CHECKING THE ABS WARNING LIGHT 4 56 HANDLEBAR 4 57 ADJUSTING THE HANDLEBAR POSITION 4 59 REMOVING THE HANDLEBAR 4 59 CHECKING THE HANDLEBAR 4 60 INSTALLING THE HANDLEBAR ...

Page 133: ...HECKING THE CONNECTING ARM AND RELAY ARM 4 81 INSTALLING THE RELAY ARM 4 81 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 4 81 SWINGARM 4 83 REMOVING THE SWINGARM 4 84 CHECKING THE SWINGARM 4 84 INSTALLING THE SWINGARM 4 84 CHAIN DRIVE 4 86 REMOVING THE DRIVE CHAIN 4 87 CHECKING THE DRIVE CHAIN 4 87 CHECKING THE DRIVE SPROCKET 4 88 CHECKING THE REAR WHEEL SPROCKET 4 88 CHECKING THE REAR WHEEL DRIVE ...

Page 134: ...he seat and battery Order Job Parts to remove Q ty Remarks 1 Rider seat 1 2 Battery holding bracket 1 3 Negative battery lead 1 Disconnect 4 Positive battery lead 1 Disconnect 5 Battery 1 1 2 5 4 3 7 N m 0 7 kgf m 5 2 lb ft T R 2 2 N m 0 22 kgf m 1 6 lb ft T R ...

Page 135: ... 1 7 Lower fender cover 1 8 Tail brake light coupler 1 Disconnect 9 Tail brake light 1 10 Cover 1 11 IMU Inertial Measurement Unit 1 12 IMU coupler 1 Disconnect 13 Rectifier regulator cover 1 14 Rectifier regulator coupler 1 Disconnect 15 Rectifier regulator 1 13 3 1 8 5 15 9 10 2 6 4 7 14 4 11 4 4 4 4 12 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 7 N m 0 7 kgf m 5 2 lb ft T R 2 0...

Page 136: ...l unit cover 1 9 Headlight assembly 1 10 Headlight control unit coupler headlight assem bly side 1 Disconnect 11 Headlight control unit coupler wire harness side 1 Disconnect 12 Headlight control unit 1 13 Horn lead connector 2 Disconnect 1 4 3 6 11 13 10 12 3 7 5 2 4 8 9 11 6 6 13 1 5 N m 0 15 kgf m 1 1 lb ft T R 4 3 N m 0 43 kgf m 3 2 lb ft T R 4 3 N m 0 43 kgf m 3 2 lb ft T R 1 5 N m 0 15 kgf m...

Page 137: ...7 Accelerator position sensor coupler 1 Disconnect 18 Clutch switch coupler 1 Disconnect for MTN890D 19 Harness clamp Coupler clamp Disconnect 20 Meter assembly bracket 1 20 4 3 14 16 15 17 17 16 19 6 18 15 14 1 5 N m 0 15 kgf m 1 1 lb ft T R 4 3 N m 0 43 kgf m 3 2 lb ft T R 4 3 N m 0 43 kgf m 3 2 lb ft T R 1 5 N m 0 15 kgf m 1 1 lb ft T R 0 7 N m 0 07 kgf m 0 52 lb ft T R 7 N m 0 7 kgf m 5 2 lb f...

Page 138: ...iator cover right 1 3 Front turn signal light coupler left 1 Disconnect 4 Front side panel left 1 5 Front turn signal light coupler right 1 Disconnect 6 Front side panel right 1 2 6 4 3 1 5 LT LT 1 5 N m 0 15 kgf m 1 1 lb ft T R 1 5 N m 0 15 kgf m 1 1 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 139: ...Order Job Parts to remove Q ty Remarks 1 Fuel tank side cover left 1 2 Fuel tank side cover right 1 3 Fuel tank center cover 1 4 Air scoop left 1 5 Air scoop right 1 5 3 4 2 1 1 0 N m 0 10 kgf m 0 73 lb ft T R 7 N m 0 7 kgf m 5 2 lb ft T R 1 0 N m 0 10 kgf m 0 73 lb ft T R ...

Page 140: ...uel tank side cover left 1 a Remove the fuel tank side cover bolt left 2 and quick fastener 3 b Remove the fuel tank side cover left TIP Remove projections a on the fuel tank side cover from grommets b Remove projections c on the fuel tank side cover from hole EAS32778 INSTALLING THE FUEL TANK SIDE COVER The following procedure applies to both of the fuel tank side cover 1 Install Fuel tank side c...

Page 141: ...Pay attention not to expose the IMU to strong shocks such as striking or drop ping it Do not place any foreign objects in and around the battery box Do not obstruct breather opening a of the IMU Do not clean the breather opening and do not blow it with compressed air When replacing the collar or grommet re place all four collars and grommets 1 Install IMU Inertial Measurement Unit 1 a Connect the ...

Page 142: ...31629 INSTALLING THE SEAT 1 Install Seat a Insert the projections 1 into the seat hold ers 2 as shown b Push the rear of the seat down to lock it in place TIP Make sure that the seat is properly secured be fore riding 2 2 2 1 1 ...

Page 143: ... Fuel tank Refer to FUEL TANK on page 7 1 1 ECU coupler 3 Disconnect 2 ECU Engine Control Unit 1 3 Intake air temperature sensor 1 Disconnect 4 Air filter case cover 1 5 Air filter element 1 6 Air filter case joint clamp screw 3 Loosen 7 Cylinder head breather hose 1 Disconnect 8 Air filter case 1 3 7 1 6 5 2 10 4 4 4 4 8 7 N m 0 7 kgf m 5 2 lb ft T R 1 6 N m 0 16 kgf m 1 2 lb ft T R 2 8 N m 0 28 ...

Page 144: ...tor bracket 2 3 Front wheel sensor 1 4 Wheel axle pinch bolt 1 Loosen 5 Wheel axle 1 6 Front wheel 1 7 Collar 2 8 Front brake disc 2 LT New LT New 7 7 8 8 4 3 1 2 5 2 6 1 18 N m 1 8 kgf m 13 lb ft 18 N m 1 8 kgf m 13 lb ft 23 N m 2 3 kgf m 17 lb ft 72 N m 7 2 kgf m 53 lb ft 35 N m 3 5 kgf m 26 lb ft 7 N m 0 7 kgf m 5 2 lb ft 35 N m 3 5 kgf m 26 lb ft ...

Page 145: ...FRONT WHEEL Disassembling the front wheel Order Job Parts to remove Q ty Remarks 1 Front wheel sensor rotor 1 2 Oil seal 2 3 Wheel bearing 2 4 Spacer 1 LT New New New 2 3 2 1 3 4 5 8 N m 0 8 kgf m 5 9 lb ft ...

Page 146: ...lace the vehicle on a maintenance stand so that the front wheel is elevated 4 Loosen Wheel axle pinch bolt 5 Remove Wheel axle Front wheel EAS31149 DISASSEMBLING THE FRONT WHEEL NOTICE ECA21340 Do not drop the wheel sensor rotor or sub ject it to shocks If any solvent gets on the wheel sensor ro tor wipe it off immediately 1 Remove Oil seal Wheel bearing a Clean the surface of the front wheel hub ...

Page 147: ...ll the spacer c Install the new wheel bearing right side TIP Place a suitable washer 1 between the socket 2 and the bearing so that both the inner race 3 and outer race 4 are pressed at the same time and then press the bearing until the inner race makes contact with the spacer 5 d Install the new oil seals 2 Install Front wheel sensor rotor NOTICE ECA17200 Replace the wheel sensor rotor bolts with...

Page 148: ...r rotor runout Out of specification Clean the installation surface of the wheel sensor rotor and correct the wheel sensor rotor runout or replace the wheel sensor rotor a Hold the dial gauge at a right angle against the wheel sensor rotor surface b Measure the wheel sensor rotor runout c If the runout is above specification remove the sensor rotor from the wheel rotate it by two or three bolt hole...

Page 149: ... in the front wheel sensor rotor and front wheel sensor Foreign materials cause damage to the front wheel sensor rotor and front wheel sensor TIP When installing the front wheel sensor check the wheel sensor lead for twists 7 Measure Distance a between the wheel sensor rotor 1 and wheel sensor 2 Out of specification Check the wheel bear ing for looseness and the front wheel sensor and sensor rotor...

Page 150: ...o not turn the front wheel while the thickness gauge is installed This may damage the front wheel sen sor rotor and the front wheel sensor 8 Install Front brake caliper WARNING EWA13500 Make sure the brake hose is routed properly Thickness gauge 90890 03268 Feeler gauge set YU 26900 9 Front brake caliper bolt 35 N m 3 5 kgf m 26 lb ft 1 1 2 2 a G088903 T R ...

Page 151: ...37 1 Rear wheel sensor 1 2 Locknut 2 Loosen 3 Adjusting bolt 2 Loosen 4 Wheel axle nut 1 5 Washer 1 6 Wheel axle 1 7 Adjusting block left 1 8 Adjusting block right 1 9 Rear wheel 1 10 Brake caliper bracket assembly 1 LS 4 5 8 1 10 9 7 6 2 3 3 2 105 N m 10 5 kgf m 77 lb ft 7 N m 0 7 kgf m 5 2 lb ft 16 N m 1 6 kgf m 12 lb ft 16 N m 1 6 kgf m 12 lb ft ...

Page 152: ...brake disc 1 3 Bracket 1 4 Rear wheel sprocket 1 5 Collar 1 6 Collar 1 7 Oil seal 1 8 Bearing 1 9 Rear wheel drive hub 1 10 Collar 1 11 Oil seal 1 12 Rear wheel drive hub damper 5 13 Rear wheel 1 LT LT New LS LS LS 1 12 11 10 9 4 3 8 7 5 6 2 5 5 5 New New New 13 30 N m 3 0 kgf m 22 lb ft 80 N m 8 0 kgf m 59 lb ft 8 N m 0 8 kgf m 5 9 lb ft ...

Page 153: ...4 20 REAR WHEEL Disassembling the rear wheel Order Job Parts to remove Q ty Remarks 1 Oil seal 1 2 Wheel bearing 1 3 Spacer 1 4 Wheel bearing 1 New 1 2 3 4 ...

Page 154: ...l Brake caliper bracket assembly NOTICE ECA27280 Be sure to remove the rear wheel sensor be fore removing the brake caliper bracket as sembly otherwise the sensor could be damaged TIP Push the rear wheel forward and remove the drive chain from the rear wheel sprocket EAS31154 DISASSEMBLING THE REAR WHEEL NOTICE ECA21340 Do not drop the wheel sensor rotor or sub ject it to shocks If any solvent get...

Page 155: ...ct 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 Refer to MAINTENANCE OF THE FRONT WH...

Page 156: ...ion c faces to the front of the vehicle Install the adjusting block right with the cham fered d facing the inside 5 Install Rear brake caliper Rear brake caliper bolt 6 Adjust Drive chain slack Refer to DRIVE CHAIN SLACK on page 3 18 7 Tighten Wheel axle nut Rear brake caliper bolt WARNING EWA13500 Make sure the brake hose is routed properly Rear brake disc bolt 30 N m 3 0 kgf m 22 lb ft LOCTITE R...

Page 157: ...tor 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 rear wheel sensor rotor and rear wheel sensor in several places in...

Page 158: ...Job Parts to remove Q ty Remarks The following procedure applies to both of the front brake calipers 1 Brake pad clip 2 2 Brake pad pin 1 3 Brake pad spring 1 4 Brake pad 2 5 Front brake caliper 1 6 Bleed screw 1 1 2 3 4 5 6 5 N m 0 5 kgf m 3 7 lb ft 35 N m 3 5 kgf m 26 lb ft ...

Page 159: ...r 1 4 Brake fluid reservoir diaphragm 1 5 Brake fluid reservoir bracket 1 6 Brake fluid reservoir 1 7 Brake fluid reservoir hose 1 8 Brake lever 1 9 Front brake light switch connector 2 Disconnect for MTN890 2 3 4 6 3 6 9 8 5 7 1 1 New New S 3 5 N m 0 35 kgf m 2 6 lb ft T R 7 N m 0 7 kgf m 5 2 lb ft T R 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 1 2 N m 0 12 kgf m 0 88 lb ft T ...

Page 160: ...er 1 14 Front brake master cylinder 1 15 Front brake light switch 1 14 12 13 15 15 10 11 11 New New S 3 5 N m 0 35 kgf m 2 6 lb ft T R 7 N m 0 7 kgf m 5 2 lb ft T R 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 1 2 N m 0 12 kgf m 0 88 lb ft T R 1 2 N m 0 12 kgf m 0 88 lb ft T R 1 0 N m 0 10 kgf m 0 73 lb ft T R 6 N m 0 6 kgf m 4 4 lb ft T R 1 2 N m 0 12 kgf m 0 88 lb ft T R 30 N m...

Page 161: ...isassembling the front brake master cylinder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder kit 1 2 Bleed screw 1 3 Cap 1 4 Brake master cylinder body 1 BF BF S 5 N m 0 5 kgf m 3 7 lb ft 1 2 3 4 1 New New ...

Page 162: ...he front brake calipers Brake fluid Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS on page 3 15 1 Brake hose union bolt 1 2 Brake hose gasket 3 3 Brake hose 2 4 Reflector bracket 1 5 Reflector 1 6 Front brake caliper 1 3 1 2 5 6 4 New 30 N m 3 0 kgf m 22 lb ft T R 35 N m 3 5 kgf m 26 lb ft T R 3 8 N m 0 38 kgf m 2 8 lb ft T R ...

Page 163: ...lies to both of the front brake calipers 1 Brake pad clip 2 2 Brake pad pin 1 3 Brake pad spring 1 4 Brake pad 2 5 Brake caliper piston 4 6 Brake caliper piston dust seal 4 7 Brake caliper piston seal 4 8 Bleed screw 1 FWD FWD BF BF S S 3 8 4 7 5 6 7 6 6 7 5 6 7 2 1 5 N m 0 5 kgf m 3 7 lb ft New New New New New New New New ...

Page 164: ...dure applies to both brake discs 1 Check Front brake disc Damage galling Replace 2 Measure Brake disc runout Out of specification Replace a Place the vehicle on a maintenance stand so that the front wheel is elevated b Remove the brake caliper c Hold the dial gauge at a right angle against the brake disc surface d Measure the runout 1 5 mm 0 06 in below the edge of the brake disc 3 Measure Brake d...

Page 165: ... the bleed screw and push the brake caliper pistons into the brake caliper with your finger c Tighten the bleed screw d Install the brake pads and brake pad spring TIP The arrow mark a on the brake pad spring must point in the direction of disc rotation 6 Install Brake pad pin Brake pad clip Front brake caliper 7 Check Brake fluid level Below the minimum level mark Add the specified brake fluid to...

Page 166: ...m the brake caliper WARNING EWA17060 Never try to pry out the brake caliper pis tons Do not loosen the bolts 4 c Remove the brake caliper piston dust seals and brake caliper piston seals d Repeat the previous steps to force out the right side pistons from the brake caliper EAS30173 CHECKING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers 1 Check Brake caliper...

Page 167: ...asket Brake hose 2 Brake hose union bolt 3 WARNING EWA13531 Proper brake hose routing is essential to in sure safe vehicle operation NOTICE ECA21410 When installing the brake hose onto the brake caliper 1 make sure the brake pipe a touches the projection b on the brake caliper Install the brake pipe c so that it is aligned with the brake pipe a 2 Remove Front brake caliper 3 Install Brake pad Brak...

Page 168: ...ing the front brake master cylinder drain the brake fluid from the entire brake sys tem 1 Disconnect Brake light switch connector for MTN890 from the front brake light switch 2 Remove Brake hose union bolt Brake hose gasket Brake hose TIP To collect any remaining brake fluid place a container under the master cylinder and the end of the brake hose EAS30725 CHECKING THE FRONT BRAKE MASTER CYLINDER ...

Page 169: ...luids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake 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 ...

Page 170: ...etaining bolt 1 3 Rear brake caliper 1 4 Brake pad 2 5 Brake pad shim 2 6 Brake pad insulator 2 7 Brake pad spring 1 8 Bleed screw 1 9 Brake caliper bracket assembly 1 LT S S S S 22 N m 2 2 kgf m 16 lb ft T R 17 N m 1 7 kgf m 13 lb ft T R 2 5 N m 0 25 kgf m 1 8 lb ft T R 7 8 3 1 2 6 6 5 4 5 5 N m 0 5 kgf m 3 7 lb ft T R 27 N m 2 7 kgf m 20 lb ft T R 9 ...

Page 171: ...SYSTEM ABS on page 3 15 1 Brake fluid reservoir bracket 1 2 Brake fluid reservoir cap 1 3 Brake fluid reservoir diaphragm holder 1 4 Brake fluid reservoir diaphragm 1 5 Brake fluid reservoir 1 6 Brake fluid reservoir hose 1 7 Brake hose union bolt 1 8 Brake hose gasket 2 9 Brake hose 1 8 7 6 2 3 4 1 5 9 14 3 8 N m 0 38 kgf m 2 8 lb ft 1 5 N m 0 15 kgf m 1 1 lb ft New 30 N m 3 0 kgf m 22 lb ft 30 N...

Page 172: ...cylinder assembly 1 12 Rear brake light switch bracket 1 13 Rear brake light switch coupler 1 Disconnect 14 Rear brake light switch 1 11 10 12 14 13 3 8 N m 0 38 kgf m 2 8 lb ft 1 5 N m 0 15 kgf m 1 1 lb ft New 30 N m 3 0 kgf m 22 lb ft 30 N m 3 0 kgf m 22 lb ft 23 N m 2 3 kgf m 17 lb ft 28 N m 2 8 kgf m 21 lb ft 5 N m 0 5 kgf m 3 7 lb ft New LT ...

Page 173: ...he rear brake master cylinder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder yoke 1 2 Brake master cylinder kit 1 3 Hose joint 1 4 Bushing 1 5 Brake master cylinder body 1 S BF BF New New New 18 N m 1 8 kgf m 13 lb ft ...

Page 174: ... Remarks Brake fluid Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS on page 3 15 1 Brake hose union bolt 1 2 Brake hose gasket 2 3 Brake hose 1 4 Rear brake caliper 1 LT S S New 1 3 4 2 30 N m 3 0 kgf m 22 lb ft 22 N m 2 2 kgf m 16 lb ft T R 27 N m 2 7 kgf m 20 lb ft T R ...

Page 175: ... 1 2 Brake pad retaining bolt 1 3 Brake pad 2 4 Brake pad shim 2 5 Brake pad insulator 2 6 Brake pad spring 1 7 Brake caliper piston 1 8 Brake caliper piston dust seal 1 9 Brake caliper piston seal 1 10 Bleed screw 1 S S S BF 2 5 N m 0 25 kgf m 1 8 lb ft 5 N m 0 5 kgf m 3 7 lb ft 17 N m 1 7 kgf m 13 lb ft ...

Page 176: ...l brake com ponents Use only clean or new brake fluid for clean ing brake components Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately Avoid brake fluid coming into contact with the eyes as it can cause serious injury FIRST AID FOR BRAKE FLUID ENTERING THE EYES Flush with water for 15 minutes and get im mediate medical attention E...

Page 177: ...r b Loosen the bleed screw and push the brake caliper piston into the brake caliper with your finger c Tighten the bleed screw d Install the brake pad insulators and brake pad shims onto each brake pads TIP Apply silicone grease between the brake pad in sulator and brake pad shim NOTICE ECA14150 Do not allow grease to contact the brake pads Remove any excess grease e Install the brake pads and bra...

Page 178: ...g Be careful not to get injured when the pis ton is expelled from the brake caliper Never try to pry out the brake caliper pis ton b Remove the brake caliper piston dust seal and brake caliper piston seal EAS30188 CHECKING THE REAR BRAKE CALIPER 1 Check Brake caliper piston Rust scratches wear Replace the brake caliper piston Brake caliper cylinder Scratches wear Replace the brake caliper assembly...

Page 179: ...Proper brake hose routing is essential to in sure safe vehicle operation NOTICE ECA19080 When installing the brake hose onto the brake caliper 1 make sure the brake pipe a passes between the projections b on the brake caliper TIP Apply Three Bond No 1521 onto the mating sur faces of the brake caliper bracket and brake cal iper bracket retainer 2 Remove Rear brake caliper 3 Install Brake pad insula...

Page 180: ...page 3 15 EAS30193 REMOVING THE REAR BRAKE MASTER CYLINDER 1 Remove Brake hose union bolt Brake hose gasket Brake hose TIP To collect any remaining brake fluid place a container under the master cylinder and the end of the brake hose EAS30194 CHECKING THE REAR BRAKE MASTER CYLINDER 1 Check Brake master cylinder Damage scratches wear Replace Brake fluid delivery passages brake master cylinder body ...

Page 181: ...l reaction leading to poor brake performance When refilling be careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock NOTICE ECA13540 Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 3 Bleed Brake system Refer to BLEEDING THE HYDRA...

Page 182: ... 4 1 Fuel tank Refer to FUEL TANK on page 7 1 Air filter case Refer to GENERAL CHASSIS 2 on page 4 10 Throttle bodies Refer to THROTTLE BODIES on page 7 5 Brake fluid Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS on page 3 15 1 Brake hose union bolt 2 2 Gasket 4 16 N m 1 6 kgf m 12 lb ft 7 N m 0 7 kgf m 5 2 lb ft 7 N m 0 7 kgf m 5 2 lb ft 6 N m 0 6 kgf m 4 4 lb ft 7 N m 0 7 kgf m 5 2 lb f...

Page 183: ... brake pipe rear brake master cyl inder to hydraulic unit 1 Disconnect 9 Hydraulic unit brake pipe hydraulic unit to rear brake caliper 1 Disconnect 10 Hydraulic unit brake pipe hydraulic unit to front brake calipers 1 11 Hydraulic unit brake pipe front brake master cylinder to hydraulic unit 1 12 Hydraulic unit assembly 1 16 N m 1 6 kgf m 12 lb ft 7 N m 0 7 kgf m 5 2 lb ft 7 N m 0 7 kgf m 5 2 lb ...

Page 184: ...leed the brake system 1 Disconnect ABS ECU coupler 1 TIP While pushing the portion a of the ABS ECU coupler pull the lock lever 2 up to release the lock 2 Remove Brake hose TIP Do not operate the brake lever and brake pedal while removing the brake hoses Do not bend the brake pipe when loosening the brake pipe flare nuts NOTICE ECA19800 When removing the brake hoses and brake pipes cover the area ...

Page 185: ... the specified torque in this or der 2 Remove Rubber plugs or bolt M10 1 0 3 Install Hydraulic unit brake pipe 4 Tighten Hydraulic unit brake pipe flare nut NOTICE ECA19820 If the brake pipe flare nut does not turn easi ly replace the hydraulic unit assembly brake pipes and related parts as a set TIP Do not bend the brake pipe when tightening the brake pipe flare nuts 5 Install Gasket Brake hose u...

Page 186: ...ODE TABLE on page 9 48 11 Perform a trial run Refer to CHECKING THE ABS WARNING LIGHT on page 4 56 EAS30930 HYDRAULIC UNIT OPERATION TESTS The reaction force pulsating action generated in the brake lever and brake pedal when the ABS is activated can be tested when the vehicle is stopped The hydraulic unit operation can be tested using the following two methods Brake line routing confirmation this ...

Page 187: ...IP ON and OFF on the tool screen indicate when the brakes are being applied and released respectively NOTICE ECA17371 Check that the pulse is felt in the brake le ver brake pedal and again in the brake le ver in this order If the pulse is felt in the brake pedal before it is felt in the brake lever check that the brake hoses and brake pipes are connected correctly to the hydraulic unit assembly If...

Page 188: ...n be con firmed using the indicator On The hydraulic unit is operating Flashing The conditions for operating the hy draulic unit have not been met Off The brake lever and brake pedal are not being operated 9 A reaction force pulsating action is generated in the brake lever 1 and continues for a few seconds TIP The reaction force pulsating action consists of quick pulses Be sure to continue operati...

Page 189: ...c unit assembly If the pulse is hardly felt in either the brake lever or brake pedal check that the brake hoses and brake pipes are connected cor rectly to the hydraulic unit assembly 12 Turn the main switch to OFF 13 Remove the YDT from the YDT coupler and then install the protective cap 14 Turn the main switch to ON 15 Set the stop run start switch to 16 Check for brake fluid leakage around the ...

Page 190: ... 7 Handlebar switch right 1 8 Rearview mirror left 1 9 Grip end left 1 10 Clutch switch connector 2 Disconnect for MTN890 11 Handlebar switch left 1 12 Handlebar switch holder 2 For MTN890D 13 Handlebar grip 1 3 8 N m 0 38 kgf m 2 8 lb ft 3 8 N m 0 38 kgf m 2 8 lb ft 17 N m 1 7 kgf m 13 lb ft 16 N m 1 6 kgf m 12 lb ft 22 N m 2 2 kgf m 16 lb ft 17 N m 1 7 kgf m 13 lb ft 11 N m 1 1 kgf m 8 1 lb ft 4...

Page 191: ...dlebar 1 19 Lower handlebar holder 2 3 8 N m 0 38 kgf m 2 8 lb ft 3 8 N m 0 38 kgf m 2 8 lb ft 17 N m 1 7 kgf m 13 lb ft 16 N m 1 6 kgf m 12 lb ft 22 N m 2 2 kgf m 16 lb ft 17 N m 1 7 kgf m 13 lb ft 11 N m 1 1 kgf m 8 1 lb ft 40 N m 4 0 kgf m 30 lb ft 1 8 N m 0 18 kgf m 1 3 lb ft 1 8 N m 0 18 kgf m 1 3 lb ft 3 5 N m 0 35 kgf m 2 6 lb ft 1 8 N m 0 18 kgf m 1 3 lb ft 8 17 14 15 15 14 16 16 19 18 LS ...

Page 192: ...ts on the front side of the handlebar holder and then on the rear side TIP Align the punch mark a on the handlebar with the left side upper surface of the lower handle bar holder left 3 The upper handlebar holders should be in stalled with the punch marks b facing for ward e Tighten the lower handlebar holder nuts EAS30203 REMOVING THE HANDLEBAR 1 Stand the vehicle on a level surface WARNING EWA13...

Page 193: ...P Align the punch mark a on the handlebar with the left side upper surface of the lower handle bar holder left 3 The upper handlebar holders should be in stalled with the punch marks b facing for ward 3 Tighten Lower handlebar holder nut 4 Install Handlebar switch right Throttle grip Grip end right a Fit the slot a in the throttle grip 1 into the projection b in the handlebar switch right front si...

Page 194: ...tall Handlebar grip Grip end left 1 a Apply a thin coat of rubber adhesive onto the end of the handlebar left b Slide the handlebar grip over the end of the handlebar left c Wipe off any excess rubber adhesive with a clean rag WARNING EWA13700 Do not touch the handlebar grip until the rub ber adhesive has fully dried TIP There should be 1 3 mm 0 04 0 12 in of clear ance a between the handlebar gri...

Page 195: ...witch left with the hole b in the handlebar 9 Adjust Clutch lever free play Refer to ADJUSTING THE CLUTCH LEVER FREE PLAY on page 3 12 A For MTN890 B For MTN890D Clutch lever free play 10 0 15 0 mm 0 39 0 59 in MTN890 5 0 10 0 mm 0 20 0 39 in MTN890D b a A b a B ...

Page 196: ... applies to both of the front fork legs Front wheel Refer to FRONT WHEEL on page 4 11 1 Front fender 1 2 Upper bracket pinch bolt 1 Loosen 3 Cap bolt 1 Loosen 4 Lower bracket pinch bolt 2 Loosen 5 Front fork leg 1 2 3 5 1 4 26 N m 2 6 kgf m 19 lb ft 23 N m 2 3 kgf m 17 lb ft 10 N m 1 0 kgf m 7 4 lb ft 23 N m 2 3 kgf m 17 lb ft ...

Page 197: ... Cap bolt 1 2 O ring 1 3 Washer 1 4 Spacer 1 5 Fork spring 1 6 Locknut 1 7 Dust seal 1 8 Oil seal clip 1 9 Outer tube 1 10 Oil seal 1 11 Washer 1 12 Outer tube bushing 1 13 Inner tube bushing 1 LT LS LS 9 12 1 2 6 3 4 5 11 10 8 7 New New New New New New New New 13 23 N m 2 3 kgf m 17 lb ft T R 15 N m 1 5 kgf m 11 lb ft T R 23 N m 2 3 kgf m 17 lb ft T R ...

Page 198: ...marks 14 Wheel axle pinch bolt 1 15 Damper rod assembly bolt 1 16 Copper washer 1 17 Damper rod assembly 1 18 Inner tube 1 Right side only LT LS LS 15 17 16 New New New New New New 18 New New 14 23 N m 2 3 kgf m 17 lb ft T R 15 N m 1 5 kgf m 11 lb ft T R 23 N m 2 3 kgf m 17 lb ft T R ...

Page 199: ...pper bracket pinch bolt 1 Cap bolt 2 Lower bracket pinch bolt 3 WARNING EWA13640 Before loosening the upper and lower brack et pinch bolts support the front fork leg 4 Remove Front fork leg EAS30207 DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Remove Cap bolt 1 from the damper rod assembly Washer 2 Spacer 3 Locknut 4 a Press down on the spacer ...

Page 200: ...st be replaced 5 Remove Damper rod assembly bolt Damper rod assembly TIP While holding the damper rod with the damper rod holder 1 loosen the damper rod assembly bolt EAS30208 CHECKING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Check Inner tube Outer tube Bends damage scratches Replace WARNING EWA13650 Do not attempt to straighten a bent inner tube as this...

Page 201: ...ed with the specified amount of the fork oil it may cause poor handling and a loss of stability For MTN890D WARNING EWA18360 If both front fork legs are not filled with the specified amount of the fork oil it may cause poor handling and a loss of stability TIP When assembling the front fork leg be sure to replace the following parts Inner tube bushing Outer tube bushing Oil seal Oil seal clip Dust...

Page 202: ...f the front fork leg with a plastic bag to protect the oil seal during installation 5 Install Outer tube to the inner tube 6 Install Outer tube bushing 1 Washer 2 with the fork seal driver 3 7 Install Oil seal 1 with the fork seal driver 2 8 Install Oil seal clip 1 TIP Adjust the oil seal clip so that it fits into the outer tube s groove Recommended oil Yamaha Suspension Oil 01 New New New New New...

Page 203: ...rt out 13 Before measuring the fork oil level wait ten minutes until the oil has settled and the air bubbles have dispersed TIP Be sure to bleed the front fork leg of any residual air 14 Measure Front fork leg oil level a from the top of the outer tube with the outer tube fully compressed and without the fork spring Out of specification Correct Fork seal driver 90890 01442 Adjustable fork seal dri...

Page 204: ...l up the rod puller and install the rod holder 2 between the locknut 3 and the washer 4 TIP Use the side of the rod holder that is marked B i Remove the rod puller and rod puller at tachment j Position the locknut 3 as distance b k Set the cap bolt distance c to specifica tion Level left 107 mm 4 2 in MTN890 110 mm 4 3 in MTN890D Level right 107 mm 4 2 in MTN890 110 mm 4 3 in MTN890D a G088930 New...

Page 205: ...lowing procedure applies to both of the front fork legs 1 Install Front fork leg Temporarily tighten the upper and lower bracket pinch bolts WARNING EWA13680 Make sure the brake hoses are routed prop erly TIP When installing the front fork set the outer tube with the specified length a from the top of the outer tube to the top of the lower bracket 2 Tighten Lower bracket pinch bolt 1 Cap bolt 2 Up...

Page 206: ...he illustration 3 Check Cable routing TIP Make sure the brake hoses clutch cable and handlebar switch leads are routed properly Re fer to CABLE ROUTING on page 2 15 4 Adjust Spring preload Rebound damping Compression damping Refer to ADJUSTING THE FRONT FORK LEGS for MTN890 on page 3 21 and AD JUSTING THE FRONT FORK LEGS for MTN890D on page 3 23 1 2 3 5 5 5 5 ...

Page 207: ...andlebar Refer to HANDLEBAR on page 4 57 Front fork legs Refer to FRONT FORK on page 4 63 1 Front brake hose bracket 1 2 Headlight bracket 1 3 Horn bracket 1 4 Lower bracket cap 1 5 Steering stem nut 1 6 Upper bracket 1 7 Lock washer 1 8 Upper ring nut 1 9 Rubber washer 1 10 Lower ring nut 1 110 N m 11 kgf m 81 lb ft T R 7 N m 0 7 kgf m 5 2 lb ft T R 1st 2nd 52 N m 5 2 kgf m 38 lb ft 14 N m 1 4 kg...

Page 208: ... specification Order Job Parts to remove Q ty Remarks 11 Lower bracket 1 12 Bearing cover 1 13 Lower bearing dust seal 1 14 Upper bearing 1 15 Lower bearing 1 110 N m 11 kgf m 81 lb ft T R 7 N m 0 7 kgf m 5 2 lb ft T R 1st 2nd 52 N m 5 2 kgf m 38 lb ft 14 N m 1 4 kgf m 10 lb ft 11 13 14 12 15 FWD LS LS LS ...

Page 209: ...mage pitting Replace the bearings and bearing races as a set 3 Replace Bearing Bearing race 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 lower bracket with a floor chisel 4 and hammer c Install a new dust seal and new bearing rac es NOTICE ECA14270 If the bearing race is not installed properly the steering head pipe cou...

Page 210: ...nut TIP Temporarily tighten the steering stem nut 4 Install Front fork legs Refer to FRONT FORK on page 4 63 TIP Temporarily tighten the upper and lower bracket pinch bolts 5 Tighten Steering stem nut 6 Tighten Lower bracket pinch bolt Upper bracket pinch bolt Recommended lubricant Lithium soap based grease Steering stem nut 110 N m 11 kgf m 81 lb ft Lower bracket pinch bolt 23 N m 2 3 kgf m 17 lb...

Page 211: ... shock absorber assembly 1 4 Relay arm nut Bolt 1 1 5 Connecting arm upper nut Bolt 1 1 6 Relay arm 2 7 Connecting arm lower nut Bolt 1 1 8 Connecting arm 1 9 Collar Oil seal Bearing 1 2 1 10 Collar Oil seal Bearing 1 2 1 11 Collar Oil seal Bearing 1 2 1 12 Collar Oil seal Bearing 1 2 1 13 Collar 1 1 6 10 9 1 6 4 5 2 7 10 9 4 5 3 2 11 11 8 12 12 13 7 LS LS LS LS LS LS New New New New New 44 N m 4 ...

Page 212: ... 7 Connecting arm upper nut Bolt 1 1 8 Relay arm 2 9 Connecting arm lower nut Bolt 1 1 10 Connecting arm 1 11 Collar Oil seal Bearing 1 2 1 12 Collar Oil seal Bearing 1 2 1 13 Collar Oil seal Bearing 1 2 1 14 Collar Oil seal Bearing 1 2 1 15 Collar 1 1 8 4 12 11 1 8 6 7 2 9 12 11 6 7 5 2 13 13 10 14 14 15 9 3 LS LT LS LS LS New New New LS New New 44 N m 4 4 kgf m 32 lb ft T R 7 N m 0 7 kgf m 5 2 l...

Page 213: ...its end as shown WARNING EWA13760 Wear eye protection to prevent eye damage from released gas or metal chips EAS30729 DISPOSING OF A REAR SHOCK ABSORBER for MTN890D 1 Gas pressure must be released before dis posing of a rear shock absorber To release the gas pressure drill a 2 3 mm 0 08 0 12 in hole through the flat portion of the gas cyl inder as shown WARNING EWA13760 Wear eye protection to prev...

Page 214: ...NSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 1 Install Gas cylinder bracket bolt for MTN890D Rear shock absorber assembly Bracket bolt for MTN890D Rear shock absorber assembly upper bolt Rear shock absorber assembly upper nut Rear shock absorber assembly lower bolt Rear shock absorber assembly lower nut TIP Install the rear shock absorber assembly upper bolt and rear shock absorber assembly lower bo...

Page 215: ...sorber assembly upper nut Rear shock absorber assembly lower nut Gas cylinder bracket bolt for MTN890D 7 N m 0 7 kgf m 5 2 lb ft LOCTITE Bracket bolt for MTN890D 7 N m 0 7 kgf m 5 2 lb ft Rear shock absorber assembly upper nut 44 N m 4 4 kgf m 32 lb ft Rear shock absorber assembly lower nut 44 N m 4 4 kgf m 32 lb ft T R ...

Page 216: ... 4 18 Relay arm nut Bolt Refer to REAR SHOCK ABSORBER ASSEMBLY on page 4 78 1 Pivot shaft nut 1 2 Washer 1 3 Pivot shaft 1 4 Swingarm 1 5 Rear fender 1 6 Drive chain guide 1 7 Bracket 1 8 Dust cover 2 9 Collar 1 10 Bearing 2 1 2 8 9 10 6 7 10 5 3 8 4 LS LS LS LS 105 N m 10 5 kgf m 77 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 7 N m 0 7 kgf m 5 2 lb ft T R ...

Page 217: ...re is binding check the pivot shaft collar bearings and dust covers 3 Remove Swingarm EAS30227 CHECKING THE SWINGARM 1 Check Swingarm Bends cracks damage Replace 2 Check Pivot shaft Roll the pivot shaft on a flat surface Bends Replace WARNING EWA13770 Do not attempt to straighten a bent pivot shaft 3 Wash Pivot shaft Dust cover Collar 4 Check Dust cover 1 Oil seal 2 Damage wear Replace Collar 3 Da...

Page 218: ...age 4 18 5 Adjust Drive chain slack Refer to DRIVE CHAIN SLACK on page 3 18 A Left side B Right side Relay arm nut 44 N m 4 4 kgf m 32 lb ft Pivot shaft nut 105 N m 10 5 kgf m 77 lb ft Drive chain slack Sidestand 36 0 41 0 mm 1 42 1 61 in Drive chain slack Maintenance stand 36 0 41 0 mm 1 42 1 61 in Drive chain slack limit Side stand 46 0 mm 1 81 in 1 1 2 1 N 2 A B a a a a A B New New T R ...

Page 219: ...d 1 5 Shift arm 1 6 Shift rod joint 2 7 Shift pedal 1 8 Drive sprocket cover 1 9 Drive chain guide 1 10 Drive chain 1 11 Drive sprocket nut 1 12 Washer 1 13 Drive sprocket 1 2 6 13 10 12 11 7 8 9 5 2 6 4 3 1 New LT LS LT LT LS LS LT LT LT 8 N m 0 8 kgf m 5 9 lb ft T R 160 N m 16 kgf m 118 lb ft T R 28 N m 2 8 kgf m 21 lb ft T R 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 14 N m 1 ...

Page 220: ...ce the drive chain a Measure the length b between the inner sides of the pins and the length c between the outer sides of the pins on a 15 link sec tion of the drive chain as shown in the illus tration b Calculate the 15 link section length a of the 15 link section of the drive chain using the following formula Drive chain 15 link section length a length b between pin inner sides length c between ...

Page 221: ...ain in kerosene for more than ten minutes otherwise the O rings can be damaged 4 Check O ring 1 Damage Replace the drive chain Drive chain roller 2 Damage wear Replace the drive chain Drive chain side plate 3 Damage wear cracks Replace the drive chain 5 Lubricate Drive chain EAS30231 CHECKING THE DRIVE SPROCKET 1 Check Drive sprocket More than 1 4 tooth a wear Replace the drive sprocket the rear w...

Page 222: ...iveting make sure the space c which is inside of the connecting link 3 and inside of the connecting plate 1 is 14 35 14 55 mm 0 565 0 573 in 2 Lubricate Drive chain 3 Install Drive sprocket Washer 1 Drive sprocket nut 2 TIP Thoroughly clean all the drive sprocket nut seat and threads of drive axle While applying the rear brake tighten the drive sprocket nut Install washer 1 with the OUT mark a fac...

Page 223: ...3550 A drive chain that is too tight will overload the engine and other vital parts and one that is too loose can skip and damage the swing arm or cause an accident Therefore keep the drive chain slack within the specified lim its EAS31729 ADJUSTING THE SHIFT PEDAL TIP The shift pedal position is determined by the in stalled shift rod length 1 Measure Installed shift rod length a Incorrect Adjust ...

Page 224: ...il the specified in stalled shift rod length is obtained c Tighten both locknuts TIP Be sure to place the shift rod joints in parallel The allowable twist of the shift rod joints is 5 d Make sure the installed shift rod length is within specification Shift rod locknut 7 N m 0 7 kgf m 5 2 lb ft a 1 1 2 T R ...

Page 225: ... 5 26 REMOVING THE CYLINDER HEAD 5 27 CHECKING THE TIMING CHAIN GUIDE EXHAUST SIDE 5 27 CHECKING THE CYLINDER HEAD 5 27 INSTALLING THE CYLINDER HEAD 5 28 VALVES AND VALVE SPRINGS 5 29 REMOVING THE VALVES 5 31 CHECKING THE VALVES AND VALVE GUIDES 5 31 CHECKING THE VALVE SEATS 5 33 CHECKING THE VALVE SPRINGS 5 34 CHECKING THE VALVE LIFTERS 5 34 INSTALLING THE VALVES 5 34 GENERATOR AND STARTER CLUTCH...

Page 226: ...P 5 57 CHECKING THE SPROCKET AND CHAIN 5 59 CHECKING THE OIL PUMP 5 59 CHECKING THE RELIEF VALVE 5 59 ASSEMBLING THE OIL PUMP 5 59 INSTALLING THE OIL PUMP 5 60 OIL PAN 5 61 REMOVING THE OIL PAN 5 62 CHECKING THE OIL STRAINER 5 62 INSTALLING THE OIL PAN 5 62 CRANKCASE 5 63 DISASSEMBLING THE CRANKCASE 5 65 CHECKING THE CRANKCASE 5 65 ASSEMBLING THE CRANKCASE 5 65 INSTALLING THE OIL PRESSURE SWITCH 5...

Page 227: ...FT 5 81 CHECKING THE BALANCER SHAFT 5 83 INSTALLING THE CRANKSHAFT 5 85 INSTALLING THE BALANCER ASSEMBLY 5 85 TRANSMISSION 5 86 REMOVING THE TRANSMISSION 5 91 CHECKING THE SHIFT FORKS 5 91 CHECKING THE SHIFT DRUM ASSEMBLY 5 92 CHECKING THE TRANSMISSION 5 92 ASSEMBLING THE MAIN AXLE AND DRIVE AXLE 5 93 INSTALLING THE TRANSMISSION 5 93 ...

Page 228: ...CHART 16 15 13 12 12 12 11 7 6 5 8 9 10 8 8 4 1 2 3 14 1 Oil strainer 2 Oil pump 3 Relief valve 4 Oil cooler 5 Oil filter cartridge 6 Main gallery 7 Oil pressure switch 8 Mission shower 9 Main axle 10 Drive axle 11 Crankshaft 12 Oil nozzle 13 Balancer shaft 14 Timing chain tensioner 15 Intake camshaft 16 Exhaust camshaft ...

Page 229: ...5 2 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS32363 LUBRICATION DIAGRAMS 1 2 3 5 4 1 Oil filter cartridge union bolt 2 Oil filter cartridge 3 Oil delivery pipe 4 Drive axle 5 Main axle ...

Page 230: ...HART AND DIAGRAMS 10 7 4 5 6 7 9 8 2 1 3 1 Timing chain tensioner 2 Intake camshaft 3 Exhaust camshaft 4 Balancer shaft 5 Crankshaft 6 Oil cooler 7 Oil strainer 8 Oil drain bolt 9 Oil pump driven sprocket 10 Oil delivery pipe ...

Page 231: ...5 4 LUBRICATION SYSTEM CHART AND DIAGRAMS 4 5 2 3 1 1 Oil cooler 2 Oil filter cartridge 3 Oil pressure switch 4 Oil strainer 5 Oil pump ...

Page 232: ...5 5 LUBRICATION SYSTEM CHART AND DIAGRAMS 2 3 1 4 5 6 1 Balancer shaft 2 Crankshaft 3 Oil delivery pipe 4 Main axle 5 Drive axle 6 Oil gallery bolt ...

Page 233: ...RT AND DIAGRAMS 1 2 3 4 5 6 7 8 1 Cylinder head 2 Intake camshaft 3 Exhaust camshaft 4 Oil passage to the cylinder head 5 Oil passage to the clutch chamber 6 Oil return passage from the cylinder head 7 Crankshaft 8 Main gallery ...

Page 234: ...ression gauge 1 Extension 2 5 Measure Compression pressure Out of specification Refer to steps c and d a Set the main switch to ON b With the throttle wide open crank the en gine until the reading on the compression gauge stabilizes WARNING EWA17100 To prevent sparking the plug remove all ig nition coil couplers and fuel injector cou plers before cranking the engine TIP The difference in compressi...

Page 235: ...K on page 7 1 Fuel tank center cover Refer to GENERAL CHASSIS 1 on page 4 1 Rider seat Refer to GENERAL CHASSIS 1 on page 4 1 Compression pressure with oil applied into the cylinder Reading Diagnosis Higher than without oil Piston ring s wear or damage Repair Same as without oil Piston valves cylin der head gasket pos sibly defective Repair Spark plug 13 N m 1 3 kgf m 9 6 lb ft T R ...

Page 236: ...o remove Q ty Remarks Radiator bracket Refer to RADIATOR on page 6 3 1 O2 sensor coupler 1 Disconnect 2 Muffler assembly 1 3 Exhaust gasket 3 4 O2 sensor 1 Remove the O2 sensor only when neces sary 3 1 4 2 6 New 20 N m 2 0 kgf m 15 lb ft 20 N m 2 0 kgf m 15 lb ft 20 N m 2 0 kgf m 15 lb ft 25 N m 2 5 kgf m 18 lb ft ...

Page 237: ... GENERAL CHASSIS 1 on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 Air filter case Refer to GENERAL CHASSIS 2 on page 4 10 Canister Refer to FUEL TANK on page 7 1 Throttle bodies Refer to THROTTLE BODIES on page 7 5 Front side panel Refer to GENERAL CHASSIS 1 on page 4 1 Radiator Refer to RADIATOR on page 6 3 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 238: ...or lead 1 Disconnect 3 Purge cut valve solenoid coupler 1 Disconnect 4 Ignition coil coupler 3 Disconnect 5 Coolant temperature sensor coupler 1 Disconnect 6 Neutral switch coupler 1 Disconnect 7 Gear position sensor coupler 1 Disconnect 8 Crankshaft position sensor coupler 1 Disconnect 9 Stator coil coupler 1 Disconnect 10 Oil pressure switch connector 1 Disconnect 7 N m 0 7 kgf m 5 2 lb ft T R 7...

Page 239: ...Engine mounting bolt left front lower side 1 9 Engine mounting nut lower 1 10 Muffler bracket bolt 1 11 Muffler bracket 1 12 Sidestand switch coupler 1 Disconnect 13 Muffler bracket bolt 1 14 Muffler bracket 1 15 Pivot shaft nut 1 Loosen 1 2 3 9 10 5 6 7 11 4 1 8 15 13 12 14 2 LT LT LT LT 25 N m 2 5 kgf m 18 lb ft 25 N m 2 5 kgf m 18 lb ft 45 N m 4 5 kgf m 33 lb ft 60 N m 6 0 kgf m 44 lb ft 60 N m...

Page 240: ...unting bolt rear upper side 1 19 Engine 1 20 Engine mounting adjust bolt 2 LT LT LT LT 20 20 19 16 18 17 25 N m 2 5 kgf m 18 lb ft 25 N m 2 5 kgf m 18 lb ft 45 N m 4 5 kgf m 33 lb ft 60 N m 6 0 kgf m 44 lb ft 60 N m 6 0 kgf m 44 lb ft 105 N m 10 5 kgf m 77 lb ft 45 N m 4 5 kgf m 33 lb ft 55 N m 5 5 kgf m 41 lb ft 7 N m 0 7 kgf m 5 2 lb ft 55 N m 5 5 kgf m 41 lb ft ...

Page 241: ...arily tighten 7 Tighten Engine mounting adjust bolt lower 1 TIP Tighten the engine mounting adjust bolt to specification with the pivot shaft wrench and pivot shaft wrench adapter Make sure that the flange on the engine mounting adjust bolt contacts the engine 8 Install Muffler bracket 11 Muffler bracket bolt 12 temporarily tighten 9 Tighten Engine mounting nut lower 13 Muffler bracket bolt 4 12 1...

Page 242: ...e bracket bolt left 17 Engine mounting bolt left front upper side 18 Engine bracket bolt right 20 Engine mounting bolt right front upper side 21 Engine mounting bolt left front lower side 60 N m 6 0 kgf m 44 lb ft Engine mounting bolt right front lower side 60 N m 6 0 kgf m 44 lb ft Pivot shaft nut 105 N m 10 5 kgf m 77 lb ft Engine mounting adjust bolt upper 7 N m 0 7 kgf m 5 2 lb ft Pivot shaft ...

Page 243: ...er to FUEL TANK on page 7 1 Air filter case Refer to GENERAL CHASSIS 2 on page 4 10 Front side panel Refer to GENERAL CHASSIS 1 on page 4 1 Radiator Refer to RADIATOR on page 6 3 1 Ignition coil coupler 3 Disconnect 2 Ignition coil 3 3 Spark plug 3 4 Cylinder head cover 1 5 Cylinder head cover gasket 1 6 Timing chain guide top side 1 3 3 3 4 1 6 5 2 2 2 New 13 N m 1 3 kgf m 9 6 lb ft T R 10 N m 1 ...

Page 244: ...er gasket 1 4 Timing chain tensioner 1 5 Timing chain tensioner gasket 1 6 Intake camshaft cap 1 7 Exhaust camshaft cap 1 8 Camshaft cap 1 9 Dowel pin 6 10 Intake camshaft 1 11 Exhaust camshaft 1 E 1 2 3 4 7 7 8 8 4 4 9 9 9 9 11 10 New 5 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 12 N m 1 2 kgf m 8 9 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 ...

Page 245: ...t sprocket 1 14 Timing chain bolt 1 15 Dowel pin 1 16 Timing chain guide intake side 1 17 Timing chain 1 E 14 7 8 4 4 15 16 17 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 12 N m 1 2 kgf m 8 9 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 18 lb ft T R M 13 12 ...

Page 246: ...s are turned away from each other 3 Remove Timing chain tensioner 1 Timing chain tensioner gasket 4 Remove Camshaft cap Intake camshaft cap Exhaust camshaft cap NOTICE ECA13720 To prevent damage to the cylinder head camshafts or camshaft caps loosen the camshaft cap bolts in stages and in a criss cross pattern working from the outside in 5 Remove Intake camshaft 1 Exhaust camshaft 2 TIP To prevent...

Page 247: ...el pins and camshaft caps Refer to INSTALLING THE CAMSHAFTS on page 5 22 TIP Do not turn the camshaft when measuring the camshaft journal to camshaft cap clearance with the Plastigauge d Remove the camshaft caps and then mea sure the width of the Plastigauge 1 5 Measure Camshaft journal diameter a Out of specification Replace the camshaft Within specification Replace the cylinder head and the cams...

Page 248: ...ert timing chain tensioner rod 2 into the timing chain tensioner housing TIP Push the timing chain tensioner rod in direction a and turn the timing chain tensioner body 3 in direction b until the circlip fits into the groove b Lock the timing chain tensioner rod by set ting the circlip 4 to groove 5 while push ing the timing chain tensioner rod c Push the timing chain tensioner rod c d If the circ...

Page 249: ...mark b 3 Install Intake camshaft sprocket 1 Exhaust camshaft sprocket 2 TIP Install the camshaft projection a at the posi tion shown in the illustration Tighten the camshaft sprocket bolt with the camshaft wrench 3 4 Install Exhaust camshaft 1 Intake camshaft 2 TIP Make sure the punch mark a on each camshaft faces up 5 Install Camshaft cap Intake camshaft cap Exhaust camshaft cap Camshaft sprocket...

Page 250: ...and in a crisscross pattern working from the inner caps out NOTICE ECA17430 Lubricate the camshaft cap bolts with the engine oil The camshaft cap bolts must be tightened evenly or damage to the cylinder head camshaft caps and camshafts will result Do not turn the crankshaft when installing the camshaft to avoid damage or improper valve timing 8 Check Camshaft punch mark a Make sure the camshaft pu...

Page 251: ... the mark a on the generator rotor is aligned with the generator rotor cover mark b Camshaft punch mark c Make sure the camshaft punch mark c on the camshaft is aligned with the camshaft cap alignment mark d Out of alignment Adjust Refer to the installation steps above 13 Measure Valve clearance Out of specification Adjust Refer to ADJUSTING THE VALVE CLEAR ANCE on page 3 5 14 Install Timing mark ...

Page 252: ...er head cover and cyl inder head cover gasket After installing the cylinder head cover gasket 1 to the cylinder head cover cut off the a section 16 Install Spark plug Ignition coil 1 TIP Install the ignition coils 1 in the direction shown in the illustration Cylinder head cover bolt 10 N m 1 0 kgf m 7 4 lb ft Spark plug 13 N m 1 3 kgf m 9 6 lb ft 1 2 New T R 1 a New T R 1 ...

Page 253: ...Intake camshaft Refer to CAMSHAFTS on page 5 16 Exhaust camshaft Refer to CAMSHAFTS on page 5 16 Timing chain Refer to CAMSHAFTS on page 5 16 1 Coolant temperature sensor 1 2 Cylinder head 1 3 Cylinder head gasket 1 4 Dowel pin 2 5 Timing chain guide exhaust side 1 1 2 3 4 5 8 E 4 New New 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft 1st 3rd 2nd 15 N m 1 5 kgf m 11 lb ft Specified angle 12...

Page 254: ...t use a sharp instrument to avoid damag ing or scratching Spark plug bore threads Valve seats 2 Check Cylinder head Damage scratches Replace Cylinder head water jacket Mineral deposits rust Eliminate 3 Measure Cylinder head warpage Out of specification Resurface the cylinder head a Place a straightedge 1 and a thickness gauge 2 across the cylinder head b Measure the warpage c If the limit is excee...

Page 255: ...inder head bolt 9 12 Following the tightening order loosen the bolt one by one and then retighten it to the specified torque and the specified angle TIP Tighten the cylinder head bolts 1 8 in the tightening sequence as shown and torque them in 3 stages 4 Install Exhaust camshaft Intake camshaft Refer to INSTALLING THE CAMSHAFTS on page 5 22 Cylinder head bolt 1 8 1st 20 N m 2 0 kgf m 15 lb ft 2nd ...

Page 256: ...lve lifter 6 2 Intake valve pad 6 3 Intake valve cotter 12 4 Intake valve spring retainer 6 5 Intake valve spring 6 6 Intake valve 6 7 Intake valve stem seal 6 8 Intake valve spring seat 6 9 Intake valve guide 6 10 Exhaust valve lifter 6 11 Exhaust valve pad 6 12 Exhaust valve cotter 12 13 Exhaust valve spring retainer 6 14 Exhaust valve spring 6 New M M E M M E 14 13 12 11 10 6 9 M 8 7 5 4 3 1 2 ...

Page 257: ... SPRINGS Removing the valves and valve springs Order Job Parts to remove Q ty Remarks 15 Exhaust valve 6 16 Exhaust valve stem seal 6 17 Exhaust valve spring seat 6 18 Exhaust valve guide 6 New 15 16 17 M M E M M E 18 M New ...

Page 258: ...P Remove the valve cotters by compressing the valve spring with the valve spring compressor 1 and the valve spring compressor attachment 2 4 Remove Valve spring retainer Valve spring Valve Valve stem seal Valve spring seat 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 GUIDES The following procedure a...

Page 259: ...lve stem 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 4 Check Valve face Pitting wear Grind the valve face Valve stem end Mushroom shape or diameter larger than the body of the valve stem Replace the valve Valve guide position 13 3 13 7 mm 0 52 0 54 in G088960 G088961 G088962 a Valve guide position...

Page 260: ...head c Press the valve through the valve guide and onto the valve seat to make a clear impres sion d Measure the valve seat contact 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 cylinder head or replacing the valve and valve guide the valve seat and valve face should be lapped a A...

Page 261: ...res sion j Measure the valve seat contact width c again If the valve seat width is out of spec ification reface 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 length a Out of specification Replace the valve spring EAS30287 CHECKING THE VALVE LIFTERS The following procedure applies to all of the valv...

Page 262: ... a soft face hammer NOTICE ECA13800 Hitting the valve tip with excessive force could damage the valve 6 Lubricate Valve pad with the recommended lubricant Valve lifter with the recommended lubricant 7 Install Valve pad Valve lifter TIP The valve lifter must move smoothly when ro tated with a finger Each valve lifter and valve pad must be rein stalled in its original position Recommended lubricant ...

Page 263: ... on page 7 1 Water pump Refer to WATER PUMP on page 6 11 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 28 1 Stator coil coupler 1 Disconnect 2 Crankshaft position sensor coupler 1 Disconnect 3 Holder fuel tank overflow hose 3 4 Bracket 1 5 Generator cover 1 6 Generator cover gasket 1 1 2 3 3 6 6 4 3 5 New New New New New LT LT LT LT E E E LT E E 10 N m 1 0 kgf m 7 4 lb ft T R 11 N m ...

Page 264: ...tor 1 11 Starter clutch 1 12 Starter clutch gear 1 13 Woodruff key 1 14 Starter clutch idle gear shaft 1 15 Starter clutch idle gear 1 16 Crankshaft end cover 1 17 Timing mark accessing bolt 1 18 Water pump outlet pipe 1 New 3 3 6 18 11 12 8 9 17 16 7 7 13 15 14 10 New New New New LT LT LT LT E E E LT E E 10 N m 1 0 kgf m 7 4 lb ft T R 11 N m 1 1 kgf m 8 1 lb ft 10 N m 1 0 kgf m 7 4 lb ft 12 N m 1...

Page 265: ...he flywheel puller is centered over the generator rotor EAS30868 REMOVING THE STARTER CLUTCH 1 Remove Starter clutch bolt Starter clutch TIP While holding the generator rotor 1 with the sheave holder 2 loosen the starter clutch bolts EAS30869 CHECKING THE STARTER CLUTCH 1 Check Starter clutch roller Damage wear Replace 2 Check Starter clutch idle gear Starter clutch gear Burrs chips roughness wear...

Page 266: ...holding the generator rotor with the sheave holder 3 tighten the starter clutch bolts EAS30872 INSTALLING THE GENERATOR 1 Install Woodruff key Generator rotor Washer Generator rotor bolt TIP Clean the tapered portion of the crankshaft and the generator rotor hub When installing the generator rotor make sure the woodruff key is properly seated in the key way of the crankshaft Lubricate the washer w...

Page 267: ...ver bolts in stages and in a crisscross pattern 5 Connect Stator coil coupler Crankshaft position sensor coupler TIP To route the stator coil lead refer to CABLE ROUTING on page 2 15 Yamaha bond No 1215 90890 85505 Three bond No 1215 Generator cover bolt 1 12 N m 1 2 kgf m 8 9 lb ft LOCTITE Generator cover bolt 2 12 N m 1 2 kgf m 8 9 lb ft 1 2 3 G088980 New T R 1 2 2 2 ...

Page 268: ...b Parts to remove Q ty Remarks Purge cut valve solenoid Refer to FUEL TANK on page 7 1 Throttle bodies Refer to THROTTLE BODIES on page 7 5 1 Starter motor lead 1 Disconnect 2 Starter motor 1 3 Canister holder 1 1 3 2 LS New 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 ...

Page 269: ... Parts to remove Q ty Remarks 1 O ring 1 2 Starter motor front cover 1 3 Starter motor yoke 1 4 Armature assembly 1 5 Gasket 2 6 Brush holder set 1 7 Starter motor rear cover 1 1 2 5 4 6 3 7 5 11 N m 1 1 kgf m 8 1 lb ft 5 N m 0 5 kgf m 3 7 lb ft New New New New New ...

Page 270: ...t tester and check the continuity b If there is no continuity replace the starter motor 4 Measure Brush length a Out of specification Replace the brush holder set 5 Check Gear teeth Damage wear Replace the starter motor assembly 6 Check Bearing Oil seal Damage wear Replace the starter motor assembly EAS30326 ASSEMBLING THE STARTER MOTOR 1 Install Brush holder set Insulator 1 TIP Install the insula...

Page 271: ...th the match marks b on the front and rear cover EAS30327 INSTALLING THE STARTER MOTOR 1 Install Canister holder Starter motor Starter motor bolt TIP Tighten the starter motor bolts in the tightening sequence as shown 2 Connect Starter motor lead Starter motor bolt 12 N m 1 2 kgf m 8 9 lb ft Starter motor lead nut 7 N m 0 7 kgf m 5 2 lb ft 1 2 3 a b b T R 1 2 T R ...

Page 272: ...ING THE ENGINE OIL on page 3 28 1 Clutch cable 1 Disconnect 2 Cover 1 3 Clutch cover 1 4 Clutch cover gasket 1 5 Dowel pin 2 6 Oil filler cap 1 2 6 8 3 4 5 5 1 LS New New 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 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 1 5 N m 0 15 kgf m 1 1 lb ft T R ...

Page 273: ...oving the pull lever shaft Order Job Parts to remove Q ty Remarks 1 Circlip 1 2 Pull lever 1 3 Pull lever spring 1 4 Circlip 1 5 Pull lever shaft 1 6 Oil seal 1 7 Bearing 1 8 Bearing 1 5 1 2 3 6 7 8 4 E LS New New New ...

Page 274: ...ion plate 2 3 Inside diameter 126 mm 4 96 in 7 Clutch plate 1 1 Inside diameter 116 mm 4 57 in 8 Clutch plate 2 7 Inside diameter 105 mm 4 13 in 9 Friction plate 1 6 Inside diameter 119 mm 4 69 in 10 Clutch damper spring 1 11 Clutch damper spring seat 1 12 Clutch boss nut 1 13 Conical spring washer 1 14 Washer 1 1 2 3 6 6 9 7 8 E 4 5 10 11 12 13 14 E E 10 11 E New 10 N m 1 0 kgf m 7 4 lb ft 125 N ...

Page 275: ...remove Q ty Remarks 15 Clutch boss 1 16 Thrust plate 1 17 Clutch housing 1 18 Oil pump drive chain 1 19 Bearing 1 20 Spacer 1 21 Thrust plate 1 22 Thrust plate 1 E 16 17 18 19 20 21 22 E E 15 New E 125 N m 12 5 kgf m 92 lb ft 10 N m 1 0 kgf m 7 4 lb ft ...

Page 276: ...5 57 3 Remove Clutch spring bolt 1 Pressure plate 1 2 Clutch spring Pressure plate 2 3 Pull rod 4 4 Remove Friction plate 2 1 5 Remove Clutch plate 1 1 Clutch plate 2 Friction plate 1 Clutch damper spring Clutch damper spring seat 6 Straighten the clutch boss nut rib a 7 Loosen Clutch boss nut 1 TIP While holding the clutch boss 2 with the univer sal clutch holder 3 loosen the clutch boss nut 1 2 ...

Page 277: ...ate 1 2 Damage Replace the clutch plates as a set 2 Measure Clutch plate 1 2 thickness with a surface plate and thickness gauge Out of specification Replace the clutch plates as a set 3 Measure Assembly width a of the friction plates and clutch plates Out of specification Adjust Friction plate 1 thickness 2 92 3 08 mm 0 115 0 121 in Wear limit 2 82 mm 0 111 in Friction plate 2 thickness 2 92 3 08 ...

Page 278: ... replace the clutch plate 2 2 EAS30351 CHECKING THE CLUTCH SPRINGS The following procedure applies to all of the clutch springs 1 Check Clutch spring Damage Replace the clutch springs as a set 2 Measure Clutch spring free length Out of specification Replace the clutch springs as a set EAS30352 CHECKING THE CLUTCH HOUSING 1 Check Clutch housing dogs Damage pitting wear Deburr the clutch housing dog...

Page 279: ...t and clutch housing as a set Excessive noise during operation Replace the crankshaft and clutch housing as a set EAS30357 CHECKING THE PRIMARY DRIVEN GEAR 1 Check Primary driven gear Damage wear Replace the clutch housing and crankshaft as a set Excessive noise during operation Replace the clutch housing and crankshaft as a set EAS30358 CHECKING THE PULL LEVER SHAFT AND PULL ROD 1 Check Pull leve...

Page 280: ...ffset from the other friction plates 2 making sure to align a projection on the friction plate with the punch mark a on the clutch housing 4 Install Pull rod Pressure plate 2 Clutch spring Pressure plate 1 Clutch spring bolt 1 Oil pump driven sprocket 2 TIP Tighten the clutch spring bolts in stages and in a crisscross pattern Apply lithium soap based grease onto the pull rod Position the pull rod ...

Page 281: ...pull rod teeth and pull lever shaft pinion gear are engaged 7 Connect Clutch cable 1 TIP For the clutch cable 1 turn the nut 2 in fully and then adjust the length a by using the nut 3 so that the cable length is 47 1 54 8 mm 1 85 2 16 in Measure the length while keeping the measur ing surface b parallel After installing the clutch cable bend the pro jection c on the pull lever 8 Adjust Clutch leve...

Page 282: ...n page 5 45 Shift arm Refer to CHAIN DRIVE on page 4 86 1 Circlip 1 2 Washer 1 3 Shift shaft 1 4 Washer 1 5 Circlip 1 6 Washer 1 7 Stopper lever 1 8 Stopper lever spring 1 9 Collar 1 10 Shift shaft spring 1 11 Shift shaft spring stopper 1 12 Oil seal 1 13 Bearing 1 11 8 3 12 1 2 13 10 9 7 6 4 5 E E New New New LT LT E E LS 22 N m 2 2 kgf m 16 lb ft T R ...

Page 283: ...tall Shift shaft spring stopper 1 Shift shaft assembly Stopper lever spring 2 TIP Hook the end of the shift shaft spring 3 onto the shift shaft spring stopper 1 Hook the ends of the stopper lever spring 2 onto the stopper lever 4 and the crankcase boss 5 Mesh the stopper lever with the shift drum seg ment assembly 2 Install Bearing Oil seal Washer 1 Circlip 2 TIP Lubricate the oil seal lips with l...

Page 284: ...il pump Order Job Parts to remove Q ty Remarks Clutch cover Refer to CLUTCH on page 5 45 1 Oil pump driven sprocket 1 2 Oil pump assembly 1 2 1 L T LT LT LT 15 N m 1 5 kgf m 11 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 285: ...rder Job Parts to remove Q ty Remarks 1 Oil pump cover 1 2 Oil pump shaft 1 3 Pin 1 4 Oil pump inner rotor 1 5 Oil pump outer rotor 1 6 Washer 1 7 Spring 1 8 Relief valve 1 9 Dowel pin 2 2 5 4 9 8 7 6 9 3 1 E E 3 8 N m 0 38 kgf m 2 8 lb ft T R ...

Page 286: ...mp cover Oil pump shaft Oil pump inner rotor Oil pump outer rotor Cracks damage wear Replace the oil pump assembly 2 Check Oil pump operation Rough movement Replace the oil pump assembly EAS30338 CHECKING THE RELIEF VALVE 1 Check Relief valve 1 Spring 2 Damage wear Replace the oil pump as sembly EAS30342 ASSEMBLING THE OIL PUMP 1 Lubricate Inner rotor Outer rotor Oil pump shaft 2 Install Outer rot...

Page 287: ...3 NOTICE ECA20940 After installing the oil pump drive chain and driven sprocket make sure the oil pump turns smoothly TIP 1RC mark of the oil pump driven sprocket is in stalled at oil pump side Install the oil pump drive chain onto the oil pump driven sprocket Oil pump bolt 10 N m 1 0 kgf m 7 4 lb ft Oil pump driven sprocket bolt 15 N m 1 5 kgf m 11 lb ft LOCTITE T R T R 1 2 2 3 ...

Page 288: ...mbly Refer to ENGINE REMOVAL on page 5 9 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 28 1 Oil pan 1 2 Oil pan gasket 1 3 Oil strainer 1 2 1 15 3 New New New LT LT LT 43 N m 4 3 kgf m 32 lb ft T R 13 N m 1 3 kgf m 9 6 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 289: ...d remove them EAS31069 CHECKING THE OIL STRAINER 1 Check Oil strainer Damage Replace Contaminants Clean with solvent EAS31070 INSTALLING THE OIL PAN 1 Install Oil pan gasket Oil pan TIP Tighten the oil pan bolts in stages and in a criss cross pattern 2 Install Gasket Engine oil drain bolt Oil pan bolt 13 N m 1 3 kgf m 9 6 lb ft LOCTITE Engine oil drain bolt 43 N m 4 3 kgf m 32 lb ft New T R New T ...

Page 290: ...ER CLUTCH on page 5 36 Starter motor Refer to ELECTRIC STARTER on page 5 41 Clutch housing Refer to CLUTCH on page 5 45 Oil strainer Refer to OIL PAN on page 5 61 2 6 2 4 2 12 E E LS E LT LT New New LS New New E E E E LT LT L T LT LS New 1st 25 N m 2 5 kgf m 18 lb ft 16 N m 1 6 kgf m 12 lb ft 2nd Specified angle 60 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 10 N m 1 0 kgf m...

Page 291: ...pin 3 9 7 6 5 9 9 4 3 8 2 6 2 4 2 12 2 1 E E LS E LT LT New New LS New New New E E E E LT LT L T LT LS 1st 25 N m 2 5 kgf m 18 lb ft 16 N m 1 6 kgf m 12 lb ft 2nd Specified angle 60 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 10 N m 1 0 kgf m 7 4 lb ft T R 13 N m 1 3 kgf m 9 6 lb ft T R 12 N m 1 2 kgf m 8 9 lb ft T R 17 N m 1 7 kgf m 13 lb ft T R 70 N m 7 0 kgf m 52 lb ft T ...

Page 292: ...e lower crankcase TIP Identify the position of each part very carefully so that it can be reinstalled in its original place EAS30390 CHECKING THE CRANKCASE 1 Thoroughly wash the crankcase halves in a mild solvent 2 Thoroughly clean all the gasket surfaces and crankcase mating surfaces 3 Check Crankcase Cracks damage Replace Oil delivery passages Obstruction Blow out with compressed air EAS30397 AS...

Page 293: ...n bolt 18 M6 65 mm 2 56 in bolt 15 16 M6 65 mm 2 56 in bolt 26 M6 50 mm 1 97 in bolt 17 19 21 23 25 27 31 M6 40 mm 1 57 in bolt 22 7 Tighten Crankcase bolt 1 8 Following the tightening order loosen the bolt one by one and then retighten it to the specified torque and the specified angle WARNING EWA16610 If the bolt is tightened more than the speci fied angle do not loosen the bolt and then re tigh...

Page 294: ...shown in the illustra tion EAS31658 INSTALLING THE GEAR POSITION SENSOR NOTICE ECA22630 To prevent damage to the gear position sen sor keep magnets including any pickup tool with a magnet magnetized screwdrivers etc away from the gear position sensor 1 Install O ring Gear position sensor 1 Crankcase bolts 9 12 22 N m 2 2 kgf m 16 lb ft Crankcase bolts 13 14 24 N m 2 4 kgf m 18 lb ft Crankcase bolt...

Page 295: ...IP Lubricate the O ring with lithium soap based grease Fit the end a of the shift drum assembly into the opening b in the gear position sensor 1 Gear position sensor bolt 4 0 N m 0 40 kgf m 3 0 lb ft LOCTITE T R a b 1 ...

Page 296: ... ty Remarks Lower crankcase Refer to CRANKCASE on page 5 63 1 Connecting rod cap 3 2 Big end lower bearing 3 3 Piston pin clip 6 4 Piston pin 3 5 Piston 3 6 Connecting rod 3 7 Big end upper bearing 3 8 Top ring 3 9 2nd ring 3 10 Oil ring 3 E 1 2 3 4 6 7 8 9 10 M M E E 3 E 5 New New New 1st 2nd 20 N m 2 0 kgf m 15 lb ft Specified angle 180 ...

Page 297: ...he piston pin bore ar ea If both areas are deburred and the piston pin is still difficult to remove remove it with the piston pin puller set 3 3 Remove Top ring 2nd ring Oil ring TIP When removing a piston ring open the end gap with your fingers and lift the other side of the ring over the piston crown EAS30747 CHECKING THE CYLINDER AND PISTON 1 Check Piston wall Cylinder wall Vertical scratches R...

Page 298: ...into the cylinder TIP Use the piston crown to level the piston ring near bottom of cylinder where cylinder wear is low est 3 Measure Piston ring end gap Out of specification Replace the piston ring TIP The oil ring expander spacer s end gap cannot be measured If the oil ring rail s gap is exces sive replace all three piston rings Piston Diameter 77 975 77 990 mm 3 0699 3 0705 in a 9 0 mm 0 35 in f...

Page 299: ...nd bearings must be installed in their origi nal positions a Clean the big end bearings crankshaft pins and the inside of the connecting rods halves b Install the big end upper bearing into the connecting rod and the big end lower bear ing into the connecting rod cap with the connecting rod big end metal installer 1 TIP From the 3 types choose the connecting rod big end metal installer 1 that fits...

Page 300: ...rod and connecting rod cap without installing them onto the crankshaft TIP Install by carrying out the following procedures in order to assemble in the most suitable condition e Tighten the connecting rod bolt while checking that the sections shown a and b are flush with each other by touching the surface TIP To install the big end bearing care should be taken not to install it at an angle and the...

Page 301: ...0 WARNING EWA16610 If the bolt is tightened more than the speci fied angle do not loosen the bolt and then re tighten it Instead replace the bolt with a new one and perform the procedure again NOTICE ECA20890 Do not use a torque wrench to tighten the bolt to the specified angle j After the installation check that the section shown a is flush with each other by touch ing the surface k Remove the co...

Page 302: ...all each big end bearing in its original place From the 3 types choose the connecting rod big end metal installer 1 that fits exactly and install it to the connecting rod and connecting rod cap as shown in the illustration Align the projections a on the big end bear ings with the notches b in the connecting rods and connecting rod caps Push the big end bearing 2 down and install it to the connecti...

Page 303: ...crank shaft d Tighten the connecting rod bolt while checking that the sections shown a and b are flush with each other by touching the surface TIP To install the big end bearing care should be taken not to install it at an angle and the position should not be out of alignment e Loosen the connecting rod bolt remove the connecting rod and connecting rod cap and install these parts to the crankshaft...

Page 304: ...shaft pin Connecting rod big end bearing inner surface with the recommended lubricant 8 Install Piston assembly 1 into the cylinder 2 and onto the crankshaft pin NOTICE ECA21490 If the projection a of the piston installing tool damages you cannot use it Please han dle with care TIP Fit the projection a of the piston installing tool 3 and blunt edged part b of the cylinder fix the position of the p...

Page 305: ...p 3 c Tighten the connecting rod bolts further to reach the specified angle 180 WARNING EWA16610 If the bolt is tightened more than the speci fied angle do not loosen the bolt and then re tighten it Instead replace the bolt with a new one and perform the procedure again NOTICE ECA20890 Do not use a torque wrench to tighten the bolt to the specified angle d After the installation check that the sec...

Page 306: ...5 79 CONNECTING RODS AND PISTONS a ...

Page 307: ...r crankcase Refer to CRANKCASE on page 5 63 Connecting rod Refer to REMOVING THE CONNECTING RODS AND PISTONS on page 5 70 1 Balancer shaft 1 2 Balancer shaft journal lower bearing 2 3 Balancer shaft journal upper bearing 2 4 Crankshaft 1 5 Crankshaft journal lower bearing 4 6 Crankshaft journal upper bearing 4 7 Oil nozzle 3 7 7 5 1 2 3 4 6 E 2 3 E New New E E ...

Page 308: ...Crankshaft journal to crankshaft journal bearing clearance Out of specification Replace the crank shaft journal bearings NOTICE ECA13920 Do not interchange the crankshaft journal bearings To obtain the correct crankshaft journal to crankshaft journal bearing clear ance and prevent engine damage the crank shaft journal bearings must be installed in their original positions a Clean the crankshaft jo...

Page 309: ...each crankshaft journal If the crankshaft journal to crankshaft jour nal bearing clearance is out of specifica tion select replacement crankshaft journal bearings 4 Select Crankshaft journal bearing J1 J4 TIP The numbers A stamped into the crankshaft web and the numbers B stamped into the lower crankcase are used to determine the re placement crankshaft journal bearing sizes J1 J4 refer to the bea...

Page 310: ... and bearing por tions of the crankcase b Place the upper crankcase upside down on a bench c Install the balancer shaft journal upper bearings 1 and the balancer shaft into the upper crankcase TIP Align the projections a on the balancer shaft journal upper bearings with the notches b in the upper crankcase d Put a piece of Plastigauge 1 on each balancer shaft journal TIP Do not put the Plastigauge...

Page 311: ...r shaft journal bearings 4 Select Balancer shaft journal bearing J1 J2 TIP The numbers A stamped into the balancer shaft web and the numbers B stamped into the lower crankcase are used to determine the replacement balancer shaft journal bearing siz es J1 J2 refer to the bearings shown in the bal ancer shaft and lower crankcase illustration For example if the crankcase J1 and bal ancer shaft web J1...

Page 312: ... journal bear ings in its original place EAS31172 INSTALLING THE BALANCER ASSEMBLY 1 Install Balancer shaft journal upper bearing into the upper crankcase Balancer shaft journal lower bearing into the lower crankcase TIP Align the projections a on the balancer shaft journal bearings 1 with the notches b in the crankcases Be sure to install each balancer shaft journal bearing in its original place ...

Page 313: ...xle assembly 1 2 Oil seal 1 3 Bearing 1 4 Circlip 1 5 Washer 1 6 Shift drum retainer 2 7 Shift fork guide bar 2 1 8 Spring 4 9 Shift fork L 1 10 Shift fork R 1 11 Shift fork guide bar 1 1 12 Shift drum assembly 1 13 Shift fork C 1 1 4 2 3 9 10 13 5 8 12 8 8 6 7 8 11 6 New New New E E E LT LT E LT LT E E E LT 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft 12 N m 1 2 kgf m 8 9 lb ft 0 5 N m 0...

Page 314: ...marks 14 Main axle assembly 1 15 Oil delivery pipe 1 16 O ring 1 17 Oil nozzle 1 18 Bearing cover plate 1 19 Bearing 1 19 14 15 16 17 New New New 18 E E E LT LT E LT LT E E E LT 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft 12 N m 1 2 kgf m 8 9 lb ft 0 5 N m 0 05 kgf m 0 37 lb ft 14 N m 1 4 kgf m 10 lb ft ...

Page 315: ...on gear 1 2 Toothed lock washer 1 3 Toothed lock washer retainer 1 4 6th pinion gear 1 5 Collar 1 6 Washer 1 7 Circlip 1 8 3rd pinion gear 1 9 Circlip 1 10 Washer 1 11 5th pinion gear 1 12 Collar 1 13 Bearing housing 1 14 Bearing 1 15 Main axle 1 9 10 12 15 13 14 7 8 6 5 4 3 2 1 11 E M M M M M M M New New ...

Page 316: ...gear 1 2 Collar 1 3 5th wheel gear 1 4 Circlip 1 5 Washer 1 6 3rd wheel gear 1 7 Collar 1 8 Toothed lock washer 1 9 Toothed lock washer retainer 1 10 4th wheel gear 1 11 Collar 1 12 Washer 1 13 Circlip 1 14 6th wheel gear 1 15 Circlip 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 M M M E M M M M M M New New New New ...

Page 317: ...embling the drive axle assembly Order Job Parts to remove Q ty Remarks 16 Washer 1 17 2nd wheel gear 1 18 Collar 1 19 Collar 1 20 Bearing 1 21 Circlip 1 22 Drive axle 1 19 M M M E 20 21 22 M M M M M 18 17 16 M New New New New ...

Page 318: ...il the main axle assembly comes free from the upper crankcase 3 Remove Oil delivery pipe 1 Oil nozzle 2 Bearing cover plate 3 Bearing 4 EAS30431 CHECKING THE SHIFT FORKS The following procedure applies to all of the shift forks 1 Check Shift fork cam follower 1 Shift fork pawl 2 Bends damage scoring wear Replace the shift fork 2 Check Shift fork guide bar 1 Shift fork guide bar 2 Roll the shift fo...

Page 319: ...rive axle runout with a centering device and dial gauge 1 Out of specification Replace the drive axle 3 Check Transmission gear Blue discoloration pitting wear Replace the defective gear s Transmission gear dogs Cracks damage rounded edges Replace the defective gear s 4 Check Transmission gear engagement each pinion gear to its respective wheel gear Incorrect Reassemble the transmission axle assem...

Page 320: ...ainer in the groove a in the axle align the projection on the retainer with an axle spline and then install the toothed lock washer Be sure to align the projection on the toothed lock washer that is between the alignment marks b with the alignment mark c on the re tainer EAS30438 INSTALLING THE TRANSMISSION 1 Install Bearing 1 Bearing cover plate 2 Oil nozzle 3 Oil delivery pipe 4 TIP Face the sea...

Page 321: ...ft drum retainer 3 Bearing 4 Circlip 5 Oil seal Drive axle assembly 6 TIP Install shift fork R into the groove a in the 5th wheel gear and shift fork L into the groove b in the 6th wheel gear on the drive axle Face the seal side of bearing 4 to the outside Install the shift drum retainer with its OUT mark c facing outward Make sure that the projection d on the drive axle assembly is inserted into ...

Page 322: ...5 95 TRANSMISSION 5 Check Transmission Rough movement Repair TIP Oil each gear shaft and bearing thoroughly ...

Page 323: ...ALLING THE RADIATOR 6 5 OIL COOLER 6 7 CHECKING THE OIL COOLER 6 8 INSTALLING THE OIL COOLER 6 8 THERMOSTAT 6 9 CHECKING THE THERMOSTAT 6 10 INSTALLING THE THERMOSTAT ASSEMBLY 6 10 WATER PUMP 6 11 DISASSEMBLING THE WATER PUMP 6 13 CHECKING THE WATER PUMP 6 13 ASSEMBLING THE WATER PUMP 6 13 ...

Page 324: ...6 1 COOLING SYSTEM DIAGRAMS EAS20299 COOLING SYSTEM DIAGRAMS 3 2 1 1 1 Water pump 2 Thermostat 3 Radiator ...

Page 325: ...6 2 COOLING SYSTEM DIAGRAMS 1 2 3 4 5 1 Water jacket 2 Thermostat 3 Water pump 4 Oil cooler 5 Coolant reservoir ...

Page 326: ...nt reservoir cover 1 3 Coolant reservoir 1 4 Coolant reservoir cap 1 5 Coolant reservoir breather hose 1 6 Radiator cap 1 7 Radiator fan motor coupler 1 Disconnect 8 Radiator hose cylinder head to radiator 1 Disconnect 9 Radiator inlet hose 1 Disconnect 10 Radiator outlet hose 1 Disconnect 2 3 4 1 6 5 10 7 9 8 LT LT 9 N m 0 9 kgf m 6 6 lb ft 0 5 N m 0 05 kgf m 0 37 lb ft 2 0 N m 0 20 kgf m 1 5 lb ...

Page 327: ...diator 1 12 Radiator fan cover 1 13 Radiator fan 1 14 Radiator bracket 1 14 11 13 12 LT LT 9 N m 0 9 kgf m 6 6 lb ft 0 5 N m 0 05 kgf m 0 37 lb ft 2 0 N m 0 20 kgf m 1 5 lb ft 10 N m 1 0 kgf m 7 4 lb ft 8 N m 0 8 kgf m 5 9 lb ft 7 N m 0 7 kgf m 5 2 lb ft 10 N m 1 0 kgf m 7 4 lb ft ...

Page 328: ... Check Radiator fan Damage Replace Malfunction Check and repair Refer to COOLING SYSTEM on page 8 39 EAS30440 INSTALLING THE RADIATOR 1 Install All removed parts 2 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 31 3 Check Cooling system Leaks Repair or replace any faulty part a Attach the radiator cap tester 1 and radia tor cap tes...

Page 329: ...e that coolant is filled up to the up per level beforehand 4 Check Pressure value No stay for 5 to 10 seconds at the test pres sure value Repair Radiator Radiator hose connections Coolant leaks Repair or replace Radiator hose Bulges Replace WARNING EWA19090 When the radiator cap tester is removed coolant will spout therefore cover it with a cloth beforehand Cooling system leak test pres sure 137 3...

Page 330: ... 6 3 Coolant Drain Refer to CHANGING THE COOLANT on page 3 31 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 28 1 Radiator inlet hose 1 2 Oil cooler inlet hose 1 3 Oil cooler outlet hose 1 4 Oil cooler 1 5 Water jacket joint 1 4 3 1 5 2 LS LT LT LT New New LT LT LS 2 0 N m 0 20 kgf m 1 5 lb ft T R 10 N m 1 0 kgf m 7 4 lb ft T R ...

Page 331: ...p based grease to the O ring Make sure the O ring is positioned properly 3 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 31 Crankcase with the specified amount of the recom mended engine oil Refer to CHANGING THE ENGINE OIL on page 3 28 4 Check Cooling system Leaks Repair or replace any faulty part Refer to INSTALLING THE RADIATOR...

Page 332: ...in Refer to CHANGING THE COOLANT on page 3 31 Radiator Refer to RADIATOR on page 6 3 Muffler assembly Refer to ENGINE REMOVAL on page 5 9 1 Oil cooler outlet hose 1 2 Radiator outlet hose 1 3 Water pump inlet hose 1 4 Thermostat housing 1 5 Thermostat cover 1 6 Thermostat 1 LS 10 N m 1 0 kgf m 7 4 lb ft T R 1 6 3 2 5 4 ...

Page 333: ...e place it A faulty thermostat could cause serious overheating or overcooling 2 Check Thermostat cover Thermostat housing Cracks damage Replace EAS30445 INSTALLING THE THERMOSTAT ASSEMBLY 1 Install Thermostat 2 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 31 3 Check Cooling system Leaks Repair or replace any faulty part Refer to ...

Page 334: ...UMP Removing the water pump Order Job Parts to remove Q ty Remarks Coolant Drain Refer to CHANGING THE COOLANT on page 3 31 1 Water pump inlet hose 1 Disconnect 2 Water pump assembly 1 1 2 LS New New LS 12 N m 1 2 kgf m 8 9 lb ft T R ...

Page 335: ...er Job Parts to remove Q ty Remarks 1 Water pump housing cover 1 2 O ring 1 3 Circlip 1 4 Water pump driven gear 1 5 Pin 1 6 Washer 1 7 Impeller shaft 1 8 Mechanical seal 1 9 Bearing 1 10 Oil seal 1 E E 1 2 3 4 5 6 7 8 9 10 10 N m 1 0 kgf m 7 4 lb ft ...

Page 336: ...cratch the impeller shaft EAS30447 CHECKING THE WATER PUMP 1 Check Water pump housing cover 1 Impeller shaft 2 Cracks damage wear Replace Water pump housing 3 Cracks damage wear Replace the water pump assembly 2 Check Bearing Rough movement Replace 3 Check Water pump inlet hose Cracks damage wear Replace EAS30448 ASSEMBLING THE WATER PUMP 1 Install Oil seal 1 Bearing 2 into the water pump housing ...

Page 337: ...ure the mechanical seal impeller side is flush with the impeller TIP Before installing the mechanical seal impeller side apply tap water or coolant onto its outer surface If the top of the mechanical seal is dirty clean it Mechanical seal installer 90890 04078 Water pump seal installer YM 33221 A Middle driven shaft bearing driv er 90890 04058 Middle drive bearing installer 40 50 mm YM 04058 2 Wat...

Page 338: ...6 15 WATER PUMP ...

Page 339: ...FUEL TANK 7 4 THROTTLE BODIES 7 5 CHECKING THE INJECTORS BEFORE REMOVING 7 7 REMOVING THE FUEL HOSE FUEL RAIL SIDE 7 7 REMOVING THE INJECTORS 7 7 CHECKING THE INJECTORS 7 7 CHECKING AND CLEANING THE THROTTLE BODIES 7 7 REPLACING THE THROTTLE BODIES 7 9 INSTALLING THE INJECTORS 7 9 CHECKING THE INJECTOR PRESSURE 7 10 CHECKING THE FUEL PRESSURE 7 10 INSTALLING THE FUEL HOSE FUEL RAIL SIDE 7 11 ADJUS...

Page 340: ...2 Fuel hose connector 1 Disconnect 3 Fuel pump coupler 1 Disconnect 4 Fuel tank breather hose 1 Disconnect 5 Fuel tank drain hose 1 Disconnect 6 Fuel tank 1 7 Fuel pump bracket 1 8 Fuel pump 1 9 Fuel pump gasket 1 10 Fuel tank cap 1 New 9 8 7 6 10 3 4 4 2 5 2 2 2 4 2 5 1 4 0 N m 0 40 kgf m 3 0 lb ft T R 11 N m 1 1 kgf m 8 1 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 7 N ...

Page 341: ...ge 7 1 1 Fuel tank breather hose fuel tank to canister 1 2 Canister purge hose purge cut valve solenoid to canister 1 3 Canister breather hose 1 4 Canister 1 5 Purge cut valve solenoid coupler 1 Disconnect 6 Canister purge hose purge cut valve solenoid to hose joint 1 7 Purge cut valve solenoid 1 3 4 1 7 2 5 6 ...

Page 342: ...over 1 in direction b slide the fuel hose connector cover in direction c and then remove the hose from the fuel pump Before removing the hose place a few rags in the area under where it will be removed It is prohibited to wear the cotton work gloves or equivalent coverings 4 Remove Fuel tank TIP Do not set the fuel tank down so that the instal lation surface of the fuel pump is directly under the ...

Page 343: ...projection a toward the fuel tank slot b Align the projection a on the fuel pump with the slot in the fuel pump bracket Tighten the fuel pump bolts in the proper tight ening sequence as shown EAS30457 INSTALLING THE FUEL TANK 1 Connect Fuel hose fuel tank side NOTICE ECA17500 When installing the fuel hose make sure that it is securely connected and that the fuel hose connector cover on the fuel ho...

Page 344: ... pressure sensor 2 coupler 1 Disconnect 4 Injector coupler 3 Disconnect 5 Throttle servo motor coupler 1 Disconnect 6 Throttle position sensor coupler 1 Disconnect 7 Canister purge hose purge cut valve solenoid to hose joint 1 Disconnect 8 Throttle body joint clamp screw 3 Loosen 9 Throttle body assembly 1 10 Throttle body joint 1 11 Throttle body joint 1 LT 10 11 1 8 3 9 6 2 3 7 4 5 3 N m 0 30 kg...

Page 345: ...ressure sensor 2 1 4 Intake air pressure sensor 1 1 5 Throttle position sensor 1 6 Negative pressure hose 6 7 Hose joint 2 8 Canister purge hose 4 9 Hose joint 2 8 6 6 6 7 9 9 8 7 8 6 6 5 3 2 2 2 4 6 New New New New New New 1 3 5 N m 0 35 kgf m 2 6 lb ft T R 3 5 N m 0 35 kgf m 2 6 lb ft T R 3 5 N m 0 35 kgf m 2 6 lb ft T R ...

Page 346: ...mbustible materials Make sure that there is no smoking or use of electric tools in the vicinity of the injectors Be careful when disconnecting the fuel hose Any remaining pressure in the fuel hose may cause the fuel to spray out Place a container or rag under the hose to catch any fuel that spills Always clean up any spilt fuel immediately Turn the main switch to OFF and discon nect the negative b...

Page 347: ...r case side facing up b Install the caps 895 14169 00 onto the hose fittings a c Hold the throttle valves in the open position WARNING EWA15940 When cleaning the throttle bodies be careful not to injure yourself on the throttle valves or other components of the throttle bodies NOTICE ECA20380 Do not open the throttle valves by supply ing electrical power to the throttle bodies Do not use tools to ...

Page 348: ...le bodies to the vehicle 3 Reset ISC idle speed control learning values Use the diagnostic code number 67 Refer to DIAGNOSTIC CODE SENSOR OPERATION TABLE on page 9 76 A F control learning value Use the diagnostic code number 87 Refer to DIAGNOSTIC CODE SENSOR OPERATION TABLE on page 9 76 4 Adjust Throttle bodies synchronizing Refer to SYNCHRONIZING THE THROT TLE BODIES on page 3 8 5 Place the vehi...

Page 349: ... g Check that the specified air pressure is held at least one minute Pressure drops Check the pressure gauge and adapter Check the seals and O rings and then rein stall Out of specification Replace the fuel in jectors EAS30482 CHECKING THE FUEL PRESSURE 1 Check Fuel pressure a Remove the rider seat fuel tank side cover and fuel tank center cover Refer to GENERAL CHASSIS 1 on page 4 1 b Remove the ...

Page 350: ...e throttle position sensor is dropped replace it 1 Check Throttle position sensor Refer to DIAGNOSTIC CODE SENSOR OPERATION TABLE on page 9 76 2 Adjust Throttle position sensor angle TIP Before adjusting the throttle position sensor the throttle bodies must be removed a Temporary tighten the throttle position sen sor screws 1 b Check that the throttle valves are fully closed c Connect the throttle...

Page 351: ...of the throttle position sensor angle so that 11 21 can appear in the YDT screen g After adjusting the throttle position sensor angle tighten the throttle position sensor screws Throttle position sensor screw 3 5 N m 0 35 kgf m 2 6 lb ft T R 1 1 ...

Page 352: ...7 13 THROTTLE BODIES ...

Page 353: ...IAGRAM 8 29 TROUBLESHOOTING 8 33 COOLING SYSTEM 8 39 CIRCUIT DIAGRAM 8 39 TROUBLESHOOTING 8 43 FUEL PUMP SYSTEM 8 45 CIRCUIT DIAGRAM 8 45 TROUBLESHOOTING 8 49 ELECTRICAL COMPONENTS 8 51 CHECKING THE SWITCHES 8 53 CHECKING THE FUSES 8 55 REPLACING THE ECU Engine Control Unit 8 56 CHECKING AND CHARGING THE BATTERY 8 56 CHECKING THE RELAYS 8 56 CHECKING THE RELAY UNIT DIODE 8 58 CHECKING THE IGNITION...

Page 354: ...LIGHT 8 62 CHECKING THE RADIATOR FAN MOTOR 8 63 CHECKING THE COOLANT TEMPERATURE SENSOR 8 63 CHECKING THE THROTTLE SERVO MOTOR 8 63 CHECKING THE INTAKE AIR TEMPERATURE SENSOR 8 64 CHECKING THE FUEL INJECTORS 8 64 CHECKING THE PURGE CUT VALVE SOLENOID 8 65 CHECKING THE WHEEL SWITCH 8 65 ...

Page 355: ......

Page 356: ...R R W R W R R R W R R R Br L R R R R B B B B B B B B W B B B B B B W B B B B R R W R W R W R W B B B W B W B W B B B B B L B L B Y B L W L W W L Y L L Y B Y B B Y W L W W L W Gy B B Gy 42 60 47 46 48 47 49 47 45 5 ON OFF R Br L 21 22 31 32 START OFF RUN R R L Y G W G R L L W W B W G B W R W B R 26 29 34 B B B 35 B 4 3 9 3 11 12 B L B L L W L B B Y B W L B Y B L W W W W L W B Y B L Y L L B Sb L W R...

Page 357: ...tery 22 Engine ground 26 Handlebar switch right 29 Stop run start switch 31 Relay unit 32 Starting circuit cut off relay 34 Neutral switch 35 Sidestand switch 42 Crankshaft position sensor 45 ECU Engine Control Unit 46 Ignition coil 1 47 Spark plug 48 Ignition coil 2 49 Ignition coil 3 60 IMU Inertial Measurement Unit ...

Page 358: ... W R R R W R Br L R R R R B B B B B B B B W B B B B B B W B B B B R R W R W R W R W B B B W B W B W B B B B B L B L B Y B L W L W W L Y L L Y B Y B B Y W L W W L W Gy B B Gy 46 64 51 50 52 51 53 51 49 5 ON OFF R Br L 23 24 35 36 START OFF RUN R L R L L W W B W G B W R W B R 31 33 38 B B B 39 4 3 3 11 12 9 B L B L L W L B B Y B W L B Y B L W W W W L W B Y B L Y L L B Sb L W R L B L B L B B L R W W ...

Page 359: ...tery 24 Engine ground 31 Handlebar switch right 33 Stop run start switch 35 Relay unit 36 Starting circuit cut off relay 38 Neutral switch 39 Sidestand switch 46 Crankshaft position sensor 49 ECU Engine Control Unit 50 Ignition coil 1 51 Spark plug 52 Ignition coil 2 53 Ignition coil 3 64 IMU Inertial Measurement Unit ...

Page 360: ... is open However the engine continues to run un der the following conditions The transmission is in gear the neutral switch is open and the sidestand is up the sidestand switch circuit is closed The transmission is in neutral the neutral switch is closed and the sidestand is down the sidestand switch circuit is open 10 11 9 1 4 5 7 2 6 3 8 1 Battery 2 Main fuse 3 Main switch 4 Ignition fuse 1 5 St...

Page 361: ...NG Clean the battery terminals Recharge or replace the battery OK 3 Check the spark plugs Refer to CHECKING THE SPARK PLUGS on page 3 5 NG Re gap or replace the spark plugs OK 4 Check the ignition spark gap Refer to CHECKING THE IGNI TION SPARK GAP on page 8 59 OK Ignition system is OK NG 5 Check the ignition coils Refer to CHECKING THE IGNI TION COILS on page 8 59 NG Replace the ignition coils OK...

Page 362: ...K 10 Check the sidestand switch Refer to CHECKING THE SWITCHES on page 8 53 NG Replace the sidestand switch OK 11 Check the relay unit diode Refer to CHECKING THE RELAY UNIT DIODE on page 8 58 NG Replace the relay unit OK 12 Check the entire ignition system s wiring Refer to CIRCUIT DIAGRAM on page 8 1 NG Properly connect or repair the ignition sys tem s wiring OK Replace the ECU Refer to REPLACIN...

Page 363: ...8 8 IGNITION SYSTEM ...

Page 364: ... R R B B B B B B B B W B B B B B B W B B B B R R W R W R W R W B B B W B W B W B B B B B L B L B Y B L W L W W L Y L L Y B Y B B Y W L W W L W L R B Y B L Y 60 45 5 ON OFF R Br L 23 24 21 22 SET UP FREE DOWN R L N OFF ON OFF ON OFF ON OFF ON 91 92 B Y L R B L Y 31 32 START OFF RUN R R L Y G W G R L L W W B W G B W R W B R W R Y G Y B B W G W B Y R 26 29 34 B B B 35 B 4 3 9 3 11 12 L W L B Y B W L ...

Page 365: ...ion fuse 1 21 Battery 22 Engine ground 23 Starter relay 24 Starter motor 26 Handlebar switch right 29 Stop run start switch 31 Relay unit 32 Starting circuit cut off relay 34 Neutral switch 35 Sidestand switch 45 ECU Engine Control Unit 60 IMU Inertial Measurement Unit 91 Handlebar switch left 92 Clutch switch ...

Page 366: ...Y R Br L B Br W R Y R W B Y B Y R R R R B B B B B B B B W B B B B B B W B B B B R R W R W R W R W B B B W B W B W B B B B B L B L B Y B L W L W W L Y L L Y B Y B B Y W L W W L W 64 49 5 ON OFF R Br L 25 26 23 24 OFF ON Y B Y W Gy L Y B Y 28 35 36 START OFF RUN R R L Y G W G R L L W W B W G B W R W B R W R Y G Y B B W G W B Y R 31 33 38 B B B 39 4 3 9 3 11 12 L W L B Y B W L B Y B L W W W W L W L W...

Page 367: ...se 2 12 Ignition fuse 1 23 Battery 24 Engine ground 25 Starter relay 26 Starter motor 28 Clutch switch 31 Handlebar switch right 33 Stop run start switch 35 Relay unit 36 Starting circuit cut off relay 38 Neutral switch 39 Sidestand switch 49 ECU Engine Control Unit 64 IMU Inertial Measurement Unit ...

Page 368: ...perating when neither of these condi tions has been met In this instance the starting circuit cut off relay is open so current cannot reach the starter motor When at least one of the above conditions has been met the starting circuit cut off relay is closed and the engine can be started by pressing the side of the stop run start switch 12 1 11 4 6 6 6 6 a b 8 6 9 7 5 2 3 10 10 a WHEN THE TRANSMISS...

Page 369: ...8 14 ELECTRIC STARTING SYSTEM ...

Page 370: ...harge or replace the battery OK 3 Check the starter motor operation Refer to CHECKING THE START ER MOTOR OPERATION on page 8 60 OK Starter motor is OK Perform the electric starting system troubleshooting starting with step 5 NG 4 Check the starter motor Refer to CHECKING THE START ER MOTOR on page 5 43 NG Repair or replace the starter motor OK 5 Check the relay unit starting circuit cut off relay ...

Page 371: ... SWITCHES on page 8 53 NG Replace the sidestand switch OK 11 Check the clutch switch Refer to CHECKING THE SWITCHES on page 8 53 NG Replace the clutch switch OK 12 Check the stop run start switch Refer to CHECKING THE SWITCHES on page 8 53 NG Replace the handlebar switch right OK 13 Check the entire starting system s wiring Refer to CIRCUIT DIAGRAM on page 8 9 NG Properly connect or repair the sta...

Page 372: ...8 17 CHARGING SYSTEM EAS20074 CHARGING SYSTEM EAS30496 CIRCUIT DIAGRAM MTN890 W W W Dgy W B W W R R R R R B B B B B B B B W B 21 22 2 4 3 1 W W W B R R R R R R B B R R B B W W W ...

Page 373: ...8 18 CHARGING SYSTEM 1 AC magneto 2 Rectifier regulator 3 Fuse box 4 Main fuse 21 Battery 22 Engine ground ...

Page 374: ...8 19 CHARGING SYSTEM MTN890D W W W Dgy W B W W R R R R R B B B B B B B B W B 23 24 2 4 3 1 W W W R R R R R B B B R R B B W W W R ...

Page 375: ...8 20 CHARGING SYSTEM 1 AC magneto 2 Rectifier regulator 3 Fuse box 4 Main fuse 23 Battery 24 Engine ground ...

Page 376: ...efer to CHECKING AND CHARGING THE BATTERY on page 8 56 NG Clean the battery terminals Recharge or replace the battery OK 3 Check the stator coil Refer to CHECKING THE STA TOR COIL on page 8 61 NG Replace the stator coil assembly OK 4 Check the rectifier regulator Refer to CHECKING THE RECTI FIER REGULATOR on page 8 61 NG Replace the rectifier regulator OK 5 Check the entire charging system s wirin...

Page 377: ...8 22 CHARGING SYSTEM ...

Page 378: ... B B B B B W B B B B B B W B B B B B B B W B W B W B B B B B B B L R Y B Y B Y B Y Y Y L B L B Y B L W L W W B B W B B R Y B Y Y B L R B Y B L Y Y B L R Y G B W L W Y B W G Br L B W R G G B B 88 45 5 ON OFF R Br L 21 22 83 84 85 77 75 64 69 65 SET UP FREE DOWN R L N OFF ON OFF ON OFF ON OFF ON 91 95 94 B Y L R B L Y B Y B L R Y G B W R W L W Y B W G Br L G R Gy 87 L Y L B B 86 4 3 9 3 10 13 3 18 1...

Page 379: ...21 Battery 22 Engine ground 45 ECU Engine Control Unit 64 Meter assembly 65 Multi function meter 69 Auxiliary system warning light 75 Meter light 77 High beam indicator light 83 Headlight control unit 84 Headlight low 85 Headlight high 86 Tail brake light 87 License plate light 88 Auxiliary light 91 Handlebar switch left 94 Pass switch 95 Dimmer switch ...

Page 380: ... L R R R R B B B B B B B B W B B B B B B W B B B B B B B W B W B W B B B B B B B L R Y B Y B Y B Y Y Y B B B W B B R Y B Y Y B L W L W W L B L B Y B G G B B 94 49 5 ON OFF R Br L 23 24 89 90 91 83 81 68 73 69 PUSH FREE UP N DOWN L R N HI PASS LO OFF ON RES SET FREE PUSH FREE OFF ON B W Gy Br L L B L R Gy Br L G L W Y W L L B W G W R G B Y W O W Y Y B 97 100 G R B Gy 93 L Y L B B 92 4 3 9 3 10 13 3...

Page 381: ...se 1 23 Battery 24 Engine ground 49 ECU Engine Control Unit 68 Meter assembly 69 Multi function meter 73 Auxiliary system warning light 81 Meter light 83 High beam indicator light 89 Headlight control unit 90 Headlight low 91 Headlight high 92 Tail brake light 93 License plate light 94 Auxiliary light 97 Handlebar switch left 100 Dimmer pass switch ...

Page 382: ... the fuse s OK 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 56 NG Clean the battery terminals Recharge or replace the battery OK 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 53 NG Replace the main switch immobilizer unit OK 4 Check the dimmer switch Refer to CHECKING THE SWITCHES on page 8 53 NG The dimmer switch is faulty Replace the handlebar switc...

Page 383: ...8 28 LIGHTING SYSTEM Replace the ECU meter assembly headlight assembly tail brake light li cense plate light or auxiliary light Refer to REPLACING THE ECU En gine Control Unit on page 8 56 ...

Page 384: ...L B Y B L W L W W B B W B B B B B L R B Y B L Y Y B L R Y G B W L W Y B W G Br L B W R Y L R B B 38 43 W R R B W B 62 57 45 5 ON OFF R Br L 21 22 A Ch B Ch 81 Ch B Ch B 82Ch B Ch 80 78 74 73 71 66 64 68 65 Ch B B Ch 79 SET UP FREE DOWN R L N OFF ON OFF ON OFF ON OFF ON 91 98 97 99 B Y L R B L Y B Y B L R Y G B W R W L W Y B W G Br L L Y L B B 86 31 START OFF RUN R R L Y G W G Y L R R 26 27 34 37 4...

Page 385: ... 57 ABS ECU Electronic Control Unit 59 Rear wheel sensor 62 Shift sensor 64 Meter assembly 65 Multi function meter 66 Neutral indicator light 68 Oil pressure and coolant temperature warn ing light 71 Fuel level warning light 73 Turn signal indicator light left 74 Turn signal indicator light right 78 Oil pressure switch 79 Rear turn signal light left 80 Rear turn signal light right 81 Front turn si...

Page 386: ... B B W B B B B B B B W B W B W B B B B B L B L B Y B L W L W W B B B W B B B B B 42 47 W R R B W B 66 61 49 5 ON OFF R Br L 23 24 A 96 Ch B Ch 87 Ch B Ch B 88Ch B Ch 86 84 78 77 75 70 68 72 69 Ch B B Ch 85 PUSH FREE UP N DOWN L R N HI PASS LO OFF ON RES SET FREE PUSH FREE OFF ON B W Gy Br L L B L R B Br L Gy Br L G L W Y W L L B W G W R G B Y W O W Y Y B 97 101 104 105 106 L Y L B B 92 OFF ON B G ...

Page 387: ...ontrol Unit 61 ABS ECU Electronic Control Unit 63 Rear wheel sensor 66 Shift sensor 68 Meter assembly 69 Multi function meter 70 Neutral indicator light 72 Oil pressure and coolant temperature warn ing light 75 Fuel level warning light 77 Turn signal indicator light left 78 Turn signal indicator light right 84 Oil pressure switch 85 Rear turn signal light left 86 Rear turn signal light right 87 Fr...

Page 388: ...ing system backup 1 backup 2 and brake light Refer to CHECKING THE FUS ES on page 8 55 NG Replace the fuse s OK 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 56 NG Clean the battery terminals Recharge or replace the battery OK 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 53 NG Replace the main switch immobilizer unit OK 4 Check the entire signaling sy...

Page 389: ...brake light switch Refer to CHECKING THE SWITCHES on page 8 53 NG Replace the front brake light switch OK 2 Check the rear brake light switch Refer to CHECKING THE SWITCHES on page 8 53 NG Replace the rear brake light switch OK 3 Check the entire signaling sys tem s wiring Refer to CIRCUIT DIAGRAM on page 8 29 NG Properly connect or repair the signaling system s wiring OK This circuit is OK The tu...

Page 390: ...ing sys tem s wiring Refer to CIRCUIT DIAGRAM on page 8 29 NG Properly connect or repair the signaling system s wiring OK Replace the meter assembly The oil pressure and coolant temperature warning light fails to come on or the oil pressure warn ing icon flashes when the main switch is set to ON 1 Check the entire signaling sys tem s wiring Refer to CIRCUIT DIAGRAM on page 8 29 NG Properly connect...

Page 391: ...el sender Refer to CHECKING THE FUEL SENDER on page 8 62 NG Replace the fuel pump assembly OK 2 Check the entire signaling sys tem s wiring Refer to CIRCUIT DIAGRAM on page 8 29 NG Properly connect or repair the signaling system s wiring OK Replace the meter assembly The oil pressure and coolant temperature warning light fails to come on 1 Check the coolant temperature sensor Refer to CHECKING THE...

Page 392: ...lit NG Operate while the QS icon is lit OK 5 Is the transmission gear display normal NG Repair the gear position sensor OK 6 Check the connection of the cou pler between the gear position sen sor and the ECU NG Connect the gear position sensor coupler OK 7 Are the clutch and neutral switches normal NG Repair the switch if it is not normal OK 8 Check the shift sensor value in the diagnostic mode 2 ...

Page 393: ...blue white blue black blue black Replace the ECU Refer to REPLACING THE ECU En gine Control Unit on page 8 56 The speedometer fails to operate 1 Check the rear wheel sensor Refer to MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR on page 4 22 NG Replace the rear wheel sensor OK 2 Check the entire wheel sensor wir ing Refer to TIP NG Properly connect or repair the wheel sen sor wiring OK Repl...

Page 394: ... B Y R R G B R W Br Y L G W R Y R W Y Br B L Y B B W B B R W R R W R W R R R W R R R Br L R R R R B B B B B W B B B B B B B W B W B W B B B B B B R B Gy L L V P P W Y L L B B L B L Br W Gy G B Y L W W Y W G G W G W L W L Y B 43 45 5 ON OFF R Br L 21 22 4 3 6 9 3 12 3 19 89 L B L B G Y B L B B L B R R R R R B B R R R R W Br L G Y R B R R R R G R R Br L R R R R Br L Br L B B B R B R R B B B W B W R ...

Page 395: ...e box 4 Main fuse 5 Main switch 6 Radiator fan motor relay 9 Backup fuse 2 12 Ignition fuse 1 19 Radiator fan motor fuse 21 Battery 22 Engine ground 43 Coolant temperature sensor 45 ECU Engine Control Unit 89 Radiator fan motor ...

Page 396: ...Br B L Y B B W B B Gy L L V P P W Lg L O W Y L L B B L B L Br W Gy G G L Br L B Y L W W Y W G G W G W Lg B L W L Y B R W R R W R W R R R W R R R W R Br L R R R R B B B B B W B B B B B B B W B W B W B B B B B B R B 47 49 5 ON OFF R Br L 23 24 4 3 6 9 3 12 3 21 95 L B L B G Y B L B B L B R R R R R B B R R R R W Br L G Y R B R R R R R G R R Br L R R R Br L Br L B B B R B R R B B B W B W R W R G G W G...

Page 397: ...e box 4 Main fuse 5 Main switch 6 Radiator fan motor relay 9 Backup fuse 2 12 Ignition fuse 1 21 Radiator fan motor fuse 23 Battery 24 Engine ground 47 Coolant temperature sensor 49 ECU Engine Control Unit 95 Radiator fan motor ...

Page 398: ...tery OK 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 53 NG Replace the main switch immobilizer unit OK 4 Check the radiator fan motor Refer to CHECKING THE RADIA TOR FAN MOTOR on page 8 63 NG Replace the radiator fan motor s OK 5 Check the radiator fan motor relay Refer to CHECKING THE RE LAYS on page 8 56 NG Replace the radiator fan motor relay OK 6 Check the coolant temperatu...

Page 399: ...8 44 COOLING SYSTEM Replace the ECU Refer to REPLACING THE ECU En gine Control Unit on page 8 56 ...

Page 400: ...P P W Y L L B B L B L Br W Gy G B Y L W W Y W G G W G W L W L Y B R W R R W R W R R R W R R R Br L R L G W B B B R R R R B B B B B B B B W B R L R L R L R L R L R R R W R W R W R W B B B W B W B W B B B B B 45 5 ON OFF R Br L 21 22 31 33 START OFF RUN R R L Y G W G R L L W W B W G B W R W B R 26 29 36 4 3 7 9 3 12 R L L W R Br R R W R W B R R R R R B B B R R W R W Br L Br R R R G R Br L R R R R R ...

Page 401: ...ain fuse 5 Main switch 7 Fuel injection system fuse 9 Backup fuse 2 12 Ignition fuse 1 21 Battery 22 Engine ground 26 Handlebar switch right 29 Stop run start switch 31 Relay unit 33 Fuel pump relay 36 Fuel pump 45 ECU Engine Control Unit ...

Page 402: ...W Gy G G L Br L B Y L W W Y W G G W G W Lg B L W L Y B R W R R W R W R R R W R R R W R Br L R L G W B B B R R R R B B B B B B B B W B R L R L R L R L R L R R R W R W R W R W B B B W B W B W B B B B B 49 5 ON OFF R Br L 23 24 35 37 START OFF RUN R R L Y G W G R L L W W B W G B W R W B R 31 33 40 4 3 9 3 12 7 R L L W R Br R R W R W B R R R R R B B B R R W R W Br L R R R R G R Br L R R R Br L Br L B ...

Page 403: ...ain fuse 5 Main switch 7 Fuel injection system fuse 9 Backup fuse 2 12 Ignition fuse 1 23 Battery 24 Engine ground 31 Handlebar switch right 33 Stop run start switch 35 Relay unit 37 Fuel pump relay 40 Fuel pump 49 ECU Engine Control Unit ...

Page 404: ... terminals Recharge or replace the battery OK 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 53 NG Replace the main switch immobilizer unit OK 4 Check the stop run start switch Refer to CHECKING THE SWITCHES on page 8 53 NG Replace the handlebar switch right OK 5 Check the relay unit fuel pump re lay Refer to CHECKING THE RE LAYS on page 8 56 NG Replace the relay unit OK 6 Check ...

Page 405: ...8 50 FUEL PUMP SYSTEM Replace the ECU Refer to REPLACING THE ECU En gine Control Unit on page 8 56 ...

Page 406: ... Relay unit 4 Radiator fan motor relay 5 Fuse box 6 Brake light relay for MTN890D 7 Starter relay 8 Gear position sensor 9 Shift sensor 10 Sidestand switch 11 AC magneto 12 Crankshaft position sensor 13 O2 sensor 14 Purge cut valve solenoid 15 Front wheel sensor 16 Horn 17 Headlight control unit 18 Intake air temperature sensor 19 Clutch switch ...

Page 407: ...essure sensor 1 5 Throttle position sensor 6 Injector 7 Accelerator position sensor 8 Front brake light switch 9 Main switch Immobilizer unit 10 Ignition coil 11 Radiator fan motor 12 Coolant temperature sensor 13 Starter motor 14 Oil pressure switch 15 Neutral switch 16 Rear brake light switch 17 Rear wheel sensor 18 Rectifier regulator 19 IMU Inertial Measurement Unit 20 Battery ...

Page 408: ...N890 R L L W W B W G B W R W B R R L B L W R W START OFF OFF ON RUN Y B Y Y B Y G B W G B W L L R W Y L R Br L L R G W R B Y L R B L Y Y B L R Y G B WR W L W Y B W G Br L ON OFF ON OFF FREE DOWN UP R N L OFF ON ON OFF SET 10 1 2 4 3 5 6 8 9 11 12 13 7 1 Mode switch 2 Dimmer switch 3 Pass switch 4 Horn switch 5 Hazard switch 6 Turn signal switch 7 Clutch switch 8 Sidestand switch 9 Front brake ligh...

Page 409: ... W Y W L L B W G W R G B Y W O W Y Y B Br G B Y OFF ON SET FREE RES HI LO PASS PUSH FREE ON OFF FREE PUSH UP N DOWN OFF ON R N L 1 12 2 3 5 4 6 7 8 9 10 11 13 14 15 1 Cruise control power switch 2 Cruise control setting switch 3 Dimmer pass switch 4 Horn switch 5 Mode switch 6 Select switch 7 Hazard switch 8 Turn signal switch 9 Sidestand switch 10 Clutch switch 11 Front brake light switch 12 Stop...

Page 410: ...cal circuit WARNING EWA13310 Never use a fuse with an amperage rating other than that specified Improvising or us ing a fuse with the wrong amperage rating may cause extensive damage to the electri cal system cause the lighting and ignition systems to malfunction and could possibly cause a fire 4 Install Fuse box cover Rider seat Refer to GENERAL CHASSIS 1 on page 4 1 Digital circuit tester CD732 ...

Page 411: ... seat Refer to GENERAL CHASSIS 1 on page 4 1 2 Disconnect Battery lead from the battery terminals NOTICE ECA13700 First disconnect the negative battery lead and then the positive battery lead 3 Remove Battery Refer to GENERAL CHASSIS 1 on page 4 1 4 Check Battery charge 5 Charge Battery 6 Install Battery Refer to GENERAL CHASSIS 1 on page 4 1 7 Connect Battery lead to the battery terminals NOTICE ...

Page 412: ...er probe Relay operation 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 L W R W 1 2 3 4 R L W R Sb B Sb W L L B R L W W W Br 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 ...

Page 413: ...0890 03243 Model 88 Multimeter with ta chometer YU A1927 L R Y Lg B B Continuity Positive tester probe sky blue 1 Negative tester probe black 2 No continuity Positive tester probe black 2 Negative tester probe sky blue 1 Continuity Positive tester probe sky blue 1 Negative tester probe blue 3 No continuity Positive tester probe blue 3 Negative tester probe sky blue 1 Continuity Positive tester pro...

Page 414: ...ap Out of specification Perform the ignition system troubleshooting starting with step 5 Refer to TROUBLESHOOTING on page 8 6 TIP If the ignition spark gap is within specification the ignition system circuit is operating normally a Remove the ignition coil from the spark plug b Connect the ignition checker 1 as shown Primary coil resistance 1 19 1 61 Ω Digital circuit tester CD732 90890 03243 Mode...

Page 415: ...ECKING THE STARTER MOTOR OPERATION 1 Check Starter motor operation Does not operate Perform the electric starting system troubleshooting starting with step 4 Refer to TROUBLESHOOTING on page 8 15 a Connect the positive battery terminal 1 and starter motor lead 2 with a jumper lead 3 WARNING EWA13810 A wire that is used as a jumper lead must have at least the same capacity of the bat tery lead othe...

Page 416: ...i mately 5000 r min c Measure the rectifier regulator input volt age 2 Check Rectifier regulator output voltage Out of specification Replace the rectifier regulator Stator coil resistance 0 152 0 228 Ω Digital circuit tester CD732 90890 03243 Model 88 Multimeter with ta chometer YU A1927 Positive tester probe white 1 Negative tester probe white 2 Positive tester probe white 1 Negative tester probe...

Page 417: ...d with a self diagnosis de vice for the fuel level detection circuit 1 Check Fuel level warning light 1 Turn the main switch to ON Warning light comes on for a few seconds then goes off Warning light is OK Warning light does not come on Replace the meter assembly Warning light flashes eight times then goes off for 3 seconds in a repeated cycle mal function detected in fuel sender Replace the fuel ...

Page 418: ...uit tester Ω to the coolant temperature sensor as shown b Immerse the coolant temperature sensor 1 in a container filled with coolant 2 TIP Make sure the coolant temperature sensor ter minals do not get wet c Place a thermometer 3 in the coolant d Heat the coolant or let it cool down to the specified temperatures e Measure the coolant temperature sensor resistance 3 Install Coolant temperature sen...

Page 419: ...r terminal as shown b Immerse the intake air temperature sensor 1 in a container filled with water 2 TIP Make sure that the intake air temperature sensor terminals do not get wet c Place a thermometer 3 in the water d Slowly heat the water then let it cool down to the specified temperature e Measure the intake air temperature sensor resistance 3 Install Intake air temperature sensor EAS30681 CHECK...

Page 420: ...ght as shown b Turn the main switch to ON c When turning the wheel switch in direction a and b check that the output voltage is within the specified values d Connect the digital circuit tester DC V to the handlebar switch coupler right as shown Resistance 12 0 Ω Digital circuit tester CD732 90890 03243 Model 88 Multimeter with ta chometer YU A1927 Positive tester probe Injector terminal 1 Negative...

Page 421: ...eel switch in direction b check that the output voltage is within the specified values Digital circuit tester CD732 90890 03243 Model 88 Multimeter with ta chometer YU A1927 Positive tester probe white black 4 Negative tester probe black white 3 Output voltage More than 5 V Output voltage Less than 0 5 V W B W G B W R W B W W B W G B W R W B R 1 2 3 4 b a ...

Page 422: ...8 67 ELECTRICAL COMPONENTS ...

Page 423: ... B THE MIL DOES NOT COME ON BUT THE ENGINE OPERATION IS NOT NORMAL 9 17 IMMOBILIZER SYSTEM 9 18 CIRCUIT DIAGRAM 9 18 SYSTEM OUTLINE 9 22 PART REPLACEMENT AND KEY CODE REGISTRATION REQUIREMENTS 9 23 TROUBLESHOOTING 9 26 HOW TO CHECK DTC 9 27 CRUISE CONTROL SYSTEM for MTN890D 9 28 CIRCUIT DIAGRAM 9 28 CRUISE CONTROL CIRCUIT OPERATION 9 30 BASIC INSTRUCTIONS FOR TROUBLESHOOTING 9 31 BASIC PROCESS FOR...

Page 424: ...LFUNCTION ARE CURRENTLY DETECTED 9 46 B 2 DIAGNOSIS USING THE DTC 9 46 B 3 DELETING THE DTC 9 47 C 1 FINAL CHECK 9 47 SELF DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE 9 48 DTC TABLE 9 48 SELF DIAGNOSTIC FUNCTION TABLE FOR FUEL INJECTION SYSTEM 9 53 SELF DIAGNOSTIC FUNCTION TABLE FOR IMMOBILIZER SYSTEM 9 71 SELF DIAGNOSTIC FUNCTION TABLE FOR ABS Anti lock Brake System 9 71 COMMUNICATION ERROR WIT...

Page 425: ...P0112 P0113 9 113 TROUBLESHOOTING 9 113 P0115 9 117 TROUBLESHOOTING 9 117 P0116 9 118 TROUBLESHOOTING 9 118 P0117 P0118 9 121 TROUBLESHOOTING 9 121 P0122 P0123 P0222 P0223 P2135 9 125 TROUBLESHOOTING 9 125 P0132 9 130 TROUBLESHOOTING 9 130 P0133 9 134 OUTLINE 9 134 FAIL SAFE SYSTEM 9 134 TROUBLESHOOTING 9 135 P0134 9 136 TROUBLESHOOTING 9 136 P0201 9 138 TROUBLESHOOTING 9 138 ...

Page 426: ...ROUBLESHOOTING 9 151 P0351 9 155 TROUBLESHOOTING 9 155 P0352 9 159 TROUBLESHOOTING 9 159 P0353 9 163 TROUBLESHOOTING 9 163 P0458 9 167 TROUBLESHOOTING 9 167 P0480 9 171 TROUBLESHOOTING 9 171 P0500 P1500 9 174 TROUBLESHOOTING 9 174 P0560 P0563 9 187 TROUBLESHOOTING 9 187 P0564 9 188 TROUBLESHOOTING 9 188 P056C 9 194 TROUBLESHOOTING 9 194 P0601 9 201 TROUBLESHOOTING 9 201 ...

Page 427: ... 213 TROUBLESHOOTING 9 213 P0915 9 215 TROUBLESHOOTING 9 215 P0916 P0917 9 217 TROUBLESHOOTING 9 217 P1004 9 221 TROUBLESHOOTING 9 221 P1600 9 223 TROUBLESHOOTING 9 223 P1601 9 227 TROUBLESHOOTING 9 227 P1602 9 231 TROUBLESHOOTING 9 231 P1606 P1607 9 235 TROUBLESHOOTING 9 235 P1608 9 239 TROUBLESHOOTING 9 239 P1609 9 241 TROUBLESHOOTING 9 241 ...

Page 428: ...TROUBLESHOOTING 9 260 51_IMMOBILIZER 9 264 TROUBLESHOOTING 9 264 52_IMMOBILIZER 9 265 TROUBLESHOOTING 9 265 53_IMMOBILIZER 9 266 TROUBLESHOOTING 9 266 54_IMMOBILIZER 9 269 TROUBLESHOOTING 9 269 55_IMMOBILIZER 9 271 TROUBLESHOOTING 9 271 56_IMMOBILIZER 9 272 TROUBLESHOOTING 9 272 11_ABS 9 275 TROUBLESHOOTING 9 275 12_ABS 9 276 TROUBLESHOOTING 9 276 13 26_ABS 9 277 TROUBLESHOOTING 9 277 ...

Page 429: ...S 9 284 TROUBLESHOOTING 9 284 33_ABS 9 286 TROUBLESHOOTING 9 286 34_ABS 9 288 TROUBLESHOOTING 9 288 41_ABS 9 289 TROUBLESHOOTING 9 289 42_ABS 9 290 TROUBLESHOOTING 9 290 43 45_ABS 9 291 TROUBLESHOOTING 9 291 44 46_ABS 9 292 TROUBLESHOOTING 9 292 51_ABS 9 293 TROUBLESHOOTING 9 293 53_ABS 9 294 TROUBLESHOOTING 9 294 55_ABS 9 296 TROUBLESHOOTING 9 296 ...

Page 430: ...HOOTING 9 297 57_ABS 9 298 TROUBLESHOOTING 9 298 62_ABS 9 302 TROUBLESHOOTING 9 302 68_ABS 9 303 TROUBLESHOOTING 9 303 89_ABS 9 304 TROUBLESHOOTING 9 304 90_ABS 9 307 TROUBLESHOOTING 9 307 91_ABS 9 310 TROUBLESHOOTING 9 310 ...

Page 431: ...C is a code that is saved within a control unit s memory when the control unit detects an abnormal condition If the abnormal condition continues a malfunction may be determined Driving cycle Driving cycle is the duration from the main switch being turned on OBD re quirements are met and until the main switch is turned off FFD Freeze frame data FFD is the data of all signal sensors saved at the mom...

Page 432: ...improper using of the vehicle may also become the cause of the MIL come on These events may cause the occurrence of the warning light coming on without malfunction Reprogramming of the ECU software Using the electrical accessory which may affect the ECU Using the incorrect specification of spark plug and fuel injector Using the third party accessories such as suspension and exhaust system Change o...

Page 433: ...s 6P 90890 03266 If you already have Yamaha diagnostic tool A I 90890 03262 YDT sub harness 6P 90890 03266 is separately required A GST can also be used to identify malfunctions Connecting the YDT Remove the protective cap and then connect the YDT to the coupler 1 System Lighting up warning light Lighting time FUEL INJECTION SYSTEM MIL 1 2 0 seconds 1 IMMOBILIZER SYSTEM Immobilizer system indicato...

Page 434: ...In this case question the customer about the conditions when the problem occurred and do the troubleshooting Refer to P0300 P0301 P0302 P0303 on page 9 147 Crankshaft position sensor Fuel pump Injector 1 O2 sensor Injector 2 ABS ECU Electronic Control Unit Injector 3 Throttle servo motor Clutch switch for MTN890D Relay unit Ignition coil 1 Starter relay Ignition coil 2 Purge cut valve solenoid Ign...

Page 435: ...gnition coil 2 48 Ignition coil 3 12 Sidestand switch 23 Tail brake light 10 Brake light relay 18 Rear brake light switch 17 Front brake light switch 1 16 Clutch switch 19 Rectifier regulator 7 Starting circuit cut off relay 13 Neutral switch 35 Cruise control power switch 36 Cruise control setting switch SET 37 Cruise control setting switch SET 38 Clutch switch 39 Front brake light switch 40 Rear...

Page 436: ...rator position sensor 32 Throttle position sensor 49 Grip warmer left 50 Grip warmer right 51 Purge cut valve solenoid 53 Dimmer switch 54 Pass switch 56 Meter assembly 57 CAN communication circuit 34 ABS ECU Electronic Control Unit 19 52 Radiator fan motor 55 Headlight control unit ...

Page 437: ...ake air pressure sensor 1 27 Coolant temperature sensor 28 Intake air temperature sensor 29 Shift sensor 30 Gear position sensor 31 O2 sensor 32 Throttle position sensor 33 Accelerator position sensor 34 ABS ECU Electronic Control Unit 35 Cruise control power switch for MTN890D 36 Cruise control setting switch SET for MTN890D 37 Cruise control setting switch RES for MTN890D 38 Clutch switch for MT...

Page 438: ...vo motor Lg R 11 12 13 14 Injector 3 L B 15 Injector 2 G B 16 Injector 1 R B 17 Ground B 18 Electronic throttle valve fuse R L 19 Radiator fan motor relay G Y 20 21 22 23 24 25 Ground B 26 Backup fuse 2 R G 27 Purge cut valve so lenoid Y R 28 Dimmer pass switch Headlight control unit Y B 29 Fuel pump relay L W 30 31 32 Fuel pump relay Fuel pump R L 33 Ground B W 34 Ground B W 35 Accelerator positi...

Page 439: ...shaft position sensor Gy 77 CAN communica tion circuit L W No Connected parts Wireharness color 78 79 80 Starting circuit cut off relay Clutch switch B Y 81 82 1 Cruise control set ting switch RES Br L 83 1 Cruise control set ting switch SET G L 84 O2 sensor Gy G 85 86 Intake air tempera ture sensor Br W 87 88 Crankshaft position sensor Intake air pressure sensor 1 Intake air pressure sensor 2 Coo...

Page 440: ...9 10 SYSTEM DIAGRAM 1 For MTN890D 103 Gear position sen sor G W 104 105 ABS ECU Electron ic Control Unit W G 106 107 ABS ECU Electron ic Control Unit W Y 108 No Connected parts Wireharness color ...

Page 441: ...9 11 SYSTEM DIAGRAM ...

Page 442: ...B 38 39 40 B B W L B B B L W 41 Gy B B Gy 42 43 44 60 61 W R R B W B 62 63 47 46 48 47 49 47 50 51 52 55 57 56 45 5 ON OFF R Br L 21 22 72 64 65 31 32 33 START OFF RUN R R L Y G W G R L L W W B W G B W R W B R W R Y G Y B B W G W B Y R 26 29 30 34 B B B 35 B 36 4 3 7 9 8 3 11 12 14 3 18 B W 58 W B 59 W B 1 W W W 6 R B R G Y R 23 L 2 B L B 89 SET UP FREE DOWN R L N OFF ON OFF ON OFF ON OFF ON 91 92...

Page 443: ...stand switch 36 Fuel pump 38 Gear position sensor 39 Intake air pressure sensor 1 40 Intake air pressure sensor 2 41 O2 sensor 42 Crankshaft position sensor 43 Coolant temperature sensor 44 Intake air temperature sensor 45 ECU Engine Control Unit 46 Ignition coil 1 47 Spark plug 48 Ignition coil 2 49 Ignition coil 3 50 Injector 1 51 Injector 2 52 Injector 3 55 Throttle position sensor 56 Throttle ...

Page 444: ...B W W R W W W Dgy Y B B Y Y W L Y 42 43 44 B B W L B B B L W 45 Gy B B Gy 46 47 48 64 65 W R R B W B 66 67 51 50 52 51 53 51 54 55 56 59 61 60 49 5 ON OFF R Br L 23 24 76 68 69 35 36 37 START OFF RUN R R L Y G W G R L L W W B W G B W R W B R W R Y G Y B B W G W B Y R 31 33 34 38 B B B 39 40 41 4 3 7 9 8 3 11 12 14 3 20 21 B W 62 W B 63 W B 25 6 95 L B L B 2 1 W W W OFF ON Y B Y W Gy L Y B Y 28 B R...

Page 445: ...Neutral switch 39 Sidestand switch 40 Fuel pump 41 Fuel sender 42 Gear position sensor 43 Intake air pressure sensor 1 44 Intake air pressure sensor 2 45 O2 sensor 46 Crankshaft position sensor 47 Coolant temperature sensor 48 Intake air temperature sensor 49 ECU Engine Control Unit 50 Ignition coil 1 51 Spark plug 52 Ignition coil 2 53 Ignition coil 3 54 Injector 1 55 Injector 2 56 Injector 3 59 ...

Page 446: ...he MIL come on Does the MIL LED work properly B Perform the checking with the diagnostic mode Temporary failure Check the MIL LED The MIL goes off after 2 seconds Still on flash A Check the DTC Delete the DTC Are DTCs displayed on the screen after performs the problem verification Do the troubleshooting according to the DTCs of malfunction Check the DTCs of malfunction are not displayed on the scr...

Page 447: ... IS NOT NORMAL 1 Monitor the operation of these sensors and actuators by using the YDT in the diagnostic mode Refer to DIAGNOSTIC CODE SENSOR OPERATION TABLE on page 9 76 and DIAGNOSTIC CODE ACTUATOR OPERATION TABLE on page 9 80 If a malfunction is detected in the sensors or actuators repair or replace all faulty parts If no malfunction is detected in the sensors and actuators check and repair the...

Page 448: ... R R G B R W Br Y L G W R Y R W Y Br B L Y B B W B B Gy L L V P P W Y L L B B L B L Br W Gy G B Y L W W Y W G G W G W L W L Y B R W R R W R W R R R W R R R Br L R R R R B B B B B W B B B B B B B W B W B W B B B B B L B L B Y B L W L W W 63 45 5 ON OFF R Br L 21 22 64 67 65 R W B R W Lg R G Y L 25 4 3 9 3 12 3 18 11 W Y B Y B W L B L B Y B L W L W W B R Y L R G Lg B R R R R R B B R R W Br L R R R G...

Page 449: ...ain switch 9 Backup fuse 2 11 Ignition fuse 2 12 Ignition fuse 1 18 Backup fuse 1 21 Battery 22 Engine ground 25 Immobilizer unit 45 ECU Engine Control Unit 63 YDT coupler 64 Meter assembly 65 Multi function meter 67 Immobilizer system indicator light ...

Page 450: ... P W Lg L O W Y L L B B L B L Br W Gy G G L Br L B Y L W W Y W G G W G W Lg B L W L Y B R W R R W R W R R R W R R R W R Br L R R R R B B B B B W B B B B B B B W B W B W B B B B B L W L W W B B B W B L B Y B L B 67 49 5 ON OFF R Br L 23 24 68 71 69 R W B R W Lg R G Y L 27 4 3 9 3 12 3 20 11 B L W Y B B L B B B B B L L W L B L B L W B B Y B W L W L W W B R Y L R G Lg B R R R R R B R R W Br L R R R R...

Page 451: ...ain switch 9 Backup fuse 2 11 Ignition fuse 2 12 Ignition fuse 1 20 Backup fuse 1 23 Battery 24 Engine ground 27 Immobilizer unit 49 ECU Engine Control Unit 67 YDT coupler 68 Meter assembly 69 Multi function meter 71 Immobilizer system indicator light ...

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

Page 453: ...the code re registering key has been registered 2 Check that the engine can be started 3 Register the standard key following the instructions in the section below Standby mode To enable the immobilizer system turn the ignition key to OFF 30 seconds later the indicator light will start flashing continuously in the standby flashing mode pattern for up to 24 hours After that time the indicator light ...

Page 454: ... switch then turn the key to ON within 5 seconds to activate the key registration mode TIP The existing standard key code is erased from the memory when the key registration mode is activated When the key registration mode is activated the immobilizer system indicator light flashes rapidly 4 While the indicator light is flashing turn the main switch to OFF remove the key and within 5 sec onds inse...

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

Page 456: ...to CHECKING AND CHARGING THE BATTERY on page 8 56 NG Clean the battery terminals Recharge or replace the battery OK 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 53 NG Replace the main switch immobilizer unit OK 4 Check the entire immobilizer sys tem wiring Refer to CIRCUIT DIAGRAM on page 9 18 NG Properly connect or repair the immobilizer system wiring OK Check the condition of...

Page 457: ...e meter display and the immobilizer sys tem indicator light flashes at the same time The pattern of flashing also shows the DTC Immobilizer system indicator light DTC indication Digit of 10 Cycles of 1 sec ON and 1 5 sec OFF Digit of 1 Cycles of 0 5 sec ON and 0 5 sec OFF Example DTC 52 a Light on b Light off ...

Page 458: ... B B B B B B B W B W B W B B B B B L B L B Y B L W L W W B B B W B L Y L L Y B Y B B Y B B B B 42 W R R B W B 66 67 49 5 ON OFF R Br L 23 24 96 80 79 76 68 69 PUSH FREE UP N DOWN L R N HI PASS LO OFF ON RES SET FREE PUSH FREE OFF ON B W Gy Br L Gy Br L G L W Y W L L B W G W R G B Y W O W Y Y B 97 99 98 OFF ON Y B Y W Gy L Y B Y 28 OFF ON B G W Y B G Y Y W 29 ON OFF Br G B Y B Br G B Y 30 START OFF...

Page 459: ...9 Front brake light switch 30 Rear brake light switch 31 Handlebar switch right 34 Accelerator position sensor 42 Gear position sensor 49 ECU Engine Control Unit 66 Shift sensor 67 YDT coupler 68 Meter assembly 69 Multi function meter 76 MIL Malfunction indicator light 79 Cruise control system indicator light 80 Cruise control setting indicator light 96 Brake light relay 97 Handlebar switch left 9...

Page 460: ...p relay 17 Multi function meter 16 ECU Engine Control Unit 18 Cruise control system indicator light 19 Cruise control setting indicator light 1 Battery 2 Main fuse 3 Ignition fuse 2 4 Fuel injection system fuse 5 Signaling system fuse 6 Brake light fuse 7 Ignition fuse 1 8 Cruise control system fuse 9 Cruise control power switch 10 Cruise control setting switch 11 Front brake light switch 12 Rear ...

Page 461: ...d then check the DTC of malfunction is not displayed TIP If another DTC is displayed repeat steps 1 to 3 until no DTC is displayed Turning the main switch to OFF will not erase the malfunction history 4 Do the final check WARNING EWA17420 Perform the troubleshooting A B C in order Be sure to follow the order since a wrong diagnosis could result if the steps are followed in a different order or omi...

Page 462: ...control system to the customer Finished Is there automatic deactivation history for the cruise control system Check the malfunction history using the malfunction mode of the YDT Is there any malfunction history Diagnosis using the DTC Yes Yes OK The cruise control power switch is defective The cruise control system fuse is blown The ECU is defective Delete the DTC Final check Return to A Return to...

Page 463: ... mode of the YDT Malfunction history is displayed on the YDT B 1 Malfunction history is not displayed on the YDT B 3 EAS32882 B 3 MALFUNCTION HISTORY IS NOT DISPLAYED Use the YDT to check whether automatic deactivation history for the cruise control system exists 1 There is automatic deactivation history for the cruise control system Explain the conditions for automatically deactivating the cruise...

Page 464: ... the rear brake light switch Refer to CHECKING THE SWITCHES on page 8 53 3 Execute the diagnostic mode No 82 and 83 to check the operation of the front brake light switch rear brake light switch and accelerator position sensor Refer to DIAGNOSTIC CODE SENSOR OPERATION TABLE on page 9 76 4 Execute the diagnostic mode No 80 and 81 to check the operation of the cruise control setting switch Refer to ...

Page 465: ...9 35 CRUISE CONTROL SYSTEM for MTN890D ...

Page 466: ...G G W G W L W L Y B R W R R W R W R R R W R R R Br L R R R R B B B B B B B B W B B B B B B W B B B B B B B W B W B W B B B B B L B L B Y B L W L W W B B W B B B B B Y L R B B 60 63 57 45 5 ON OFF R Br L 21 22 76 72 64 65 L Y L B B 86 START OFF RUN R R L Y G W G Y L R R 26 27 4 3 9 3 10 11 12 14 3 16 17 18 B W 58 W B 59 W B Br Y Br 90 B B W Y B L W L B L B L W Y B W L R L R L R L B L B Y B L W L W ...

Page 467: ...use 18 Backup fuse 1 21 Battery 22 Engine ground 26 Handlebar switch right 27 Front brake light switch 45 ECU Engine Control Unit 57 ABS ECU Electronic Control Unit 58 Front wheel sensor 59 Rear wheel sensor 60 IMU Inertial Measurement Unit 63 YDT coupler 64 Meter assembly 65 Multi function meter 72 MIL Malfunction indicator light 76 ABS warning light 86 Tail brake light 90 Rear brake light switch...

Page 468: ... Y B B Y Y W L Y R Br L R R R R B B B B B B B B W B B B B B B W B B B B B B B W B W B W B B B B B L B L B Y B L W L W W B B B W B B B B B 64 67 61 49 5 ON OFF R Br L 23 24 96 82 76 68 69 L Y L B B 92 OFF ON Y B Y W Gy L Y B Y 28 OFF ON B G W Y B G Y Y W 29 ON OFF Br G B Y B Br G B Y 30 4 3 9 3 10 11 12 14 16 3 17 18 19 20 B W 62 W B 63 W B B B W Y B L W L B L B L W Y B W L R L R L R L R L B L B Y ...

Page 469: ...e 19 ABS motor fuse 20 Backup fuse 1 23 Battery 24 Engine ground 28 Clutch switch 29 Front brake light switch 30 Rear brake light switch 49 ECU Engine Control Unit 61 ABS ECU Electronic Control Unit 62 Front wheel sensor 63 Rear wheel sensor 64 IMU Inertial Measurement Unit 67 YDT coupler 68 Meter assembly 69 Multi function meter 76 MIL Malfunction indicator light 82 ABS warning light 92 Tail brak...

Page 470: ...eter assembly 2 Hydraulic unit assembly ABS ECU 3 Fuse box ABS motor fuse ABS ECU fuse ABS solenoid fuse 4 YDT coupler 5 Rear wheel sensor 6 Rear wheel sensor rotor 7 Rear brake caliper 8 Front brake caliper left 9 Front wheel sensor 10 Front wheel sensor rotor 11 Front brake caliper right ...

Page 471: ... Y Br R G R G R W B W Lg L W L B G W Y W G W R G B W W G W BSb W G L W Y W L Br L B G OBr WBr B G Br W B R GY B R L W B B W W G G Y L R B Br L W G OW Y L B W Y L B 5 4 2 1 3 1 Meter assembly coupler 2 YDT coupler 3 ABS ECU coupler 4 Rear wheel sensor coupler 5 Front wheel sensor coupler ...

Page 472: ... perform a final check before delivering the vehicle to the customer TIP To final check refer to C 1 FINAL CHECK on page 9 47 ABS operation when the ABS warning light comes on 1 The ABS warning light remains on ABS operates as a normal brake system A malfunction was detected using the ABS self diagnosis function The ABS self diagnosis has not been completed The ABS self diagnosis starts when the m...

Page 473: ... not to damage components by subjecting them to shocks or pulling on them with too much force since the ABS components are precisely adjusted The ABS ECU and hydraulic unit are united assemblies and cannot be disassembled The malfunction history is stored in the memory of the ABS ECU Delete the DTC when the service is finished This is because the past DTC will be displayed again if another malfunc...

Page 474: ...ks Were all of the final checks completed normally The reaction force generated during brake line routing confirmation is incorrect Refer to C 1 FINAL CHECK The brake hoses and brake pipes are not connected correctly The ABS warning light does not go off when the light is checked Refer to C 1 FINAL CHECK The malfunction is not corrected There is a break in the wire harness between the ABS ECU and ...

Page 475: ...in switch for continuity Refer to CHECKING THE SWITCHES on page 8 53 If there is no continuity replace the main switch immobilizer unit 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 56 If the battery is defective clean the battery terminals and recharge it or replace the battery 3 Main fuse Check the fuse for continuity Refer to CHECKING THE FUSE...

Page 476: ...DT is properly connected 2 Wire harness Open circuit in the wire harness between the ABS ECU coupler and the YDT coupler Check for continuity between blue white terminal of the ABS ECU coupler and blue white terminal of the YDT coupler CANH Check for continuity between blue black terminal of the ABS ECU coupler and blue black terminal of the YDT coupler CANL EAS32903 B 1 MALFUNCTION ARE CURRENTLY ...

Page 477: ...ID LEVEL on page 3 13 2 Check the wheel sensors for proper installation Refer to INSTALLING THE FRONT WHEEL FRONT BRAKE DISCS on page 4 16 and IN STALLING THE REAR WHEEL REAR BRAKE DISC on page 4 23 3 Perform brake line routing confirmation Refer to HYDRAULIC UNIT OPERATION TESTS on page 4 53 If it does not have reaction force properly the brake hose is not properly routed or connected 4 Delete th...

Page 478: ...S Hydraulic unit assembly defective ABS solenoid power circuit 33_ABS Hydraulic unit assembly abnormal ABS motor power supply 34_ABS Hydraulic unit assembly short circuit in ABS motor power supply circuit 41_ABS Front wheel ABS intermittent wheel speed pulses or incorrect depressuriza tion 42_ABS Rear wheel ABS intermittent wheel speed pulses or incorrect depressuriza tion 43 45_ABS Front wheel se...

Page 479: ...BS CAN communication between ECU and hydraulic unit assembly 91_ABS CAN communication between IMU and hydraulic unit assembly C0520 ECU no normal signals or malfunction signals are received from the IMU Able Unable Able Unable P0030 O2 sensor heater defective heater con troller detected Able Able P00D1 P2195 P00D1 O2 sensor heater performance deterioration P2195 O2 sensor open circuit detected Abl...

Page 480: ...utput voltage deviation error Able Unable Able Unable 01 13 P0132 O2 sensor short circuit detected power short circuit Able Able P0133 O2 sensor deterioration detected Able Able P0134 O2 sensor signal stuck Able Able P0201 Injector 1 malfunction in injector 1 Able depending on the num ber of faulty cylinders Able depending on the num ber of faulty cylinders 36 P0202 Injector 2 malfunction in injec...

Page 481: ...received from the rear wheel sensor Neutral switch open or short circuit is de tected Clutch switch open or short circuit is de tected Able Able 07 21 P0560 P0563 P0560 Charging voltage is abnormal P0563 Vehicle system power voltage out of range Able Able P0564 Cruise control setting switch RES open or short circuit is detected Cruise control setting switch SET open or short circuit is detected Ab...

Page 482: ...Intake air pressure sensor 2 open or power short circuit detected Able Able 04 P1608 Intake air pressure sensor 2 signal out of range Able Able 04 P1609 Intake air pressure sensor 2 clogging of hose or sensor disconnection Able Able 04 P1806 P1807 P1806 Shift sensor open or ground short circuit detected P1807 Shift sensor power short circuit detected Able Able 95 P2122 P2123 P2127 P2128 P2138 P212...

Page 483: ...s are received from the IMU Defective IMU coupler or ECU coupler Open or short cir cuit in wire har ness between IMU and ECU Improperly in stalled IMU Malfunction in IMU Malfunction in ECU Engine cannot be started depending on the circumstanc es Engine cannot be started depending on the circumstanc es P0030 O2 sensor heater defective heater controller detected Open circuit in wire harness Disconne...

Page 484: ...ange Defective coupler between intake air pressure sensor and ECU Open or short cir cuit in wire har ness between intake air pressure sensor and ECU Defective intake air pressure sen sor Malfunction in ECU Engine idling speed is unstable Engine response is poor Loss of engine pow er Increased exhaust emissions Intake air pressure is fixed to 101 3 kPa Intake air pressure difference is fixed to 0 k...

Page 485: ... for MTN890D P0107 P0108 P0107 Intake air pressure sensor 1 ground short circuit detected P0108 Intake air pressure sensor 1 open or power short circuit detected P0107 Lowvoltage of the intake air pressure sensor 1 circuit 0 5 V or less P0108 High volt age of the intake air pressure sensor 1 circuit 4 8 V or more Defective coupler between intake air pressure sensor 1 and ECU Open or short cir cuit...

Page 486: ... MTN890D P0111 Intake air tempera ture sensor signal out of range Defective coupler between intake air temperature sen sor and ECU Open or short cir cuit in wire har ness between intake air tempera ture sensor and ECU Improperly in stalled intake air temperature sen sor Defective intake air temperature sensor Malfunction in ECU Engine is difficult to start Increased exhaust emissions Engine idling...

Page 487: ...issions Engine idling speed is unstable The intake air tem perature is fixed to 20 C O2 sensor heater driving is not carried out O2 feedback is not carried out ISC feedback is not carried out ISC learning is not carried out QSS is not carried out Cruise control sys tem cannot be oper ated for MTN890D P0115 Coolant tempera ture sensor signal stuck Defective coolant temperature sen sor Malfunction i...

Page 488: ...aturesensor ground short circuit detected P0118 Coolant temperaturesensor open or power short circuit detected P0117 Lowvoltage of the coolant tem perature sensor cir cuit 0 1 V or less P0118 High volt age of the coolant temperature sensor circuit 4 9 V or more Defective coupler between coolant temperature sen sor and ECU Open or short cir cuit in wire har ness between coolant tempera ture sensor ...

Page 489: ...ed is high Engine idling speed is unstable Engine response is poor Loss of engine pow er Deceleration is poor Increased exhaust emissions Vehicle cannot be driven Change in the throt tle opening is 0 transient control is not carried out D j is fixed Throttle opening is fixed to 125 O2 feedback is not carried out Fuel is not cut off due to the throttle opening Output is restricted ISC feedback is n...

Page 490: ... Malfunction in ECU Improperly in stalled injector Loss of engine pow er Engine is difficult to start Engine cannot be started Engine stops Engine idling speed is unstable Increased exhaust emissions O2 feedback is not carried out ISC feedback is not carried out ISC learning is not carried out QSS is not carried out Cruise control sys tem cannot be oper ated for MTN890D P0300 Misfire in multiple c...

Page 491: ...ngine response is poor Increased exhaust emissions P0335 Crankshaft position sensor no normal signals are received from the crankshaft position sensor Defective coupler between crank shaft position sen sor and ECU Open or short cir cuit in wire har ness between crankshaftposition sensor and ECU Improperly in stalled crankshaft position sensor Malfunction in generator rotor Defective crank shaft po...

Page 492: ...ried out ISC feedback is not carried out ISC learning is not carried out QSS is not carried out Cruise control sys tem cannot be oper ated for MTN890D P0480 Radiator fan motor relay open or short circuit detected Open or short cir cuit in wire har ness Disconnected cou pler Defective radiator fan motor relay Defective radiator fan motor relay controller Mal function in ECU Engine is difficult to s...

Page 493: ...le speed dis played on the meter 0 km h O2 feedback is not carried out Fuel cut off control when the rear wheel sensor or neutral switch malfunctions is carried out ISC feedback is not carried out ISC learning is not carried out Traction control does not work P0500 QSS is not carried out Cruise control sys tem cannot be oper ated for MTN890D P0560 Charging voltage is abnormal Battery over dis char...

Page 494: ...ht not appear on the tool display Malfunction in ECU Engine cannot be started Engine cannot be started Cruise control sys tem cannot be oper ated for MTN890D P0606 Internal malfunction in ECU When this malfunction is de tected in the ECU the DTC might not appear on the tool display Malfunction in ECU Engine cannot be started Engine response is poor Loss of engine pow er Engine cannot be started Ig...

Page 495: ...uck mech anism or motor Malfunction in ECU Blown electric throttle valve fuse Engine response is poor Loss of engine pow er Engine idling speed is unstable O2 feedback is not carried out YCC T evacuation is activated Output is restricted ISC feedback is not carried out ISC learning is not carried out QSS is not carried out Cruise control sys tem cannot be oper ated for MTN890D P0657 Fuel system vo...

Page 496: ...si tion sensor open or ground short circuit detected P0917 Gear posi tion sensor power short circuit detect ed P0916 Lowvoltage of the gear position sensor circuit 0 2 V or less P0917 High volt age of the gear posi tion sensor circuit 4 8 V or more Defective coupler between gear po sition sensor and ECU Open or power short circuit in wire harness between gear position sen sor and ECU Improperly in...

Page 497: ...SC learning is not carried out Cruise control sys tem cannot be oper ated for MTN890D P1600 Lean angle sensor open or short circuit detected Open or short cir cuit in wire har ness Malfunction in IMU Malfunction in ECU Engine cannot be started Engine cannot be started Cruise control sys tem cannot be oper ated for MTN890D P1601 Sidestand switch open or short circuit of the blue yellow lead of the ...

Page 498: ...r pressure sensor 2 Defective intake air pressure sen sor 2 Malfunction in ECU Engine is difficult to start Increased exhaust emissions Insufficient power at high altitudes Engine idling speed is unstable α N is fixed Intake air pressure difference is fixed to 0 kPa Atmospheric pres sure is fixed to 101 3 kPa Fuel is not cut off due to the intake air pressure difference O2 feedback is not carried ...

Page 499: ...error P2122 P2127 Low voltage of the accel erator position sen sor circuit 0 25 V or less P2123 P2128 High voltage of the accelerator position sensor circuit 4 75 V or more P2138 Difference in output voltage 1 and output voltage 2 of the accelerator position sensor Defective coupler between accelera tor position sensor and ECU Open or short cir cuit in wire har ness between accelerator posi tion s...

Page 500: ...ltage of the O2 sensor circuit 0 18 0 49 V Improperly in stalled O2 sensor Defective coupler between O2 sen sor and ECU Open or short cir cuit in wire har ness between O2 sensor and ECU Incorrect fuel pres sure Defective O2 sen sor Malfunction in ECU Increased exhaust emissions O2 feedback is not carried out O2 feedback learn ing is not carried out QSS is not carried out Cruise control sys tem can...

Page 501: ...istration malfunction 56 ECU Unidentified code is received DTC Item Symptom Check point 11 Front wheel sensor inter mittent pulses or no puls es Front wheel sensor signal is not received properly Pulses are not received or are received intermit tently while the vehicle is traveling Foreign material ad hered around the front wheel sensor Incorrect installation of the front wheel Defective sensor ro...

Page 502: ...fective rear wheel sensor or incorrect in stallation of the sensor 15 Front wheel sensor open or short circuit Open or short circuit is de tected in the front wheel sensor Defective coupler be tween the front wheel sensor and the hydraulic unit assembly Open or short circuit in the wire harness be tween the front wheel sensor and the hydraulic unit assembly Defective front wheel sensor or hydrauli...

Page 503: ...is detected in the motor power supply circuit in the hydraulic unit assembly Defective hydraulic unit assembly 41 Front wheel ABS intermit tent wheel speed pulses or incorrect depressuriza tion Pulses from the front wheel sensor are re ceived intermittently while the vehicle is trav eling Front wheel will not re cover from the locking tendency even though the signal is transmitted from the ABS ECU...

Page 504: ... rotor Defective rear wheel sensor or incorrect in stallation of the sensor 51 Vehicle system power supply voltage of ABS ECU power supply is high Power voltage supplied to the ABS ECU in the hy draulic unit assembly is too high Defective battery Disconnected battery terminal Defective charging sys tem 53 Vehicle system power supply voltage of ABS ECU power supply is low Power voltage supplied to ...

Page 505: ...fective front brake line Defective hydraulic unit assembly 89 CAN communication be tween meter assembly and hydraulic unit assem bly Transmitted data from the meter cannot be normally received Defective coupler be tween meter assembly and hydraulic unit as sembly Harness is broken or short circuit between meter assembly and hy draulic unit assembly Defective meter assem bly Defective hydraulic uni...

Page 506: ...rried out Cruise control sys tem cannot be oper ated for MTN890D Diagnostic code No Item Tool display Procedure 01 Throttle position sensor signal 1 Fully closed position 11 21 Check with throttle valves fully closed Fully open position 96 107 Check with throttle valves fully open 03 Intake air pressure Displays the intake air pressure Operate the throttle while pushing the side of the stop run st...

Page 507: ...Check with throttle valves fully open 14 Accelerator position sen sor signal 1 Fully closed position 14 18 Check with throttle grip ful ly closed position Fully open position 82 92 Check with throttle grip ful ly open position For MTN890D Turn the throttle grip past the closed position in the deceleration direction 7 12 15 Accelerator position sen sor signal 2 Fully closed position 14 18 Check wit...

Page 508: ...ssion is in neu tral ON Transmission is in gear or the clutch lever re leased OFF Clutch lever is squeezed with the transmission in gear and when the side stand is retracted ON Clutch lever is squeezed with the transmission in gear and when the side stand is extended OFF 60 EEPROM DTC display No history 00 No malfunctions detect ed If the DTC P062F is indicated the ECU is de fective History exists...

Page 509: ...itch is released OFF 81 Cruise control setting switch SET Push and release the SET side of the cruise control setting switch Switch is pushed ON Switch is released OFF 82 Cruise control cancel cir cuit Operate the clutch lever brake lever brake pedal and throttle grip Clutch lever is squeezed ON Clutch lever is released OFF Brake lever is squeezed ON Brake lever is released OFF Brake pedal is depr...

Page 510: ...ime the ignition coil is actuated Check that a spark is gen erated five times Connect an ignition checker 31 Cylinder 2 ignition coil Actuates the cylinder 2 ignition coil five times at one second intervals The check indicator on the YDT screen come on each time the ignition coil is actuated Check that a spark is gen erated five times Connect an ignition checker 32 Cylinder 3 ignition coil Actuate...

Page 511: ...each time the intake sole noid is actuated Check that the purge cut valve solenoid is actuated five times by listening for the operating sound 50 Main relay Actuates the relay unit five times at one second inter vals The check indicator on the YDT screen come on each time the relay is actu ated Check that the relay unit is actuated five times by lis tening for the operating sound 51 Radiator fan m...

Page 512: ...ature sensor Brief abnormality detected in the in takeairtemperature sensor Same as for DTC num ber P0112 and P0113 Perform the inspection items listed for DTC num ber P0112 and P0113 199 Intake air pres sure sensor 2 Brief abnormality detected in the in take air pressure sensor 2 Same as for DTC No P1606 and P1607 Perform the inspection items listed for DTC No P1606 and P1607 207 Accelerator po s...

Page 513: ...hen the sys tem is functioning properly 243 ISC Stuck at the lower limit for adjustment During idling the adjustment is main tained at the lower limit Idling engine speed is fast Poorly adjusted clutch cable Malfunction in the fuel injection system Dirty or worn spark plug Malfunction in the battery Malfunction in ECU If a DTC is occurring respond to that first Rarely Code 243 oc curs even when th...

Page 514: ...traveling up a steep slope Wheel slip detected Engine stalls Sidestand is extend ed Engine stop switch is set to the position The automatic turning off of the cruise control sys tem does not indicate a malfunction in the sys tem 251 Shift sensor Brief abnormality detected in the shift sensor Same as for DTC num ber P1806 and P1807 Perform the inspection items listed for DTC num ber P1806 and P1807...

Page 515: ... 4 1 Check the grommet for cracks 3 Defective IMU Execute the diagnostic mode Code 17 Check that 0 5 is displayed when the vehicle is vertical and that the displayed value increases as the vehicle continues to incline Is the MIL on YES Go to step 2 NO Service is completed Is check result OK YES Go to step 3 NO a Fix the IMU installation condition b Turn the main switch to ON then to OFF and then b...

Page 516: ...9 86 30_EVENT 4 Malfunction in ECU Replace the ECU and complete the service Refer to REPLACING THE ECU Engine Control Unit on page 8 56 Is the MIL on YES Go to step 4 NO Service is completed ...

Page 517: ...s displayed at the same time check the other error code first and repair it 1 Allow to idle for a long period Turn the main switch to OFF Check whether it is possible to start the engine 2 Malfunction in ECU Replace the ECU and complete the service Refer to REPLACING THE ECU Engine Control Unit on page 8 56 Can the engine starting YES Service is completed NO Go to step 2 ...

Page 518: ... Wire harness continuity Disconnect the ECU coupler 1 IMU coupler 3 and ignition fuse 1 4 Remove the joint coupler cap 2 Open circuit check Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Turn the main switch to ON and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to...

Page 519: ... L B L Br W Gy G G L Br L B Y L W W Y W G G W G W Lg B L W L Y R W L B L W B W L W W W L W B B L B L B Y B Y B L R L R L R L R B L B B L B B B B B Gy L L V P P W Lg L Y L L B B L B L Br W Gy G G L B Y L W W Y W G G W G W L W L Y 1 1 4 3 2 MTN890 MTN890D Is resistance 0 Ω YES Go to Short circuit check NO a Replace the wire harness b Turn the main switch to ON and then check the condition of the DTC...

Page 520: ...B L W B W Gy L L V P P W Lg L O W Y L L B B L B L Br W Gy G G L Br L B Y L W W Y W G G W G W Lg B L W L Y Gy L L V P P W Lg L O W Y L L B B L B L Br W Gy G G L Br L B Y L W W Y W G G W G W Lg B L W L Y B A Gy L L V P P W Lg L Y L L B B L B L Br W Gy G G L B Y L W W Y W G G W G W L W L Y Gy L L V P P W Lg L Y L L B B L B L Br W Gy G G L B Y L W W Y W G G W G W L W L Y L W W W L W B B L B L B Y B Y ...

Page 521: ...8 56 7 Delete the DTC and check that the MIL goes off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC Is check result OK YES Go to step 5 NO a Fix the IMU installation condition b Turn the main switch to ON and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service ...

Page 522: ...on of the pins TIP For this check also set the stop run start switch to ON 2 Connection of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Turn the main switch to ON and then chec...

Page 523: ...overed condition YES Go to step 6 and complete the service NO Start the engine and then check the condition of the DTC Is it in the Recovered condition YES Go to step 6 and complete the service NO Go to step 3 Between O2 sensor coupler 1 and ECU cou pler 2 pink black pink black Between O2 sensor coupler 1 and ignition fuse holder 3 red red Is resistance 0 Ω YES Go to Short circuit check NO a Repla...

Page 524: ...ice NO Go to Short circuit check Between O2 sensor coupler 1 and ground red ground pink black ground O2 sensor coupler 1 red any other coupler terminal pink black any other coupler terminal ECU coupler 2 pink black any other coupler terminal Is resistance Ω YES Go to step 4 NO a Replace the wire harness b Turn the main switch to ON and then check the condition of the DTC using the malfunction mode...

Page 525: ...the ECU and complete the service Refer to REPLACING THE ECU Engine Control Unit on page 8 56 6 Delete the DTC and check that the MIL goes off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC Is it in the Recovered condition YES Go to step 6 and complete the service NO Go to step 4 Is it in the Recovered condition YES Go to step 6 and complete the service NO S...

Page 526: ...t or broken terminals and locking condition of the pins Is check result OK YES Go to step 2 NO a Reinstall or replace the O2 sensor Refer to ENGINE REMOVAL on page 5 9 b Start the engine and let it idle for approximately 1 minute c Check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 8 and complete the service NO Go to step 2 Is the c...

Page 527: ...n the Recovered condition YES Go to step 8 and complete the service NO Go to step 4 Between O2 sensor coupler 1 and ECU cou pler 2 gray green gray green pink black pink black black blue black blue Between O2 sensor coupler 1 and ignition fuse 1 holder 3 red red 2 2 Gy L L V P P W Y L L B B L B L Br W Gy G B Y L W W Y W G G W G W L W L Y Gy L L V P P W Lg L O W Y L L B B L B L Br W Gy G G L Br L B ...

Page 528: ...inal black blue any other coupler terminal red any other coupler terminal ECU coupler 2 gray green any other coupler terminal pink black any other coupler terminal black blue any other coupler terminal Gy L L V P P W Y L L B B L B L Br W Gy G B Y L W W Y W G G W G W L W L Y Gy L L V P P W Lg L O W Y L L B B L B L Br W Gy G G L Br L B Y L W W Y W G G W G W Lg B L W L Y R P B Gy G B L R P B Gy G B L...

Page 529: ... 8 Delete the DTC and check that the MIL goes off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC Is it in the Recovered condition YES Go to step 8 and complete the service NO Go to step 5 Is check result OK YES Go to step 6 NO a Replace the fuel pump Refer to REMOVING THE FUEL PUMP on page 7 3 b Start the engine and let it idle for approximately 1 minute c ...

Page 530: ...ce the intake air pressure sensor Refer to THROTTLE BODIES on page 7 5 Turn the main switch to ON and then check the condition of the DTC using the malfunction mode of the YDT 3 Defective wire harness Replace the wire harness Turn the main switch to ON and then check the condition of the DTC using the malfunction mode of the YDT Is the coupler condition normal YES Go to step 2 NO a Connect the cou...

Page 531: ...to REPLACING THE ECU Engine Control Unit on page 8 56 5 Delete the DTC and check that the MIL goes off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC Is it in the Recovered condition YES Go to step 5 and complete the service NO Go to step 4 ...

Page 532: ...ic pressure at the current altitude and weather conditions is in dicated When engine is cranking Make sure that the indication value changes Is check result OK YES Go to step 2 NO a Repair or replace the intake air pressure sensor 1 hose Refer to THROTTLE BODIES on page 7 5 b Start the engine and let it idle for approximately 5 seconds with the throttle fully closed and then check the condition of...

Page 533: ...d then delete the DTC NO a Replace the intake air pressure sensor 1 Refer to THROTTLE BODIES on page 7 5 b Start the engine and let it idle for approximately 5 seconds with the throttle fully closed and then check the condition of the DTC using the malfunction mode of the YDT c Confirm the Recovered condition then go to step 3 ...

Page 534: ...minals and locking condition of the pins 3 Wire harness continuity Disconnect the intake air pressure sensor 1 coupler 1 and ECU coupler 3 Remove the joint coupler cap 2 Open circuit check Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Turn the main switch to ON and then check the condition of the DTC using the malfunction mode of t...

Page 535: ... joint coupler 2 P0108 black black Gy L L V P P W O W Y L L B B L B L Br W Gy G Br L B Y L W W Y W G G W G W Lg B L W L Y Gy L L V P P W Y L L B B L B L Br W Gy G B Y L W W Y W G G W G W L W L Y B P W L L B W L B L B L B B L B L B L B L B L B L B L B L R B L B B L B B B B B 3 3 2 1 MTN890 MTN890D Is resistance 0 Ω YES Go to Short circuit check NO a Replace the wire harness b Turn the main switch t...

Page 536: ...ther coupler terminal Joint coupler 2 P0108 black blue any other coupler terminal P0108 black any other coupler terminal Gy L L V P P W O W Y L L B B L B L Br W Gy G Br L B Y L W W Y W G G W G W Lg B L W L Y L W W W L W B B L B L B Y B Y B L R L R L R L R B L B B L B B B B B B P W L B P W L Gy L L V P P W Y L L B B L B L Br W Gy G B Y L W W Y W G G W G W L W L Y B A 3 2 1 1 3 MTN890 MTN890D Is res...

Page 537: ... Reinstall or replace the sensor b Turn the main switch to ON and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to step 5 At sea level Approx 101 kPa 757 6 mmHg 29 8 inHg ap prox 3 64 V 1000 m 3300 ft above sea level Approx 90 kPa 675 1 mmHg 26 6 inHg ap prox 3 30 V 2000 m 6700 ft above sea...

Page 538: ...nt temperature Heat the intake air temperature sensor using warm water or hot air and measure the intake air tem perature sensor resistance then compare the noted resistance at ambient temperature Is check result OK YES Go to step 2 NO a Clean around the intake air temperature sensor then reinstall it b Turn the main switch to ON then heat the intake air temperature sensor using warm water or hot ...

Page 539: ...he ECU and complete the service Refer to REPLACING THE ECU Engine Control Unit on page 8 56 4 Delete the DTC and check that the MIL goes off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC NO Go to step 3 ...

Page 540: ...k the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness and or sub wire harness b Execute the diagnostic mode Code 05 When engine is cold Displayed temperature is close to the ambient temperature Is check ...

Page 541: ...xecute the diagnostic mode Code 05 When engine is cold Displayed temperature is close to the ambient temperature Is check result OK YES Go to step 7 and complete the service NO Go to step 4 Intake air temperature sensor resistance 6 0 0 6 kΩ at 0 C 6 0 0 6 kΩ at 32 F 0 29 0 39 kΩ at 80 C 0 29 0 39 kΩ at 176 F Is check result OK YES Go to step 5 NO a Replace the intake air temperature sensor Refer ...

Page 542: ...eplace the ECU and complete the service Refer to REPLACING THE ECU Engine Control Unit on page 8 56 7 Delete the DTC and check that the MIL goes off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC ...

Page 543: ...eck the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Turn the main switch to ON and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go ...

Page 544: ...k blue black blue Between intake air temperature sensor coupler 1 and joint coupler 2 P0113 black black Gy L L V P P W O W Y L L B B L B L Br W Gy G Br L B Y L W W Y W G G W G W Lg B L W L Y B Br W Gy L L V P P W Y L L B B L B L Br W Gy G B Y L W W Y W G G W G W L W L Y L W W W L W B B L B L B Y B Y B L R L R L R L R B L B B L B B B B B 3 3 2 1 MTN890 MTN890D Is resistance 0 Ω YES Go to Short circ...

Page 545: ...113 brown white any other coupler terminal P0113 black blue any other coupler terminal Gy L L V P P W O W Y L L B B L B L Br W Gy G Br L B Y L W W Y W G G W G W Lg B L W L Y B Br W B Br W Gy L L V P P W Y L L B B L B L Br W Gy G B Y L W W Y W G G W G W L W L Y B A L W W W L W B B L B L B Y B Y B L R L R L R L R B L B B L B B B B B 3 1 1 3 2 MTN890 MTN890D Is resistance Ω YES Go to step 5 NO a Repl...

Page 546: ... ECU Engine Control Unit on page 8 56 7 Delete the DTC and check that the MIL goes off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC Is check result OK YES Go to step 5 NO a Reinstall the sensor b Turn the main switch to ON and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and co...

Page 547: ...e coolant temperature sensor resistance at engine warmed up then compare the noted resistance at ambient temperature 2 Malfunction in ECU Replace the ECU and complete the service Refer to REPLACING THE ECU Engine Control Unit on page 8 56 3 Delete the DTC and check that the MIL goes off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC Is the resistance change...

Page 548: ...pler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Execute the diagnostic mode Code 06 When engine is cold Displayed temperature is close to the ambient temperature Is check result OK YES G...

Page 549: ...YES Go to step 4 NO a Reinstall the sensor b Execute the diagnostic mode Code 06 When engine is cold Displayed temperature is close to the ambient temperature Is check result OK YES Go to step 7 and complete the service NO Go to step 4 Coolant temperature sensor resistance 2 645 kΩ 5 at 20 C 2 645 kΩ 5 at 68 F 0 216 kΩ 2 5 at 100 C 0 216 kΩ 2 5 at 212 F Is check result OK YES Go to step 5 NO a Rep...

Page 550: ... Refer to REPLACING THE ECU Engine Control Unit on page 8 56 7 Delete the DTC and check that the MIL goes off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC Is check result OK YES Go to step 7 and complete the service NO Go to step 6 ...

Page 551: ...he locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Turn the main switch to ON and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to st...

Page 552: ...ler 2 P0118 black black Between joint coupler 2 and ECU coupler 3 P0118 black blue black blue Gy L L V P P W O W Y L L B B L B L Br W Gy G Br L B Y L W W Y W G G W G W Lg B L W L Y L W W W L W B B L B L B Y B Y B L R L R L R L R B L B B L B B B B B B G W Gy L L V P P W Y L L B B L B L Br W Gy G B Y L W W Y W G G W G W L W L Y 3 3 2 1 MTN890 MTN890D Is resistance 0 Ω YES Go to step Short circuit ch...

Page 553: ...18 black any other coupler terminal ECU coupler 3 P0117 P0118 green white any other coupler terminal P0118 black blue any other coupler terminal Gy L L V P P W O W Y L L B B L B L Br W Gy G Br L B Y L W W Y W G G W G W Lg B L W L Y B G W B G W Gy L L V P P W Y L L B B L B L Br W Gy G B Y L W W Y W G G W G W L W L Y B A L W W W L W B B L B L B Y B Y B L R L R L R L R B L B B L B B B B B 3 1 1 3 2 M...

Page 554: ...k that the MIL goes off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC Is check result OK YES Go to step 5 NO a Reinstall the sensor b Turn the main switch to ON and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to step 5 Is check result OK YES Go to...

Page 555: ...oupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins 2 Connection of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Is the coupler condition normal YES Go to step 2 NO a Connect the coupler sec...

Page 556: ... and ECU coupler 2 P0122 P0123 P0222 P0223 P2135 white white P0123 P0223 black blue black blue P0122 P0222 blue blue P0122 P0123 P0222 P0223 P2135 black black Is resistance 0 Ω YES Go to Short circuit check NO a Replace the wire harness b Turn the main switch to ON and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 8 and co...

Page 557: ...upler terminal P0123 P0223 black blue any other coupler terminal P0122 P0222 blue any other coupler terminal P0122 P0123 P0222 P0223 P2135 black any other coupler terminal ECU coupler 2 P0122 P0123 P0222 P0223 P2135 white any other coupler terminal P0123 P0223 black blue any other coupler terminal P0122 P0222 blue any other coupler terminal P0122 P0123 P0222 P0223 P2135 black any other coupler ter...

Page 558: ...stall or adjust the sensor b Turn the main switch to ON and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 8 and complete the service NO Go to step 5 When the throttle valves are fully closed 11 21 When throttle valves are fully open 96 107 Is check result OK YES Go to step 6 NO a Replace the throttle position sensor Refer ...

Page 559: ...that the DTC has a condition of Recovered using the YDT and then delete the DTC Is check result OK YES Go to step 7 NO a Replace the throttle position sensor Refer to ADJUSTING THE THROTTLE POSITION SENSOR on page 7 11 b Turn the main switch to ON and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 8 and complete the service...

Page 560: ...g condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Is check result OK YES Go to step 2 NO a Reinstall or replace the sensor b Turn the main switch to ON and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to step 2 I...

Page 561: ...etween O2 sensor coupler 1 and ECU cou pler 3 gray green gray green Between O2 sensor coupler 1 and joint coupler 2 black blue black blue Between joint coupler 2 and ECU coupler 3 black blue black blue Gy L L V P P W O W Y L L B B L B L Br W Gy G Br L B Y L W W Y W G G W G W Lg B L W L Y R P B Gy G B L Gy L L V P P W Y L L B B L B L Br W Gy G B Y L W W Y W G G W G W L W L Y L W W W L W B B L B L B...

Page 562: ... coupler terminal Joint coupler 2 black blue any other coupler terminal ECU coupler 3 gray green any other coupler terminal black blue any other coupler terminal Gy L L V P P W Lg L Y L L B B L B L Br W Gy G G L B Y L W W Y W G G W G W L W L Y R P B Gy G B L R P B Gy G B L Gy L L V P P W Lg L O W Y L L B B L B L Br W Gy G G L Br L B Y L W W Y W G G W G W Lg B L W L Y B A L W W W L W B B L B L B Y ...

Page 563: ...U Replace the ECU and complete the service Refer to REPLACING THE ECU Engine Control Unit on page 8 56 7 Delete the DTC and check that the MIL goes off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to step 5 Is it in the Recovered condition YES Go to step 7 and complete the se...

Page 564: ...next two driving cycles the MIL comes on and the DTC and FFD are stored If the vehicle is judged to be operating normally for three consecutive driving cycles the MIL goes off However the DTC pending DTC and FFD will not be deleted even if a battery terminal is dis connected Reproduction test Perform the test using the driving pattern according to the detection method WARNING EWA20860 When test ri...

Page 565: ...t the YDT Check that the pending DTC is not detected and readiness status is Complete Then complete the troubleshooting 60 40 A B C D E F G A Speed km h B Time min C Start the engine D Idle warm up E 5 min F Total 15 min G Stop the engine Is pending DTC displayed Yes Delete the pending DTC then go to step 4 No Check the readiness status Readiness status is Complete Check the coupler between the EC...

Page 566: ...Check for looseness or pinching Is check result OK YES Go to step 2 NO a Check the ignition spark gap Refer to CHECKING THE IGNITION SPARK GAP on page 8 59 b Test ride the vehicle according to the test ride conditions for the O2 deterioration diagnosis Refer to step 2 in TROUBLESHOOTING on page 9 135 At this time do not check the malfunction diagnosis status readiness c Check the condition of the ...

Page 567: ...Delete the DTC and check that the MIL goes off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC Is it in the Recovered condition YES Go to step 6 and complete the service NO Go to step 3 Is check result OK YES Go to step 4 NO a Replace the fuel pump Refer to REMOVING THE FUEL PUMP on page 7 3 b Test ride the vehicle according to the test ride conditions for t...

Page 568: ...sure the injector resistance Refer to CHECKING THE FUEL INJECTORS on page 8 64 3 Connection of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Execute the diagnostic mode Code 36 ...

Page 569: ...t hear operating sound YES Go to step 6 NO Go to step 4 Between injector 1 coupler 1 and ECU cou pler 2 red black red black Between injector 1 coupler 1 and relay unit coupler 3 red blue red Is resistance 0 Ω YES Go to Short circuit check NO a Replace the wire harness b Execute the diagnostic mode Code 36 Is it hear operating sound YES Go to step 6 NO Go to Short circuit check R B R L W L W R L B ...

Page 570: ...of Recovered using the malfunction mode of the YDT and then delete the DTC Between injector 1 coupler 1 and ground red black ground red blue ground Injector 1 coupler 1 red black any other coupler terminal red blue any other coupler terminal ECU coupler 2 red black any other coupler terminal Relay unit coupler 3 red any other coupler terminal Is resistance Ω YES Go to step 5 NO a Replace the wire ...

Page 571: ...sure the injector resistance Refer to CHECKING THE FUEL INJECTORS on page 8 64 3 Connection of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Execute the diagnostic mode Code 37 ...

Page 572: ...hear operating sound YES Go to step 6 NO Go to step 4 Between injector 2 coupler 1 and ECU cou pler 2 green black green black Between injector 2 coupler 1 and relay unit coupler 3 red blue red Is resistance 0 Ω YES Go to Short circuit check NO a Replace the wire harness b Execute the diagnostic mode Code 37 Is it hear operating sound YES Go to step 6 NO Go to Short circuit check G B R L W L W R L ...

Page 573: ...Recovered using the malfunction mode of the YDT and then delete the DTC Between injector 2 coupler 1 and ground green black ground red blue ground Injector 2 coupler 1 green black any other coupler terminal red blue any other coupler terminal ECU coupler 2 green black any other coupler terminal Relay unit coupler 3 red any other coupler terminal Is resistance Ω YES Go to step 5 NO a Replace the wi...

Page 574: ...sure the injector resistance Refer to CHECKING THE FUEL INJECTORS on page 8 64 3 Connection of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Execute the diagnostic mode Code 38 ...

Page 575: ... hear operating sound YES Go to step 6 NO Go to step 4 Between injector 3 coupler 1 and ECU cou pler 2 blue black blue black Between injector 3 coupler 1 and relay unit coupler 3 red blue red Is resistance 0 Ω YES Go to Short circuit check NO a Replace the wire harness b Execute the diagnostic mode Code 38 Is it hear operating sound YES Go to step 6 NO Go to Short circuit check L B R L W L W R L B...

Page 576: ... Recovered using the malfunction mode of the YDT and then delete the DTC Between injector 3 coupler 1 and ground blue black ground red blue ground Injector 3 coupler 1 blue black any other coupler terminal red blue any other coupler terminal ECU coupler 2 blue black any other coupler terminal Relay unit coupler 3 red any other coupler terminal Is resistance Ω YES Go to step 5 NO a Replace the wire...

Page 577: ...s on Requirement for detection Related sensors for detection Intake air pressure sensor coolant temperature sensor or engine temperature sensor front wheel sensor rear wheel sensor crankshaft position sensor and throttle position sensor Frequency of detection Always Time required for detection Always Malfunction determination method Catalyst damage When an abnormality is detected three times in on...

Page 578: ...gine Able Unable to drive vehicle EAS32820 TROUBLESHOOTING TIP If more than one DTC is detected at the same time perform troubleshooting of DTCs listed below first DTC except P0300 P0301 P0302 P0303 If more than one misfire DTC has been detected at the same time open each FFD and check the total ECU energization time at the time of failure or event and refer to the latest FFD How to identify the m...

Page 579: ...ngine Conversion table of steady driving time Engine speed r min Time sec 2000 240 3000 160 4000 120 5000 96 6000 80 7000 70 8000 60 9000 54 10000 48 Is the pending DTC displayed Yes Delete the pending DTC then go to step 4 No Confirm the engine speed vehicle speed and gear position to the customer when the customer feels an abnormality Go to step 2 If the pending DTC is not displayed after severa...

Page 580: ...ant temperature sensor or Engine temperature sensor Speed sensor Crankshaft position sensor Throttle position sensor Gear position sensor 6 Perform a reproduction test and connect the YDT Check that the pending DTC is not detected then complete the troubleshooting Is the inspection result OK Yes Go to step 5 No Repair or replace the defective part then go to step 6 ...

Page 581: ...d locking condition of the pins 3 Wire harness continuity Disconnect the crankshaft position sensor coupler 1 and ECU coupler 3 Remove the joint coupler cap 2 Open circuit check Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Crank the engine and then check the condition of the DTC using the malfunction mode of the YDT Is it in the R...

Page 582: ...B Y L W W Y W G G W G W Lg B L W L Y L B W L B L B L B B L B L B L B L B L B L B L B L R B L B B L B B B B B 1 2 MTN890 MTN890D Is resistance 0 Ω YES Go to Short circuit check NO a Replace the wire harness b Crank the engine and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to Short circuit...

Page 583: ... L B Y B Y B L R L R L R L R B L B B L B B B B B A B 1 1 3 3 2 MTN890 MTN890D Is resistance Ω YES Go to step 4 NO a Replace the wire harness b Crank the engine and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to step 4 Is check result OK YES Go to step 5 NO a Reinstall or replace the senso...

Page 584: ...U Engine Control Unit on page 8 56 7 Delete the DTC and check that the MIL goes off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC Is check result OK YES Go to step 6 NO a Replace the crankshaft position sensor b Crank the engine and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 a...

Page 585: ...on of the pins 3 Wire harness continuity Disconnect the cylinder 1 ignition coil coupler 1 and ECU coupler 2 Open circuit check Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Start the engine and let it idle for approximately 5 seconds c Check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered cond...

Page 586: ...heck the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to Short circuit check Between cylinder 1 ignition coil coupler 1 and ground orange ground Cylinder 1 ignition coil coupler 1 orange any other coupler terminal ECU coupler 2 orange any other coupler terminal O R W O Gy R O G P B Y R B R B G B L B Lg R...

Page 587: ...o step 7 and complete the service NO Go to step 4 Is check result OK YES Go to step 5 NO a Reinstall or replace the ignition coil b Start the engine and let it idle for approximately 5 seconds c Check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to step 5 Is check result OK YES Go to step 6 NO a Repl...

Page 588: ...irm that spark plug does not sparking Replace the ECU and complete the service Refer to REPLACING THE ECU Engine Control Unit on page 8 56 7 Delete the DTC and check that the MIL goes off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC ...

Page 589: ... of the pins 3 Wire harness continuity Disconnect the cylinder 2 ignition coil coupler 1 and ECU coupler 2 Open circuit check Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Start the engine and let it idle for approximately 5 seconds c Check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condit...

Page 590: ...e condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to Short circuit check Between cylinder 2 ignition coil coupler 1 and ground gray red ground Cylinder 2 ignition coil coupler 1 gray red any other coupler terminal ECU coupler 2 gray red any other coupler terminal Gy R R W O Gy R O G P B Y R B R B G B L B Lg...

Page 591: ...o step 7 and complete the service NO Go to step 4 Is check result OK YES Go to step 5 NO a Reinstall or replace the ignition coil b Start the engine and let it idle for approximately 5 seconds c Check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to step 5 Is check result OK YES Go to step 6 NO a Repl...

Page 592: ...irm that spark plug does not sparking Replace the ECU and complete the service Refer to REPLACING THE ECU Engine Control Unit on page 8 56 7 Delete the DTC and check that the MIL goes off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC ...

Page 593: ...the pins 3 Wire harness continuity Disconnect the cylinder 3 ignition coil coupler 1 and ECU coupler 2 Open circuit check Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Start the engine and let it idle for approximately 5 seconds c Check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition ...

Page 594: ...dition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to Short circuit check Between cylinder 3 ignition coil coupler 1 and ground orange green ground Cylinder 3 ignition coil coupler 1 orange green any other coupler terminal ECU coupler 2 orange green any other coupler terminal O G R W O Gy R O G P B Y R B R B G B ...

Page 595: ...o step 7 and complete the service NO Go to step 4 Is check result OK YES Go to step 5 NO a Reinstall or replace the ignition coil b Start the engine and let it idle for approximately 5 seconds c Check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to step 5 Is check result OK YES Go to step 6 NO a Repl...

Page 596: ...irm that spark plug does not sparking Replace the ECU and complete the service Refer to REPLACING THE ECU Engine Control Unit on page 8 56 7 Delete the DTC and check that the MIL goes off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC ...

Page 597: ...continuity Disconnect the ignition fuse 1 1 purge cut valve solenoid coupler 2 ECM coupler 3 and main switch coupler 4 Open circuit check Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Turn the main switch to ON and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to s...

Page 598: ...O a Replace the wire harness b Turn the main switch to ON and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to Short circuit check Between purge cut valve solenoid coupler 2 and ground red white ground yellow red ground Between main switch coupler 4 and ground brown blue ground Purge cut va...

Page 599: ...lfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to step 4 Is check result OK YES Go to step 5 NO a Replace the purge cut valve solenoid Refer to FUEL TANK on page 7 1 b Turn the main switch to ON and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the ...

Page 600: ... the malfunction mode of the YDT and then delete the DTC Is it hear operationg sound YES Go to step 7 and complete the service NO Check the purge cut valve solenoid Refer to CHECKING THE PURGE CUT VALVE SOLENOID on page 8 65 Is check result OK YES Go to step 6 NO a Replace the purge cut valve solenoid b Turn the main switch to ON and then check the condition of the DTC using the malfunc tion mode ...

Page 601: ...pins 3 Wire harness continuity Disconnect the radiator fan motor relay 1 ECU coupler 2 and ignition fuse 1 3 Open circuit check Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Turn the main switch to ON and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 6 and ...

Page 602: ...rt circuit check NO a Replace the wire harness b Turn the main switch to ON and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 6 and complete the service NO Go to Short circuit check Between radiator fan motor relay 1 and ground green yellow ground red ground Radiator fan motor relay 1 green yellow any other coupler termina...

Page 603: ...es off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC Is resistance Ω YES Go to step 4 NO a Replace the wire harness b Turn the main switch to ON and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 6 and complete the service NO Go to step 4 Is it in the Recovered condition YES Go to s...

Page 604: ...1 Locate the malfunction DTCs P0500 or P0500 and P1500 detected a Execute the diagnostic mode Code 07 b Rotate the rear wheel by hand and check that the indicated value increases TIP Perform the procedure from step 2 to step 7 and step 21 DTC P1500 detected a Execute the diagnostic mode Code 21 TIP Perform the procedure from step 8 to step 14 and step 21 b Execute the diagnostic mode Code 21 Is th...

Page 605: ... the coupler and check the pins bent or broken terminals and locking condition of the pins Is check result OK YES Go to step 21 NO Go to step 15 Is the coupler condition normal YES Go to step 3 NO a Connect the coupler securely or replace the wire harness b Execute the diagnostic mode Code 07 c Rotate the rear wheel by hand and check that the indicated value increases Is that value increased YES G...

Page 606: ... sensor coupler 1 and ABS ECU coupler 2 black black white white Between ABS ECU coupler 2 and ECU cou pler 3 white yellow white yellow 3 3 Gy L L V P P W Y L L B B L B L Br W Gy G B Y L W W Y W G G W G W L W L Y Gy L L V P P W Lg L O W Y L L B B L B L Br W Gy G G L Br L B Y L W W Y W G G W G W Lg B L W L Y R L W B B W W G G Y L R B Br L W G OW Y L B W Y L B W B 2 1 MTN890 MTN890D Is resistance 0 Ω...

Page 607: ... terminal white any other coupler terminal white yellow any other coupler terminal ECU coupler 3 white yellow any other coupler terminal R L W B B W W G G Y L R B Br L W G OW Y L B W Y L B R L W B B W W G G Y L R B Br L W G OW Y L B W Y L B W B Gy L L V P P W Y L L B B L B L Br W Gy G B Y L W W Y W G G W G W L W L Y Gy L L V P P W Lg L O W Y L L B B L B L Br W Gy G G L Br L B Y L W W Y W G G W G W...

Page 608: ...ocking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Is that value increased YES Go to step 21 NO Go to step 6 Is that value increased YES Go to step 21 NO Go to step 7 Is the coupler condition normal YES Go to step 9 NO a Connect the coupler securely or replace the wire harness b Execute the diagnostic mode Code 21 Wh...

Page 609: ...ween joint coupler 4 and ECU coupler 2 black yellow black yellow Between relay unit coupler 1 and neutral switch coupler 3 sky blue sky blue Gy L L V P P W Lg L O W Y L L B B L B L Br W Gy G G L Br L B Y L W W Y W G G W G W Lg B L W L Y Gy L L V P P W Lg L Y L L B B L B L Br W Gy G G L B Y L W W Y W G G W G W L W L Y 2 2 1 3 4 B Y B B Y W L W R L B L B Sb W Sb W Br L W R R MTN890 MTN890D Is resist...

Page 610: ... terminal sky blue any other coupler terminal ECU coupler 2 black yellow any other coupler terminal Gy L L V P P W Lg L O W Y L L B B L B L Br W Gy G G L Br L B Y L W W Y W G G W G W Lg B L W L Y Gy L L V P P W Lg L Y L L B B L B L Br W Gy G G L B Y L W W Y W G G W G W L W L Y 2 2 1 W L W R L B L B Sb W Sb W Br L W R R 1 W L W R L B L B Sb W Sb W Br L W R R B A MTN890 MTN890D Is resistance Ω YES G...

Page 611: ... step 11 Is check result OK YES Go to step 12 NO a Replace the relay unit b Execute the diagnostic mode Code 21 When the transmission is in neutral ON When the transmission is in gear with the clutch lever released OFF Is it correct indication YES Go to step 21 NO Go to step 12 Is check result OK YES Go to step 13 NO a Replace the neutral switch Refer to CRANKCASE on page 5 63 b Execute the diagno...

Page 612: ...p 21 Refer to TRANSMISSION on page 5 86 When the clutch lever is released with the transmission in gear and when the sidestand is retracted OFF When the clutch lever is squeezed with the transmission in gear and when the sidestand is retracted ON Is it correct indication YES Go to step 21 NO Go to step 16 Is the coupler condition normal YES Go to step 17 NO a Connect the coupler securely or replac...

Page 613: ... the wire harness b Execute the diagnostic mode Code 21 When the clutch lever is released with the transmission in gear and when the sidestand is retracted OFF When the clutch lever is squeezed with the transmission in gear and when the sidestand is retracted ON Is it correct indication YES Go to step 21 NO Go to step 18 Between ECU coupler 2 and joint coupler 4 black yellow black yellow Between r...

Page 614: ...B L W L Y B Y L Y Y B B Y Y W L Y 2 2 1 4 5 3 3 B Y B B Y W L W R L B L B Sb W Sb W Br L W R R L Y L L Y MTN890 MTN890D Is resistance 0 Ω YES Go to Short circuit check NO a Replace the wire harness b Execute the diagnostic mode Code 21 When the clutch lever is released with the transmission in gear and when the sidestand is retracted OFF When the clutch lever is squeezed with the transmission in g...

Page 615: ... G L B Y L W W Y W G G W G W L W L Y Gy L L V P P W Lg L O W Y L L B B L B L Br W Gy G G L Br L B Y L W W Y W G G W G W Lg B L W L Y 2 2 1 3 W L W R L B L B Sb W Sb W Br L W R R 1 W L W R L B L B Sb W Sb W Br L W R R B A Y B B Y Y W L Y 3 B Y L Y MTN890 MTN890D Is resistance Ω YES Go to step 19 NO a Replace the wire harness b Execute the diagnostic mode Code 21 When the clutch lever is released wi...

Page 616: ...ng the vehicle at 20 to 30 km h 12 to 19 mph Confirm that the DTC has a condition of Recovered using the malfunction mode of the YDT and then delete the DTC Delete this DTC even if it has a condition of Detected Is check result OK YES Go to step 20 NO a Replace the clutch switch Refer to HANDLEBAR on page 4 57 b Execute the diagnostic mode Code 21 When the clutch lever is released with the transmi...

Page 617: ...efer to CHARGING SYSTEM on page 8 17 2 Delete the DTC and check that the MIL goes off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC Is check result OK YES Repeat step 1 NO a Defective rectifier regulator or AC magneto Replace b Defective connection in the charging system circuit Properly connect or replace the wire har ness c Start the engine and let it id...

Page 618: ... step 3 to step 5 and from step 9 to step 10 b Execute the diagnostic mode Code 81 c Confirm that it is defective d Go to step 6 Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Turn the main switch to ON and then push the RES side and SET side of the cruise con trol setting switch c Check the condition of the DTC using the malfunctio...

Page 619: ...se control setting switch and then check the condi tion of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 10 and complete the service NO Go to step 4 Between ignition fuse 1 holder 4 and cruise control fuse holder 1 red white red Between cruise control fuse holder 1 and han dlebar switch coupler left 2 yellow white yellow white Between handlebar switc...

Page 620: ...e NO Go to Short circuit check Between handlebar switch coupler left 2 and ground brown blue ground yellow white ground Handlebar switch coupler left 2 brown blue any other coupler terminal yellow white any other coupler terminal ECU coupler 3 brown blue any other coupler terminal Is resistance Ω YES Go to step 5 NO a Replace the wire harness b Turn the main switch to ON c Push and release the RES...

Page 621: ...overed condition YES Go to step 10 and complete the service NO Go to step 9 Is check result OK YES Go to step 7 NO a Replace the fuse b Turn the main switch to ON c Push and release the SET side of the cruise control setting switch and then check the condi tion of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 10 and complete the service NO Go to step...

Page 622: ...d condition YES Go to step 10 and complete the service NO Go to Short circuit check Between handlebar switch coupler left 2 and ground green blue ground yellow white ground Between main switch coupler 6 and ground red ground brown blue ground Handlebar switch coupler left 2 green blue any other coupler terminal yellow white any other coupler terminal ECU coupler 3 green blue any other coupler term...

Page 623: ...covered using the YDT and then delete the DTC Is resistance Ω YES Go to step 8 NO a Replace the wire harness b Turn the main switch to ON c Push and SET side of the cruise control setting switch and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 10 and complete the service NO Go to step 8 Is it in the Recovered condition YE...

Page 624: ...o step 11 2 Connection of ECU coupler front brake light switch coupler brake light relay coupler and main switch 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 When the front brake is applied ON When the front brake is not applied OFF Is check result OK YES Go to step b NO Go to step 2 When the...

Page 625: ...unction mode of the YDT Is it in the Recovered condition YES Go to step 11 and complete the service NO Go to step 4 Between brake light fuse holder 1 and front brake light switch coupler 2 green white green white Between front brake light switch coupler 2 and rear brake light switch coupler 3 green yellow green yellow Between rear brake light switch coupler 3 and brake light relay coupler 4 light ...

Page 626: ... Between brake light relay coupler 4 and ground light green black ground Between front brake light switch coupler 2 and ground green white ground green yellow ground Brake light relay coupler 4 light green black any other coupler terminal Front brake light switch coupler 2 green white any other coupler terminal green yellow any other coupler terminal Rear brake light switch coupler 3 green yellow ...

Page 627: ... resistance Ω YES Go to step 5 NO a Replace the wire harness b Turn the main switch to ON c Operate the front brake lever and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 11 and complete the service NO Go to step 5 Is it in the Recovered condition YES Go to step 11 and complete the service NO Go to step 10 Is the coupler ...

Page 628: ... condition YES Go to step 11 and complete the service NO Go to step 8 Between brake light fuse holder 1 and front brake light switch coupler 2 green white green white Between front brake light switch coupler 2 and rear brake light switch coupler 3 green yellow green yellow Between rear brake light switch coupler 3 and brake light relay coupler 4 light green black light green black Between brake li...

Page 629: ...Between brake light relay coupler 4 and ground light green black ground Between front brake light switch coupler 2 and ground green white ground green yellow ground Brake light relay coupler 4 light green black any other coupler terminal Front brake light switch coupler 2 green white any other coupler terminal green yellow any other coupler terminal Rear brake light switch coupler 3 green yellow a...

Page 630: ...the DTC Is resistance Ω YES Go to step 9 NO a Replace the wire harness b Turn the main switch to ON c Operate the rear brake pedal and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 11 and complete the service NO Go to step 9 Is check result OK YES Go to step 10 NO a Turn the main switch to ON b Operate the rear brake pedal...

Page 631: ...ion is detected in the ECU the DTC might not appear on the tool display Fail safe system Unable to start engine Unable to drive vehicle Procedure 1 Malfunction in ECU Replace the ECU Refer to REPLACING THE ECU Engine Control Unit on page 8 56 Turn the main switch to ON Check that the MIL does not come on ...

Page 632: ...are detected at the same time correct the P0122 P0123 P0222 P0223 and P2135 first Turn the main switch to ON and then check the condition of the DTC using the malfunction mode of the YDT 2 Malfunction in ECU Replace the ECU Refer to REPLACING THE ECU Engine Control Unit on page 8 56 Turn the main switch to ON Check that the MIL does not come on 3 Delete the DTC and check that the MIL goes off Conf...

Page 633: ...s made turn the main switch to OFF Turn the main switch to ON and then check the condition of the DTC using the malfunction mode of the YDT 3 02 is indicated in diagnostic mode code D60 EEPROM data error for adjustment of CO concen tration of cylinder 2 Change the CO concentration of cylinder 2 and rewrite in EEPROM Refer to ADJUSTING THE EXHAUST GAS VOLUME on page 3 11 After this adjustment is ma...

Page 634: ...ng learning memory values Turn the main switch to OFF Turn the main switch to ON and then check the condition of the DTC using the malfunction mode of the YDT 6 Malfunction in ECU Replace the ECU and complete the service Refer to REPLACING THE ECU Engine Control Unit on page 8 56 7 Delete the DTC and check that the MIL goes off Confirm that the DTC has a condition of Recovered using the YDT and th...

Page 635: ...ins bent or broken terminals and locking condition of the pins Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Turn the main switch to ON and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to step 2 Is the coupler condition nor...

Page 636: ...tion YES Go to step 7 and complete the service NO Go to step 4 Between throttle servo motor coupler 1 and ECU coupler 2 yellow red yellow red light green red light green red Between ECU coupler 2 and electronic throttle valve fuse holder 3 red blue red blue Is resistance 0 Ω YES Go to Short circuit check NO a Replace the wire harness b Turn the main switch to ON and then check the condition of the...

Page 637: ...er coupler terminal light green red any other coupler terminal ECU coupler 2 yellow red any other coupler terminal light green red any other coupler terminal red blue any other coupler terminal Is resistance Ω YES Go to step 5 NO a Replace the wire harness b Turn the main switch to ON and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES...

Page 638: ...at the DTC has a condition of Recovered using the YDT and then delete the DTC Is check result OK YES Go to step 6 NO a Replace the throttle bodies Refer to REPLACING THE THROTTLE BODIES on page 7 9 b Turn the main switch to ON and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to step 6 ...

Page 639: ...ect the coupler and check the pins bent or broken terminals and locking condition of the pins Refer to HANDLEBAR on page 4 57 Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Start the engine and let it idle for approximately 5 seconds c Check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condit...

Page 640: ...ine and let it idle for approximately 5 seconds c Check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 8 and complete the service NO Go to step 4 Between fuel injection system fuse holder 1 and relay unit coupler 2 brown brown Between ignition fuse 1 holder 3 and handle bar switch right coupler 4 red red white Between handlebar switch...

Page 641: ...k Between relay unit coupler 2 and ground brown ground blue white ground red ground Between handlebar switch right coupler 4 and ground red white ground red white ground Relay unit coupler 2 brown any other coupler terminal blue white any other coupler terminal red any other coupler terminal Handlebar switch right coupler 4 red white any other coupler terminal red white any other coupler terminal ...

Page 642: ...Check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 8 and complete the service NO Go to step 5 Is check result OK YES Go to step 6 NO a Replace the relay unit b Start the engine and let it idle for approximately 5 seconds c Check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to...

Page 643: ...fective gear position sensor Disconnect the ECU coupler 1 Measure the gear position sensor resistance Shift the transmission to each position Is check result OK YES Go to step 2 NO a Reinstall the sensor Refer to CRANKCASE on page 5 63 b Make sure that the position of each gear is correctly displayed on the meter Is check result OK YES Go to step 4 and complete the service NO Go to step 2 ECU coup...

Page 644: ...e MIL goes off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC Is the resistance change YES Go to step 3 NO a Replace the gear position sensor Refer to CRANKCASE on page 5 63 b Make sure that the position of each gear is correctly displayed on the meter Is check result OK YES Go to step 4 and complete the service NO Go to step 3 ...

Page 645: ...locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Is check result OK YES Go to step 2 NO a Reinstall the sensor Refer to CRANKCASE on page 5 63 b Make sure that the position of each gear is correctly displayed on the meter Is check result OK YES Go to step 7 and complete the service NO Go to step 2 Is the coupler c...

Page 646: ...ter 6 Malfunction in ECU Replace the ECU and complete the service Refer to REPLACING THE ECU Engine Control Unit on page 8 56 7 Delete the DTC and check that the MIL goes off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC Is the coupler condition normal YES Go to step 4 NO a Connect the coupler securely or replace the wire harness b Make sure that the posit...

Page 647: ...ken terminals and locking condition of the pins 3 Wire harness continuity Disconnect the gear position sensor coupler 1 and ECU coupler 2 Open circuit check Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Turn the main switch to ON and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered co...

Page 648: ... B L W L Y L G W B L 1 2 2 MTN890 MTN890D Is resistance 0 Ω YES Go to Short circuit check NO a Replace the wire harness b Turn the main switch to ON and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to Short circuit check Between gear position sensor coupler 1 and ground green white ground ...

Page 649: ... step 4 NO a Replace the wire harness b Turn the main switch to ON and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to step 4 Is check result OK YES Go to step 5 NO a Reinstall or replace the sensor Refer to CRANKCASE on page 5 63 b Turn the main switch to ON and then check the condition o...

Page 650: ... 8 56 7 Delete the DTC and check that the MIL goes off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC Is check result OK YES Go to step 6 NO a Replace the gear position sensor Refer to CRANKCASE on page 5 63 b Turn the main switch to ON and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to s...

Page 651: ...nsor 2 Execute the diagnostic mode Code 04 When engine is stopped Atmospheric pressure at the current altitude and weather conditions is in dicated At sea level Approx 101 kPa 757 6 mmHg 29 8 inHg ap prox 3 64 V 1000 m 3300 ft above sea level Approx 90 kPa 675 1 mmHg 26 6 inHg ap prox 3 30 V 2000 m 6700 ft above sea level Approx 80 kPa 600 0 mmHg 23 6 inHg ap prox 3 00 V 3000 m 9800 ft above sea l...

Page 652: ... ft above sea level Approx 90 kPa 675 1 mmHg 26 6 inHg ap prox 3 30 V 2000 m 6700 ft above sea level Approx 80 kPa 600 0 mmHg 23 6 inHg ap prox 3 00 V 3000 m 9800 ft above sea level Approx 70 kPa 525 0 mmHg 20 7 inHg ap prox 2 70 V Is check result OK YES Go to step 3 NO a Replace the intake air pressure sensor 2 Refer to THROTTLE BODIES on page 7 5 b Turn the main switch to ON and then check the c...

Page 653: ...he coupler and check the pins bent or broken terminals and locking condition of the pins Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Turn the main switch to ON then to OFF and back to ON c Check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the servic...

Page 654: ...und black white ground Between ignition fuse 2 holder 4 and IMU cou pler 3 red white red white Gy L L V P P W Lg L O W Y L L B B L B L Br W Gy G G L Br L B Y L W W Y W G G W G W Lg B L W L Y R W L B L W B W L W W W L W B B L B L B Y B Y B L R L R L R L R B L B B L B B B B B Gy L L V P P W Lg L Y L L B B L B L Br W Gy G G L B Y L W W Y W G G W G W L W L Y 1 1 4 3 2 MTN890 MTN890D Is resistance 0 Ω ...

Page 655: ... W L B L W B W Gy L L V P P W Lg L O W Y L L B B L B L Br W Gy G G L Br L B Y L W W Y W G G W G W Lg B L W L Y Gy L L V P P W Lg L O W Y L L B B L B L Br W Gy G G L Br L B Y L W W Y W G G W G W Lg B L W L Y B A Gy L L V P P W Lg L Y L L B B L B L Br W Gy G G L B Y L W W Y W G G W G W L W L Y Gy L L V P P W Lg L Y L L B B L B L Br W Gy G G L B Y L W W Y W G G W G W L W L Y L W W W L W B B L B L B Y...

Page 656: ...e the ECU and complete the service Refer to REPLACING THE ECU Engine Control Unit on page 8 56 7 Delete the DTC and check that the MIL goes off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC Is check result OK YES Go to step 5 NO a Fix the IMU installation condition b Turn the main switch to ON c Check the condition of the DTC using the malfunction mode of ...

Page 657: ...locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Turn the main switch to ON and then extend and retract the sidestand c Check the condition of the DTC using the malfunction mode of the YDT Is it in the ...

Page 658: ... Go to step 4 Between relay unit coupler 1 and joint coupler cap 4 blue blue Between joint coupler 4 and ECU coupler 2 blue yellow blue yellow Between relay unit coupler 1 and sidestand switch coupler 3 blue black blue black Gy L L V P P W Lg L Y L L B B L B L Br W Gy G G L B Y L W W Y W G G W G W L W L Y L B B W L W R L B L B Sb W Sb W Br L W R R Gy L L V P P W Lg L O W Y L L B B L B L Br W Gy G ...

Page 659: ...lue yellow any other coupler terminal Sidestand switch coupler 3 blue black any other coupler terminal W L W R L B L B Sb W Sb W Br L W R R W L W R L B L B Sb W Sb W Br L W R R Gy L L V P P W Y L L B B L B L Br W Gy G B Y L W W Y W G G W G W L W L Y Gy L L V P P W Lg L O W Y L L B B L B L Br W Gy G G L Br L B Y L W W Y W G G W G W Lg B L W L Y L B B A B 1 1 3 2 2 MTN890 MTN890D Is resistance Ω YES...

Page 660: ... that the MIL goes off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC Sidestand retracted ON Sidestand extended OFF Is check result OK YES Go to step 6 NO a Replace the sidestand switch b Turn the main switch to ON and then extend and retract the sidestand c Check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered conditio...

Page 661: ...ch 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 Is check result OK YES Go to step 2 NO a Reinstall or replace the battery leads b Turn the main switch to ON and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and comp...

Page 662: ... the Recovered condition YES Go to step 7 and complete the service NO Go to step 4 Is check result OK YES Go to step 5 NO a Replace the fuse b Turn the main switch to ON and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to step 5 Between battery 1 and backup fuse 2 holder 2 red red Between ...

Page 663: ...de of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to Short circuit check Between battery 1 and ground red ground Between ECU coupler 3 and ground red green ground red white ground Between main switch coupler 4 and ground brown blue ground ECU coupler 3 red green any other coupler terminal red white any other coupler terminal Main switch coupler 4 brown ...

Page 664: ...ep 6 NO a Replace the wire harness b Turn the main switch to ON and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to step 6 O Gy R O G P B Y R B R B G B L B Lg R B G Y R L B W B W R L L W Y B Y R R G R W Br Y L G W R Y R W Y Br B L Y B B W B O Gy R O G P B Y R B R B G B L B Lg R B G Y R L B...

Page 665: ...minals and locking condition of the pins 3 Wire harness continuity Disconnect the intake air pressure sensor 2 coupler 1 and ECU coupler 3 Remove the joint coupler cap 2 Open circuit check Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Turn the main switch to ON and then check the condition of the DTC using the malfunction mode of t...

Page 666: ...nt coupler 2 P1607 black black B P L Gy L L V P P W Y L L B B L B L Br W Gy G B Y L W W Y W G G W G W L W L Y Gy L L V P P W Lg L O W Y L L B B L B L Br W Gy G G L Br L B Y L W W Y W G G W G W Lg B L W L Y L W W W L W B B L B L B Y B Y B L R L R L R L R B L B B L B B B B B 3 3 1 2 MTN890 MTN890D Is resistance 0 Ω YES Go to Short circuit check NO a Replace the wire harness b Turn the main switch to...

Page 667: ...r coupler terminal P1606 P1607 pink any other coupler terminal Joint coupler 2 P1607 black blue any other coupler terminal P1607 black any other coupler terminal B P L B P L Gy L L V P P W Y L L B B L B L Br W Gy G B Y L W W Y W G G W G W L W L Y Gy L L V P P W Lg L O W Y L L B B L B L Br W Gy G G L Br L B Y L W W Y W G G W G W Lg B L W L Y L W W W L W B B L B L B Y B Y B L R L R L R L R B L B B L...

Page 668: ...then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to step 5 At sea level Approx 101 kPa 757 6 mmHg 29 8 inHg ap prox 3 64 V 1000 m 3300 ft above sea level Approx 90 kPa 675 1 mmHg 26 6 inHg ap prox 3 30 V 2000 m 6700 ft above sea level Approx 80 kPa 600 0 mmHg 23 6 inHg ap prox 3 00 V 3000 m 98...

Page 669: ...lace the intake air pressure sensor 2 Refer to THROTTLE BODIES on page 7 5 Turn the main switch to ON and then check the condition of the DTC using the malfunction mode of the YDT 3 Defective wire harness Replace the wire harness Turn the main switch to ON and then check the condition of the DTC using the malfunction mode of the YDT Is the coupler condition normal YES Go to step 2 NO a Connect the...

Page 670: ...to REPLACING THE ECU Engine Control Unit on page 8 56 5 Delete the DTC and check that the MIL goes off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC Is it in the Recovered condition YES Go to step 5 and complete the service NO Go to step 4 ...

Page 671: ...hen engine is stopped Atmospheric pressure at the current altitude and weather conditions is in dicated When engine is cranking Make sure that the indication value changes Is check result OK YES Go to step 2 NO a Repair or replace the intake air pressure sensor 2 hose Refer to THROTTLE BODIES on page 7 5 b Start the engine and let it idle for approximately 5 seconds and then check the condition of...

Page 672: ...k result OK YES Go to step 3 and complete the service NO a Replace the intake air pressure sensor Refer to THROTTLE BODIES on page 7 5 b Start the engine and let it idle for approximately 5 seconds with the throttle fully closed and then check the condition of the DTC using the malfunction mode of the YDT c Confirm the Recovered condition then go to step 3 ...

Page 673: ...ng condition of the pins 3 Wire harness continuity Disconnect the shift sensor coupler 1 and ECU coupler 2 Remove the joint coupler cap 3 Open circuit check Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Turn the main switch to ON and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered co...

Page 674: ... P P W Lg L O W Y L L B B L B L Br W Gy G G L Br L B Y L W W Y W G G W G W Lg B L W L Y B V L L W W W L W B B L B L B Y B Y B L R L R L R L R B L B B L B B B B B Gy L L V P P W Lg L Y L L B B L B L Br W Gy G G L B Y L W W Y W G G W G W L W L Y 2 2 1 3 MTN890 MTN890D Is resistance 0 Ω YES Go to Short circuit check NO a Replace the wire harness b Turn the main switch to ON and then check the conditi...

Page 675: ... terminal Joint coupler 3 black blue any other coupler terminal black any other coupler terminal Gy L L V P P W Lg L O W Y L L B B L B L Br W Gy G G L Br L B Y L W W Y W G G W G W Lg B L W L Y B V L B A Gy L L V P P W Lg L Y L L B B L B L Br W Gy G G L B Y L W W Y W G G W G W L W L Y B V L 2 2 3 1 1 L W W W L W B B L B L B Y B Y B L R L R L R L R B L B B L B B B B B MTN890 MTN890D Is resistance Ω ...

Page 676: ...in switch to ON and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to step 5 Shift sensor output voltage display 0 2 4 8 V With no shift weighting input Approx 2 5 V Shift up weighting Changes to the low side Shift down weighting Changes to the high side Is check result OK YES Go to step 6 N...

Page 677: ...k the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins 2 Connection of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or re...

Page 678: ...oupler 1 and ECU coupler 2 P2122 P2127 yellow red yellow red P2122 P2127 white red white red P2122 P2123 P2127 P2128 P2138 yellow yellow P2123 P2128 white black white black P2123 P2128 yellow black yellow black P2122 P2123 P2127 P2128 P2138 brown brown Is resistance 0 Ω YES Go to Short circuit check NO a Replace the wire harness b Turn the main switch to ON and then check the condition of the DTC ...

Page 679: ...122 P2127 yellow red any other coupler terminal P2122 P2123 P2127 P2128 P2138 yellow any other coupler terminal P2123 P2128 yellow black any other coupler terminal P2123 P2128 white black any other coupler terminal ECU coupler 2 P2122 P2123 P2127 P2128 P2138 brown any other coupler terminal P2122 P2127 white red any other coupler terminal P2122 P2127 yellow red any other coupler terminal P2122 P21...

Page 680: ...e harness b Turn the main switch to ON and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 6 and complete the service NO Go to step 4 When the throttle valves are fully closed 14 18 When the throttle valves are fully open 82 92 Turn the throttle grip past the closed position in the deceleration direc tion 7 12 When the throt...

Page 681: ...t or broken terminals and locking condition of the pins 4 Connection of ABS 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 Is the ABS warning light on YES Refer to BASIC INSTRUCTIONS FOR TROUBLESHOOTING on page 9 43 NO Go to step 2 Is that value increased YES Go to step 10 and complete the ...

Page 682: ...stic mode Code 16 c Rotate the front wheel by hand and check that the indicated value increases Is that value increased YES Go to step 10 and complete the service NO Go to step 5 Is the coupler condition normal YES Go to step 6 NO a Connect the coupler securely or replace the wire harness b Execute the diagnostic mode Code 16 c Rotate the front wheel by hand and check that the indicated value incr...

Page 683: ... W L W L Y 3 3 1 2 MTN890 MTN890D Is resistance 0 Ω YES Go to Short circuit check NO a Replace the wire harness b Execute the diagnostic mode Code 16 c Rotate the front wheel by hand and check that the indicated value increases Is that value increased YES Go to step 10 and complete the service NO Go to Short circuit check Between ABS ECU coupler 2 and ground brown ground yellow ground white green ...

Page 684: ...L W L Y 3 3 1 2 2 MTN890 MTN890D Is resistance Ω YES Go to step 7 NO a Replace the wire harness b Execute the diagnostic mode Code 16 c Rotate the front wheel by hand and check that the indicated value increases Is that value increased YES Go to step 10 and complete the service NO Go to step 7 Is check result OK YES Go to step 8 NO a Reinstall or replace the front wheel sensor Refer to FRONT WHEEL...

Page 685: ...o step 10 and complete the service 10 Delete the DTC and check that the MIL goes off Turn the main switch to ON and then rotate the front wheel by hand Start the engine and input the vehicle speed signals by operating the vehicle at 20 to 30 km h 12 to 19 mph Confirm that the DTC has a condition of Recovered using the malfunction mode of the YDT and then delete the DTC Delete this DTC even if it h...

Page 686: ...of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Turn the main switch to ON and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 6 and complete the...

Page 687: ... 3 and ignition fuse 2 holder 4 red white red white Between IMU coupler 3 and ground black white ground Gy L L V P P W Lg L O W Y L L B B L B L Br W Gy G G L Br L B Y L W W Y W G G W G W Lg B L W L Y R W L B L W B W L W W W L W B B L B L B Y B Y B L R L R L R L R B L B B L B B B B B Gy L L V P P W Lg L Y L L B B L B L Br W Gy G G L B Y L W W Y W G G W G W L W L Y 1 1 4 3 2 MTN890 MTN890D Is resist...

Page 688: ... L W B W R W L B L W B W Gy L L V P P W Lg L O W Y L L B B L B L Br W Gy G G L Br L B Y L W W Y W G G W G W Lg B L W L Y Gy L L V P P W Lg L O W Y L L B B L B L Br W Gy G G L Br L B Y L W W Y W G G W G W Lg B L W L Y B A Gy L L V P P W Lg L Y L L B B L B L Br W Gy G G L B Y L W W Y W G G W G W L W L Y Gy L L V P P W Lg L Y L L B B L B L Br W Gy G G L B Y L W W Y W G G W G W L W L Y L W W W L W B B...

Page 689: ...nction mode of the YDT 5 Malfunction in ECU Replace the ECU and complete the service Refer to REPLACING THE ECU Engine Control Unit on page 8 56 6 Delete the DTC and check that the MIL goes off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC Is it in the Recovered condition YES Go to step 6 and complete the service NO Go to step 5 ...

Page 690: ...the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Turn the main switch to ON and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to s...

Page 691: ... blue black blue black Between joint coupler 3 and ECU coupler 4 blue white blue white Gy L L V P P W Lg L O W Y L L B B L B L Br W Gy G G L Br L B Y L W W Y W G G W G W Lg B L W L Y R G R G R W B W Lg L W L B G W Y W G W R G B W W G W BSb W G L W Y W L Br L B G OBr WBr B G Br L B L B Y B L W L W W Gy L L V P P W Lg L Y L L B B L B L Br W Gy G G L B Y L W W Y W G G W G W L W L Y 4 4 1 2 3 MTN890 M...

Page 692: ...W B W Lg L W L B G W Y W G W R G B W W G W BSb W G L W Y W L Br L B G OBr WBr B G Br R G R G R W B W Lg L W L B G W Y W G W R G B W W G W BSb W G L W Y W L Br L B G OBr WBr B G Br Gy L L V P P W Lg L O W Y L L B B L B L Br W Gy G G L Br L B Y L W W Y W G G W G W Lg B L W L Y Gy L L V P P W Lg L O W Y L L B B L B L Br W Gy G G L Br L B Y L W W Y W G G W G W Lg B L W L Y A B Gy L L V P P W Lg L Y L ...

Page 693: ...fer to REPLACING THE ECU Engine Control Unit on page 8 56 6 Delete the DTC and check that the MIL goes off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC Is it in the Recovered condition YES Go to step 6 and complete the service NO Go to step 5 ...

Page 694: ...ntified by the flashing pattern Refer to HOW TO CHECK DTC on page 9 27 1 Keep magnets metal objects and other immobilizer system keys away from the keys and antennas Turn the main switch to ON 2 Turn the main switch to ON with another key 3 Replace the main switch immobilizer unit ECU and all key and complete the service Refer to HANDLEBAR on page 4 57 and REPLACING THE ECU Engine Control Unit on ...

Page 695: ...pattern Refer to HOW TO CHECK DTC on page 9 27 1 Place the immobilizer unit at least 50 mm away from the transponder of other vehicles Turn the main switch to ON 2 Register the standard key Turn the main switch to ON 3 Turn the main switch to ON with another key 4 Replace the main switch immobilizer unit ECU and all key and complete the service Refer to HANDLEBAR on page 4 57 and REPLACING THE ECU...

Page 696: ...nit coupler and 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 2 Turn the main switch to ON 3 Wire harness continuity Disconnect the immobilizer unit coupler 1 ECU coupler 2 and backup fuse 2 3 Open circuit check Is the coupler condition normal YES Go to step 2 NO Connect the coupler secure...

Page 697: ... B L W L Y R G Y L Lg B R 1 3 MTN890 MTN890D Is resistance 0 Ω YES Go to Short circuit check NO Replace the wire harness Between immobilizer unit coupler 1 and ground yellow blue ground light green any other coupler terminal red green any other coupler terminal red any other coupler terminal Immobilizer unit coupler 1 yellow blue any other coupler terminal light green any other coupler terminal re...

Page 698: ...E ECU Engine Control Unit on page 8 56 Gy L L V P P W Y L L B B L B L Br W Gy G B Y L W W Y W G G W G W L W L Y Gy L L V P P W Lg L O W Y L L B B L B L Br W Gy G G L Br L B Y L W W Y W G G W G W Lg B L W L Y R G Y L Lg B R R G Y L Lg B R A B 1 2 2 1 MTN890 MTN890D Is resistance Ω YES Go to step 4 NO Replace the wire harness Is DTC displayed YES Go to step 5 NO Service is completed ...

Page 699: ... 1 Connection of Immobilizer unit coupler and 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 2 Turn the main switch to ON 3 Register the code re registering key and standard keys Turn the main switch to ON 4 Replace the main switch immobilizer unit Refer to HANDLEBAR on page 4 57 Turn the m...

Page 700: ...9 270 54_IMMOBILIZER 5 Replace the main switch immobilizer unit ECU and all key and complete the service Refer to HANDLEBAR on page 4 57 and REPLACING THE ECU Engine Control Unit on page 8 56 ...

Page 701: ...e Same standard key was attempted to be registered two consecutive times Procedure TIP When a system malfunction occurs the immobilizer system indicator light will flash The DTC can be identified by the flashing pattern Refer to HOW TO CHECK DTC on page 9 27 1 Register another standard key and complete the service ...

Page 702: ...nit coupler and 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 2 Turn the main switch to ON 3 Wire harness continuity Disconnect the immobilizer unit coupler 1 ECU coupler 2 and backup fuse 2 3 Open circuit check Is the coupler condition normal YES Go to step 2 NO Connect the coupler secure...

Page 703: ... B L W L Y R G Y L Lg B R 1 3 MTN890 MTN890D Is resistance 0 Ω YES Go to Short circuit check NO Replace the wire harness Between immobilizer unit coupler 1 and ground yellow blue ground light green any other coupler terminal red green any other coupler terminal red any other coupler terminal Immobilizer unit coupler 1 yellow blue any other coupler terminal light green any other coupler terminal re...

Page 704: ...E ECU Engine Control Unit on page 8 56 Gy L L V P P W Y L L B B L B L Br W Gy G B Y L W W Y W G G W G W L W L Y Gy L L V P P W Lg L O W Y L L B B L B L Br W Gy G G L Br L B Y L W W Y W G G W G W Lg B L W L Y R G Y L Lg B R R G Y L Lg B R A B 1 2 2 1 MTN890 MTN890D Is resistance Ω YES Go to step 4 NO Replace the wire harness Is DTC displayed YES Go to step 5 NO Service is completed ...

Page 705: ...e sensor rotor or incorrect installation of the rotor Check the surface of the sensor rotor for damage Refer to MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR on page 4 15 4 Defective front wheel sensor or incorrect installation of the sensor Check the wheel sensor for damage and the installed condition of the sensor Refer to MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR on page 4...

Page 706: ...he surface of the sensor rotor for damage Refer to MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR on page 4 22 4 Defective rear wheel sensor or incorrect installation of the sensor Check the wheel sensor for damage and the installed condition of the sensor Refer to MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR on page 4 22 Is check result OK YES Go to step 2 NO Clean the sensor roto...

Page 707: ...er to CHECKING THE FRONT WHEEL on page 4 13 3 Defective sensor rotor or incorrect installation of the rotor Check the surface of the sensor rotor for damage Refer to MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR on page 4 15 4 Defective front wheel sensor or incorrect installation of the sensor Check the wheel sensor for damage and the installed condition of the sensor Refer to MAINTENANC...

Page 708: ...er to CHECKING THE REAR WHEEL on page 4 21 3 Defective sensor rotor or incorrect installation of the rotor Check the surface of the sensor rotor for damage Refer to MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR on page 4 22 4 Defective rear wheel sensor or incorrect installation of the sensor Check the wheel sensor for damage and the installed condition of the sensor Refer to MAINTENANCE O...

Page 709: ...coupler 1 and front wheel sensor coupler 2 Open circuit check Short circuit check TIP Disconnect the ABS ECU related connectors before checking Refer to PARTS CONNECTED TO THE ABS ECU on page 9 4 Ground short circuit check A Is check result OK YES Go to step 2 NO If there is a malfunction repair it and connect the coupler securely Between ABS ECU coupler 1 and front wheel sensor coupler 2 brown br...

Page 710: ...mbly is defective Replace the wheel sensor or hydraulic unit assembly Refer to FRONT WHEEL on page 4 11 and ABS ANTI LOCK BRAKE SYSTEM on page 4 49 ABS ECU coupler 1 yellow any other coupler terminal brown any other coupler terminal Is resistance Ω YES Go to step 3 NO Replace the wire harness R L W B B W W G G Y L R B Br L W G OW Y L B W Y L B R L W B B W W G G Y L R B Br L W G OW Y L B W Y L B B ...

Page 711: ... Wire harness continuity Disconnect the ABS ECU coupler 1 and rear wheel sensor coupler 2 Open circuit check Short circuit check TIP Disconnect the ABS ECU related connectors before checking Refer to PARTS CONNECTED TO THE ABS ECU on page 9 4 Is check result OK YES Go to step 2 NO If there is a malfunction repair it and connect the coupler securely Between ABS ECU coupler 1 and rear wheel sensor c...

Page 712: ... Replace the wheel sensor or hydraulic unit assembly Refer to REAR WHEEL on page 4 18 and ABS ANTI LOCK BRAKE SYSTEM on page 4 49 Between ABS ECU coupler 1 and ground white ground black ground ABS ECU coupler 1 white any other coupler terminal black any other coupler terminal Is resistance Ω YES Go to step 3 NO Replace the wire harness R L W B B W W G G Y L R B Br L W G OW Y L B W Y L B R L W B B ...

Page 713: ...21_ABS EAS33320 TROUBLESHOOTING Item Hydraulic unit assembly defective solenoid drive circuit Procedure 1 Defective hydraulic unit assembly Replace the hydraulic unit assembly Refer to ABS ANTI LOCK BRAKE SYSTEM on page 4 49 ...

Page 714: ...urn the main switch to OFF before disconnecting or connecting a coupler 3 Wire harness continuity Disconnect the ABS solenoid fuse 1 and ABS ECU coupler 2 Open circuit check Short circuit check Is check result OK YES Go to step 2 NO Replace the fuse and check the wire harness Is check result OK YES Go to step 3 NO If there is a malfunction repair it and connect the coupler securely Between ABS sol...

Page 715: ...ve hydraulic unit assembly Replace the hydraulic unit assembly Refer to ABS ANTI LOCK BRAKE SYSTEM on page 4 49 Between ABS ECU coupler 2 and ground blue white ground ABS ECU coupler 2 blue white any other coupler terminal Is resistance Ω YES Go to step 4 NO Replace the wire harness R L W B B W W G G Y L R B Br L W G OW Y L B W Y L B R L W B B W W G G Y L R B Br L W G OW Y L B W Y L B B A 2 2 ...

Page 716: ... the coupler TIP Turn the main switch to OFF before disconnecting or connecting a coupler 3 Wire harness continuity Disconnect the ABS motor fuse 1 and ABS ECU coupler 2 Open circuit check Is check result OK YES Go to step 2 NO Replace the fuse and check the wire harness Is check result OK YES Go to step 3 NO If there is a malfunction repair it and connect the coupler securely Between ABS motor fu...

Page 717: ...check B 4 Defective hydraulic unit assembly Replace the hydraulic unit assembly Refer to ABS ANTI LOCK BRAKE SYSTEM on page 4 49 Between ABS ECU coupler 2 and ground red ground ABS ECU coupler 2 red any other coupler terminal Is resistance Ω YES Go to step 4 NO Replace the wire harness R L W B B W W G G Y L R B Br L W G OW Y L B W Y L B R L W B B W W G G Y L R B Br L W G OW Y L B W Y L B B A 2 2 ...

Page 718: ...AS33323 TROUBLESHOOTING Item Hydraulic unit assembly short circuit in ABS motor power supply circuit Procedure 1 Defective hydraulic unit assembly Replace the hydraulic unit assembly Refer to ABS ANTI LOCK BRAKE SYSTEM on page 4 49 ...

Page 719: ...NG THE FRONT WHEEL on page 4 13 and CHECKING THE FRONT BRAKE DISCS on page 4 31 3 Front brake dragging Check that the brake fluid pressure is correctly transmitted to the brake caliper when the brake lever is operated and that the pressure decreases when the lever is released Refer to CHECKING THE FRONT BRAKE DISCS on page 4 31 4 Defective hydraulic unit assembly Replace the hydraulic unit assembl...

Page 720: ...ING THE REAR WHEEL on page 4 21 and CHECKING THE REAR BRAKE DISC on page 4 43 3 Rear brake dragging Check that the brake fluid pressure is correctly transmitted to the brake caliper when the brake pedal is operated and that the pressure decreases when the pedal is released Refer to CHECKING THE REAR BRAKE DISC on page 4 43 4 Defective hydraulic unit assembly Replace the hydraulic unit assembly Ref...

Page 721: ...incorrect installation of the rotor Check the surface of the sensor rotor for damage Refer to MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR on page 4 15 4 Defective front wheel sensor or incorrect installation of the sensor Check the wheel sensor for damage and the installed condition of the sensor Refer to MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR on page 4 15 Is check resul...

Page 722: ...incorrect installation of the rotor Check the surface of the sensor rotor for damage Refer to MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR on page 4 22 4 Defective rear wheel sensor or incorrect installation of the sensor Check the wheel sensor for damage and the installed condition of the sensor Refer to MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR on page 4 22 Is check result O...

Page 723: ...Refer to CHECKING AND CHARGING THE BATTERY on page 8 56 2 Disconnected battery terminal Check the connection 3 Defective charging system Check the charging system Refer to CHARGING SYSTEM on page 8 17 Is check result OK YES Go to step 3 NO Replace or reconnect the terminal Is check result OK YES Replace the hydraulic unit assembly ABS ECU NO Confirm the cause of the problem and repair it and check...

Page 724: ...upler TIP Turn the main switch to OFF before disconnecting or connecting a coupler 3 Wire harness continuity Disconnect the ABS ECU fuse 1 and ABS ECU coupler 2 Open circuit check Short circuit check TIP Disconnect the ABS ECU related connectors before checking Refer to PARTS CONNECTED TO THE ABS ECU on page 9 4 Is check result OK YES Go to step 3 NO If there is a malfunction repair it and connect...

Page 725: ... and ground red black ground ABS ECU coupler 2 red black any other coupler terminal Is resistance Ω YES Go to step 4 NO Replace the wire harness Is check result OK YES Replace the hydraulic unit assembly ABS ECU NO Confirm the cause of the problem and repair it and check again R L W B B W W G G Y L R B Br L W G OW Y L B W Y L B R L W B B W W G G Y L R B Br L W G OW Y L B W Y L B B A 2 2 ...

Page 726: ...S20700 55_ABS EAS33328 TROUBLESHOOTING Item Hydraulic unit assembly defective ABS ECU Procedure 1 Defective hydraulic unit assembly Replace the hydraulic unit assembly Refer to ABS ANTI LOCK BRAKE SYSTEM on page 4 49 ...

Page 727: ...01 56_ABS EAS33329 TROUBLESHOOTING Item Hydraulic unit assembly abnormal internal circuit Procedure 1 Defective hydraulic unit assembly Replace the hydraulic unit assembly Refer to ABS ANTI LOCK BRAKE SYSTEM on page 4 49 ...

Page 728: ...er 3 blue black blue black Between ECM coupler 1 and joint coupler 4 blue white blue white Between joint coupler 2 and joint coupler 3 yellow black yellow black Between joint coupler 2 and joint coupler 4 white white Between joint coupler 2 and ABS ECU coupler 5 blue black blue black blue white blue white Gy L L V P P W Lg L O W Y L L B B L B L Br W Gy G G L Br L B Y L W W Y W G G W G W Lg B L W L...

Page 729: ...t coupler 2 yellow black any other coupler terminal white any other coupler terminal ABS ECU coupler 5 blue white any other coupler terminal blue black any other coupler terminal R L W B B W W G G Y L R B Br L W G OW Y L B W Y L B B A Gy L L V P P W Lg L O W Y L L B B L B L Br W Gy G G L Br L B Y L W W Y W G G W G W Lg B L W L Y R L W B B W W G G Y L R B Br L W G OW Y L B W Y L B Gy L L V P P W Lg...

Page 730: ...hort circuit check B Is check result OK YES Go to step 4 NO If there is a malfunction repair it and connect the coupler securely Between ABS ECU fuse holder 1 and ABS ECU coupler 3 red black red black Between ABS solenoid fuse holder 2 and ABS ECU coupler 3 blue white blue white Is resistance 0 Ω YES Go to Short circuit check NO Replace the wire harness Between ABS ECU coupler 3 and ground red bla...

Page 731: ...7 Is resistance Ω YES Go to step 5 NO Replace the wire harness Is resistance Ω YES Replace the hydraulic unit assembly ABS ECU NO Confirm the cause of the problem and repair it and check again R L W B B W W G G Y L R B Br L W G OW Y L B W Y L B R L W B B W W G G Y L R B Br L W G OW Y L B W Y L B B A 3 3 ...

Page 732: ...702 62_ABS EAS33333 TROUBLESHOOTING Item Power supply voltage failure in pressure sensor Procedure 1 Defective hydraulic unit assembly Replace the hydraulic unit assembly Refer to ABS ANTI LOCK BRAKE SYSTEM on page 4 49 ...

Page 733: ...ont pressure sensor Procedure 1 Defective front brake line Check the front brake line 2 Defective hydraulic unit assembly Replace the hydraulic unit assembly Refer to ABS ANTI LOCK BRAKE SYSTEM on page 4 49 Is check result OK YES Go to step 2 NO If there is bending or blocking replace the front brake line ...

Page 734: ...r cap 5 Open circuit check Is check result OK YES Go to step 2 NO If there is a malfunction repair it and connect the coupler securely Between meter assembly coupler 1 and joint coupler 4 blue black blue black Between meter assembly coupler 1 and joint coupler 5 blue white blue white Between joint coupler 2 and joint coupler 4 yellow black yellow black Between joint coupler 2 and joint coupler 5 w...

Page 735: ...embly coupler 1 blue white any other coupler terminal blue black any other coupler terminal Joint coupler 2 blue white any other coupler terminal blue black any other coupler terminal ABS ECU coupler 3 blue white any other coupler terminal blue black any other coupler terminal Is resistance Ω YES Go to step 3 NO Replace the wire harness R L W B B W W G G Y L R B Br L W G OW Y L B W Y L B R L W B B...

Page 736: ...9 306 89_ABS 4 Defective hydraulic unit assembly Replace the hydraulic unit assembly ...

Page 737: ... step 2 NO If there is a malfunction repair it and connect the coupler securely Between ECM coupler 1 and joint coupler 3 blue black blue black Between ECM coupler 1 and joint coupler 4 blue white blue white Between joint coupler 2 and joint coupler 3 yellow black yellow black Between joint coupler 2 and joint coupler 4 white white Between joint coupler 2 and ABS ECU coupler 5 blue black blue blac...

Page 738: ...r terminal Joint coupler 2 yellow black any other coupler terminal white any other coupler terminal ABS ECU coupler 5 blue white any other coupler terminal blue black any other coupler terminal R L W B B W W G G Y L R B Br L W G OW Y L B W Y L B B A Gy L L V P P W Lg L O W Y L L B B L B L Br W Gy G G L Br L B Y L W W Y W G G W G W Lg B L W L Y R L W B B W W G G Y L R B Br L W G OW Y L B W Y L B Gy...

Page 739: ...9 309 90_ABS 3 Defective ECU Replace the ECU and check again 4 Defective hydraulic unit assembly Replace the hydraulic unit assembly Is resistance Ω YES Go to step 3 NO Replace the wire harness ...

Page 740: ... coupler 2 Wire harness continuity Disconnect the IMU coupler 1 and ABS ECU coupler 3 Remove the joint coupler cap 2 Open circuit check Is check result OK YES Go to step 2 NO If there is a malfunction repair it and connect the coupler securely Between IMU coupler 1 and joint coupler 2 blue white blue white blue black blue black Between joint coupler 2 and ABS ECU coupler 3 blue white blue white bl...

Page 741: ...U coupler 3 and ground blue white ground blue black ground IMU coupler 1 blue white any other coupler terminal blue black any other coupler terminal Joint coupler 2 blue white any other coupler terminal blue black any other coupler terminal ABS ECU coupler 3 blue white any other coupler terminal blue black any other coupler terminal Is resistance Ω YES Go to step 3 NO Replace the wire harness R W ...

Page 742: ...9 312 91_ABS 4 Defective hydraulic unit assembly Replace the hydraulic unit assembly ...

Page 743: ... 50 Injector 1 51 Injector 2 52 Injector 3 53 Grip warmer left 54 Grip warmer right 55 Throttle position sensor 56 Throttle servo motor 57 ABS ECU Electronic Control Unit 58 Front wheel sensor 59 Rear wheel sensor 60 IMU Inertial Measurement Unit 61 Purge cut valve solenoid 62 Shift sensor 63 YDT coupler 64 Meter assembly 65 Multi function meter 66 Neutral indicator light 67 Immobilizer system ind...

Page 744: ...tor 3 57 Grip warmer left 58 Grip warmer right 59 Throttle position sensor 60 Throttle servo motor 61 ABS ECU Electronic Control Unit 62 Front wheel sensor 63 Rear wheel sensor 64 IMU Inertial Measurement Unit 65 Purge cut valve solenoid 66 Shift sensor 67 YDT coupler 68 Meter assembly 69 Multi function meter 70 Neutral indicator light 71 Immobilizer system indicator light 72 Oil pressure and cool...

Page 745: ...O Green Orange G W Green White G Y Green Yellow Gy G Gray Green Gy R Gray Red L B Blue Black L R Blue Red L W Blue White L Y Blue Yellow Lg B Light green Black Lg L Light green Blue Lg R Light green Red O G Orange Green O W Orange White P B Pink Black P W Pink White R B Red Black R G Red Green R L Red Blue R W Red White R Y Red Yellow Sb W Sky blue White W B White Black W G White Green W L White B...

Page 746: ......

Page 747: ......

Page 748: ......

Page 749: ... 67 68 69 65 70 Ch B B Ch 79 SET UP FREE DOWN R L N OFF ON OFF ON OFF ON OFF ON 91 92 98 97 96 95 94 93 99 B Y L R B L Y B Y B L R Y G B W R W L W Y B W G Br L G R B Gy 87 L Y L B B 86 R W B R W Lg R G Y L 25 31 32 33 START OFF RUN R R L Y G W G R L L W Y L R R W B W G B W R W B R W RY G Y B B W G W B Y R 26 27 28 29 30 34 B B B 35 B 36 37 2 4 3 20 6 7 9 8 3 10 11 12 13 14 15 3 16 17 18 19 1 W W W...

Page 750: ... B B B B B B Gy B B 88 38 39 40 B 41 42 43 44 60 61 B 62 63 47 46 48 47 49 47 50 51 52 B 53 Gy 54 55 57 56 45 5 ON OFF 23 24 21 22 A 83 84 85 81 B 82 80 78 76 77 75 74 73 72 71 66 64 67 68 69 65 70 B 79 SET UP FREE DOWN R L N OFF ON OFF ON OFF ON OFF ON 91 92 98 97 96 95 94 93 99 B Gy 87 B 86 25 31 32 33 START OFF RUN R B 26 27 28 29 30 34 B 35 36 37 2 4 3 20 6 7 9 8 3 10 11 12 13 14 15 3 16 17 18...

Page 751: ...R N HI PASS LO OFF ON RES SET FREE PUSH FREE OFF ON B W Gy Br L L B L R B Br L Gy Br L G L W Y W L L B W G W R G B Y W O W Y Y B 97 99 100 101 102 103 104 105 106 98 B Gy 93 L Y L B B 92 R W B R W Lg R G Y L 27 OFF ON Y B Y W Gy L Y B Y 28 OFF ON B G W Y B G Y Y W 29 ON OFF Br G B Y B Br G B Y 30 35 36 37 START OFF RUN R R L Y G W G R L L W W B W G B W R W B R W RY G Y B B W G W B Y R 31 32 33 34 ...

Page 752: ... 45 46 47 48 64 65 B 66 67 51 50 52 51 53 51 54 55 56 B 57 Gy 58 59 61 60 49 5 ON OFF 25 26 23 24 A 96 89 90 91 87 B 88 86 84 82 83 81 80 79 78 77 76 75 70 68 71 72 73 69 74 B 85 PUSH FREE UP N DOWN L R N HI PASS LO OFF ON RES SET FREE PUSH FREE OFF ON L B Gy 97 99 100 101 102 103 104 105 106 98 Gy 93 B 92 27 OFF ON Gy 28 OFF ON B 29 ON OFF B 30 35 36 37 START OFF RUN B 31 32 33 34 38 B 39 40 41 2...

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