Yamaha MT 10 2016 Service Manual Download Page 360

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CONNECTING RODS AND PISTONS

5-77

TIP

•

Apply engine oil onto the piston pin.

•

Make sure that the “Y” mark “a” on the connect-
ing rod faces left when the punch mark “b” on
the piston is pointing up as shown.

•

Make sure that the clip ends “c” are positioned
away from the cutout “d” in the piston as shown
in the illustration.

•

Reinstall each piston into its original cylinder.

5. Lubricate:

•

Piston

•

Piston rings

•

Cylinder
(with the recommended lubricant)

6. Offset:

•

Piston ring end gaps

7. Lubricate:

•

Crankshaft pins

•

Connecting rod big end bearing inner surface
and side surface
(with the recommended lubricant)

8. Install:

•

Piston assemblies “1”
(into the cylinder “2”)

TIP

•

While holding the piston rings with the hand, in-
stall the piston assembly into the cylinder from
underneath.

•

Install the piston assembly into the cylinder so
that the piston ring end gap is aligned with the
cylinder skirt “a”.

9. Install:

•

Cylinder gasket

•

Dowel pins

•

Cylinder assembly

•

Connecting rod caps

•

Connecting rod bolts

Recommended lubricant

Engine oil

a. Top ring
b. 2nd ring
c. Upper oil ring rail
d. Oil ring expander
e. Lower oil ring rail

A. Exhaust side

Recommended lubricant

Engine oil

a,c

b,e

New

Summary of Contents for MT 10 2016

Page 1: ...2016 SERVICE MANUAL MTN1000 MTN1000G B67 28197 E0 ...

Page 2: ......

Page 3: ...000 MTN1000G SERVICE MANUAL 2016 by Yamaha Motor Co Ltd First edition March 2016 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited ...

Page 4: ...nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable TIP Designs and specifications are subject to change without notice EAS30001 IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following notations This is the safety alert symbol I...

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

Page 6: ...rviceable with engine mounted Gear oil Filling fluid Molybdenum disulfide oil Lubricant Brake fluid Special tool Wheel bearing grease Tightening torque Lithium soap based grease Wear limit clearance Molybdenum disulfide grease Engine speed Silicone grease Electrical data Apply locking agent LOCTITE Engine oil Replace the part with a new one Silicone fluid G M BF B T R LS M S LT E New S ...

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

Page 8: ......

Page 9: ...4 OUTLINE OF THE TCS Traction Control System 1 11 MULTI FUNCTION DISPLAY 1 14 IMPORTANT INFORMATION 1 21 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 21 REPLACEMENT PARTS 1 21 GASKETS OIL SEALS AND O RINGS 1 21 LOCK WASHERS PLATES AND COTTER PINS 1 21 BEARINGS AND OIL SEALS 1 21 CIRCLIPS 1 22 RUBBER PARTS 1 22 BASIC SERVICE INFORMATION 1 23 QUICK FASTENERS 1 23 ELECTRICAL SYSTEM 1 24 SPECIAL TOOLS 1 ...

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

Page 11: ...stem to respond extremely quickly to the slightest adjustments made by the rider In par ticular optimized control of the throttle valve opening provides the optimum volume of intake air for easy to use torque even in a high revving engine Aims and advantages of using YCC T Increased engine power By shortening the air intake path higher engine speed is possible Increased engine power Improved drive...

Page 12: ...6 7 8 9 3 2 1 4 1 Throttle position sensor 2 Throttle servo motor 3 Accelerator position sensor 4 ECU Engine Control Unit 5 Sensor input 6 Gear position sensor 7 Crankshaft position sensor 8 Rear wheel sensor 9 Coolant temperature sensor ...

Page 13: ...tem allows the rider to maintain a set cruising speed without operating the throttle the system reduces the burden of maintaining a constant speed during long distance touring In addition the cruise control system is equipped with a self diagnosis function 16 15 14 13 10 11 12 9 8 7 6 5 4 3 2 1 1 Battery 2 Main switch 3 Meter assembly 4 ECU Engine Control Unit 5 Clutch switch 6 Cruise control sett...

Page 14: ...he cruise control power switch located on the left handlebar The cruise control system indicator light will come on 2 Push the SET side of the cruise control setting switch to activate the cruise control system Your current traveling speed will become the set cruising speed The cruise control setting indicator light SET will come on TIP The cruise control system operates only when riding in 4th 5t...

Page 15: ...cancel the set cruising speed The SET indicator light will go off Turn the throttle grip past the closed position in the deceleration direction Apply the front or rear brake Disengage the clutch Push the power switch to turn off the cruise control system The indicator light and the SET indi cator light will go off TIP Traveling speed decreases as soon as the cruise control system is deactivated un...

Page 16: ...has not been turned off the traction control system will work The start engine stop switch is set to the position The engine stalls The sidestand is extended RES SET RES SET A C D E F B a b d c e b f g b j h i A Operation B Indication C Speed D 180 km h 112 mph E 50 km h 31 mph F Time a Cruise control power switch ON b Manual acceleration c Push the SET side of the cruise control setting switch d ...

Page 17: ... speed may become higher than the set cruising speed If this occurs the setting switch cannot be used to adjust the set cruising speed To reduce the traveling speed apply the brakes When the brakes are applied the cruise control system will become deactivated Automatic deactivation con dition Vehicle condition for detection Multi function meter indication Unable to maintain the set cruising speed ...

Page 18: ...ing light come on the vehicle should be checked as soon as possible in order to avoid engine damage C D B A d c b a a A Cruise control system is activated cruising speed is set B Cruise control system is turned off cruise control setting indicator light SET flashes C Cruise control system is turned off D Cruise control system is turned on cruising speed is not set a Condition for automatically dea...

Page 19: ...ising speed is set B Cruise control system is turned off engine trouble warning light comes on cruise control system is deactivated and cruise control system indicator light flashes C Cruise control system is turned off engine trouble warning light goes off cruise control system is deactivated and cruise control system indicator light flashes D Cruise control system is turned off E Cruise control ...

Page 20: ...the YCC T system The traction control system can be set to one of three operation modes or turned off TCS Traction control system layout TCS Traction control system block diagram The signals from the front and rear wheel sensors are sent to the ECU through the ABS ECU and the ECU calculates the amount of slip according to the difference between the detected front and rear wheel speeds If the amoun...

Page 21: ...th caution and avoid especially slippery surfaces The indicator light flashes when traction control has engaged You may notice slight changes in engine and exhaust sounds when the system has engaged In certain conditions the traction control system may be automatically disabled Should this happen the indicator light and the warning light will come on The TCS display indicates the current TCS setti...

Page 22: ... switch down to change from TCS 1 or 2 to 3 Push up to change from TCS 3 or 2 to 1 With the vehicle stopped push this switch up for two seconds to turn the system off Push down to turn the system on TIP The current TCS setting is shown in the TCS display Resetting the traction control system The traction control system will automatically disable when the front wheel or rear wheel comes off the gro...

Page 23: ...e multi function meter QS requires an accessory part and cannot be selected For the UK To switch the speedometer and multi function displays between kilometers and miles push both the CLOCK button and RE SET button at the same time Speedometer The speedometer shows the vehicle s traveling speed Tachometer The tachometer allows the rider to monitor the engine speed and keep it within the ideal powe...

Page 24: ...le TIP If a problem is detected in the electrical circuit the fuel level segments and will flash repeat edly If this occurs check the electrical circuit Refer to CHECKING THE FUEL METER FUEL LEVEL WARNING LIGHT on page 8 204 Coolant temperature air temperature dis play Push the select switch SELECT for two sec onds to switch the display between the coolant temperature mode C and air temperature mo...

Page 25: ...he transmission gear that is appropri ate for the vehicle speed Transmission gear display This display shows the selected gear The neu tral position is indicated by and by the neu tral indicator light Drive mode display This display indicates which drive mode has been selected STD A or B For more de tails on the modes and on how to select them refer to D mode drive mode on page 1 19 TCS display Th...

Page 26: ...T for one sec ond to switch the display between the odometer mode ODO tripmeter modes TRIP 1 and TRIP 2 instantaneous fuel consumption mode km L L 100 km or MPG average fuel con sumption mode AVE km L AVE L 100 km or AVE MPG in the following order ODO TRIP 1 TRIP 2 km L L 100 km or MPG AVE km L AVE L 100 km or AVE MPG ODO TIP The fuel reserve tripmeter comes on automati cally If the last segment o...

Page 27: ... shown To switch between the average fuel consump tion display settings push the CLOCK and RESET button together To reset the average fuel consumption push the RESET button for two seconds TIP After resetting the average fuel consumption will be shown until the vehicle has traveled 1 km 0 6 mi Display brightness and shift timing indica tor light control mode This mode cycles through five control f...

Page 28: ...rm the se lected engine speed The control mode changes to the shift timing indicator light de activation function To set the shift timing indicator light deac tivation function TIP The shift timing indicator light deactivation function can be set between 7000 r min and 13000 r min The indicator light can be set in in crements of 200 r min Be sure to set the deactivation function to a higher engine...

Page 29: ...rious riding condi tions This mode allows the rider to enjoy smooth and sporty drivability from the low speed range to the high speed range Mode A Mode A offers a sportier engine response than mode STD Mode B Mode B offers the sportest engine response ...

Page 30: ...m any source of fire EAS30007 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace ments Use oil and grease recommended by Yamaha for all lubrication jobs Other brands may be similar in function and appearance but inferior in quality EAS30008 GASKETS OIL SEALS AND O RINGS 1 When overhauling the engine replace all gaskets seals and O rings All gasket surfac es oil seal lips and O rings m...

Page 31: ... CIRCLIPS Before reassembly check all circlips carefully and replace damaged or distorted circlips Al ways replace piston pin clips after one use When installing a circlip 1 make sure the sharp edged corner 2 is positioned opposite the thrust 3 that the circlip receives EAS30012 RUBBER PARTS Check rubber parts for deterioration during in spection Some of the rubber parts are sensitive to gasoline ...

Page 32: ...ener push its pin so that it protrudes from the fastener head then insert the fastener into the part to be secured and push the pin a in with a screwdriver Make sure that the pin is flush with the fastener s head Screw type 1 Remove Quick fastener TIP To remove the quick fastener loosen the screw with a screwdriver then pull the fastener out 2 Install Quick fastener TIP To install the quick fasten...

Page 33: ...uld be gener ated which is extremely dangerous TIP If a battery lead is difficult to disconnect due to rust on the battery terminal remove the rust us ing hot water NOTICE ECA16760 Be sure to connect the battery leads to the correct battery terminals Reversing the bat tery lead connections could damage the electrical components NOTICE ECA16771 When connecting the battery leads to the battery be su...

Page 34: ...city Therefore never touch the terminals and be sure to keep the contacts clean TIP When resetting the ECU by turning the main switch to OFF be sure to wait approximately 5 seconds before turning the main switch back to ON Checking the electrical system TIP Before checking the electrical system make sure that the battery voltage is at least 12 V NOTICE ECA14371 Never insert the tester probes into ...

Page 35: ...the coupler lock hold both sections of the cou pler securely and then disconnect the cou pler There are many types of coupler locks therefore be sure to check the type of cou pler lock before disconnecting the coupler NOTICE ECA16790 When disconnecting a connector do not pull the leads Hold both sections of the connec tor securely and then disconnect the con nector 2 Check Lead Coupler Connector M...

Page 36: ...lizer available at most part stores 5 Check Resistance TIP The resistance values shown were obtained at the standard measuring temperature of 20 C 68 F If the measuring temperature is not 20 C 68 F the specified measuring conditions will be shown Pocket tester 90890 03112 Analog pocket tester YU 03112 C Pocket tester 90890 03112 Analog pocket tester YU 03112 C Intake air temperature sensor re sist...

Page 37: ...r U S A and Canada use part number starting with YM YU or ACC For others use part number starting with 90890 Tool name Tool No Illustration Reference pages Pocket tester 90890 03112 Analog pocket tester YU 03112 C 1 27 8 193 8 194 8 198 8 199 8 200 8 201 8 203 8 204 8 205 8 206 8 207 8 208 Yamaha diagnostic tool 90890 03250 3 4 3 12 4 70 4 71 8 36 8 163 8 178 Thickness gauge 90890 03180 Feeler gau...

Page 38: ... nut tool 90890 01574 YM 01574 4 35 4 36 Fork spring compressor 90890 01441 Fork spring compressor YM 01441 4 81 4 87 Rod holder 90890 01434 Damper rod holder double ended YM 01434 4 81 4 87 Damper rod holder ø30 90890 01506 Damper rod holder YM 01506 4 82 4 84 Fork seal driver 90890 01442 Adjustable fork seal driver 36 46 mm YM 01442 4 84 4 85 Tool name Tool No Illustration Reference pages ø18 ...

Page 39: ...od bleeding tool set YM A8703 4 85 4 87 Ring nut wrench 90890 01268 Spanner wrench YU 01268 4 91 Ring nut wrench 90890 01507 Ring nut wrench YM 01507 4 100 4 102 Damper rod holder ø22 90890 01365 4 100 4 102 Drive chain cut rivet tool 90890 01550 Drive chain cut rivet tool YM 01550 4 105 4 107 Tool name Tool No Illustration Reference pages YM A8703 YM A8703 ...

Page 40: ...5 17 5 20 5 28 5 33 Valve spring compressor attachment 90890 01243 Valve spring compressor adapter 26 mm YM 01253 1 5 28 5 33 Valve guide remover ø4 5 90890 04116 Valve guide remover 4 5 mm YM 04116 5 30 Valve guide remover ø5 90890 04097 Valve guide remover 5 0 mm YM 04097 5 30 Valve guide installer ø4 5 90890 04117 Valve guide installer 4 5 mm YM 04117 5 30 Tool name Tool No Illustration Referen...

Page 41: ...ve guide reamer 5 0 mm YM 04099 5 30 15mm pin type rotor holding tool 90890 04171 YM 04171 5 35 5 36 Crankshaft protector 10mm 90890 04180 Crankshaft protector 10mm YM 04180 5 35 Flywheel puller 90890 01404 Flywheel puller YM 01404 5 35 Yamaha bond No 1215 90890 85505 Three bond No 1215 5 36 5 65 Sheave holder 90890 01701 Primary clutch holder YS 01880 A 5 38 5 39 Tool name Tool No Illustration Re...

Page 42: ...2 8 202 Universal clutch holder 90890 04086 Universal clutch holder YM 91042 5 54 5 58 Piston pin puller set 90890 01304 Piston pin puller YU 01304 5 70 Radiator cap tester 90890 01325 Mityvac cooling system tester kit YU 24460 A 6 2 6 3 Tool name Tool No Illustration Reference pages YU 01304 YU 24460 A ...

Page 43: ...aft bearing driver 90890 04058 Middle drive bearing installer 40 50 mm YM 04058 6 12 Pressure gauge 90890 03153 Pressure gauge YU 03153 7 11 7 12 Fuel injector pressure adapter 90890 03210 Fuel injector pressure adapter YU 03210 7 11 Fuel pressure adapter 90890 03176 Fuel pressure adapter YM 03176 7 12 OBD GST Leadwire kit 90890 03249 8 36 Tool name Tool No Illustration Reference pages YU 33984 ...

Page 44: ...4000 spark checker YM 34487 8 200 Test harness lean angle sensor 6P 90890 03209 Test harness lean angle sensor 6P YU 03209 8 201 Test harness speed sensor 3P 90890 03208 Test harness speed sensor 3P YU 03208 8 206 Tool name Tool No Illustration Reference pages ...

Page 45: ...HTENING TORQUES 2 12 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 12 ENGINE TIGHTENING TORQUES 2 13 CHASSIS TIGHTENING TORQUES 2 13 LUBRICATION POINTS AND LUBRICANT TYPES 2 15 ENGINE 2 15 CHASSIS 2 16 LUBRICATION SYSTEM CHART AND DIAGRAMS 2 19 ENGINE OIL LUBRICATION CHART 2 19 LUBRICATION DIAGRAMS 2 21 COOLING SYSTEM DIAGRAMS 2 35 CABLE ROUTING 2 39 ...

Page 46: ...S Dimensions Overall length 2095 mm 82 5 in Overall width 800 mm 31 5 in Overall height 1110 mm 43 7 in Seat height 825 mm 32 5 in Wheelbase 1400 mm 55 1 in Ground clearance 130 mm 5 12 in Minimum turning radius 3 3 m 10 83 ft Weight Curb weight 210 kg 463 lb Loading Maximum load 170 kg 375 lb Riding capacity 2 person ...

Page 47: ...SAE viscosity grades 10W 40 15W 50 Recommended engine oil grade API service SG type or higher JASO standard MA Lubrication system Wet sump Engine oil quantity Oil change 3 90 L 4 12 US qt 3 43 Imp qt With oil filter removal 4 10 L 4 33 US qt 3 61 Imp qt Quantity disassembled 4 90 L 5 18 US qt 4 31 Imp qt Oil filter Oil filter type Cartridge Oil pump Inner rotor to outer rotor tip clearance 0 000 0...

Page 48: ...1 3282 in Limit 33 537 mm 1 3204 in Camshaft runout limit 0 030 mm 0 0012 in Rocker arm rocker arm shaft Rocker arm inside diameter 7 987 8 002 mm 0 3144 0 3150 in Limit 8 017 mm 0 3156 in Rocker arm shaft outside diameter 7 967 7 979 mm 0 3137 0 3141 in Limit 7 936 mm 0 3124 in Valve valve seat valve guide Valve clearance cold Intake 0 09 0 17 mm 0 0035 0 0067 in Exhaust 0 20 0 26 mm 0 0079 0 010...

Page 49: ... Piston pin outside diameter 16 991 17 000 mm 0 6689 0 6693 in Limit 16 971 mm 0 6681 in Piston pin to piston pin bore clearance 0 002 0 022 mm 0 0001 0 0009 in Piston ring Top ring Ring type Barrel End gap installed 0 15 0 25 mm 0 0059 0 0098 in End gap limit 0 50 mm 0 0197 in Ring side clearance 0 030 0 065 mm 0 0012 0 0026 in Side clearance limit 0 115 mm 0 0045 in 2nd ring Ring type Taper End ...

Page 50: ...ess 2 72 2 88 mm 0 107 0 113 in Wear limit 2 62 mm 0 103 in Plate quantity 7 pcs Clutch plate 1 thickness 2 46 2 74 mm 0 097 0 108 in Plate quantity 1 pcs Warpage limit 0 10 mm 0 004 in Clutch plate 2 thickness 2 18 2 42 mm 0 086 0 095 in Plate quantity 8 pcs Warpage limit 0 10 mm 0 004 in Clutch spring free length 47 36 mm 1 86 in Limit 44 99 mm 1 77 in Spring quantity 3 pcs Drivetrain Primary re...

Page 51: ...73 V Idling condition Engine idling speed 1200 1400 r min AI system Inactive O2 feedback control Inactive Exhaust gas sampling point Sampling port on the exhaust pipe To be measured Coolant temperature Temperature 90 110 C 194 230 F Intake vacuum 26 0 kPa 195 mmHg 7 7 inHg Difference in vacuum pressure between the cylinders 1 3 kPa 10 mmHg 0 4 inHg CO 0 5 4 5 Fuel line pressure at idle 300 0 390 0...

Page 52: ...M C 75W Manufacturer model BRIDGESTONE BATTLAX HYPERSPORT S20R 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 Disc outside diameter thickness 320 0 5 0 mm 12 60 0 20 in Brake disc thickness limit 4 5 mm 0 18 in Bra...

Page 53: ...98 Imp oz Level left 114 mm 4 5 in Level right 114 mm 4 5 in Spring preload Adjusting system Mechanical adjustable type Unit for adjustment Turn Adjustment value Soft 0 Adjustment value STD 9 Adjustment value Hard 15 Rebound damping Adjusting system Mechanical adjustable type Unit for adjustment Click Adjustment value from the start position Soft 14 Adjustment value from the start position STD 6 A...

Page 54: ...le type Fast compression damping Unit for adjustment Turn Adjustment value from the start position Soft 5 5 Adjustment value from the start position STD 3 Adjustment value from the start position Hard 0 Slow compression damping Unit for adjustment Click Adjustment value from the start position Soft 18 Adjustment value from the start position STD 12 Adjustment value from the start position Hard 1 D...

Page 55: ...andard output 14 0 V 368 W at 5000 r min Stator coil resistance 0 112 0 168 W W Rectifier regulator Regulator type Three phase Regulated voltage DC 14 3 14 7 V Rectifier capacity DC 35 0 A Battery Model YTZ10S Voltage capacity 12 V 8 6 Ah 10 HR Bulb wattage quantity Headlight LED Brake tail light LED Front turn signal light LED Rear turn signal light LED Auxiliary light LED License plate light LED...

Page 56: ...1 Cylinder identification sensor output voltage ON 4 8 V Cylinder identification sensor output voltage OFF 0 8 V Intake air temperature sensor resistance 5400 0 6600 0 at 0 C 5400 0 6600 0 at 32 F Intake air temperature sensor resistance 290 389 at 80 C 290 389 at 176 F Coolant temperature sensor resistance 2512 2777 at 20 C 2512 2777 at 68 F Coolant temperature sensor resistance 210 220 at 100 C ...

Page 57: ... To avoid warpage tight en multi fastener assemblies in a crisscross pat tern and progressive stages until the specified tightening torque is reached Unless otherwise specified tightening torque specifications re quire clean dry threads Components should be at room temperature A Distance between flats B Outside thread diameter A nut B bolt General tightening torques N m kgf m lb ft 10 mm 6 mm 6 0 ...

Page 58: ... bolt M20 1 70 N m 7 0 kgf m 51 lb ft Water pump drain bolt M6 1 10 N m 1 0 kgf m 7 2 lb ft Engine oil drain bolt M14 1 23 N m 2 3 kgf m 17 lb ft Item Thread size Q ty Tightening torque Remarks Front wheel axle nut M24 1 115 N m 11 5 kgf m 83 lb ft Front wheel axle pinch bolt M8 4 21 N m 2 1 kgf m 15 lb ft See TIP Rear wheel sprocket nut M10 6 80 N m 8 0 kgf m 58 lb ft Rear wheel axle nut M24 1 19...

Page 59: ...nt axle or lightly tap it with a soft hammer until its end is flush with the front fork However if the surface of the front axle end is not parallel to the surface of the front fork align a point on the outer edge of the axle with the fork making sure that the axle does not protrude past the fork 3 Tighten the pinch bolt 4 pinch bolt 3 and pinch bolt 4 to 21 N m 2 1 kgf m 15 lb ft in this order TI...

Page 60: ... Connecting rod bolts Crankshaft journals Balancer shaft journals Generator rotor bolt thread and washer Timing chain sprocket bolt Coolant pipe O ring Water or Oil pump rotors inner and outer Oil filter cartridge union bolt Plug oil gallery O ring Water or Crankcase bolt O ring Timing chain cover oil seal outer surface Starter clutch idle gear inner surface and end Starter clutch outer assembly S...

Page 61: ... E E Lubrication point Lubricant Steering bearings seal lip and ball race lip Tube guide throttle grip inner surface and throttle cables Brake lever pivot bolt and metal to metal moving parts Clutch lever pivot bolt metal to metal moving parts and clutch cable end Engine mounting bolt rear side Collar outer surface Relay arm connecting arm rear shock absorber assembly lower side Pivot shaft Swinga...

Page 62: ...ting surface Rear wheel oil seal Rear wheel drive hub oil seal Rear wheel drive hub mating surface Rear wheel drive hub and rear wheel mating surfaces Brake caliper piston seal Master cylinder inside Brake caliper piston dust seal Rear brake caliper bolts Lubrication point Lubricant LS LS LS LS LS LS S S ...

Page 63: ...LUBRICATION POINTS AND LUBRICANT TYPES 2 18 ...

Page 64: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 19 EAS20019 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS30020 ENGINE OIL LUBRICATION CHART ...

Page 65: ...r cartridge 6 Main gallery 7 Oil pressure switch 8 Crankshaft 9 Generator rotor 10 Balancer shaft 11 Oil nozzle 12 Sub gallery 13 Timing chain tensioner 14 Intake rocker arm 15 Intake camshaft 16 Exhaust rocker arm 17 Exhaust camshaft 18 Shift fork guide bar upper 19 Main axle 20 Drive axle 21 Mission shower ...

Page 66: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 21 EAS30021 LUBRICATION DIAGRAMS Crankcase cylinder and cylinder head left side view ...

Page 67: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 22 1 Intake camshaft 2 Oil nozzle 3 Oil delivery pipe 2 4 Oil filter cartridge 5 Crankshaft 6 Exhaust camshaft 7 Sub gallery ...

Page 68: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 23 Crankcase and cylinder right side view ...

Page 69: ... DIAGRAMS 2 24 1 Timing chain tensioner 2 Intake camshaft 3 Exhaust camshaft 4 Crankshaft 5 Relief valve 6 Oil pipe 1 7 Oil delivery pipe 1 8 Oil pan 9 Oil strainer 10 Oil pump 11 Shift fork guide bar 12 Shift fork C 13 Drive axle ...

Page 70: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 25 Timing chain cover and oil pipe right side view ...

Page 71: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 26 1 Timing chain cover 2 Oil pipe 3 3 Oil pipe 2 4 Crankshaft 5 Crankcase ...

Page 72: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 27 Oil pump and oil cooler bottom view ...

Page 73: ...il cooler 2 Oil delivery pipe 1 3 Oil cooler outlet hose 4 Oil filter cartridge 5 Oil pressure switch 6 Oil delivery pipe 2 7 Oil strainer 8 Oil pump 9 Oil pipe 1 10 Main gallery 11 Relief valve 12 Oil pipe 2 13 Oil pipe 3 14 Oil cooler inlet hose ...

Page 74: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 29 Camshaft and balancer shaft top view ...

Page 75: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 30 1 Cylinder head 2 Exhaust camshaft 3 Intake camshaft 4 Balancer shaft ...

Page 76: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 31 Crankshaft rear view ...

Page 77: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 32 1 Oil nozzle 2 Oil pipe 3 3 Timing chain cover 4 Crankshaft 5 Oil pipe 2 6 Oil pressure switch 7 Generator rotor 8 Shaft ...

Page 78: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 33 Crankshaft and transmission top view ...

Page 79: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 34 1 Oil pump 2 Main axle 3 Clutch housing 4 Drive axle 5 Oil delivery pipe 3 ...

Page 80: ...COOLING SYSTEM DIAGRAMS 2 35 EAS20020 COOLING SYSTEM DIAGRAMS ...

Page 81: ...COOLING SYSTEM DIAGRAMS 2 36 1 Radiator outlet hose 2 Cooling system air bleed hose 3 Thermostat assembly 4 Radiator inlet hose 5 Radiator 6 Water pump outlet pipe 7 Water pump 8 Water pump inlet pipe ...

Page 82: ...COOLING SYSTEM DIAGRAMS 2 37 ...

Page 83: ...COOLING SYSTEM DIAGRAMS 2 38 1 Cooling system air bleed hose 2 Radiator 3 Radiator outlet hose 4 Radiator inlet hose 5 Water pump inlet pipe 6 Water pump outlet pipe 7 Water pump 8 Thermostat assembly ...

Page 84: ...CABLE ROUTING 2 39 EAS20021 CABLE ROUTING Handlebar front view ...

Page 85: ...ead positioning tape gray and the white paint mark on the brake hose Route the horn lead to the inside of the brake hose and fasten it with the clamp C Pass the clutch cable through the clamp D Fasten the brake hose and throttle cables with the clamp Position the clamp on the caulked section of the brake hose Face the opening of the clamp forward E The position of the horn lead may shift within th...

Page 86: ...CABLE ROUTING 2 41 Headlight front view ...

Page 87: ... 2 Meter assembly 3 Coupler cover 4 Wire harness clamp 5 Main switch lead 6 Auxiliary light coupler 7 Immobilizer unit coupler A Install the wire harness clamp to the head light stay B Install the main switch lead clamp to the headlight stay ...

Page 88: ...CABLE ROUTING 2 43 Radiator cover right side view ...

Page 89: ...l the clamp of the steering damper sole noid lead to the headlight assembly M Insert the clamp of handlebar switch lead left and clutch switch lead into the upper hole in the headlight stay N Install the wire harness clamp to the head light assembly O Gray tape P Route the steering damper solenoid lead handlebar switch lead left and clutch switch lead to the inside of the guide Q Blue tape R Route...

Page 90: ...CABLE ROUTING 2 45 Clutch cable and O2 sensor lead right side view ...

Page 91: ...at the painted section and the clutch cable with the clamp C Route the O2 sensor lead between the water pump assembly and crankcase D Push in the O2 sensor lead from the outside until it reaches the mating surface of the clutch cover E Fasten the coolant reservoir breather hose at the painted section and the clutch cable with the clamp Make sure that the end of the clamp contacts the radiator brac...

Page 92: ...CABLE ROUTING 2 47 Electrical components tray left side view ...

Page 93: ...shown in the illustration E Install the relay unit to the bracket F Install the radiator fan motor relay to the bracket G Install the clamp of the front turn signal light lead left to the air scoop stay H Install the clamp of the front turn signal light lead left to the bracket I Pass the two fuse box leads radiator fan motor lead left right front turn signal light lead left and auxiliary DC jack ...

Page 94: ...CABLE ROUTING 2 49 ECU Engine Control Unit left side view ...

Page 95: ...tand switch coupler shift switch coupler for optional components O2 sensor coupler and crankshaft position sensor coupler inside the coupler cover The couplers may be posi tioned in any order E Fasten the fuel tank drain hose oil pressure switch lead sidestand switch lead and O2 sensor lead with the clamp Install the clamp to the holder Face the opening of the clamp forward F The fuel tank drain h...

Page 96: ...CABLE ROUTING 2 51 Handlebar top view ...

Page 97: ...switch lead right with the clamp Fasten the leads at the positions as shown in the illustration Install the clamp securely to the guide Cut off the excess end of the clamp Point the end of the clamp as shown in the illustration J Route the main switch lead and immobilizer unit lead K Fasten the main switch lead and immobilizer unit lead at the blue tape with the plastic lock ing tie L Fasten the p...

Page 98: ...CABLE ROUTING 2 53 Frame top view ...

Page 99: ...re harnesses through the guide from the left side of the vehicle starting from the one with the gray positioning tape first fol lowed by the ones with the blue and then the yellow positioning tape Align the positioning tape on the wire harness with the guide G Route the auxiliary DC jack lead from the out let of the inner panel to the inside of the guide and then to the inside of the air scoop H T...

Page 100: ...CABLE ROUTING 2 55 Frame top view ...

Page 101: ...nward The wire harness and the section of the starter motor lead fastened by the plastic locking tie may be positioned in any order E Install the wire harness clamp to the frame F Make sure that the starter motor lead is not routed over the canister purge hose hose joint to canister G Route the fuel tank drain hose inside of the wire harness H Fasten the fuel rail and wire harness with the plastic...

Page 102: ...CABLE ROUTING 2 57 Frame top view ...

Page 103: ... through the hole in the battery box 1 In this case route the EXUP cables under the rear side cover Make sure that the EXUP cables are not pinched in the rear side cover G Install the service tool leads into the groove on the battery box 2 H Route the starter motor lead and negative battery leads over the service tool leads The starter motor lead negative battery lead and wire harness may be route...

Page 104: ...CABLE ROUTING 2 59 Rear fender top view ...

Page 105: ...plastic locking tie E Insert the rear right turn signal light coupler white into the hole in the plate F Insert the rear left turn signal light coupler black into the hole in the plate G Insert the starter relay until it comes into con tact with the plate H Route the rear turn signal light leads tail brake light lead and license plate light lead through the ribs of the plate Route the rear turn si...

Page 106: ...CABLE ROUTING 2 61 Rear fender left side view ...

Page 107: ...t relay lead 10 EXUP servo motor lead 11 Starter motor lead 12 Positive battery lead 13 Main fuse lead 14 Plate 15 Joint coupler 16 Battery box 1 A Route the starter relay lead behind the main fuse B Route the brake light relay lead behind the starter relay C Install the main fuse and brake light relay to the plate securely D Insert the joint coupler until it contacts the battery box 1 ...

Page 108: ...CABLE ROUTING 2 63 Rear brake hose right side view ...

Page 109: ...locking tie downward with the end pointing inward The rear wheel sensor lead and rear brake light switch lead may be routed in any order G Outside of vehicle H Route the EXUP cable 1 and EXUP cable 2 through the outside of the vehicle past the guide part of the rear brake light switch bracket I Fasten the grommet of the rear wheel sensor lead with the rear wheel sensor lead hook J When installing ...

Page 110: ...CABLE ROUTING 2 65 Front brake hose left side view ...

Page 111: ...nt wheel sensor A To front brake master cylinder B Install the clamp with the opening facing upward C Route the front wheel sensor lead along the brake hose left without any slack D Make sure that the metal fitting of the brake hose contacts the stopper of the brake cali per E Fasten the front wheel sensor lead at the white tape with the holder F Fasten the front wheel sensor lead and paint mark o...

Page 112: ...CABLE ROUTING 2 67 Front brake hose left side view ...

Page 113: ... 2 Brake hose bracket 3 Frame 4 Brake hose front brake master cylinder to hydraulic unit 5 Hydraulic unit 6 Brake hose hydraulic unit to front brake cali pers A Insert the clamp all the way to the rear of the brake hose bracket ...

Page 114: ...CABLE ROUTING 2 69 Hydraulic unit assembly top and left side view ...

Page 115: ...e that the projection on the brake pipe contacts the hydraulic unit brake pipe rear brake master cylinder to hydraulic unit C Install the brake pipe onto the hydraulic unit making sure that the projection on the brake pipe contacts the brake hose front brake master cylinder to hydraulic unit D Install the brake hose onto the hydraulic unit making sure that the projection on the brake hose contacts...

Page 116: ...CABLE ROUTING 2 71 Fuel tank bottom and left side view ...

Page 117: ...CABLE ROUTING 2 72 1 Fuel tank cap 2 Fuel tank 3 Fuel hose 4 Fuel pump A Align the fuel pump positioning to the inner panel marking visual guide during installa tion B Connector color White ...

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

Page 119: ... ing upward E 2 mm 0 08 in or less F Install the fuel tank breather hose with its white paint mark facing upward G Install the fuel tank breather hose to the port of the fuel tank Insert the hose until the end of the R section of the canister H Install the clamp with its end pointing forward Make sure that the clip does not go on top of the stopper I Install the canister purge hose to the purge po...

Page 120: ...CABLE ROUTING 2 75 Air filter case and throttle bodies top and left side view ...

Page 121: ...assembly 7 Clamp 8 Fuel hose 9 Throttle cable accelerator cable 10 Throttle cable decelerator cable A To canister B Point the end of the clamp to the right C Install the clamp so that the bottom edge of the clamp is 0 5 mm 0 0 2 in from the hose end D To fuel pump E 5 mm 0 2 in or less F Protector position 26 mm 1 02 in ...

Page 122: ...CABLE ROUTING 2 77 Air cut off valve right side view ...

Page 123: ...left Install the air induction system hose with its white paint mark facing outward Make sure that the clamp does not go on top of the stopper When installing the air induction system hose may apply silicone fluid or water to the air induction system hose B Point the end of the clamp rearward C Point the end of the clamp to the left D Insert the air induction system hose until it contacts the reed...

Page 124: ...CABLE ROUTING 2 79 Radiator left side view ...

Page 125: ...ow paint mark on the radiator inlet hose with the projection on the thermo stat assembly and oval shaped projections on the hose clamp Insert the radiator inlet hose until it contacts the projection on the thermostat assembly F Clamp installation details G 2 mm 0 08 in or more H Installed length 20 mm 0 79 in I Make sure that the clamp is not installed on the flange of the hose fitting of the ther...

Page 126: ...CABLE ROUTING 2 81 Radiator right side view ...

Page 127: ...adiator outlet hose up to the center of the white paint mark on the water pump inlet pipe D Clamp installation details E 2 mm 0 08 in or more F Installed length 20 mm 0 79 in G Make sure that the clamp is not installed on the flange of the hose fitting H Yellow paint mark on the radiator outlet hose I Hose clamp opening J 45 K Point the projections 2 locations on the hose clamp downward L Hose cla...

Page 128: ...CABLE ROUTING 2 83 Muffler top and left side view ...

Page 129: ...TING 2 84 1 Exhaust chamber 2 EXUP valve pulley cover 3 Muffler 4 EXUP servo motor 5 EXUP cable 6 EXUP cable 1 7 EXUP cable 2 A EXUP cable securing location B 1 stamped on the bracket C 2 stamped on the bracket ...

Page 130: ...CABLE ROUTING 2 85 ...

Page 131: ...UID LEVEL 3 14 ADJUSTING THE FRONT DISC BRAKE 3 15 CHECKING THE FRONT BRAKE PADS 3 15 ADJUSTING THE REAR DISC BRAKE 3 15 CHECKING THE REAR BRAKE PADS 3 16 CHECKING THE FRONT BRAKE HOSES 3 16 CHECKING THE REAR BRAKE HOSE 3 16 BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS 3 16 CHECKING THE WHEELS 3 17 CHECKING THE TIRES 3 17 CHECKING THE WHEEL BEARINGS 3 19 CHECKING THE SWINGARM OPERATION 3 19 LUBRICATING...

Page 132: ...COOLANT LEVEL 3 29 CHECKING THE COOLING SYSTEM 3 29 CHANGING THE COOLANT 3 29 ADJUSTING THE EXUP CABLES 3 32 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 33 CHECKING AND CHARGING THE BATTERY 3 35 CHECKING THE FUSES 3 35 ADJUSTING THE HEADLIGHT BEAMS 3 35 ...

Page 133: ...EMISSION CONTROL SYSTEM EAS30615 GENERAL 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...

Page 134: ...n or riding in wet areas 13 Steering bearings Check bearing assemblies for looseness Moderately repack with lith ium soap based grease 14 Steering damper Check operation and for oil leakage 15 Chassis fasteners Make sure that all nuts bolts and screws are properly tight ened 16 Brake lever pivot shaft Lubricate with silicone grease 17 Brake pedal pivot shaft Lubricate with lithium soap based greas...

Page 135: ... points Check operation Lubricate with lithium soap based grease 25 Engine oil Change warm engine before draining Check oil level and vehicle for oil leakage 26 Engine oil filter cartridge Replace 27 Cooling system Check coolant level and vehi cle for coolant leakage Change Every 3 years 28 EXUP system Check operation cable free play and pulley position 29 Front and rear brake switches Check opera...

Page 136: ...after to perform the dynamic inspection For information about using the Yamaha diagnostic tool refer to the operation manual that is included with the tool 5 Install 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 Air scoop Air scoop stay Refer to GENERAL CHASSIS 1 on p...

Page 137: ...brush 6 Measure Spark plug gap a with a wire thickness gauge Out of specification Regap 7 Install Spark plugs Ignition coils TIP Before installing the spark plug clean the spark plug and gasket surface If the spark plug is a new one tighten it to 18 N m 1 8 kgf m 13 lb ft 8 Install Air cut off valve Refer to AIR INDUCTION SYSTEM on page 7 15 Air filter case Refer to GENERAL CHASSIS 3 on page 4 20 ...

Page 138: ...ve clearance Out of specification Adjust a Turn the crankshaft counterclockwise b When piston 1 is at TDC on the compres sion stroke align the TDC mark a on the generator rotor with the generator rotor cover slot b TIP TDC on the compression stroke can be found when the camshaft lobes are turned away from each other c Measure the valve clearance 1 with a thick ness gauge 1 TIP Measure the valve cl...

Page 139: ...terclockwise k When piston 4 is at TDC on the compres sion stroke align the TDC mark f on the generator rotor with the generator rotor cover slot b l Measure the valve clearance 4 with a thick ness gauge 5 Remove Camshaft TIP Refer to CAMSHAFTS on page 5 9 When removing the timing chain and cam shafts fasten the timing chain with a wire to re trieve it if it falls into the crankcase 6 Adjust Valve...

Page 140: ...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 The valve pad number is 163 e Round off the valve pad number according to the following table and then select the suit able valve pad TIP Refer to the following table for the available valve pads Example Valve pad number 163 Rounded value 165 New valve pad number 165 f Install the new ...

Page 141: ...2 Check Crankcase breather hose 1 Cracks damage Replace Loose connection Connect properly NOTICE ECA13450 Make sure the crankcase breather hose is routed correctly 3 Install Fuel tank Refer to FUEL TANK on page 7 1 Fuel tank cover Refer to GENERAL CHASSIS 2 on page 4 13 Air scoop stay Air scoop Rider seat Refer to GENERAL CHASSIS 1 on page 4 1 EAS31017 CHECKING THE ENGINE IDLING SPEED TIP Prior to...

Page 142: ...l tank Refer to FUEL TANK on page 7 1 6 Check Throttle body synchronization a Start the engine warm it up for several min utes and then let it run at the specified en gine idling speed b Check the vacuum pressure If out of specification Adjust the throttle body synchronization Adjusting the throttle body synchronization 1 Adjust Throttle body synchronization a Start the engine warm it up for sever...

Page 143: ...ment 3 Install Caps 4 Install Air filter case Refer to GENERAL CHASSIS 3 on page 4 20 Fuel tank Refer to FUEL TANK on page 7 1 Fuel tank cover Refer to GENERAL CHASSIS 2 on page 4 13 Air scoop stay Air scoop Rider seat Refer to GENERAL CHASSIS 1 on page 4 1 5 Adjust Throttle grip free play Refer to CHECKING THE THROTTLE GRIP on page 3 33 EAS31318 CHECKING THE THROTTLE BODY JOINTS 1 Remove Throttle...

Page 144: ...c tool For more information refer to the opera tion manual of the Yamaha diagnostic tool 1 Connect the Yamaha diagnostic tool to the coupler For information about connecting the Yamaha diagnostic tool refer to YAMAHA DIAGNOSTIC TOOL on page 8 36 EAS30627 CHECKING THE AIR INDUCTION SYSTEM Refer to AIR INDUCTION SYSTEM on page 7 15 EAS30628 REPLACING THE AIR FILTER ELEMENT 1 Remove Rider seat Air sc...

Page 145: ...e slots b of the air filter case and install When installing the air filter element into the air filter case make sure that the sealing surfaces are aligned to prevent any air leaks 5 Install Fuel tank Refer to FUEL TANK on page 7 1 Fuel tank cover Refer to GENERAL CHASSIS 2 on page 4 13 Air scoop stay Air scoop Rider seat Refer to GENERAL CHASSIS 1 on page 4 1 EAS30629 ADJUSTING THE CLUTCH LEVER ...

Page 146: ... EWA13090 Use only the designated brake fluid Other brake fluids 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 fluid reservoir Water...

Page 147: ... lever position make sure there is no brake drag EAS30633 CHECKING THE FRONT BRAKE PADS The following procedure applies to all of the brake pads 1 Operate the brake 2 Check Front brake pad Wear indicators 1 almost touch the brake disc Replace the brake pads as a set Refer to FRONT BRAKE on page 4 40 EAS30631 ADJUSTING THE REAR DISC BRAKE 1 Adjust Brake pedal position a Loosen the locknut 1 b Turn ...

Page 148: ...ear Replace 2 Check Brake hose holder Loose Connection Tighten the holder bolt 3 Hold the vehicle upright and apply the rear brake several times 4 Check Brake hose Brake fluid leakage Replace the damaged hose Refer to REAR BRAKE on page 4 53 EAS30893 BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS WARNING EWA14000 Always bleed the brake system when the brake related parts are removed NOTICE ECA18050 Bleed...

Page 149: ... Refer to HYDRAULIC UNIT OPERATION TEST on page 4 70 NOTICE ECA17061 Make sure that the main switch is turned to OFF before checking the operation of the hydraulic unit k After operating the ABS repeat steps e to i and then fill the brake master cylinder reservoir or brake fluid reservoir to the prop er level with the specified brake fluid l Tighten the bleed screw to specification m Fill the brak...

Page 150: ...r tires should always be by the same manufacturer and of the same design No guarantee con cerning handling characteristics can be giv en if a tire combination other than one approved by Yamaha is used on this vehicle 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 a...

Page 151: ... is no danger of it falling over NOTICE ECA13550 A drive chain that is too tight will overload the engine and other vital parts and one that is too loose can skip and damage the swing arm or cause an accident Therefore keep the drive chain slack within the specified lim its 1 Shift the transmission into the neutral posi tion 2 Check Drive chain slack a Out of specification Adjust NOTICE ECA20870 I...

Page 152: ...ore 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 rings EAS30645 CHECKING AND ADJUSTING THE STEERING HEAD 1 Stand the vehicle on a level surface WARNING EWA13120 Securely su...

Page 153: ...ing nuts If necessary hold the lower ring nut and tighten the upper ring nut until their slots are aligned h Install the lock washer 9 TIP Make sure the lock washer tabs a sit correctly in the ring nut slots b 5 Install Upper bracket Refer to STEERING HEAD on page 4 89 EAS30646 LUBRICATING THE STEERING HEAD 1 Lubricate Upper bearing Lower bearing Bearing race EAS31634 CHECKING THE STEERING DAMPER ...

Page 154: ...d 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 79 EAS30806 ADJUSTING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs WARNING EWA13120 Securely support t...

Page 155: ...may not exactly match the above 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 Spring preload Minimum soft 0 turn s in direction a Standard 9 turn s in direction a Maximum hard 15 turn s in direction a With the adjusting nut fully tu...

Page 156: ...he owner s tool kit addi tional tool kit c Turn the adjusting ring 2 in direction a or b TIP The spring preload setting is determined by measuring distance c The longer distance c is the higher the spring preload the shorter dis tance c is the lower the spring preload d Tighten the locknut to the specified torque Rebound damping NOTICE ECA13590 Never go beyond the maximum or minimum adjustment pos...

Page 157: ... due to small differences in production Compression damping for slow compres sion damping NOTICE ECA13590 Never go beyond the maximum or minimum adjustment positions 1 Adjust Compression damping for slow compression damping a Turn the adjusting screw 1 in direction a or b Direction a Rebound damping is increased sus pension is harder Direction b Rebound damping is decreased sus pension is softer R...

Page 158: ... 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 level again TIP Before checking the ...

Page 159: ... oil drain bolt along with the gasket 7 Fill Crankcase with the specified amount of the recom mended engine oil 8 Install Engine oil filler cap along with the O ring 9 Start the engine warm it up for several min utes and then turn it off 10 Check Engine for engine oil leaks 11 Check Engine oil level Refer to CHECKING THE ENGINE OIL LEVEL on page 3 26 EAS30810 MEASURING THE ENGINE OIL PRESSURE 1 Ch...

Page 160: ...nt 18 mm 1 Oil pressure switch joint bolt 2 5 Install Oil pressure gauge 1 Adapter C 2 6 Measure Engine oil pressure at the following conditions Out of specification Check 7 Remove Oil pressure gauge Adapter C Oil pressure switch joint bolt Oil pressure switch joint with the O ring 8 Install O ring 1 Oil pressure switch joint with the oil pressure Oil pressure gauge joint 18 mm 90890 04176 YU 0417...

Page 161: ...p for several min utes and then turn it off 4 Check Coolant level TIP Before checking the coolant level wait a few minutes until it settles EAS30812 CHECKING THE COOLING SYSTEM 1 Check Radiator 1 Radiator inlet hose 2 Radiator outlet hose 3 Water pump inlet pipe 4 Water pump outlet pipe 5 Oil cooler 6 Oil cooler outlet hose 7 Oil cooler inlet hose 8 Cracks damage Replace Refer to RADIATOR on page ...

Page 162: ... Install Water pump drain bolt Copper washer 5 Remove Quick fastener 1 Coolant reservoir cover bolt 2 Coolant reservoir cover 3 6 Remove Radiator cover bolt 1 Radiator cover 2 Coolant reservoir 3 Collar 4 7 Remove Coolant reservoir cap 1 8 Drain Coolant from the coolant reservoir 9 Install Collar Coolant reservoir Radiator cover Radiator cover bolt 10 Install Coolant reservoir cover Coolant reserv...

Page 163: ...Fill Coolant reservoir with the recommended coolant to the maxi mum level mark a 13 Install Coolant reservoir cap 14 Loosen the water pump air bleed bolt 1 to allow any trapped air to escape from the wa ter pump 15 When coolant begins to flow out tighten the water pump air bleed bolt to the specified torque 16 Pour the specified coolant into the radiator until it is full 17 Install Radiator cap Ra...

Page 164: ...st EXUP cable free play a Slide back the rubber cover 1 b Turn the main switch to ON c Loosen the locknut 2 d Turn the adjusting nut 3 in direction c or d until the projection a on the EXUP valve pul ley slightly contacts the stopper b and make sure the EXUP cable black metal 4 is not slack e Tighten the locknut 2 f Slide back the rubber cover 5 g Loosen the locknut 6 h Turn the adjusting nut 7 in...

Page 165: ...r brake light operation timing a Hold the main body 1 of the rear brake light switch so that it does not rotate and turn the adjusting nut 2 in direction a or b until the rear brake light comes on at the proper time EAS31147 CHECKING AND LUBRICATING THE CABLES The following procedure applies to all of the in ner and outer cables WARNING EWA13270 Damaged outer cable may cause the cable to corrode a...

Page 166: ...d c Tighten the locknut TIP If the specified throttle grip free play cannot be obtained on the throttle body side of the cable use the adjusting nut on the handlebar side Handlebar side a Slide back the rubber cover 1 b Loosen the locknut 2 c Turn the adjusting nut 3 in direction a or b until the specified throttle grip free play is ob tained d Tighten the locknut e Slide the rubber cover to its o...

Page 167: ...ally insert a crosshead screwdriver into the holes a and turn the adjusting screw a Turn the adjusting screws 1 in direction b or c 2 Adjust Headlight beam horizontally TIP To adjust the headlight beam horizontally in sert a crosshead screwdriver into the holes a and turn the adjusting screw a Turn the adjusting screws 1 in direction b or c Left headlight Direction b Headlight beam is raised Direc...

Page 168: ...PERIODIC MAINTENANCE 3 36 Right headlight Direction b Headlight beam moves to the left Direction c Headlight beam moves to the right 1 c b 1 c b ...

Page 169: ...HECKING THE INTAKE FUNNEL 4 21 FRONT WHEEL 4 22 REMOVING THE FRONT WHEEL 4 24 DISASSEMBLING THE FRONT WHEEL 4 24 CHECKING THE FRONT WHEEL 4 24 ASSEMBLING THE FRONT WHEEL 4 25 MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR 4 26 ADJUSTING THE FRONT WHEEL STATIC BALANCE 4 27 INSTALLING THE FRONT WHEEL DISC BRAKE 4 28 REAR WHEEL 4 31 REMOVING THE REAR WHEEL 4 34 DISASSEMBLING THE REAR WHEEL 4 ...

Page 170: ...2 REMOVING THE REAR BRAKE MASTER CYLINDER 4 63 CHECKING THE REAR BRAKE MASTER CYLINDER 4 63 ASSEMBLING THE REAR BRAKE MASTER CYLINDER 4 64 INSTALLING THE REAR BRAKE MASTER CYLINDER 4 64 ABS Anti lock Brake System 4 65 ABS COMPONENTS CHART 4 67 REMOVING THE HYDRAULIC UNIT ASSEMBLY 4 68 CHECKING THE HYDRAULIC UNIT ASSEMBLY 4 68 INSTALLING THE HYDRAULIC UNIT ASSEMBLY 4 69 HYDRAULIC UNIT OPERATION TES...

Page 171: ...Y ARM 4 96 ASSEMBLING THE REAR SHOCK ABSORBER ASSEMBLY 4 96 INSTALLING THE RELAY ARM 4 96 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 4 97 SWINGARM 4 98 REMOVING THE SWINGARM 4 100 CHECKING THE SWINGARM 4 100 INSTALLING THE SWINGARM 4 101 CHAIN DRIVE 4 104 REMOVING THE DRIVE CHAIN 4 105 CHECKING THE DRIVE CHAIN 4 105 CHECKING THE DRIVE SPROCKET 4 106 CHECKING THE REAR WHEEL SPROCKET 4 106 CHECKING...

Page 172: ...arts to remove Q ty Remarks 1 Rider seat 1 2 Battery band 1 3 Negative battery lead 1 Disconnect 4 Positive battery lead 1 Disconnect 5 Battery 1 6 Yamaha diagnostic tool coupler 1 7 Battery box 2 1 8 Seat back assembly 1 1 2 3 5 4 6 7 8 7 N m 0 7 kgf m 5 1 lb ft 2 2 N m 0 22 kgf m 1 6 lb ft ...

Page 173: ...ing the rear cowling center or rear side cover always remove them together 3 Rear cowling left 1 4 Rear side cover right 1 When removing the rear cowling center or rear side cover always remove them together 5 Rear cowling right 1 6 Tail cover left 1 7 Tail cover right 1 1 2 3 5 6 7 4 3 5 N m 0 35 kgf m 2 5 lb ft 1 8 N m 0 18 kgf m 1 3 lb ft 7 N m 0 7 kgf m 5 1 lb ft 1 8 N m 0 18 kgf m 1 3 lb ft 7...

Page 174: ... Refer to GENERAL CHASSIS 1 on page 4 1 1 Seat lock bracket 1 2 Tail brake light coupler 1 Disconnect 3 Tail brake light bracket 1 4 Tail brake light 1 5 Rear turn signal light coupler 2 Disconnect 6 License plate light coupler 1 Disconnect 7 Mudguard assembly 1 1 2 3 4 5 6 7 7 N m 0 7 kgf m 5 1 lb ft 7 N m 0 7 kgf m 5 1 lb ft 7 N m 0 7 kgf m 5 1 lb ft ...

Page 175: ...guard assembly cover 1 2 Stay 1 3 Plate 1 4 Stay 2 5 Rear turn signal light 2 6 Cover 1 7 License plate light 1 8 Rear reflector 1 FWD FWD LT 7 8 2 6 4 3 5 1 5 4 3 8 N m 0 38 kgf m 2 8 lb ft 3 8 N m 0 38 kgf m 2 8 lb ft 3 8 N m 0 38 kgf m 2 8 lb ft 2 3 N m 0 23 kgf m 1 7 lb ft 10 N m 1 0 kgf m 7 2 lb ft ...

Page 176: ...uel tank cover Refer to GENERAL CHASSIS 2 on page 4 13 Fuel tank Refer to FUEL TANK on page 7 1 Hydraulic unit Refer to ABS Anti lock Brake System on page 4 65 EXUP servo motor Refer to ENGINE REMOVAL on page 5 3 1 Plate 1 2 Battery box 1 1 3 Rear frame 1 4 Passenger footrest 2 1 2 3 4 4 LT LT LT 7 N m 0 7 kgf m 5 1 lb ft 28 N m 2 8 kgf m 20 lb ft 28 N m 2 8 kgf m 20 lb ft 50 N m 5 0 kgf m 36 lb f...

Page 177: ...pler left 1 Disconnect 3 Stay 1 4 Turn signal light left 1 5 Side cover left 1 6 ECU cover 1 7 ECU coupler 2 Disconnect 8 ECU Engine Control Unit 1 9 Side cover bracket left 1 FWD FWD 2 6 5 4 3 1 7 8 9 7 N m 0 7 kgf m 5 1 lb ft 7 N m 0 7 kgf m 5 1 lb ft 7 N m 0 7 kgf m 5 1 lb ft 7 N m 0 7 kgf m 5 1 lb ft 1 5 N m 0 15 kgf m 1 1 lb ft 1 5 N m 0 15 kgf m 1 1 lb ft ...

Page 178: ...ervoir cover 1 2 Radiator cover right 1 3 Turn signal light coupler right 1 Disconnect 4 Stay 1 5 Turn signal light right 1 6 Side cover right 1 7 Side cover bracket right 1 FWD FWD 2 6 4 5 3 1 7 7 N m 0 7 kgf m 5 1 lb ft 7 N m 0 7 kgf m 5 1 lb ft 7 N m 0 7 kgf m 5 1 lb ft 1 5 N m 0 15 kgf m 1 1 lb ft 1 5 N m 0 15 kgf m 1 1 lb ft ...

Page 179: ...ary DC jack coupler 1 Disconnect 6 Radiator fan motor coupler left 1 Disconnect 7 Radiator fan motor coupler right 1 Disconnect 8 Wire harness 1 9 Wire harness bracket 1 10 Air scoop stay left 1 11 Radiator fan motor relay 1 12 Relay unit 1 1 5 N m 0 15 kgf m 1 1 lb ft 1 5 N m 0 15 kgf m 1 1 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 7 N m 0 7 kgf m 5 1 lb ft 1 3 2 10 9 12 11 ...

Page 180: ...6 Clutch switch coupler 1 Disconnect 7 Steering damper solenoid coupler 1 Disconnect 8 Handlebar switch coupler right 2 Disconnect 9 Front brake light switch coupler 1 Disconnect 10 Turn signal light coupler right 1 Disconnect 11 Wire harness 1 12 Air scoop stay right 1 13 Intake air temperature sensor 1 FWD FWD 1 5 N m 0 15 kgf m 1 1 lb ft 1 5 N m 0 15 kgf m 1 1 lb ft 1 8 N m 0 18 kgf m 1 3 lb ft...

Page 181: ...b Install the side cover bolt 2 and then tighten the bolt to specification EAS31264 REMOVING THE SIDE COVER right 1 Remove Side cover right 1 a Remove the side cover bolt 2 b Remove the side cover 1 by sliding it for ward EAS31265 INSTALLING THE SIDE COVER right 1 Install Side cover right 1 a Install the side cover 1 TIP Insert projections a on the side cover into slots b b Install the side cover ...

Page 182: ... Quick fastener 1 Air scoop cap 2 2 Remove Air scoop bolt 1 Washer Air scoop 2 TIP Remove the projections a on the air scoop from the slots b in the fuel tank cover Remove the parts c on the air scoop from the cutouts d in the air scoop stay Remove the projection e on the air scoop from the hole f in the air scoop stay EAS31773 INSTALLING THE AIR SCOOP The following procedure applies to both of th...

Page 183: ...GENERAL CHASSIS 1 4 12 Air scoop bolt 1 5 N m 0 15 kgf m 1 1 lb ft T R 2 1 b b d a a c ...

Page 184: ...coupler 1 Disconnect 7 Main switch coupler 2 Disconnect 8 Auxiliary light coupler 1 Disconnect 9 Meter assembly coupler 1 Disconnect 10 Meter assembly 1 Disconnect 11 Meter assembly inner panel 1 12 Auxiliary light 1 7 0 8 N m 0 08 kgf m 0 58 lb ft 1 3 N m 0 13 kgf m 0 94 lb ft 1 3 N m 0 13 kgf m 0 94 lb ft 1 3 N m 0 13 kgf m 0 94 lb ft 1 8 N m 0 18 kgf m 1 3 lb ft 7 N m 0 7 kgf m 5 1 lb ft 7 N m ...

Page 185: ...ront cowling inner panel left 1 4 Auxiliary DC jack 1 5 Front side panel right 1 6 Front cowling inner panel right 1 7 Headlight control unit coupler 1 Disconnect 8 Headlight assembly 1 7 N m 0 7 kgf m 5 1 lb ft 7 N m 0 7 kgf m 5 1 lb ft 1 5 N m 0 15 kgf m 1 1 lb ft 1 5 N m 0 15 kgf m 1 1 lb ft 1 5 N m 0 15 kgf m 1 1 lb ft 1 5 N m 0 15 kgf m 1 1 lb ft 1 2 3 4 5 6 7 8 1 3 N m 0 13 kgf m 0 94 lb ft ...

Page 186: ...emove Q ty Remarks 1 Headlight cover 1 2 Intake grill 1 3 Plate 1 4 Headlight control unit coupler 1 Disconnect 5 Headlight control unit 1 6 Headlight 1 4 3 N m 0 43 kgf m 3 1 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 1 2 3 4 5 0 5 N m 0 05 kgf m 0 36 lb ft 6 ...

Page 187: ...ir scoop Air scoop stay Refer to GENERAL CHASSIS 1 on page 4 1 Meter assembly Auxiliary light Refer to GENERAL CHASSIS 2 on page 4 13 Headlight assembly Refer to GENERAL CHASSIS 2 on page 4 13 1 Headlight stay 1 2 Air intake duct 1 18 N m 1 8 kgf m 13 lb ft 18 N m 1 8 kgf m 13 lb ft LT LT 1 2 ...

Page 188: ...o GENERAL CHASSIS 1 on page 4 1 1 Fuel tank cover 1 2 Fuel tank cover left 1 3 Fuel tank mole left 1 4 Fuel tank cover right 1 5 Fuel tank mole right 1 1 2 3 4 5 0 4 N m 0 04 kgf m 0 29 lb ft 0 4 N m 0 04 kgf m 0 29 lb ft 1 5 N m 0 15 kgf m 1 1 lb ft 1 5 N m 0 15 kgf m 1 1 lb ft 3 8 N m 0 38 kgf m 2 8 lb ft 3 8 N m 0 38 kgf m 2 8 lb ft ...

Page 189: ... Fuel tank cover 1 Collar Fuel tank cover screw Fuel tank cover bolt TIP Install the projection a on the fuel tank cover into the grommet b Install the parts c on the fuel tank cover into the hole d 2 Install Fuel tank cover 1 Quick fastener 2 3 Install Air scoop stay Air scoop Rider seat Refer to GENERAL CHASSIS 1 on page 4 1 EAS32041 REMOVING THE FUEL TANK COVER RIVET The following procedure app...

Page 190: ...GENERAL CHASSIS 2 4 19 TIP Slide the fuel tank rivet in the arrow direction and remove it 1 2 ...

Page 191: ... GENERAL CHASSIS 2 on page 4 13 Fuel tank Refer to FUEL TANK on page 7 1 1 Plug 1 2 Air filter case cover 1 3 Air filter element 1 4 Intake funnel assembly bolt 6 Loosen 5 Crankcase breather hose 1 Disconnect 6 Air induction system hose 1 Disconnect 7 Air filter case 1 8 Intake funnel assembly 2 9 Air duct 1 2 3 7 1 8 4 9 5 3 3 10 6 4 0 N m 0 40 kgf m 2 9 lb ft 1 6 N m 0 16 kgf m 1 2 lb ft 8 N m 0...

Page 192: ...take funnel assembly NOTICE ECA17530 Do not disassemble the intake funnel assem bly a Keep the two tabs a pushed in the direction shown in the illustration and separate the in take funnel assembly from air filter case NOTICE ECA22590 Do not remove the bolts 1 from the intake funnel joint EAS32032 CHECKING THE AIR FILTER CASE SEAL 1 Check Air filter case seal 1 Damage Replace EAS32033 CHECKING THE ...

Page 193: ...caliper 2 6 Wheel axle pinch bolt 4 Loosen 7 Front wheel axle nut 1 8 Front wheel axle 1 9 Front wheel 1 10 Collar 2 11 Front brake disc 2 1 2 3 4 5 6 7 8 9 10 11 LT 11 10 6 1 2 3 5 LT 6 N m 0 6 kgf m 4 3 lb ft 3 8 N m 0 38 kgf m 2 8 lb ft 35 N m 3 5 kgf m 25 lb ft 6 N m 0 6 kgf m 4 3 lb ft 3 8 N m 0 38 kgf m 2 8 lb ft 21 N m 2 1 kgf m 15 lb ft 7 N m 0 7 kgf m 5 1 lb ft 17 N m 1 7 kgf m 12 lb ft 1...

Page 194: ...FRONT WHEEL 4 23 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 1 2 2 3 3 4 LT 8 N m 0 8 kgf m 5 8 lb ft ...

Page 195: ...ensor from the sensor housing 3 Elevate Front wheel TIP Place the vehicle on a maintenance stand so that the front wheel is elevated 4 Loosen Wheel axle pinch bolt 5 Remove Front wheel axle Front wheel EAS30146 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...

Page 196: ... sensor ro tor wipe it off immediately 1 Install Wheel bearings Oil seals a Install the new wheel bearing right side NOTICE ECA18110 Do not contact the wheel bearing inner race 1 or balls 2 Contact should be made only with the outer race 3 TIP Use a socket 4 that matches the diameter of the wheel bearing outer race b Install the spacer c Install the new wheel bearing left side TIP Place a suitable...

Page 197: ... tools magnetic screwdrivers etc away from the front wheel sensor or front wheel sensor rotor Do not drop or shock the wheel sensor or the wheel sensor rotor 1 Check Front wheel sensor 1 Cracks bends distortion Replace Iron powder dust Clean 2 Check Front wheel sensor rotor 1 Cracks damage scratches Replace the front wheel sensor rotor Iron powder dust solvent Clean TIP The wheel sensor rotor is i...

Page 198: ...ight s 2 Find Front wheel s heavy spot TIP Place the front wheel on a suitable balancing stand a Spin the front wheel b When the front wheel stops put an X1 mark at the bottom of the wheel c Turn the front wheel 90 so that the X1 mark is positioned as shown d Release the front wheel e When the wheel stops put an X2 mark at the bottom of the wheel f Repeat steps c through e several times until all ...

Page 199: ...cate Oil seal lips 4 Install Collar Front wheel Front wheel axle Front wheel axle nut TIP Apply lithium soap based grease onto the mat ing surface of the front wheel axle nut 5 Tighten Front wheel axle nut NOTICE ECA14140 Before tightening the wheel axle nut push down hard on the handlebar s several times and check if the front fork rebounds smooth ly 6 Tighten Front wheel axle pinch bolt a Tighte...

Page 200: ...he front wheel sensor and sensor rotor installation conditions warpage caused by overtorque wrong in stallation direction rotor decentering LOC TITE on the mounting surface of the rotor deformation caused by an impact during ser vice and caught foreign materials If there is any defective part repair or replace the de fective part TIP Measure the distance between the front wheel sensor rotor and fr...

Page 201: ...FRONT WHEEL 4 30 WARNING EWA13500 Make sure the brake hose is routed properly ...

Page 202: ...ensor protector 1 2 Rear wheel sensor 1 3 Locknut 2 Loosen 4 Adjusting bolt 2 Loosen 5 Rear wheel axle nut 1 6 Washer 1 7 Rear wheel axle 1 8 Adjusting block left 1 9 Adjusting block right 1 10 Rear wheel 1 11 Brake caliper bracket 1 1 2 3 4 5 6 7 8 9 11 10 3 4 7 N m 0 7 kgf m 5 1 lb ft 190 N m 19 kgf m 137 lb ft 16 N m 1 6 kgf m 12 lb ft 16 N m 1 6 kgf m 12 lb ft ...

Page 203: ...Wheel ring 1 3 Rear brake disc 1 4 Bracket 1 5 Rear wheel sprocket 1 6 Collar 1 7 Collar 1 8 Oil seal 1 9 Bearing 1 10 Rear wheel drive hub 1 11 Rear wheel drive hub damper 6 12 Rear wheel 1 LT 1 3 5 4 6 8 9 10 11 12 LT 5 5 5 6 7 2 8 N m 0 8 kgf m 5 8 lb ft 8 N m 0 8 kgf m 5 8 lb ft 30 N m 3 0 kgf m 22 lb ft 80 N m 8 0 kgf m 58 lb ft ...

Page 204: ... 33 Disassembling the rear wheel Order Job Parts to remove Q ty Remarks 1 Collar 1 2 Wheel bearing 1 3 Spacer 1 4 Oil seal 1 5 Wheel bearing ring nut 1 6 Wheel bearing 1 1 2 3 4 5 6 LT LT 80 N m 8 0 kgf m 58 lb ft ...

Page 205: ...ted 2 Remove Rear brake caliper 1 Rear wheel sensor protector 2 Rear wheel sensor 3 NOTICE ECA21040 Do not depress the brake pedal when re moving the brake caliper Be sure not to contact the sensor electrode to any metal part when removing the rear wheel sensor from the rear brake caliper bracket 3 Loosen Locknuts 1 Adjusting bolts 2 4 Remove Rear wheel axle nut 1 Washer Rear wheel axle 2 Rear whe...

Page 206: ... WHEEL on page 4 24 2 Check Tire Rear wheel Damage wear Replace Refer to CHECKING THE TIRES on page 3 17 and CHECKING THE WHEELS on page 3 17 3 Measure Radial wheel runout Lateral wheel runout Refer to CHECKING THE FRONT WHEEL on page 4 24 EAS30160 CHECKING THE REAR WHEEL DRIVE HUB 1 Check Rear wheel drive hub 1 Cracks damage Replace Rear wheel drive hub dampers 2 Damage wear Replace EAS30161 CHEC...

Page 207: ...tely 1 Install Wheel bearings Oil seal Refer to ASSEMBLING THE FRONT WHEEL on page 4 25 2 Install Wheel bearing ring nut TIP Apply locking agent LOCTITE onto the two symmetric places on the circumference of the threads of the wheel bearing ring nut 3 Tighten Wheel bearing ring nut 1 TIP Use the wheel bearing ring nut tool 2 to tighten the wheel bearing ring nut by turning it counter clockwise a b ...

Page 208: ...R AND SENSOR ROTOR on page 4 26 3 Measure Wheel sensor rotor runout Refer to MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR on page 4 26 EAS30164 ADJUSTING THE REAR WHEEL STATIC BALANCE TIP After replacing the tire wheel or both the rear wheel static balance should be adjusted Adjust the rear wheel static balance with the brake disc and rear wheel drive hub installed 1 Adjust Rear wheel st...

Page 209: ... wheel sensor Rear wheel sensor protector NOTICE ECA21080 Make sure there are no foreign materials in the rear wheel sensor rotor and rear wheel sensor Foreign materials cause damage to the rear wheel sensor rotor and rear wheel sensor TIP When installing the rear wheel sensor check the rear wheel sensor lead for twists 9 Measure Distance a between the wheel sensor rotor 1 and rear wheel sensor 2 ...

Page 210: ... If there is any defective part repair or replace the de fective part TIP Measure the distance between the rear wheel sensor rotor and rear wheel sensor in several places in one rotation of the rear wheel Do not turn the rear wheel while the thickness gauge is installed This may damage the rear wheel sen sor rotor and the rear wheel sensor Distance a between the rear wheel sensor rotor and rear wh...

Page 211: ...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 reflector 1 6 Front brake hose holder 1 7 Front brake caliper 1 8 Bleed screw 1 9 Bleed screw 1 Right brake caliper side FWD FWD 3 4 7 8 9 2 1 5 6 5 N m 0 5 kgf m 3 6 lb ft 6 N m 0 6 kgf m 4 3 lb ft 35 N m 3 5 kgf m 25 lb ft ...

Page 212: ...ake master cylinder reservoir diaphragm holder 1 3 Brake master cylinder reservoir diaphragm 1 4 Brake lever 1 5 Front brake light switch 1 6 Brake hose union bolt 1 7 Brake hose gasket 2 8 Brake hose 1 9 Front brake master cylinder holder 1 10 Front brake master cylinder assembly 1 1 2 3 4 5 6 7 8 9 10 S S 1 5 N m 0 15 kgf m 1 1 lb ft 1 0 N m 0 10 kgf m 0 72 lb ft 1 2 N m 0 12 kgf m 0 87 lb ft 6 ...

Page 213: ...FRONT BRAKE 4 42 Disassembling the front brake master cylinder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder kit 1 2 Brake master cylinder body 1 2 1 S BF BF FWD FWD ...

Page 214: ...he front brake calipers Brake fluid Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS on page 3 16 1 Front reflector 1 2 Front brake hose holder 1 3 Brake hose union bolt 1 4 Brake hose gasket 2 5 Brake hose 1 6 Front brake caliper 1 FWD FWD 6 3 1 2 6 N m 0 6 kgf m 4 3 lb ft 35 N m 3 5 kgf m 25 lb ft 32 N m 3 2 kgf m 23 lb ft 4 5 ...

Page 215: ...ront 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 9 Bleed screw 1 Right brake caliper side 1 2 3 4 5 6 6 7 5 6 6 7 7 7 8 9 S S BF S BF S 5 N m 0 5 kgf m 3 6 lb ft 5 N m 0 5 kgf m 3 6 lb ft FWD FWD ...

Page 216: ...Remove Front wheel Refer to FRONT WHEEL on page 4 22 2 Check Front brake disc Damage galling Replace 3 Measure Brake disc runout Out of specification Correct the brake disc runout or replace the brake disc a Place the vehicle on a maintenance stand so that the front wheel is elevated b Before measuring the brake disc runout turn the handlebar to the left or right to ensure that the front wheel is ...

Page 217: ...to disconnect the brake hose or disassem ble the brake caliper 1 Remove Brake pad clips 1 Brake pad pin 2 Brake pad spring 3 2 Remove Brake pads 1 3 Measure Brake pad wear limit a Out of specification Replace the brake pads as a set 4 Remove Brake caliper 5 Install Brake pads Brake pad spring TIP Always install new brake pads and new brake pad spring as a set a Connect a clear plastic hose 1 tight...

Page 218: ... lever operation Soft or spongy feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS on page 3 16 EAS30171 REMOVING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers TIP Before removing the brake caliper drain the brake fluid from the entire brake system 1 Remove Brake hose union bolts 1 Brake hose gaskets 2 Brake hoses 3 TIP Put the...

Page 219: ...e the brake caliper pistons Brake caliper cylinders 2 Scratches wear Replace the brake caliper assembly Brake caliper body 3 Cracks damage Replace the brake caliper assembly Brake fluid delivery passages brake caliper body Obstruction Blow out with compressed air WARNING EWA13611 Whenever a brake caliper is disassembled replace the brake caliper piston dust seals and brake caliper piston seals EAS...

Page 220: ...signated brake fluid Other brake fluids 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 fluid reservoir Water will significantly lower...

Page 221: ...ake master cylinder body Obstruction Blow out with compressed air 2 Check Brake master cylinder kit Damage scratches wear Replace 3 Check Brake master cylinder reservoir 1 Brake master cylinder reservoir diaphragm holder 2 Cracks damage Replace Brake master cylinder reservoir diaphragm 3 Damage wear Replace 4 Check Brake hoses Cracks damage wear Replace EAS30181 ASSEMBLING THE FRONT BRAKE MASTER C...

Page 222: ...r reservoir with the specified amount of the specified brake fluid WARNING EWA13540 Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing 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 refi...

Page 223: ...FRONT BRAKE 4 52 6 Check Brake lever operation Soft or spongy feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS on page 3 16 ...

Page 224: ...1 2 Brake pad retaining 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 FWD FWD 2 5 N m 0 25 kgf m 1 8 lb ft 5 N m 0 5 kgf m 3 6 lb ft 27 N m 2 7 kgf m 20 lb ft 17 N m 1 7 kgf m 12 lb ft 22 N m 2 2 kgf m 16 lb ft 1 2 3 4 5 5 6 6 7 8 LT S S S S ...

Page 225: ...id reservoir cap 1 2 Brake fluid reservoir diaphragm holder 1 3 Brake fluid reservoir diaphragm 1 4 Brake fluid reservoir 1 5 Brake fluid reservoir bracket 1 6 Brake hose union bolt 1 7 Brake hose gasket 2 8 Brake hose 1 9 Rear brake light switch coupler 1 Disconnect 10 Right footrest assembly 1 11 Brake pedal 1 FWD FWD 7 N m 0 7 kgf m 5 1 lb ft 7 N m 0 7 kgf m 5 1 lb ft 30 N m 3 0 kgf m 22 lb ft ...

Page 226: ...r brake master cylinder assembly 1 14 Rear brake light switch bracket 1 15 Rear brake light switch 1 FWD FWD 7 N m 0 7 kgf m 5 1 lb ft 7 N m 0 7 kgf m 5 1 lb ft 30 N m 3 0 kgf m 22 lb ft 20 N m 2 0 kgf m 14 lb ft 23 N m 2 3 kgf m 17 lb ft 28 N m 2 8 kgf m 20 lb ft 2 5 N m 0 25 kgf m 1 8 lb ft 32 N m 3 2 kgf m 23 lb ft LT 12 13 14 15 ...

Page 227: ...ling the 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 18 N m 1 8 kgf m 13 lb ft ...

Page 228: ...ty Remarks Brake fluid Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS on page 3 16 1 Brake hose union bolt 1 2 Brake hose gasket 2 3 Brake hose 1 4 Rear brake caliper 1 FWD FWD 27 N m 2 7 kgf m 20 lb ft 22 N m 2 2 kgf m 16 lb ft 32 N m 3 2 kgf m 23 lb ft LT S S 3 2 4 1 ...

Page 229: ...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 11 Sleeve 1 12 Sleeve boot 1 2 5 N m 0 25 kgf m 1 8 lb ft 5 N m 0 5 kgf m 3 6 lb ft 17 N m 1 7 kgf m 12 lb ft 3 1 2 10 5 4 5 4 6 9 7 8 S S S BF 12 11 FWD FWD ...

Page 230: ...sure Brake disc runout Out of specification Correct the brake disc runout or replace the brake disc Refer to CHECKING THE FRONT BRAKE DISCS on page 4 45 4 Measure Brake disc thickness Measure the brake disc thickness at a few dif ferent locations Out of specification Replace Refer to CHECKING THE FRONT BRAKE DISCS on page 4 45 5 Adjust Brake disc runout Refer to CHECKING THE FRONT BRAKE DISCS on p...

Page 231: ...o contact the brake pads Remove any excess grease 4 Install Rear brake caliper Brake pad retaining bolts Screw plug 5 Check Brake fluid level Below the minimum level mark a Add the specified brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 14 6 Check Brake pedal operation Soft or spongy feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM AB...

Page 232: ...e caliper piston dust seal and brake caliper piston seal EAS30188 CHECKING THE REAR BRAKE CALIPER 1 Check Brake caliper piston 1 Rust scratches wear Replace the brake caliper piston Brake caliper cylinder 2 Scratches wear Replace the brake caliper assembly Brake caliper body 3 Cracks damage Replace the brake caliper assembly Brake fluid delivery passages brake caliper body Obstruction Blow out wit...

Page 233: ...ets Brake hose 2 Brake hose union bolt 3 WARNING EWA13531 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 2 Remove Rear brake caliper 3 Install Brake pad insulators Brake pad shims onto the brake pads Brake pad spring into...

Page 234: ...ke fluid level Below the minimum level mark a Add the specified brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 14 7 Check Brake pedal operation Soft or spongy feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS on page 3 16 EAS30193 REMOVING THE REAR BRAKE MASTER CYLINDER 1 Remove Brake hose union bolt 1 Brake hose gaskets 2 Brake hos...

Page 235: ...ate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake performance When refilling be careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock NOTICE ECA135...

Page 236: ...ge 3 16 1 Fuel tank bracket 1 2 Brake hose union bolt 4 3 Gasket 8 4 Rear brake hose hydraulic unit to rear brake caliper 1 5 Rear brake hose rear brake master cylinder to hydraulic unit 1 6 Front brake hose front brake master cylinder to hydraulic unit 1 7 Front brake hose hydraulic unit to front brake calipers 1 7 N m 0 7 kgf m 5 1 lb ft 7 N m 0 7 kgf m 5 1 lb ft 7 N m 0 7 kgf m 5 1 lb ft 7 N m ...

Page 237: ...ulator 1 10 ABS ECU coupler 1 Disconnect 11 Hydraulic unit bracket 1 12 Hydraulic unit 1 13 Rear brake hose bracket 1 7 N m 0 7 kgf m 5 1 lb ft 7 N m 0 7 kgf m 5 1 lb ft 7 N m 0 7 kgf m 5 1 lb ft 7 N m 0 7 kgf m 5 1 lb ft 7 N m 0 7 kgf m 5 1 lb ft 7 N m 0 7 kgf m 5 1 lb ft 26 N m 2 6 kgf m 19 lb ft 26 N m 2 6 kgf m 19 lb ft 26 N m 2 6 kgf m 19 lb ft 8 9 10 11 12 13 ...

Page 238: ...or 6 Front wheel sensor 7 Front brake caliper 8 Rear wheel sensor 9 Rear wheel sensor rotor 10 Rear brake caliper 11 ABS motor fuse 12 Yamaha diagnostic tool coupler 13 Front brake hose hydraulic unit to front brake calipers 14 Front brake hose front brake master cylinder to hydraulic unit 15 Rear brake hose rear brake master cylinder to hydraulic unit 16 Rear brake hose hydraulic unit to rear bra...

Page 239: ...ave been removed be sure to tighten them to the specified torque and bleed the brake system 1 Disconnect ABS ECU coupler 1 TIP While pushing the portion a of the ABS ECU coupler pull the lock lever up to release the lock NOTICE ECA20080 Do not use a tool to disconnect the ABS ECU coupler 2 Remove Brake hoses TIP Do not operate the brake lever and brake pedal while removing the brake hoses NOTICE E...

Page 240: ... ABS ECU coupler and then push the lock lever of the coupler in the direction of the arrow shown 5 Fill Brake master cylinder reservoir Brake fluid reservoir with the specified amount of the specified brake fluid WARNING EWA13090 Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of b...

Page 241: ...tic tool Before performing the brake line routing confir mation make sure that no malfunctions have been detected in the ABS ECU and that the wheels are not rotating 1 Place the vehicle on a maintenance stand 2 Turn the main switch to OFF 3 Remove Rider seat Refer to GENERAL CHASSIS 1 on page 4 1 4 Check Battery voltage Lower than 12 8 V Charge or replace the battery TIP If the battery voltage is ...

Page 242: ...mal delete all of the fault codes ABS reaction force confirmation WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over TIP For the ABS reaction force confirmation use the diagnosis of function of the Yamaha diag nostic tool For more information refer to the operation manual of the Yamaha diagnostic tool Before performing the ABS reaction force con firmation m...

Page 243: ...action force pulsating action consists of quick pulses Be sure to continue operating the brake lever and brake pedal even after the pulsating action has stopped ON and OFF on the tool screen indicate when the brakes are being applied and re leased respectively 10 After the pulsating action has stopped in the brake lever it is generated in the brake pedal 1 and continues for a few seconds TIP The r...

Page 244: ...lic unit assembly 12 Turn the main switch to OFF 13 Remove the Yamaha diagnostic tool from the Yamaha diagnostic tool coupler and then in stall the protective cap 14 Turn the main switch to ON 15 Set the start engine stop switch to 16 Check for brake fluid leakage around the hy draulic unit Brake fluid leakage Replace the hydraulic unit brake pipes and related parts as a set 17 If the operation of...

Page 245: ... left 1 11 Handlebar switch holder 2 12 Handlebar grip 1 13 Clutch switch 1 14 Clutch cable 1 Disconnect 15 Clutch lever holder 1 11 N m 1 1 kgf m 8 0 lb ft 26 N m 2 6 kgf m 19 lb ft 22 N m 2 2 kgf m 16 lb ft 17 N m 1 7 kgf m 12 lb ft 1 8 N m 0 18 kgf m 1 3 lb ft 26 N m 2 6 kgf m 19 lb ft 17 N m 1 7 kgf m 12 lb ft 10 N m 1 0 kgf m 7 2 lb ft 3 8 N m 0 38 kgf m 2 8 lb ft 3 5 N m 0 35 kgf m 2 5 lb ft...

Page 246: ...lb ft 26 N m 2 6 kgf m 19 lb ft 22 N m 2 2 kgf m 16 lb ft 17 N m 1 7 kgf m 12 lb ft 1 8 N m 0 18 kgf m 1 3 lb ft 26 N m 2 6 kgf m 19 lb ft 17 N m 1 7 kgf m 12 lb ft 10 N m 1 0 kgf m 7 2 lb ft 3 8 N m 0 38 kgf m 2 8 lb ft 3 5 N m 0 35 kgf m 2 5 lb ft 3 5 N m 0 35 kgf m 2 5 lb ft 40 N m 4 0 kgf m 29 lb ft 40 N m 4 0 kgf m 29 lb ft 1 2 N m 0 12 kgf m 0 87 lb ft 16 17 19 18 FWD FWD ...

Page 247: ...this may dangerously weaken it EAS30205 INSTALLING THE HANDLEBAR 1 Stand the vehicle on a level surface WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over 2 Install Lower handlebar holders temporarily Handlebar 1 Upper handlebar holders 2 NOTICE ECA19130 First tighten the bolts on the front side of the upper handlebar holder and then on the rear side Turn t...

Page 248: ...able TIP Align the center of slit on the clutch lever holder with the punch mark a on the handlebar 8 Install Handlebar switch holder Handlebar switch left TIP Align the projection a on the left handlebar switch with the hole b in the handlebar 9 Install Handlebar grip 1 Grip end 2 a Apply a thin coat of rubber adhesive onto the Lower handlebar holder nut 40 N m 4 0 kgf m 29 lb ft Throttle cable h...

Page 249: ...the rub ber adhesive has fully dried TIP There should be 1 3 mm 0 04 0 12 in of clear ance a between the handlebar grip and the grip end 10 Adjust Throttle grip free play Refer to CHECKING THE THROTTLE GRIP on page 3 33 11 Adjust Clutch lever free play Refer to ADJUSTING THE CLUTCH LEVER FREE PLAY on page 3 13 Throttle grip free play 3 0 5 0 mm 0 12 0 20 in Clutch lever free play 5 0 10 0 mm 0 20 ...

Page 250: ...e applies to both of the front fork legs Front wheel Refer to FRONT WHEEL on page 4 22 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 6 N m 0 6 kgf m 4 3 lb ft 6 N m 0 6 kgf m 4 3 lb ft 23 N m 2 3 kgf m 17 lb ft 26 N m 2 6 kgf m 19 lb ft 1 4 2 3 5 ...

Page 251: ...p bolt 1 2 O ring 1 3 Guide 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 14 Damper rod assembly 1 15 Inner tube 1 7 9 8 13 14 10 11 12 15 23 N m 2 3 kgf m 17 lb ft 15 N m 1 5 kgf m 11 lb ft 21 N m 2 1 kgf m 15 lb ft 40 N m 4 0 kgf m 29 lb ft ...

Page 252: ...port 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 Turn the spring preload adjusting nut 1 counterclockwise until it stops 2 Remove Cap bolt 1 from the damper rod assembly Guide 2 Spacer 3 Locknut 4 a Press down on the spacer with the fork spring compressor 5 b Install the rod holder 6 between ...

Page 253: ...ntally b Securely clamp the brake caliper bracket in a vise with soft jaws c Separate the outer tube from the inner tube by pulling the outer tube forcefully but careful ly NOTICE ECA19880 Excessive force will damage the bushings Damaged bushings must be replaced 6 Remove Damper rod assembly TIP Remove the damper rod assembly with the damper rod holder 1 EAS30208 CHECKING THE FRONT FORK LEGS The f...

Page 254: ...olt collar projection 2 Cracks damage Replace EAS30209 ASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 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...

Page 255: ... soap based grease Lubricate the outer surface of the inner tube with fork oil Before installing the oil seal cover the top of the front fork leg with a plastic bag to protect the oil seal during installation 5 Install Outer tube to the inner tube 6 Install Outer tube bushing 1 Washer 2 with the fork seal driver 3 Front fork damper rod assembly 40 N m 4 0 kgf m 29 lb ft Damper rod holder ø30 90890...

Page 256: ...TICE ECA14230 Be sure to use the recommended fork oil Other oils may have an adverse effect on front fork performance Fork seal driver 90890 01442 Adjustable fork seal driver 36 46 mm YM 01442 Fork seal driver 90890 01442 Adjustable fork seal driver 36 46 mm YM 01442 1 Rod puller 90890 01437 Universal damping rod bleeding tool set YM A8703 Rod puller attachment M10 90890 01436 Universal damping ro...

Page 257: ...er tube with the outer tube fully compressed and without the fork spring Out of specification Correct 15 Install Fork spring 1 Spacer 2 Locknut 3 Damper adjusting rod 2 4 Damper adjusting rod 1 5 Guide 6 Cap bolt 7 along with the O ring a Remove the rod puller and rod puller attach ment b Install the fork spring TIP Install the fork spring with the smaller diameter a facing up A c Install the lock...

Page 258: ...r installing the front fork leg to the vehicle and tightening the lower bracket pinch bolts EAS30210 INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Install Front fork leg Temporarily tighten the upper and lower bracket pinch bolts WARNING EWA13680 Make sure the brake hoses are routed prop erly TIP Install the front fork leg as shown in the illustra ...

Page 259: ...he angles shown in the illustration 4 Check Cable routing TIP Make sure the brake hose throttle cables clutch cable and handlebar switch leads are routed properly Refer to CABLE ROUTING on page 2 39 5 Adjust Spring preload Rebound damping Compression damping Refer to ADJUSTING THE FRONT FORK LEGS on page 3 22 Lower bracket pinch bolt 23 N m 2 3 kgf m 17 lb ft Front fork cap bolt 23 N m 2 3 kgf m 1...

Page 260: ...ar Refer to HANDLEBAR on page 4 74 Front wheel Refer to FRONT WHEEL on page 4 22 Front fork legs Refer to FRONT FORK on page 4 79 1 Horn connector 2 Disconnect 2 Horn 1 3 Front brake hose 1 4 Horn bracket 1 5 Steering damper solenoid coupler 1 Disconnect 6 Steering damper solenoid 1 7 Handlebar switch lead right Front brake light switch lead 1 1 LT 23 N m 2 3 kgf m 17 lb ft 23 N m 2 3 kgf m 17 lb ...

Page 261: ...em nut 1 11 Upper bracket 1 12 Lock washer 1 13 Upper ring nut 1 14 Rubber washer 1 15 Lower ring nut 1 16 Lower bracket 1 17 Bearing cover 1 18 Lower bearing dust seal 1 19 Upper bearing 1 20 Lower bearing 1 LT 23 N m 2 3 kgf m 17 lb ft 23 N m 2 3 kgf m 17 lb ft 11 N m 1 1 kgf m 8 0 lb ft 115 N m 11 5 kgf m 83 lb ft 7 N m 0 7 kgf m 5 1 lb ft 1st 2nd 52 N m 5 2 kgf m 38 lb ft 14 N m 1 4 kgf m 10 l...

Page 262: ...Wash Bearing Bearing race 2 Check Bearing 1 Bearing race 2 Damage pitting Replace the bearings and bearing races as a set 3 Replace Bearing Bearing race a Remove the bearing races from the steering head pipe 1 with a long rod 2 and hammer b Remove the bearing race 3 from the lower bracket with a floor chisel 4 and hammer c Install a new dust seal and new bearing rac es NOTICE ECA14270 If the beari...

Page 263: ...ll Upper bracket Steering stem nut Refer to HANDLEBAR on page 4 74 TIP Temporarily tighten the steering stem nut 4 Install Front fork legs Refer to FRONT FORK on page 4 79 TIP Temporarily tighten the upper and lower bracket pinch bolts EAS30215 CHECKING THE STEERING DAMPER 1 Check Steering damper body Damage oil leaks Replace the steering damper assembly Steering damper rod Bends scratch Replace t...

Page 264: ...ar brake caliper Refer to REAR BRAKE on page 4 53 Rear wheel Refer to REAR WHEEL on page 4 31 1 Connecting arm upper nut Washer Bolt 1 1 1 2 Rear shock absorber assembly lower nut Bolt 1 1 3 Connecting arm lower nut Washer Bolt 1 1 1 4 Connecting arm 2 5 Rear shock absorber assembly upper nut Col lar Bolt 1 1 1 6 Relay arm nut Bolt 1 1 7 Collar 1 8 Relay arm 1 9 Rear shock absorber assembly 1 2 4 ...

Page 265: ...sembly Order Job Parts to remove Q ty Remarks 10 Oil seal Bearing 2 1 11 Collar Oil seal Bearing 1 2 2 12 Collar Oil seal Bearing 1 2 1 13 Collar Oil seal Bearing 1 2 2 13 13 12 12 40 N m 4 0 kgf m 29 lb ft 40 N m 4 0 kgf m 29 lb ft 11 11 10 10 35 N m 3 5 kgf m 25 lb ft ...

Page 266: ...ng of a rear shock absorber To release the gas pressure drill a 2 3 mm 0 08 0 12 in hole through the rear shock absorber as shown WARNING EWA13760 Wear eye protection to prevent eye damage from released gas or metal chips EAS30219 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 1 Stand the vehicle on a level surface WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling o...

Page 267: ... ARM AND RELAY ARM 1 Check Connecting arms 1 Relay arm 2 Damage wear Replace 2 Check Bearings Oil seals Damage pitting Replace 3 Check Collars Damage scratches Replace EAS31654 ASSEMBLING THE REAR SHOCK ABSORBER ASSEMBLY 1 Install Bearing 1 Oil seal TIP Install the bearing with a socket 2 that matches its outside diameter EAS30222 INSTALLING THE RELAY ARM 1 Lubricate Collars Oil seals 2 Install Be...

Page 268: ... connecting arm upper bolt from the left When installing the rear shock absorber as sembly lift up the swingarm 2 Tighten Relay arm nut Rear shock absorber assembly upper nut Connecting arm lower nut Rear shock absorber assembly lower nut Connecting arm upper nut 3 Relay arm 4 Connecting arm 5 Rear shock absorber assembly 6 Frame A Left side B Right side 1 1 3 4 2 6 2 4 5 a b b Relay arm nut 40 N ...

Page 269: ...DRIVE on page 4 104 1 Drive chain guard 1 2 Rear fender 1 3 Cover 1 4 Drive chain guide 1 5 Rear wheel sensor lead cover 1 6 Pivot shaft nut Washer 1 1 7 Pivot shaft ring nut Washer 1 1 8 Pivot shaft 1 9 Rear wheel sensor lead hook 1 10 Swingarm 1 11 Drive chain 1 1 2 4 5 8 7 10 11 9 3 7 N m 0 7 kgf m 5 1 lb ft 7 N m 0 7 kgf m 5 1 lb ft 7 N m 0 7 kgf m 5 1 lb ft 7 N m 0 7 kgf m 5 1 lb ft 16 N m 1 ...

Page 270: ...ust cover 2 13 Washer 1 14 Bushing 1 15 Bearing 2 13 15 14 12 12 15 7 N m 0 7 kgf m 5 1 lb ft 7 N m 0 7 kgf m 5 1 lb ft 7 N m 0 7 kgf m 5 1 lb ft 7 N m 0 7 kgf m 5 1 lb ft 16 N m 1 6 kgf m 12 lb ft 65 N m 6 5 kgf m 47 lb ft 105 N m 10 5 kgf m 76 lb ft LT 7 N m 0 7 kgf m 5 1 lb ft ...

Page 271: ...rtical movement B by moving the swingarm up and down If the swingarm vertical movement is not smooth or if there is binding check the pivot shaft collars bearings and dust covers 4 Remove Drive chain Refer to REMOVING THE DRIVE CHAIN on page 4 105 5 Remove Pivot shaft nut Pivot shaft ring nut 1 TIP Loosen the pivot shaft ring nut with the ring nut wrench 2 6 Remove Pivot shaft 1 TIP Loosen the piv...

Page 272: ...ING THE SWINGARM 1 Lubricate Dust covers Pivot shaft Oil seals Collar Bushing 2 Install Bearings 1 to the swingarm Oil seals 2 to the swingarm TIP When installing the oil seals to the swingarm face the character stamp of the oil seals out side Press in the oil seal so it does not protrude from the end surface of the swingarm Recommended cleaning solvent Kerosene Recommended lubricant Lithium soap ...

Page 273: ... page 4 107 Rear shock absorber assembly Refer to REAR SHOCK ABSORBER AS SEMBLY on page 4 93 Rear wheel Refer to REAR WHEEL on page 4 31 7 Adjust Drive chain slack Refer to Adjusting the drive chain slack on page 3 19 A Left side B Right side Pivot shaft 7 N m 0 7 kgf m 5 1 lb ft Damper rod holder ø22 90890 01365 Pivot shaft ring nut 65 N m 6 5 kgf m 47 lb ft 1 1 a a b 1 2 2 T R 1 2 T R Ring nut w...

Page 274: ...SWINGARM 4 103 Drive chain slack Maintenance stand 25 0 35 0 mm 0 98 1 38 in Drive chain slack Sidestand 20 0 30 0 mm 0 79 1 18 in ...

Page 275: ...Drive sprocket cover 1 7 Holder 1 8 Drive chain guide 1 9 Drive sprocket nut 1 10 Washer 1 11 Drive sprocket 1 12 Drive chain 1 7 N m 0 7 kgf m 5 1 lb ft 10 N m 1 0 kgf m 7 2 lb ft 10 N m 1 0 kgf m 7 2 lb ft 28 N m 2 8 kgf m 20 lb ft 10 N m 1 0 kgf m 7 2 lb ft 7 N m 0 7 kgf m 5 1 lb ft 10 N m 1 0 kgf m 7 2 lb ft 140 N m 14 kgf m 100 lb ft E LT LT LT 2 4 5 6 8 9 10 11 12 1 1 7 3 4 ...

Page 276: ...length c between the outer sides of the pins on a 15 link section of the drive chain as shown in the illustration b Calculate the 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 pin outer sides 2 TIP When measuring a 15 link section of the drive chain make sure that the drive chain...

Page 277: ... Check O rings 1 Damage Replace the drive chain Drive chain rollers 2 Damage wear Replace the drive chain Drive chain side plates 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 wheel sprocket and the drive chain as a set Bent teeth Replace the drive sproc...

Page 278: ...de 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 While applying the rear brake tighten the drive sprocket nut Install washer 1 with the OUT mark a fac ing out Stake the drive sprocket nut 2 at cutouts b in the drive axle 4 Install Shift arm 1 TIP Before installing mak...

Page 279: ...t 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 2 Adjust Installed shift rod length a Loosen both locknuts 1 b Turn the shift rod 2 in directio...

Page 280: ...ocknuts 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 1 lb ft b 2 1 a 1 T R ...

Page 281: ... CHAIN COVER 5 17 INSTALLING THE ROCKER ARMS AND ROCKER ARM SHAFTS 5 17 INSTALLING THE TIMING CHAIN COVER 5 18 INSTALLING THE CAMSHAFTS 5 19 CYLINDER HEAD 5 23 REMOVING THE CYLINDER HEAD 5 24 CHECKING THE CYLINDER HEAD 5 24 INSTALLING THE CYLINDER HEAD 5 24 VALVES AND VALVE SPRINGS 5 26 REMOVING THE VALVES 5 28 CHECKING THE VALVES AND VALVE GUIDES 5 28 CHECKING THE VALVE SEATS 5 30 CHECKING THE VA...

Page 282: ...EVER SHAFT AND PULL ROD 5 57 INSTALLING THE CLUTCH 5 57 SHIFT SHAFT 5 60 CHECKING THE SHIFT SHAFT 5 61 CHECKING THE STOPPER LEVER 5 61 INSTALLING THE SHIFT SHAFT 5 61 CRANKCASE 5 62 DISASSEMBLING THE CRANKCASE 5 65 CHECKING THE CRANKCASE 5 65 ASSEMBLING THE CRANKCASE 5 65 INSTALLING THE OIL PRESSURE SWITCH 5 67 INSTALLING THE GEAR POSITION SENSOR 5 68 CONNECTING RODS AND PISTONS 5 69 REMOVING THE ...

Page 283: ...E BALANCER ASSEMBLY 5 86 TRANSMISSION 5 87 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 92 INSTALLING THE TRANSMISSION 5 93 ...

Page 284: ...lat ed in the spark plug wells to prevent it from falling into the cylinders 4 Install Compression gauge 1 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 engine until the reading on the compression gauge stabilizes WARNING EWA17100 To prevent sparking the plug remove all ig nition coil couplers and fuel...

Page 285: ...ter case Refer to GENERAL CHASSIS 3 on page 4 20 Fuel tank Refer to FUEL TANK on page 7 1 Fuel tank cover Refer to GENERAL CHASSIS 2 on page 4 13 Rider seat Air scoop stay Air scoop 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 cylinder he...

Page 286: ...1 Radiator Refer to RADIATOR on page 6 1 Oil cooler Refer to OIL COOLER on page 6 4 1 Muffler protector 1 2 Muffler joint 1 3 Muffler 1 4 Ring 1 5 Gasket 1 6 EXUP valve pulley cover 1 7 Front muffler protector 1 8 EXUP cable 2 1 9 EXUP cable 1 1 FWD FWD 1 2 3 4 5 7 8 9 8 6 2 0 N m 0 20 kgf m 1 4 lb ft 6 N m 0 6 kgf m 4 3 lb ft 20 N m 2 0 kgf m 14 lb ft 20 N m 2 0 kgf m 14 lb ft 20 N m 2 0 kgf m 14...

Page 287: ...ket 4 14 Gasket 2 15 Band 1 16 EXUP servo motor coupler 1 Disconnect 17 EXUP servo motor 1 18 EXUP servo motor cover 1 FWD FWD 10 11 13 14 16 17 18 15 8 10 12 2 0 N m 0 20 kgf m 1 4 lb ft 6 N m 0 6 kgf m 4 3 lb ft 20 N m 2 0 kgf m 14 lb ft 20 N m 2 0 kgf m 14 lb ft 20 N m 2 0 kgf m 14 lb ft 25 N m 2 5 kgf m 18 lb ft 10 N m 1 0 kgf m 7 2 lb ft 10 N m 1 0 kgf m 7 2 lb ft LT LT ...

Page 288: ...d Drive sprocket Refer to CHAIN DRIVE on page 4 104 1 Clutch cable 1 Disconnect 2 Starter motor lead 1 Disconnect 3 Cylinder identification sensor coupler 1 Disconnect 4 Ignition coil coupler 4 Disconnect 5 Coolant temperature sensor coupler 1 Disconnect 6 Neutral switch connector 1 Disconnect 7 Stator coil coupler 1 Disconnect 8 Crankshaft position sensor coupler 1 Disconnect 9 Oil pressure switc...

Page 289: ...ront side 1 5 Engine mounting bolt rear upper side Engine mounting nut rear upper side 1 1 6 Engine mounting bolt rear lower side Engine mounting nut rear lower side 1 1 7 Engine 1 8 Engine mounting adjust bolt 2 FWD FWD 1 2 3 4 5 6 7 5 6 8 8 8 N m 0 8 kgf m 5 8 lb ft 70 N m 7 0 kgf m 51 lb ft 56 N m 5 6 kgf m 41 lb ft 56 N m 5 6 kgf m 41 lb ft 70 N m 7 0 kgf m 51 lb ft ...

Page 290: ...pecification with the pivot shaft wrench Make sure that the flange on the engine mounting adjust bolt contacts the engine 7 Install Engine mounting nut rear lower side 8 Engine mounting nut rear upper side 9 8 Tighten Engine mounting nut rear lower side 8 9 Tighten Engine mounting nut rear upper side 9 10 Tighten Engine mounting bolt left front side 4 11 Tighten Engine mounting bolt right front si...

Page 291: ... Install Exhaust pipe Gasket 1 to exhaust chamber Muffler TIP When installing the gasket install it so that the chamfered side a of the gasket faces the ex haust pipe side as shown in the illustration Installed depth of gasket b 5 0 mm 0 20 in 1 2 3 4 5 6 7 8 9 New 1 a b ...

Page 292: ... to RADIATOR on page 6 1 Air cut off valve Refer to AIR INDUCTION SYSTEM on page 7 15 1 Ignition coil coupler 4 Disconnect 2 Ignition coil 4 3 Spark plug 4 If the spark plug is a new one tighten it to 18 N m 1 8 kgf m 13 lb ft 4 Cylinder identification sensor coupler 1 Disconnect 5 Cylinder identification sensor 1 6 Cylinder head cover 1 7 Cylinder head cover gasket 1 8 Cylinder head cover gasket ...

Page 293: ...l onto the mating surface and threads of the bolt If the camshaft cap bolt is a new one tighten it to 10 N m 1 0 kgf m 7 2 lb ft 4 Camshaft cap 2 1 If the camshaft cap bolt is a new one it is not necessary to apply engine oil onto the mating surface and threads of the bolt If the camshaft cap bolt is a new one tighten it to 10 N m 1 0 kgf m 7 2 lb ft 5 Intake camshaft 1 6 Exhaust camshaft 1 1 2 3 ...

Page 294: ...e crankcase 3 Timing chain cover gasket 1 4 Dowel pin 2 5 Timing chain guide intake side 1 6 Timing chain guide exhaust side 1 7 Timing chain 1 8 Timing chain sprocket bolt 1 9 Timing chain sprocket 1 10 Straight key 1 11 Circlip 1 12 Washer 1 13 Oil seal 1 14 Oil pipe 2 1 When removing the oil pipe 2 also remove the water pump inlet pipe Refer to WATER PUMP on page 6 9 1 2 3 14 5 4 9 10 7 6 5 LT ...

Page 295: ... REMOVAL on page 5 3 Intake camshaft Exhaust camshaft Refer to CAMSHAFTS on page 5 9 1 Rocker arm shaft bolt 4 2 Straight plug rocker arm shaft 3 3 Rocker arm shaft 4 4 Rocker arm 16 1 3 E 2 3 4 2 3 4 E LT E LT E LT 6 N m 0 6 kgf m 4 3 lb ft 10 N m 1 0 kgf m 7 2 lb ft 10 N m 1 0 kgf m 7 2 lb ft FWD FWD ...

Page 296: ... rotor cover slot b TIP BTDC105 on the compression stroke can be found when the camshaft lobes are turned away from each other 3 Remove Timing chain tensioner 1 Timing chain tensioner gasket 4 Remove Camshaft cap 1 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 Remo...

Page 297: ... 4 Measure Camshaft journal to camshaft cap clearance Out of specification Measure the camshaft journal diameter a Install the camshaft into the cylinder head without the camshaft caps b Position strip of Plastigauge 1 onto the camshaft journal as shown Camshaft lobe dimensions Lobe height Intake 33 902 34 002 mm 1 3347 1 3387 in Limit 33 802 mm 1 3308 in Lobe height Exhaust 33 637 33 737 mm 1 324...

Page 298: ... clearance with the Plastigauge d Remove the camshaft caps and then mea sure the width of the Plastigauge 2 5 Measure Camshaft journal diameter a Out of specification Replace the camshaft Within specification Replace the cylinder head and the camshaft caps as a set EAS30259 CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS The following procedure applies to all of the rocker arms and rocker arm shaft...

Page 299: ...t sprockets and timing chain guides 1 Check Timing chain guide exhaust side 1 Timing chain guide intake side 2 Timing chain guide top side 3 Damage wear Replace the defective part s EAS30266 CHECKING THE TIMING CHAIN TENSIONER 1 Check Timing chain tensioner Cracks damage rough movement Re place a Using the valve spring compressor 1 push and insert timing chain tensioner rod 2 into the timing chain...

Page 300: ... matches its outside diameter 2 Install Washer Circlip EAS31657 INSTALLING THE ROCKER ARMS AND ROCKER ARM SHAFTS 1 Install Rocker arm Rocker arm shaft 1 Rocker arm shaft bolt 2 Straight plug 3 TIP Install the rocker arm shaft so that the rocker arm shaft bolt is aligned with the groove a in the rocker arm shaft After installing the rocker arm shaft bolt make sure that the rocker arm shaft turns sm...

Page 301: ...ings might be caught c Install the oil pipe bolt 3 and tighten it tem porarily until there is no clearance at a tim ing chain cover to oil pipe and b oil pipe to oil pipe bolt TIP Apply locking agent LOCTITE onto the oil pipe bolt d Install the timing chain cover assembly and a new timing chain cover gasket e Install the timing chain cover bolts and tighten them f Install the oil pipe bolts 4 and ...

Page 302: ...e exhaust camshaft to the intake camshaft The intake camshaft sprocket timing mark a and exhaust camshaft sprocket timing mark b should align with the cylinder head surface c Check the timing mark position of the camshaft sprocket using a mirror The timing chain exhaust side should be stretched and the timing chain intake side should be sagged 4 Install Camshaft cap TIP Make sure each camshaft cap...

Page 303: ... to avoid damage or improper valve timing NOTICE ECA23010 There are two kinds of camshaft cap bolts with different lengths Be sure to install each bolt onto the correct position 6 Install Timing chain tensioner Timing chain tensioner gasket a Using the valve spring compressor 1 push and insert timing chain tensioner rod 2 into the timing chain tensioner housing TIP Push the timing chain tensioner ...

Page 304: ...e sure the punch mark c on the cam shaft sprocket is aligned with the cylinder head mating surface d Out of alignment Adjust Refer to the installation steps above TIP Check the timing mark position of the camshaft sprocket using a mirror 9 Measure Valve clearance Out of specification Adjust Refer to ADJUSTING THE VALVE CLEAR ANCE on page 3 5 10 Install Timing mark accessing bolt 1 Crankshaft end c...

Page 305: ... Ignition coils 1 TIP Before installing the spark plug clean the spark plug and gasket surface If the spark plug is a new one tighten it to 18 N m 1 8 kgf m 13 lb ft Hold the ignition coil so it faces the intake side and install it Make sure that the ignition coil does not con tact the reed valve cover Cylinder head cover bolt 10 N m 1 0 kgf m 7 2 lb ft Spark plug 13 N m 1 3 kgf m 9 4 lb ft Spark ...

Page 306: ...fer to ENGINE REMOVAL on page 5 3 Intake camshaft Exhaust camshaft Refer to CAMSHAFTS on page 5 9 1 Coolant temperature sensor 1 2 Cylinder head 1 3 Cylinder head gasket 1 4 Dowel pin 2 5 Oil delivery pipe 1 FWD FWD 1 2 4 E 5 3 12 N m 1 2 kgf m 8 7 lb ft 15 N m 1 5 kgf m 11 lb ft 1st 3rd 2nd Specified angle 160 10 N m 1 0 kgf m 7 2 lb ft 25 N m 2 5 kgf m 18 lb ft 45 N m 4 5 kgf m 33 lb ft 15 N m 1...

Page 307: ...ats 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 exceeded resurface the cylinder head as follows d Place a 400 600 grit wet sandpaper on the sur...

Page 308: ...olt one by one and then retighten it to the specific torque and the specific angle TIP Tighten the cylinder head bolts in the tightening sequence as shown and torque them in 4 stag es 4 Install Exhaust camshaft Intake camshaft Refer to INSTALLING THE CAMSHAFTS on page 5 19 Cylinder head bolt 1 10 1st 10 N m 1 0 kgf m 7 2 lb ft 2nd 25 N m 2 5 kgf m 18 lb ft 3rd 45 N m 4 5 kgf m 33 lb ft 4th 15 N m ...

Page 309: ...ylinder head Refer to CYLINDER HEAD on page 5 23 1 Exhaust valve pad 8 2 Exhaust valve cotter 16 3 Exhaust valve spring retainer 8 4 Exhaust valve spring 8 5 Exhaust valve 8 6 Exhaust valve stem seal 8 7 Exhaust valve spring seat 8 8 Exhaust valve guide 8 9 Intake valve pad 8 10 Intake valve cotter 16 1 2 3 4 5 6 7 8 9 10 M M M M M S FWD FWD ...

Page 310: ... springs Order Job Parts to remove Q ty Remarks 11 Intake valve spring retainer 8 12 Intake valve spring 8 13 Intake valve 8 14 Intake valve stem seal 8 15 Intake valve spring seat 8 16 Circlip 8 17 Intake valve guide 8 FWD FWD 11 12 14 15 16 M M M M M S 17 13 ...

Page 311: ...valves properly seal TIP There should be no leakage at the valve seat 1 3 Remove Valve cotters TIP Remove the valve cotters by compressing the valve spring with the valve spring compressor 1 and the valve spring compressor attachment 2 4 Remove Valve spring retainer 1 Valve spring 2 Valve 3 Valve stem seal 4 Valve spring seat 5 TIP Identify the position of each part very carefully so that it can b...

Page 312: ...e guide with the valve guide reamer 3 to ob tain the proper valve stem to valve guide clearance TIP After replacing the valve guide reface the valve seat Valve stem to valve guide clearance Valve guide inside diameter a Valve stem diameter b Valve stem to valve guide clear ance intake 0 010 0 037 mm 0 0004 0 0015 in Limit 0 080 mm 0 0032 in Valve stem to valve guide clear ance exhaust 0 025 0 052 ...

Page 313: ...Valve seat Pitting wear Replace the cylinder head 3 Measure Valve seat contact width a Out of specification Replace the cylinder head a Apply blue layout fluid b onto the valve face Valve guide remover ø4 5 90890 04116 Valve guide remover 4 5 mm YM 04116 Valve guide remover ø5 90890 04097 Valve guide remover 5 0 mm YM 04097 Valve guide installer ø4 5 90890 04117 Valve guide installer 4 5 mm YM 041...

Page 314: ...nstall the valve into the cylinder head d Turn the valve until the valve face and valve seat are evenly polished then clean off all of the lapping compound TIP For the best lapping results lightly tap the valve seat while rotating the valve back and forth be tween your hands e Apply a fine lapping compound to the valve face and repeat the above steps f After every lapping procedure be sure to clea...

Page 315: ...e Valve stem 1 Valve stem seal 2 with the recommended lubricant 3 Install Valve spring seat 1 Valve stem seal 2 Valve 3 Valve spring 4 Valve spring retainer 5 into the cylinder head TIP Make sure each valve is installed in its original place Install the valve springs with the larger pitch a facing up Free length intake 41 25 mm 1 62 in Limit 39 18 mm 1 54 in Free length exhaust 42 33 mm 1 67 in Li...

Page 316: ... with 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 7 Install Valve pad TIP Each valve pad must be reinstalled in its original position b Smaller pitch Valve spring compressor 90890 04019 Valve spring compressor YM 04019 Valve spring compressor attach ment 90890 01243 Valve spring compressor...

Page 317: ...ver 1 4 Generator cover gasket 1 5 Dowel pin 2 6 Stator coil lead holder 1 7 Stator coil assembly stator coil crankshaft posi tion sensor 1 8 Shaft 1 9 Generator rotor 1 10 Woodruff key 1 11 Crankshaft end cover 1 12 Timing mark accessing bolt 1 FWD FWD E LT 1 2 3 4 5 6 7 8 9 10 11 12 8 5 LT LT 6 N m 0 6 kgf m 4 3 lb ft 10 N m 1 0 kgf m 7 2 lb ft 10 N m 1 0 kgf m 7 2 lb ft 12 N m 1 2 kgf m 8 7 lb ...

Page 318: ...or bolt 3 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 with engine oil Install the shaft to the hole of the generator ro tor bolt Lubricate the generator rotor bolt threads and washer mating surfaces with engine oil 2 Tighten Generat...

Page 319: ...over bolt TIP Tighten the generator cover bolts in stages and in a crisscross pattern 5 Connect Stator coil coupler Crankshaft position sensor coupler TIP To route the stator coil lead refer to CABLE ROUTING on page 2 39 15mm pin type rotor holding tool 90890 04171 YM 04171 Yamaha bond No 1215 90890 85505 Three bond No 1215 Generator cover bolt 12 N m 1 2 kgf m 8 7 lb ft 2 3 1 New T R ...

Page 320: ...ter clutch Order Job Parts to remove Q ty Remarks Clutch housing assembly Refer to CLUTCH on page 5 51 1 Starter clutch gear 1 2 Bearing 1 3 Starter clutch assembly 1 4 Circlip 1 5 Starter clutch idle gear 1 FWD FWD 1 2 3 4 5 E E E LT E 14 N m 1 4 kgf m 10 lb ft ...

Page 321: ...rter clutch operation a Install the starter clutch gear 1 onto the clutch housing assembly 2 and hold the clutch housing assembly b When turning the starter clutch gear clock wise A the starter clutch and the starter clutch gear should engage otherwise the starter clutch is faulty and must be replaced c When turning the starter clutch gear counter clockwise B it should turn freely otherwise the st...

Page 322: ...the clutch housing assembly 1 with the sheave holder 2 tighten the starter clutch holder bolt 3 Fix the flat surface of the clutch housing as sembly with the sheave holder Sheave holder 90890 01701 Primary clutch holder YS 01880 A 2 3 1 ...

Page 323: ...IS 2 on page 4 13 Fuel tank Refer to FUEL TANK on page 7 1 Air filter case Refer to GENERAL CHASSIS 3 on page 4 20 Canister Refer to FUEL TANK on page 7 1 Throttle bodies Refer to THROTTLE BODIES on page 7 5 Coolant Drain Refer to CHANGING THE COOLANT on page 3 29 Thermostat Refer to THERMOSTAT on page 6 6 1 Starter motor lead 1 Disconnect 2 Starter motor 1 F W D F W D 1 2 6 N m 0 6 kgf m 4 3 lb f...

Page 324: ...er motor Order Job 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 3 4 5 5 6 FWD FWD 7 4 5 N m 0 45 kgf m 3 3 lb ft ...

Page 325: ...tor a Measure the armature assembly resistances with the digital circuit tester b If any resistance is out of specification re place the starter motor 4 Measure Brush length a Out of specification Replace the brush holder set 5 Measure Brush spring force Out of specification Replace the brush holder set Mica undercut depth 2 40 mm 0 09 in Digital circuit tester 90890 03174 Model 88 Multimeter with...

Page 326: ...l seal Damage wear Replace the starter motor front cover EAS30326 ASSEMBLING THE STARTER MOTOR 1 Install Starter motor rear cover 1 Starter motor yoke 2 Starter motor front cover 3 TIP Align the match mark a on the starter motor yoke with the match mark b on the starter mo tor front cover 1 2 3 a b ...

Page 327: ...page 3 26 Clutch Refer to CLUTCH on page 5 51 Radiator Refer to RADIATOR on page 6 1 Oil cooler Refer to OIL COOLER on page 6 4 Exhaust pipe Muffler Refer to ENGINE REMOVAL on page 5 3 1 Oil pan 1 2 Oil pan gasket 1 3 Oil strainer 1 4 Oil delivery pipe 1 1 5 Oil pipe 1 1 6 Relief valve assembly 1 FWD FWD 1 2 3 4 5 6 LT LT LT LT LT LT 9 E E LT 12 N m 1 2 kgf m 8 7 lb ft 10 N m 1 0 kgf m 7 2 lb ft 1...

Page 328: ...Oil pump drive sprocket 1 11 Washer 1 12 Oil pump drive chain 1 13 Oil pump 1 14 Dowel pin 2 15 Baffle plate 1 FWD FWD LT LT LT LT LT LT 9 E E LT 9 10 11 13 14 15 7 8 12 12 N m 1 2 kgf m 8 7 lb ft 10 N m 1 0 kgf m 7 2 lb ft 10 N m 1 0 kgf m 7 2 lb ft 23 N m 2 3 kgf m 17 lb ft 10 N m 1 0 kgf m 7 2 lb ft 10 N m 1 0 kgf m 7 2 lb ft 10 N m 1 0 kgf m 7 2 lb ft ...

Page 329: ...ling the oil pump Order Job Parts to remove Q ty Remarks 1 Oil pump cover 1 2 Dowel pin 2 3 Oil pump outer rotor 1 4 Oil pump inner rotor 1 5 Pin 1 6 Oil pump driven sprocket 1 1 2 3 4 5 6 E 10 N m 1 0 kgf m 7 2 lb ft FWD FWD ...

Page 330: ...rocket as a set EAS30337 CHECKING THE OIL PUMP 1 Check Oil pump driven sprocket 1 Cracks damage wear Replace Oil pump housing 2 Cracks damage wear Replace 2 Measure Inner rotor to outer rotor tip clearance a Outer rotor to oil pump housing clearance b Out of specification Replace the defective part s 3 Check Oil pump operation Rough movement Repeat steps 1 and 2 or replace the defective part s 1 1...

Page 331: ...h com pressed air EAS30340 CHECKING THE OIL STRAINER 1 Check Oil strainer 1 Damage Replace Contaminants Clean with solvent EAS30342 ASSEMBLING THE OIL PUMP 1 Lubricate Inner rotor Outer rotor Oil pump shaft with the recommended lubricant 2 Install Oil pump driven sprocket 1 Pin 2 Inner rotor 3 Outer rotor 4 Oil pump cover 5 Oil pump housing bolt TIP When installing the inner rotor align the pin 2 ...

Page 332: ... and drive sprocket make sure the oil pump turns smoothly 3 Install Oil pump drive chain guide 1 4 Install O ring Oil pipe 1 1 O ring Oil delivery pipe 1 2 Oil strainer 3 O ring Relief valve assembly 4 5 Install O ring Oil delivery pipe 2 1 Oil pump bolt 10 N m 1 0 kgf m 7 2 lb ft T R 1 2 2 1 2 Oil pump drive chain guide bolt 10 N m 1 0 kgf m 7 2 lb ft LOCTITE Oil pipe 1 bolt 10 N m 1 0 kgf m 7 2 ...

Page 333: ... the bolts installed in the bolt holes marked with arrows a on the oil pan Tighten the oil pan bolts in stages and in a crisscross pattern 3 Install Engine oil drain bolt Gasket Oil delivery pipe 2 bolt 10 N m 1 0 kgf m 7 2 lb ft LOCTITE Oil pan bolt 12 N m 1 2 kgf m 8 7 lb ft Engine oil drain bolt 23 N m 2 3 kgf m 17 lb ft T R 1 New T R a a New T R ...

Page 334: ...arts to remove Q ty Remarks Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 26 1 Clutch cable 1 Disconnect 2 Clutch cover 1 3 Clutch cover gasket 1 4 Dowel pin 2 5 Oil filler cap 1 FWD FWD 1 2 3 4 5 12 N m 1 2 kgf m 8 7 lb ft 10 7 N m 0 7 kgf m 5 1 lb ft ...

Page 335: ...Removing 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 1 2 3 4 5 6 7 8 E FWD FWD ...

Page 336: ...ate 1 1 Inside diameter 110 2 mm 4 34 in 8 Clutch plate 2 8 Inside diameter 103 5 mm 4 07 in 9 Friction plate 2 7 Whitish shoe 10 Clutch damper spring 1 11 Clutch damper spring seat 1 12 Clutch boss nut 1 13 Conical spring washer 1 14 Clutch boss 1 15 Thrust plate 1 16 Clutch housing assembly 1 17 Bearing 1 18 Washer 1 FWD FWD 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 6 E E E E 10 N m 1 0 kgf m...

Page 337: ...4 3 Remove Friction plates 1 1 4 Remove Clutch plate 1 1 Clutch plates 2 Friction plates 2 Clutch damper spring Clutch damper spring seat 5 Straighten the clutch boss nut rib a 6 Loosen Clutch boss nut 1 TIP While holding the clutch boss 2 with the uni versal clutch holder 3 loosen the clutch boss nut Do not use an impact wrench for removing the clutch boss nut 7 Remove Clutch boss nut Conical spr...

Page 338: ...ce the clutch plates as a set 3 Measure Assembly width a of the friction plates and clutch plates Out of specification Adjust TIP Perform the thickness measurement without applying the oil This step should be performed only if the fric tion plates and clutch plates were replaced To measure the total width of the friction plates and clutch plates combine 10 friction plates and 9 clutch plates as sh...

Page 339: ... housing TIP Pitting on the clutch housing dogs will cause er ratic clutch operation 2 Check Bearing Damage wear Replace the bearing and clutch housing EAS30353 CHECKING THE CLUTCH BOSS 1 Check Clutch boss splines Damage pitting wear Replace the clutch boss TIP Pitting on the clutch boss splines will cause er ratic clutch operation EAS30354 CHECKING THE PRESSURE PLATE 1 Check Pressure plate 1 1 Pr...

Page 340: ...amage wear Replace EAS30363 INSTALLING THE CLUTCH TIP After assembling the clutch assembly the noise like a dry type clutch might occur with the gear position in neutral and half clutch This is due to the clutch dragging by engine oil when assem bled The pressure plate makes chattering by the clutch dragging and noise occurs between pressure plate cam and clutch boss cam This noise will disappeare...

Page 341: ...tch damper spring seat Clutch damper spring Friction plates 1 Clutch plates 2 Friction plates 2 Clutch plate 1 TIP First install a friction plate and then alternate between a clutch plate and a friction plate Install the last friction plate 1 offset 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 5 Install Pull ro...

Page 342: ...t TIP Tighten the clutch cover bolts in stages and in a crisscross pattern 8 Install Pull lever spring 1 Pull lever 2 Washer Circlip TIP The end of the pull lever should be closest to the clutch cover match mark a when there is no free play of the pull lever Make sure that the pull rod teeth and pull lever shaft pinion gear are engaged 9 Adjust Clutch lever free play Refer to ADJUSTING THE CLUTCH ...

Page 343: ... page 5 51 Shift arm Refer to CHAIN DRIVE on page 4 104 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 Bearing 1 13 Oil seal 1 14 Bearing 1 FWD FWD 1 2 3 4 5 6 7 8 9 10 11 12 13 14 LT E E E E 22 N m 2 2 kgf m 16 lb ft ...

Page 344: ...hift 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 lithium soap based grease Lubricate ...

Page 345: ... pump Refer to WATER PUMP on page 6 9 Clutch housing assembly Refer to CLUTCH on page 5 51 Oil strainer Oil pump Relief valve assembly Refer to OIL PUMP on page 5 44 1 Gear position sensor 1 2 Oil pressure switch 1 3 Oil pressure switch joint 1 4 Oil filter cartridge 1 5 Oil filter cartridge union bolt 1 6 Crankcase breather cover 1 1 2 3 4 5 6 E LT LT 8 4 0 N m 0 40 kgf m 2 9 lb ft 1 8 N m 0 18 k...

Page 346: ... 8 Clutch cable holder 1 9 Neutral switch 1 10 Gasket 1 11 Holder 1 8 9 10 E LT LT 7 8 11 4 0 N m 0 40 kgf m 2 9 lb ft 1 8 N m 0 18 kgf m 1 3 lb ft 10 N m 1 0 kgf m 7 2 lb ft 12 N m 1 2 kgf m 8 7 lb ft 17 N m 1 7 kgf m 12 lb ft 13 N m 1 3 kgf m 9 4 lb ft 10 N m 1 0 kgf m 7 2 lb ft 17 N m 1 7 kgf m 12 lb ft 70 N m 7 0 kgf m 51 lb ft FWD FWD ...

Page 347: ...l gallery 2 2 Plug balancer shaft end 2 3 Lower crankcase 1 4 Dowel pin 3 1 2 3 4 2 2 10 6 2 5 4 4 2 8 E E E E LT E 10 N m 1 0 kgf m 7 2 lb ft 10 N m 1 0 kgf m 7 2 lb ft 10 N m 1 0 kgf m 7 2 lb ft 10 N m 1 0 kgf m 7 2 lb ft 24 N m 2 4 kgf m 17 lb ft 24 N m 2 4 kgf m 17 lb ft 1st 3rd 2nd 20 N m 2 0 kgf m 14 lb ft 15 N m 1 5 kgf m 11 lb ft Specified angle 75 8 N m 0 8 kgf m 5 8 lb ft FWD FWD ...

Page 348: ...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 ASSEMBLING THE CRANKCASE 1 Lubricate Crankshaf...

Page 349: ...oil Apply the bolts 28 40 thread with LOC TITE M9 100 mm 3 94 in bolts with washers 1 10 M8 58 mm 2 28 in bolts with new O rings 11 18 M8 60 mm 2 36 in bolts 19 20 M6 65 mm 2 56 in bolts 21 22 M6 70 mm 2 76 in bolt 23 M6 60 mm 2 36 in bolts 24 27 35 38 M6 50 mm 1 97 in bolts 31 34 M6 50 mm 1 97 in bolts LOCTITE 28 40 M6 40 mm 1 57 in bolts 29 30 36 37 39 7 Tighten Crankcase bolts 1 10 Following th...

Page 350: ...e switch 1 Oil pressure switch lead 2 TIP Apply Three bond No 1215B to the threads a of the oil pressure switch However do not apply Three bond No 1215B to the portion b of the oil pressure switch Install the oil pressure switch lead so that it is routed within the range shown in the illustra tion Crankcase bolts 11 20 24 N m 2 4 kgf m 17 lb ft Crankcase bolts 21 40 10 N m 1 0 kgf m 7 2 lb ft 10 6...

Page 351: ...kup tool with a magnet magnetized screwdrivers etc away from the gear position sensor 1 Install O ring Gear position sensor 1 TIP 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 2 9 lb ft LOCTITE 1 2 53 New T R a b 1 ...

Page 352: ...r to CRANKCASE on page 5 62 1 Connecting rod cap 4 2 Big end lower bearing 4 3 Big end upper bearing 4 4 Connecting rod 4 5 Piston pin clip 8 6 Piston pin 4 7 Piston 4 8 Top ring 4 9 2nd ring 4 10 Oil ring 4 11 Cylinder 1 12 Cylinder gasket 1 13 Dowel pin 2 E 1 2 3 4 5 6 7 8 9 10 11 12 13 8 E 5 E E E 13 E M M FWD FWD 1st 2nd 24 N m 2 4 kgf m 17 lb ft Specified angle 150 ...

Page 353: ...in out TIP For reference during installation put identifica tion marks on the piston crown Before removing the piston pin deburr the pis ton pin clip groove and the piston pin bore ar ea If both areas are deburred and the piston pin is still difficult to remove remove it with the piston pin puller set 4 3 Remove Top ring 2nd ring Oil ring TIP When removing a piston ring open the end gap with your ...

Page 354: ...ce eliminate any carbon deposits from the piston ring grooves and piston rings Bore 79 000 79 010 mm 3 1102 3 1106 in Taper limit 0 008 mm 0 0003 in Out of round limit 0 050 mm 0 0020 in C maximum of D1 D2 D3 D4 D5 D6 Taper front to back maximum difference between D1 D3 D5 Taper side to side maximum difference between D2 D4 D6 Out of round top difference between D1 D2 Out of round middle differenc...

Page 355: ...pin 2 Measure Piston pin bore inside diameter b Out of specification Replace the piston 3 Calculate Piston pin to piston pin bore clearance Out of specification Replace the piston pin and piston as a set Top ring End gap installed 0 15 0 25 mm 0 0059 0 0098 in End gap limit 0 50 mm 0 0197 in 2nd ring End gap installed 0 65 0 80 mm 0 0256 0 0315 in End gap limit 1 15 mm 0 0453 in b Upper of cylinde...

Page 356: ...e 1 on the crank shaft pin d Assemble the connecting rod halves NOTICE ECA18390 Tighten the connecting rod bolts using the plastic region tightening angle method Al ways install new bolts TIP Clean the connecting rod bolts and lubricate the bolt threads and seats with molybdenum disulfide oil Make sure that the projection a on the con necting rod cap faces the same direction as the Y mark b on the...

Page 357: ... position c or d g Tighten the connecting rod bolts with a torque wrench h Put a mark 1 on the corner of the connecting rod bolt 2 and the connecting rod cap 3 i Tighten the connecting rod bolts further to reach the specified angle 145 155 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 a...

Page 358: ... determine the replacement big end bearings sizes P1 P4 refer to the bearings shown in the crankshaft illustration For example if the connecting rod P1 and the crankshaft web P1 numbers are 6 and 2 respectively then the bearing size for P1 is EAS30751 INSTALLING THE CONNECTING ROD AND PISTON The following procedure applies to all of the con necting rods and pistons 1 Install Big end bearings Conne...

Page 359: ...ng the big end bearing assemble the connecting rod and connecting rod cap without installing them onto the crankshaft d Tighten the connecting rod bolt while check ing that the sections shown a and b are flush with each other by touching the surface TIP To install the connecting rod cap care should be taken not to install it at an angle and the position should not be out of alignment e Loosen the ...

Page 360: ...haft pins Connecting rod big end bearing inner surface and side surface with the recommended lubricant 8 Install Piston assemblies 1 into the cylinder 2 TIP While holding the piston rings with the hand in stall the piston assembly into the cylinder from underneath Install the piston assembly into the cylinder so that the piston ring end gap is aligned with the cylinder skirt a 9 Install Cylinder g...

Page 361: ...nnecting rod bolts further to reach the specified angle 145 155 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 section shown a is ...

Page 362: ...CONNECTING RODS AND PISTONS 5 79 a ...

Page 363: ... rod Refer to REMOVING THE CONNECTING RODS AND PISTONS on page 5 70 1 Balancer shaft 1 2 Balancer shaft journal lower bearing 4 3 Balancer shaft journal upper bearing 4 4 Crankshaft 1 5 Crankshaft journal lower bearing 5 6 Crankshaft journal upper bearing 5 7 Thrust bearing 2 8 Oil nozzle 1 4 9 Oil nozzle 2 5 1 2 2 3 3 4 5 6 8 7 E E LT LT E E 9 9 E E FWD FWD 3 0 N m 0 30 kgf m 2 2 lb ft 10 N m 1 0...

Page 364: ...es wear Replace the crankshaft Bearing surfaces Scratches wear Replace the crankshaft journal bearing 3 Measure 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...

Page 365: ... shaft journal lower bearings h Measure the compressed Plastigauge width a on each crankshaft journal If the crankshaft journal to crankshaft jour nal bearing clearance is out of specification select replacement crankshaft journal bear ings 4 Select Crankshaft journal bearings J1 J5 TIP The numbers A stamped into the crankshaft web and the numbers B stamped into the lower crankcase are used to det...

Page 366: ... and prevent engine damage the balancer shaft journal bearings must be installed in their original positions a Clean the balancer shaft journal bearings balancer shaft journals and bearing portions of the crankcase b Place the upper crankcase upside down on a bench c Install the balancer shaft journal upper bear ings 1 and the balancer shaft into the upper crankcase TIP Align the projections a on ...

Page 367: ... shaft journal If the balancer shaft journal to balancer shaft jour nal bearing clearance is out of specification select replacement balancer shaft journal bearings 4 Select Balancer shaft journal bearing J1 J4 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 J4 re...

Page 368: ...en the thrust bearing and the crankshaft Install the thrust bearing with the grooves a side is facing the crankshaft Apply engine oil on the grooves a side of the thrust bearing a Insert the thrust bearing 1 into the slot of the upper crankcase as shown in the illustration and slide it in the direction of the arrow TIP When installing the thrust bearing shift the crankshaft to the left to widen th...

Page 369: ...haft journal lower bearings into the lower crankcase TIP Align the projections a on the balancer shaft journal bearings 1 with the notches b in the crankcases Be sure to install each balancer shaft journal bearing in its original place 2 Install Balancer shaft TIP Install by aligning the crankshaft match mark a and the balancer shaft match marks b 1 a b a b b ...

Page 370: ... axle assembly 1 2 Shift drum retainer 2 3 Spring 2 4 Shift fork guide bar 2 5 Shift fork L 1 6 Shift fork R 1 7 Shift drum assembly 1 8 Shift fork C 1 9 Main axle assembly 1 10 Oil delivery pipe 3 1 11 O ring 3 12 Oil baffle plate 1 13 Bearing 2 1 2 3 3 4 4 5 6 7 8 9 10 11 12 13 13 LT E E E E LT LT LT LT E FWD FWD 10 N m 1 0 kgf m 7 2 lb ft 12 N m 1 2 kgf m 8 7 lb ft 10 N m 1 0 kgf m 7 2 lb ft ...

Page 371: ...ed side of the pinion gear faces to the left 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 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 M M M M E M FWD FWD ...

Page 372: ...er 1 4 1st wheel gear 1 5 Collar 1 6 5th wheel gear 1 7 Circlip 1 8 Washer 1 9 3rd wheel gear 1 10 Collar 1 11 Toothed lock washer 1 12 Toothed lock washer retainer 1 13 4th wheel gear 1 14 Collar 1 15 Washer 1 16 Circlip 1 17 6th wheel gear 1 18 Circlip 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 M M M M M M M E E FWD FWD ...

Page 373: ...ling the drive axle assembly Order Job Parts to remove Q ty Remarks 19 Washer 1 20 2nd wheel gear 1 21 Collar 1 22 Collar 1 23 Oil seal 1 24 Circlip 1 25 Bearing 1 26 Drive axle 1 19 20 21 22 23 24 25 26 M M M M M M M E E FWD FWD ...

Page 374: ...tening the bolts until the main axle assembly comes free from the upper crankcase 3 Remove Oil delivery pipe 3 1 Bearings 2 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 Roll the shift fork guide bar on a flat surface Bends ...

Page 375: ... and dial gauge 1 Out of specification Replace the drive axle 3 Check Transmission gears 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 assemblies 5 Check Transmission gear movemen...

Page 376: ...ainer 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 Bearings 1 Oil delivery pipe 3 2 TIP Face the seal side of bearing to the outside 2 Install Main axle assembly 1 Bearing housing 2 b c 1 2 a A 2 1...

Page 377: ...Shift fork R 1 Shift fork L 2 Shift fork guide bar Shift drum retainers 3 Bearing Oil seal Circlip 4 Drive axle assembly 5 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 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...

Page 378: ...TRANSMISSION 5 95 ...

Page 379: ...NG THE OIL COOLER 6 5 INSTALLING THE OIL COOLER 6 5 THERMOSTAT 6 6 REMOVING THE THERMOSTAT ASSEMBLY 6 7 CHECKING THE THERMOSTAT 6 7 ASSEMBLING THE THERMOSTAT ASSEMBLY 6 7 INSTALLING THE THERMOSTAT ASSEMBLY 6 7 WATER PUMP 6 9 DISASSEMBLING THE WATER PUMP 6 11 CHECKING THE WATER PUMP 6 11 ASSEMBLING THE WATER PUMP 6 11 INSTALLING THE WATER PUMP 6 12 ...

Page 380: ... 2 Coolant reservoir 1 3 Coolant reservoir cap 1 4 Radiator cap 1 5 Radiator fan motor coupler 2 Disconnect 6 Cooling system air bleed hose 1 Disconnect 7 Radiator outlet hose 1 Disconnect 8 Radiator inlet hose 1 Disconnect 9 Radiator 1 10 Radiator fan 2 10 N m 1 0 kgf m 7 2 lb ft 7 N m 0 7 kgf m 5 1 lb ft 8 N m 0 8 kgf m 5 8 lb ft 8 N m 0 8 kgf m 5 8 lb ft 10 N m 1 0 kgf m 7 2 lb ft 10 N m 1 0 kg...

Page 381: ...n flat head screwdriver 2 Check Radiator hoses Cracks damage Replace 3 Measure Radiator cap valve opening pressure Below the specified pressure Replace the radiator cap a Install the radiator cap tester 1 and radiator cap tester adapter 2 to the radiator cap 3 b Apply the specified pressure for ten seconds and make sure there is no drop in pressure 4 Check Radiator fan Damage Replace Malfunction C...

Page 382: ...ed amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 29 5 Check Cooling system Leaks Repair or replace any faulty part a Attach the radiator cap tester 1 and radiator cap tester adapter 2 to the radiator b Apply 137 3 kPa 1 37 kgf cm 19 9 psi of pressure c Measure the indicated pressure with the gauge 6 Measure Radiator cap valve opening pressure Below the specified pressu...

Page 383: ... 1 2 Oil cooler inlet hose 1 Disconnect When removing the oil cooler inlet hose also remove the water pump inlet pipe Refer to WATER PUMP on page 6 9 3 Oil cooler outlet hose 1 4 Oil cooler 1 10 N m 1 0 kgf m 7 2 lb ft 10 N m 1 0 kgf m 7 2 lb ft 10 N m 1 0 kgf m 7 2 lb ft 10 N m 1 0 kgf m 7 2 lb ft 10 N m 1 0 kgf m 7 2 lb ft LT LT LT LT 1 2 4 3 FWD FWD 9 N m 0 9 kgf m 6 5 lb ft ...

Page 384: ...Oil cooler 1 O ring Oil cooler bolt upper 2 Oil cooler bolt lower 3 Radiator bolt 4 TIP Apply lithium soap based grease to the O ring 3 Tighten Oil cooler bolt upper 2 4 Tighten Oil cooler bolt lower 3 5 Tighten Radiator bolt 4 6 Fill Crankcase with the specified amount of the recom mended engine oil Refer to CHANGING THE ENGINE OIL on page 3 26 7 Measure Engine oil pressure Refer to MEASURING THE...

Page 385: ... 1 Air filter case Refer to GENERAL CHASSIS 3 on page 4 20 Canister Refer to FUEL TANK on page 7 1 Throttle bodies Refer to THROTTLE BODIES on page 7 5 Coolant Drain Refer to CHANGING THE COOLANT on page 3 29 1 Cooling system air bleed hose 1 Disconnect 2 Radiator inlet hose 1 3 Thermostat housing cover 1 4 O ring 1 5 Thermostat 1 6 Thermostat housing 1 7 O ring 1 FWD FWD 1 2 3 4 5 6 7 10 N m 1 0 ...

Page 386: ... thermo stat and thermometer s indicated tempera ture TIP If the accuracy of the thermostat is in doubt re place it A faulty thermostat could cause serious overheating or overcooling 2 Check Thermostat housing Thermostat housing cover Cracks damage Replace EAS30444 ASSEMBLING THE THERMOSTAT ASSEMBLY 1 Install Thermostat housing 1 Thermostat 2 O ring 3 Thermostat housing cover 4 TIP Install the the...

Page 387: ...n page 2 39 3 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 29 4 Check Cooling system Leaks Repair or replace any faulty part Refer to INSTALLING THE RADIATOR on page 6 3 5 Measure Radiator cap valve opening pressure Below the specified pressure Replace the radiator cap Refer to CHECKING THE RADIATOR on page 6 2 New ...

Page 388: ...el tank Refer to FUEL TANK on page 7 1 Radiator Refer to RADIATOR on page 6 1 Oil cooler Refer to OIL COOLER on page 6 4 Muffler Exhaust pipe Refer to ENGINE REMOVAL on page 5 3 1 Water pump inlet pipe 1 2 Water pump outlet pipe 1 3 Water pump assembly 1 4 Oil cooler stay 3 1 2 4 4 LT 4 3 10 N m 1 0 kgf m 7 2 lb ft 10 N m 1 0 kgf m 7 2 lb ft 10 N m 1 0 kgf m 7 2 lb ft 10 N m 1 0 kgf m 7 2 lb ft 10...

Page 389: ...ater pump Order Job Parts to remove Q ty Remarks 1 Water pump housing cover 1 2 O ring 1 3 Circlip 1 4 Impeller shaft 1 5 Mechanical seal 1 6 Bearing 1 7 Oil seal 1 1 2 3 4 5 6 7 10 N m 1 0 kgf m 7 2 lb ft 10 N m 1 0 kgf m 7 2 lb ft FWD ...

Page 390: ...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 pipe Water pump outlet pipe Cracks damage wear Replace EAS30448 ASSEMBLING THE WATER PUMP 1 Install Oil seal 1 Bearing 2 into the water p...

Page 391: ...cal seal impeller side is flush with the impeller EAS30449 INSTALLING THE WATER PUMP 1 Install Water pump assembly 1 TIP Align the slit a on the impeller shaft with the projection b on the oil pump driven sprocket 2 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 29 3 Check Cooling system Leaks Repair or replace the faulty part Mech...

Page 392: ...WATER PUMP 6 13 4 Measure Radiator cap valve opening pressure Below the specified pressure Replace the radiator cap Refer to CHECKING THE RADIATOR on page 6 2 ...

Page 393: ...FUEL HOSE FUEL RAIL SIDE 7 8 REMOVING THE INJECTORS 7 8 CHECKING THE INJECTORS 7 8 CHECKING AND CLEANING THE THROTTLE BODIES 7 8 REPLACING THE THROTTLE BODIES 7 10 INSTALLING THE INJECTORS 7 10 CHECKING THE INJECTOR PRESSURE 7 11 CHECKING THE FUEL PRESSURE 7 11 INSTALLING THE FUEL HOSE FUEL RAIL SIDE 7 12 ADJUSTING THE THROTTLE POSITION SENSOR 7 12 ADJUSTING THE ACCELERATOR POSITION SENSOR 7 13 AI...

Page 394: ...ge 4 13 1 Fuel hose connector 1 Disconnect 2 Fuel pump coupler 1 Disconnect 3 Fuel tank breather hose 1 Disconnect 4 Fuel tank drain hose 1 Disconnect 5 Fuel tank 1 6 Fuel pump bracket 1 7 Fuel pump 1 8 Fuel pump gasket 1 9 Fuel tank cap 1 7 N m 0 7 kgf m 5 1 lb ft 7 N m 0 7 kgf m 5 1 lb ft 7 N m 0 7 kgf m 5 1 lb ft 7 N m 0 7 kgf m 5 1 lb ft 4 0 N m 0 40 kgf m 2 9 lb ft 4 0 N m 0 40 kgf m 2 9 lb f...

Page 395: ...tay Refer to GENERAL CHASSIS 1 on page 4 1 Fuel tank cover Refer to GENERAL CHASSIS 2 on page 4 13 Fuel tank Refer to FUEL TANK on page 7 1 1 Canister purge hose hose joint to canister 1 2 Fuel tank breather hose fuel tank to canister 1 3 Canister holder 1 4 Canister 1 5 Canister bracket 1 10 N m 1 0 kgf m 7 2 lb ft 2 5 4 3 1 ...

Page 396: ... connector cover 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 directl...

Page 397: ...P Temporarily tighten the rear fuel tank bolt 2 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 hose is in the correct position otherwise the fuel hose will not be properly installed TIP Install the fuel hose onto the fuel pump secure ly and slide the fuel hose connector cover ...

Page 398: ... on page 4 20 Canister Refer to FUEL TANK on page 7 1 Air filter case duct Refer to AIR INDUCTION SYSTEM on page 7 15 1 Throttle position sensor coupler 1 Disconnect 2 Intake air pressure sensor coupler 1 Disconnect 3 Grip cancel switch coupler 1 Disconnect 4 Throttle servo motor coupler 1 Disconnect 5 Accelerator position sensor coupler 1 Disconnect 6 Coolant temperature sensor coupler Sub wire h...

Page 399: ...hrottle cable 2 Disconnect 9 Fuel hose 1 10 Throttle body joint clamp screw 4 Loosen 11 Throttle body assembly 1 12 Neutral switch connector 1 Disconnect 13 Heat protector 1 14 Throttle body joint 2 FW FWD 4 5 N m 0 45 kgf m 3 3 lb ft 3 0 N m 0 30 kgf m 2 2 lb ft LT LT 10 N m 1 0 kgf m 7 2 lb ft 7 8 7 9 10 12 13 11 10 14 14 ...

Page 400: ...3 5 Intake air pressure sensor 1 6 Accelerator position sensor 1 7 Throttle position sensor 1 8 Grip cancel switch 1 9 Fuel rail 2 10 Injector joint 1 11 Injector 4 1 2 8 5 6 7 10 11 9 9 1 2 1 11 11 11 3 4 4 3 3 3 5 N m 0 35 kgf m 2 5 lb ft 3 5 N m 0 35 kgf m 2 5 lb ft 3 5 N m 0 35 kgf m 2 5 lb ft 3 5 N m 0 35 kgf m 2 5 lb ft 0 28 N m 0 028 kgf m 0 207 lb ft ...

Page 401: ...ll ventilated area free of combustible 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 a...

Page 402: ... be affected a Place the throttle bodies on a flat surface with the air filter 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 valv...

Page 403: ... Speed Control learning values Use the diagnostic code number 67 Refer to SELF DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE on page 9 5 4 Adjust Throttle bodies synchronizing Refer to SYNCHRONIZING THE THROT TLE BODIES on page 3 10 5 Place the vehicle on a maintenance stand so that the rear wheel is elevated 6 Check Engine idling speed Start the engine warm it up and then mea sure the engine idli...

Page 404: ...tor pressure adapter 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 injec tors EAS30482 CHECKING THE FUEL PRESSURE 1 Remove Rider seat Air scoop Air scoop stay Refer to GENERAL CHASSIS 1 on page 4 1 Fuel tank cover Refer to GENERAL CHASSIS 2...

Page 405: ...l hose connector cover 1 in the direction shown in the illustration To install the fuel hose onto the fuel rail joint slide the fuel hose connector cover 1 on the end of the hose in the direction of the arrow shown It is prohibited to wear the cotton work gloves or equivalent coverings EAS30485 ADJUSTING THE THROTTLE POSITION SENSOR NOTICE ECA17540 Handle the throttle position sensor with special ...

Page 406: ...celerator position sensor Refer to DIAGNOSTIC CODE SENSOR OPERATION TABLE on page 9 16 2 Adjust Accelerator position sensor angle TIP Before adjusting the accelerator position sensor the throttle bodies must be removed a Temporary tighten the accelerator position sensor bolts b Check that the throttle valves are fully closed c Connect the accelerator position sensor to the wire harness d Connect t...

Page 407: ...e Yamaha diagnostic tool screen value is not 10 24 adjust the accelerator po sition sensor angle o Turn the throttle grip to the fully open position p Check the Yamaha diagnostic tool screen value If the Yamaha diagnostic tool screen value is not 94 109 adjust the accelerator position sensor angle q Repeat steps f to p until the Yamaha diag nostic tool screen values are within the spec ified range...

Page 408: ...AIR INDUCTION SYSTEM 7 15 EAS20071 AIR INDUCTION SYSTEM ...

Page 409: ...UCTION SYSTEM 7 16 1 Air filter case 2 Cylinder head cover 3 Air cut off valve 4 Air induction system hose air filter case to air cut off valve 5 Air induction system hose air cut off valve to reed valve cover ...

Page 410: ...TANK on page 7 1 Air filter case Refer to GENERAL CHASSIS 3 on page 4 20 Canister Refer to FUEL TANK on page 7 1 Throttle bodies Refer to THROTTLE BODIES on page 7 5 1 Atmospheric pressure sensor coupler 1 Disconnect 2 Air filter case duct 1 3 Atmospheric pressure sensor hose 1 4 Atmospheric pressure sensor 1 5 Damper 1 6 Air cut off valve coupler 1 Disconnect FWD FWD LT LT LT LT 2 1 3 4 5 6 0 3 N...

Page 411: ...cut off valve 1 8 Air induction system hose air cut off valve to reed valve cover 1 9 Air induction system hose air cut off valve to reed valve cover 1 10 Air cut off valve 1 11 Reed valve cover 2 12 Reed valve assembly 2 13 Reed valve plate 4 FWD FWD LT LT LT LT 7 8 9 10 11 12 13 11 12 13 0 3 N m 0 03 kgf m 0 22 lb ft 9 N m 0 9 kgf m 6 5 lb ft 10 N m 1 0 kgf m 7 2 lb ft ...

Page 412: ...ECU in accordance with the combus tion conditions Ordinarily the air cut off valve opens to allow the air to flow during idle and closes to cut off the flow when the vehicle is be ing driven However if the coolant temperature is below the specified value the air cut off valve remains open and allows the air to flow into the exhaust pipe until the temperature becomes higher than the specified value...

Page 413: ...STALLING THE AIR INDUCTION SYSTEM 1 Install Reed valve plate TIP Align the projection a on the cylinder head cov er 1 with the hole b in the reed valve plate 2 Install Reed valve assembly TIP Install the reed valve assembly so that the open side turns to the exhaust side of the engine 3 Install Reed valve cover A Exhaust side A Reed valve cover bolt 10 N m 1 0 kgf m 7 2 lb ft LOCTITE T R ...

Page 414: ...AIR INDUCTION SYSTEM 7 21 ...

Page 415: ...EM 8 29 CIRCUIT DIAGRAM 8 29 TROUBLESHOOTING 8 31 FUEL INJECTION SYSTEM 8 33 CIRCUIT DIAGRAM 8 33 ECU SELF DIAGNOSTIC FUNCTION 8 35 TROUBLESHOOTING METHOD 8 35 YAMAHA DIAGNOSTIC TOOL 8 36 TROUBLESHOOTING DETAILS FAULT CODE 8 37 CRUISE CONTROL SYSTEM 8 123 CIRCUIT DIAGRAM 8 123 CRUISE CONTROL CIRCUIT OPERATION 8 125 BASIC INSTRUCTIONS FOR TROUBLESHOOTING 8 127 BASIC PROCESS FOR TROUBLESHOOTING 8 12...

Page 416: ...ME ON 8 162 A 3 THE ABS WARNING LIGHT COMES ON 8 162 A 4 ONLY THE ABS ECU FAILS TO COMMUNICATE 8 163 A 5 ABS ECU AND FI ECU FAIL TO COMMUNICATE 8 163 B 1 MALFUNCTION ARE CURRENTLY DETECTED 8 163 B 2 DIAGNOSIS USING THE FAULT CODES 8 163 B 3 DELETING THE FAULT CODES 8 178 C 1 FINAL CHECK 8 178 STEERING DAMPER SYSTEM 8 181 CIRCUIT DIAGRAM 8 181 SELF DIAGNOSTIC FUNCTION 8 183 TROUBLESHOOTING METHOD 8...

Page 417: ...METER FUEL LEVEL WARNING LIGHT 8 204 CHECKING THE RADIATOR FAN MOTORS 8 204 CHECKING THE COOLANT TEMPERATURE SENSOR 8 204 CHECKING THE THROTTLE SERVO MOTOR 8 205 CHECKING THE AIR INDUCTION SYSTEM SOLENOID 8 206 CHECKING THE CYLINDER IDENTIFICATION SENSOR 8 206 CHECKING THE INTAKE AIR TEMPERATURE SENSOR 8 206 CHECKING THE STEERING DAMPER SOLENOID 8 207 CHECKING THE FUEL INJECTORS 8 207 ...

Page 418: ...IGNITION SYSTEM 8 1 EAS20072 IGNITION SYSTEM EAS30490 CIRCUIT DIAGRAM ...

Page 419: ...andlebar switch right 35 Start engine stop switch 37 Neutral switch 38 Sidestand switch 41 Joint connector 42 Joint coupler 44 Cylinder identification sensor 48 Crankshaft position sensor 52 Lean angle sensor 54 ECU Engine Control Unit 55 Ignition coil 1 56 Ignition coil 2 57 Ignition coil 3 58 Ignition coil 4 59 Spark plug ...

Page 420: ... is open However the engine continues to run under 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 5 Start...

Page 421: ...the spark plugs Refer to CHECKING THE SPARK PLUGS on page 3 5 NG Re gap or replace the spark plug s OK 4 Check the ignition spark gap Refer to CHECKING THE SPARK PLUGS on page 3 5 OK Ignition system is OK NG 5 Check the ignition coils Refer to CHECKING THE IGNI TION COILS on page 8 200 NG Replace the ignition coil s OK 6 Check the crankshaft position sen sor Refer to CHECKING THE CRANK SHAFT POSIT...

Page 422: ...HES on page 8 191 NG Replace the sidestand switch OK 12 Check the relay unit diode Refer to CHECKING THE RELAY UNIT DIODE on page 8 199 NG Replace the relay unit OK 13 Check the lean angle sensor Refer to CHECKING THE LEAN ANGLE SENSOR on page 8 201 NG Replace the lean angle sensor OK 14 Check the entire ignition system s wiring Refer to CIRCUIT DIAGRAM on page 8 1 NG Properly connect or repair th...

Page 423: ...IGNITION SYSTEM 8 6 ...

Page 424: ...ELECTRIC STARTING SYSTEM 8 7 EAS20073 ELECTRIC STARTING SYSTEM EAS30493 CIRCUIT DIAGRAM ...

Page 425: ...se 18 Battery 19 Engine ground 21 Starter relay 22 Starter motor 27 Relay unit 28 Starting circuit cut off relay 30 Clutch switch 33 Handlebar switch right 35 Start engine stop switch 37 Neutral switch 38 Sidestand switch 41 Joint connector 42 Joint coupler 54 ECU Engine Control Unit ...

Page 426: ...erating when neither of these condi tions has been met In this instance the starting circuit cut off relay is open so current cannot reach the starter motor When at least one of the above conditions has been met the starting circuit cut off relay is closed and the engine can be started by pressing the side of the start engine stop switch 12 1 11 4 6 6 6 6 a b 8 6 9 7 5 2 3 10 10 a WHEN THE TRANSMI...

Page 427: ...rter motor operation Refer to CHECKING THE START ER MOTOR OPERATION on page 8 202 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 42 NG Repair or replace the starter motor OK 5 Check the relay unit starting circuit cut off relay Refer to CHECKING THE RE LAYS on page 8 198 NG...

Page 428: ...1 Check the clutch switch Refer to CHECKING THE SWITCHES on page 8 191 NG Replace the clutch switch OK 12 Check the start engine stop switch Refer to CHECKING THE SWITCHES on page 8 191 NG Replace the right handlebar switch OK 13 Check the entire starting system s wiring Refer to CIRCUIT DIAGRAM on page 8 7 NG Properly connect or repair the starting sys tem s wiring OK Replace the ECU Refer to REP...

Page 429: ...ELECTRIC STARTING SYSTEM 8 12 ...

Page 430: ...CHARGING SYSTEM 8 13 EAS20074 CHARGING SYSTEM EAS30496 CIRCUIT DIAGRAM ...

Page 431: ...CHARGING SYSTEM 8 14 1 AC magneto 2 Rectifier regulator 4 Main fuse 18 Battery 19 Engine ground ...

Page 432: ... on page 8 195 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 8 202 NG Replace the stator coil assembly OK 4 Check the rectifier regulator Refer to CHECKING THE RECTI FIER REGULATOR on page 8 202 NG Replace the rectifier regulator OK 5 Check the entire charging system s wiring Refer to CIRCUIT DIAGRAM on page 8 1...

Page 433: ...CHARGING SYSTEM 8 16 ...

Page 434: ...LIGHTING SYSTEM 8 17 EAS20075 LIGHTING SYSTEM EAS30498 CIRCUIT DIAGRAM ...

Page 435: ... ground 41 Joint connector 42 Joint coupler 54 ECU Engine Control Unit 74 Meter assembly 80 Multi function meter 88 High beam indicator light 89 Meter light 92 Handlebar switch left 95 Dimmer pass switch 105 Headlight control unit 106 Headlight high beam 107 Headlight low beam 108 Tail brake light 109 License plate light 111 Auxiliary light ...

Page 436: ...e fuse s OK 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 195 NG Clean the battery terminals Recharge or replace the battery OK 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 191 NG Replace the main switch OK 4 Check the dimmer pass switch Refer to CHECKING THE SWITCHES on page 8 191 NG The dimmer pass switch is faulty Replace the left handlebar switch ...

Page 437: ...LIGHTING SYSTEM 8 20 ...

Page 438: ...SIGNALING SYSTEM 8 21 EAS20076 SIGNALING SYSTEM EAS30500 CIRCUIT DIAGRAM ...

Page 439: ...it 69 Rear wheel sensor 70 ABS ECU Electronic Control Unit 72 Shift switch OPTION 74 Meter assembly 77 Neutral indicator light 78 Oil pressure warning light 79 Shift timing indicator light 80 Multi function meter 82 Coolant temperature warning light 84 Turn signal indicator light left 85 Turn signal indicator light right 91 Oil pressure switch 92 Handlebar switch left 96 Horn switch 97 Horn 100 Tu...

Page 440: ...s Main ignition signaling system backup ABS ECU brake light and hazard lighting Refer to CHECKING THE FUSES on page 8 194 NG Replace the fuse s OK 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 195 NG Clean the battery terminals Recharge or replace the battery OK 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 191 NG Replace the main switch OK 4 Check the...

Page 441: ...CHES on page 8 191 NG Replace the rear brake light switch OK 3 Check the brake light relay Refer to CHECKING THE RE LAYS on page 8 198 NG Replace the brake light relay OK 4 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 8 21 NG Properly connect or repair the signaling system s wiring OK Replace the tail brake light 1 Check the turn signal switch Refer to CHECKING THE S...

Page 442: ...tem s wiring OK Replace the meter assembly 1 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 8 21 NG Properly connect or replace the wiring har ness OK 2 Disconnect the oil pressure switch lead from the oil pressure switch and then check whether the oil pres sure warning light comes on when the lead is connected to the engine ground NG Replace the meter assembly OK Repl...

Page 443: ...SENSOR on page 8 204 NG Replace the coolant temperature sensor OK 2 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 8 21 NG Properly connect or replace the wiring har ness OK Replace the ECU or meter assembly Refer to REPLACING THE ECU Engine Control Unit on page 8 194 1 Check that the engine trouble light does not come on NG Repair the faulty parts OK 2 Check that the ...

Page 444: ...switch OK 6 Check the neutral switch Refer to DIAGNOSTIC CODE SENSOR OPERATION TABLE on page 9 16 and CHECKING THE SWITCHES on page 8 191 NG Replace the neutral switch OK 7 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 8 21 NG Properly connect or repair the signaling system s wiring OK Replace the ECU Refer to REPLACING THE ECU Engine Control Unit on page 8 194 1 Chec...

Page 445: ...SIGNALING SYSTEM 8 28 Between joint coupler and ECU coupler blue white blue white blue black blue black Between joint coupler and meter assembly coupler blue white blue white blue black blue black ...

Page 446: ...COOLING SYSTEM 8 29 EAS20077 COOLING SYSTEM EAS30502 CIRCUIT DIAGRAM ...

Page 447: ... radiator fan motor fuse 11 Radiator fan motor fuse 12 Ignition fuse 18 Battery 19 Engine ground 41 Joint connector 49 Coolant temperature sensor 54 ECU Engine Control Unit 112 Radiator fan motor left 113 Sub radiator fan motor right A Wire harness B Sub wire harness coolant temperature sen sor ...

Page 448: ...OK 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 191 NG Replace the main switch OK 4 Check the radiator fan motor Refer to CHECKING THE RADIA TOR FAN MOTORS on page 8 204 NG Replace the radiator fan motor OK 5 Check the radiator fan motor relay Refer to CHECKING THE RE LAYS on page 8 198 NG Replace the radiator fan motor relay OK 6 Check the coolant temperature sen sor Refer to ...

Page 449: ...COOLING SYSTEM 8 32 ...

Page 450: ...FUEL INJECTION SYSTEM 8 33 EAS20078 FUEL INJECTION SYSTEM EAS30504 CIRCUIT DIAGRAM ...

Page 451: ...sensor 50 Intake air temperature sensor 51 O2 sensor 2 right side 52 Lean angle sensor 53 EXUP servo motor 54 ECU Engine Control Unit 55 Ignition coil 1 56 Ignition coil 2 57 Ignition coil 3 58 Ignition coil 4 59 Spark plug 60 Air induction system solenoid 61 Injector 1 62 Injector 2 63 Injector 3 64 Injector 4 65 Accelerator position sensor 66 Throttle position sensor 67 Throttle servo motor 68 F...

Page 452: ...gine to continue operating or stop operating depending on the conditions EAS30506 TROUBLESHOOTING METHOD The engine operation is not normal and the engine trouble warning light comes on 1 Check Fault code number a Check the fault code numbers that have a condition of Detected using the Yamaha diagnostic tool b Identify the faulty system with the fault code number c Identify the probable cause of t...

Page 453: ...amaha diagnostic tool 01 Throttle position sensor signal 1 throttle angle 13 Throttle position sensor signal 2 throttle angle 14 Accelerator position sensor signal 1 throttle angle 15 Accelerator position sensor signal 2 throttle angle 30 Cylinder 1 ignition coil 31 Cylinder 2 ignition coil 32 Cylinder 3 ignition coil 33 Cylinder 4 ignition coil 36 Injector 1 37 Injector 2 38 Injector 3 39 Injecto...

Page 454: ... when the diagnostic mode is operated Refer to SELF DIAGNOS TIC FUNCTION AND DIAGNOSTIC CODE TABLE on page 9 5 Parts connected to the ECU The following parts are connected to the ECU When checking for a power short circuit the couplers must be disconnected from all of the following parts beforehand Monitoring Displays a graph of sensor output values for actual operating condi tions Logging Records...

Page 455: ...s P0030 and P0223 are both indicated take the actions specified for fault code number P0223 first If fault code numbers P0030 and P2135 are both indicated take the actions specified for fault code number P2135 first Ignition coil 3 Relay unit Ignition coil 4 Brake light relay Throttle position sensor Radiator fan motor relay Accelerator position sensor Meter assembly Intake air pressure sensor Imm...

Page 456: ...n of the fault code using the mal function mode of the Yamaha diagnostic tool Condition is Recovered Go to item 6 and finish the service Condition is Detected Start the engine and then check the condition of the fault code Condition is Recovered Go to item 6 and finish the service Condition is Detected Go to item 3 TIP For this check also set the start engine stop switch to ON 3 Wire harness conti...

Page 457: ...0050 and P2135 are both indicated take the actions specified for fault code number P2135 first 4 Defective O2 sensor 1 heater Replace the O2 sensor 1 Turn the main switch to ON and then check the condition of the fault code using the mal function mode of the Yamaha diagnostic tool Condition is Recovered Go to item 6 and finish the service Condition is Detected Start the engine and then check the c...

Page 458: ...e service Condition is Detected Start the engine and then check the condition of the fault code Condition is Recovered Go to item 6 and finish the service Condition is Detected Go to item 2 TIP For this check also set the start engine stop switch to ON 2 Connection of wire harness ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken termin...

Page 459: ... For this check also set the start engine stop switch to ON 4 Defective O2 sensor 2 heater Replace the O2 sensor 2 Turn the main switch to ON and then check the condition of the fault code using the mal function mode of the Yamaha diagnostic tool Condition is Recovered Go to item 6 and finish the service Condition is Detected Start the engine and then check the condition of the fault code Conditio...

Page 460: ...ox 70 kPa 525 0 mmHg 20 7 inHg Displayed value is incorrect Replace the intake air pressure sensor Turn the main switch to ON and then check the condition of the fault code using the mal function mode of the Yamaha diagnostic tool Condition is Recovered Go to item 4 and finish the service Condition is Detected Go to item 2 2 Defective atmospheric pressure sensor Execute the diagnostic mode Code No...

Page 461: ... the condition of the fault code using the mal function mode of the Yamaha diagnostic tool Condition is Recovered Go to item 7 and finish the service Condition is Detected Go to item 2 2 Connection of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the coupler s...

Page 462: ...arness 3 4 For P0108 Open circuit Between intake air pressure sensor coupler and ECU coupler blue blue If there is no continuity replace the wire harness 3 5 For P0108 Open circuit Between intake air pressure sensor coupler and ECU coupler pink white pink white If there is no continuity replace the wire harness Fault code No P0107 P0108 Item P0107 Intake air pressure sensor ground short circuit de...

Page 463: ...ny other ECU coupler terminal b If there is continuity replace the wire harness 4 Installed condition of intake air pressure sensor Check for looseness or pinch ing Improperly installed sensor Reinstall or replace the sensor Turn the main switch to ON and then check the condition of the fault code using the mal function mode of the Yamaha diagnostic tool Condition is Recovered Go to item 7 and fin...

Page 464: ...pressure sensor Replace if defective Refer to REPLACING THE ECU Engine Control Unit on page 8 194 Crank the engine and then check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item 7 and finish the service Condition is Detected Go to item 6 6 Malfunction in ECU Replace the ECU Refer to REPLACING THE ECU Engine Control Unit on ...

Page 465: ... or replace the wire harness Turn the main switch to ON and then check the condition of the fault code using the mal function mode of the Yamaha diagnostic tool Condition is Recovered Go to item 7 and finish the service Condition is Detected Go to item 2 2 Connection of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and loc...

Page 466: ...take air temperature sensor coupler and ground brown white ground If there is continuity replace the wire harness 3 4 For P0113 Open circuit Between intake air temperature sensor coupler and ECU coupler brown white brown white If there is no continuity replace the wire harness Fault code No P0112 P0113 Item P0112 Intake air temperature sensor ground short circuit detected P0113 Intake air temperat...

Page 467: ...fault code using the mal function mode of the Yamaha diagnostic tool Condition is Recovered Go to item 7 and finish the service Condition is Detected Go to item 5 5 Defective intake air tempera ture sensor Execute the diagnostic mode Code No 05 When engine is cold Displayed temperature is close to the ambient temperature The displayed temperature is not close to the ambient temper ature Check the ...

Page 468: ...of service com pletion 1 Connection of coolant tempera ture sensor coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the coupler securely or replace the wire harness Turn the main switch to ON and then check the condition of the fault code using the mal function mode ...

Page 469: ... ECU coupler from the ECU Disconnect the coolant temperature sensor coupler from the coolant temperature sensor 3 3 For P0117 Ground short circuit Between wire harness coupler ECU side and ground green white ground Between sub wire harness coupler coolant temperature sensor side and ground green white ground If there is continuity replace the wire harness and or sub wire harness A Wire harness cou...

Page 470: ... wire harness coupler ECU side and ECU coupler black blue black blue Between sub wire harness coupler coolant temperature sensor side and coolant temperature sen sor coupler black blue black blue If there is no continuity replace the wire harness and or sub wire harness A Wire harness coupler ECU side B Sub wire harness coupler coolant temperature sensor side 3 6 Disconnect the couplers from the p...

Page 471: ...nt temperature sensor Execute the diagnostic mode Code No 06 When engine is cold Displayed temperature is close to the ambient temperature The displayed temperature is not close to the ambient temper ature Check the coolant tem perature sensor Replace if defective Refer to CHECKING THE COOLANT TEMPERATURE SENSOR on page 8 204 Turn the main switch to ON and then check the condition of the fault cod...

Page 472: ...ation of service com pletion 1 Connection of throttle position sensor coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the coupler securely or replace the wire harness Turn the main switch to ON and then check the condition of the fault code using the mal function mo...

Page 473: ...een throttle position sensor coupler and ground white ground If there is continuity replace the wire harness Fault code No P0122 P0123 P0222 P0223 P2135 Item P0122 Throttle position sensor ground short circuit detected P0123 Throttle position sensor open or power short circuit detected P0222 Throttle position sensor ground short circuit detected P0223 Throttle position sensor open or power short c...

Page 474: ...ess 3 6 For P0223 Open circuit Between throttle position sensor coupler and ECU coupler black black If there is no continuity replace the wire harness Fault code No P0122 P0123 P0222 P0223 P2135 Item P0122 Throttle position sensor ground short circuit detected P0123 Throttle position sensor open or power short circuit detected P0222 Throttle position sensor ground short circuit detected P0223 Thro...

Page 475: ... Refer to Parts connected to the ECU on page 8 37 3 10 For P0122 P0123 Short circuit Between throttle position sensor output terminal white a of ECU coupler and any other ECU cou pler terminal b If there is continuity replace the wire harness Fault code No P0122 P0123 P0222 P0223 P2135 Item P0122 Throttle position sensor ground short circuit detected P0123 Throttle position sensor open or power sh...

Page 476: ...fully open A value of 97 106 is indicated Check throttle position sensor signal 2 Execute the diagnostic mode Code No 13 When the throttle valves are fully closed A value of 10 24 is indicated When the throttle valves are fully open A value of 94 109 is indicated An indicated value is out of the specified range Replace the throttle position sensor Turn the main switch to ON and then check the cond...

Page 477: ... broken terminals and locking condition of the pins Improperly connected Con nect the coupler securely or replace the wire harness Turn the main switch to ON and then check the condition of the fault code using the mal function mode of the Yamaha diagnostic tool Condition is Recovered Go to item 7 and finish the service Condition is Detected Go to item 3 3 Connection of wire harness ECU coupler Ch...

Page 478: ...e Condition is Detected Go to item 6 6 Malfunction in ECU Replace the ECU Refer to REPLACING THE ECU Engine Control Unit on page 8 194 Service is finished 7 Delete the fault code and check that the engine trouble warning light goes off Confirm that the fault code has a condition of Recovered using the Yamaha diagnostic tool and then delete the fault code Fault code No P0152 Item O2 sensor 2 short ...

Page 479: ...en or short circuit Properly connect or replace the wire har ness Between O2 sensor 2 coupler and joint connector black blue black blue Between joint connector and ECU coupler black blue black blue Between O2 sensor 2 coupler and ECU coupler gray yellow gray yellow Turn the main switch to ON and then check the condition of the fault code using the mal function mode of the Yamaha diagnostic tool Co...

Page 480: ...njector 1 Measure the fuel injector resis tance Replace if out of specification Refer to CHECKING THE FUEL INJECTORS on page 8 207 Execute the diagnostic mode Code No 36 Operating sound Go to item 6 No operating sound Go to item 3 3 Connection of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pi...

Page 481: ...ector 2 Measure the fuel injector resis tance Replace if out of specification Refer to CHECKING THE FUEL INJECTORS on page 8 207 Execute the diagnostic mode Code No 37 Operating sound Go to item 6 No operating sound Go to item 3 3 Connection of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins...

Page 482: ...jector 3 Measure the fuel injector resis tance Replace if out of specification Refer to CHECKING THE FUEL INJECTORS on page 8 207 Execute the diagnostic mode Code No 38 Operating sound Go to item 6 No operating sound Go to item 3 3 Connection of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pin...

Page 483: ...ctor 4 Measure the fuel injector resis tance Replace if out of specification Refer to CHECKING THE FUEL INJECTORS on page 8 207 Execute the diagnostic mode Code No 39 Operating sound Go to item 6 No operating sound Go to item 3 3 Connection of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins ...

Page 484: ...nect the coupler securely or replace the wire harness Crank the engine and then check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item 7 and finish the service Condition is Detected Go to item 3 3 Wire harness continuity Open or short circuit Replace the wire harness Between crankshaft position sensor coupler and ECU cou ple...

Page 485: ...obable cause of malfunc tion and check Maintenance job Confirmation of service com pletion 1 Connection of cylinder identifi cation sensor coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the coupler securely or replace the wire harness Crank the engine and then chec...

Page 486: ...n check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item 7 and finish the service Condition is Detected Go to item 5 5 Defective cylinder identification sensor Replace the cylinder identifica tion sensor Crank the engine and then check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool C...

Page 487: ... Detected Go to item 2 2 Connection of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the coupler securely or replace the wire harness Start the engine and let it idle for approximately 5 seconds Check the condition of the fault code using the malfunction mode ...

Page 488: ...il safe system Able to start engine depending on the number of faulty cylinders Able to drive vehicle depending on the number of faulty cylinders Diagnostic code No 31 Actuation Actuates the cylinder 2 ignition coil five times at one second intervals The check indicator on the Yamaha diagnostic tool screen comes on each time the ignition coil is actuated Procedure Check that a spark is generated f...

Page 489: ...oseness or pinch ing Improperly installed ignition coil Reinstall or replace the igni tion coil Start the engine and let it idle for approximately 5 seconds Check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item 7 and finish the service Condition is Detected Go to item 5 5 Defective cylinder 2 ignition coil Measure the prima...

Page 490: ...ted Go to item 2 2 Connection of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the coupler securely or replace the wire harness Start the engine and let it idle for approximately 5 seconds Check the condition of the fault code using the malfunction mode of the...

Page 491: ...il safe system Able to start engine depending on the number of faulty cylinders Able to drive vehicle depending on the number of faulty cylinders Diagnostic code No 33 Actuation Actuates the cylinder 4 ignition coil five times at one second intervals The check indicator on the Yamaha diagnostic tool screen comes on each time the ignition coil is actuated Procedure Check that a spark is generated f...

Page 492: ...looseness or pinch ing Improperly installed ignition coil Reinstall or replace the igni tion coil Start the engine and let it idle for approximately 5 seconds Check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item 7 and finish the service Condition is Detected Go to item 5 5 Defective cylinder 4 ignition coil Measure the pri...

Page 493: ...7 and finish the service Conditions is Detected Go to item 2 2 Connection of wire harness ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the coupler securely or replace the wire harness Turn the main switch to ON and then check the condition of the fault code u...

Page 494: ...o motor open or ground short circuit detected P048E EXUP servo motor power short circuit detected Fail safe system Able to start engine Able to drive vehicle Diagnostic code No 53 Actuation After the EXUP is fully closed it stops at the opening base position inter mediate position This operation takes approximately 3 seconds during which the check indicator is displayed on the Yamaha diagnostic to...

Page 495: ...ace the wire harness Turn the main switch to ON and then check the condition of the fault code using the mal function mode of the Yamaha diagnostic tool Condition is Recovered Go to item 6 and finish the service Condition is Detected Go to item 4 3 1 1 EXUP servo motor 2 ECU 3 Sensor input lead 4 Sensor output lead 5 Sensor ground lead 3 2 Disconnect the ECU coupler from the ECU Disconnect the EXU...

Page 496: ...ere is no continuity replace the wire harness 3 6 For P048E Open circuit Between EXUP servo motor coupler and ECU coupler black blue black blue If there is no continuity replace the wire harness 3 7 Disconnect the couplers from the parts that are connected to the ECU Refer to REPLACING THE ECU Engine Control Unit on page 8 194 Fault code No P048D P048E Item P048D EXUP servo motor open or ground sh...

Page 497: ... using the mal function mode of the Yamaha diagnostic tool Condition is Recovered Go to item 6 and finish the service Condition is Detected Go to item 5 5 Malfunction in ECU Replace the ECU Refer to REPLACING THE ECU Engine Control Unit on page 8 194 Service is finished 6 Delete the fault code and check that the engine trouble warning light goes off Confirm that the fault code has a condition of R...

Page 498: ...ted Execute the diagnostic mode Code No 07 Rotate the rear wheel by hand and check that the indicated value increases Value does not increase Go to item A 2 Fault code No P1500 detected Execute the diagnostic mode Code No 21 When the transmission is in neutral ON When the transmission is in gear with the clutch lever released OFF Incorrect indication Go to item B 2 for the neutral switch When the ...

Page 499: ...upler black black white white Between ABS ECU coupler and ECU coupler white yellow white yellow Execute the diagnostic mode Code No 07 Rotate the rear wheel by hand and check that the indicated value increases Value increases Go to item A 8 Value does not increase Go to item A 6 A 6 Malfunction in ECU Replace the ECU Refer to REPLACING THE ECU Engine Control Unit on page 8 194 Execute the diagnost...

Page 500: ... check that the indicated value increases Value does not increase Go to item A 2 for the rear wheel sensor Fault code No P1500 detected Execute the diagnostic mode Code No 21 When the transmission is in neutral ON When the transmission is in gear with the clutch lever released OFF Incorrect indication Go to item B 2 When the transmission is in gear with the clutch lever squeezed and the sidestand ...

Page 501: ...nit Replace if defective Refer to CHECKING THE RELAY UNIT DIODE on page 8 199 Execute the diagnostic mode Code No 21 When the transmission is in neutral ON When the transmission is in gear with the clutch lever released OFF Correct indication Go to item B 9 Incorrect indication Go to item B 6 B 6 Defective neutral switch Check the neutral switch Replace if defective Refer to CHECKING THE SWITCHES ...

Page 502: ...eel sensor no normal signals are received from the rear wheel sensor B Neutral switch open or short circuit is detected C Clutch switch open or short circuit is detected Fail safe system Able to start engine Able to drive vehicle Diagnostic code No 21 Tool display Clutch switch ON when the clutch lever is squeezed with the transmission in gear and when the sidestand is retracted OFF when the clutc...

Page 503: ...nsmission in gear and when the sidestand is retracted OFF When the clutch lever is squeezed with the transmission in gear and when the sidestand is retracted ON Correct indication Go to item C 8 Incorrect indication Go to item C 3 C 3 Connection of clutch switch cou pler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condit...

Page 504: ...black yellow blue yellow blue yellow Execute the diagnostic mode Code No 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 Correct indication Go to item C 8 Incorrect indication Go to item C 6 C 6 Defective clutch switch Check the clutch sw...

Page 505: ...ation of service com pletion 1 Malfunction in charging system Check the charging system Refer to CHARGING SYSTEM on page 8 13 Defective rectifier regulator or AC magneto Replace Defective connection in the charging system circuit Prop erly connect or replace the wire harness Start the engine and let it idle for approximately 5 seconds Check the condition of the fault code using the malfunction mod...

Page 506: ...code number an error is detected while reading or writing on EEPROM Fail safe system Able Unable to start engine Able Unable to drive vehicle Diagnostic code No 60 Tool display 00 No malfunctions detected If the self diagnosis fault code P062F is indi cated the ECU is defective 01 04 CO adjustment value If more than one cylinder is defective the display alternates every two seconds to show all the...

Page 507: ... this adjustment is made turn the main switch to OFF Set the main switch to ON and then check the condition of the fault code using the mal function mode of the Yamaha diagnostic tool Condition is Recovered Go to item 8 and finish the service Condition is Detected Repeat item 1 If the same number is indicated go to item 7 5 04 is indicated in diagnostic mode code No 60 EEPROM data error for adjust...

Page 508: ...rness Turn the main switch to ON and then check the condition of the fault code using the mal function mode of the Yamaha diagnostic tool Condition is Recovered Go to item 8 and finish the service Condition is Detected Go to item 2 2 Connection of wire harness ECU coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected Con n...

Page 509: ... condition of the fault code using the mal function mode of the Yamaha diagnostic tool Condition is Recovered Go to item 8 and finish the service Condition is Detected Go to item 6 6 Defective throttle bodies Check the throttle bodies Replace if defective Refer to CHECKING THE THROTTLE SERVO MOTOR on page 8 205 Turn the main switch to ON and then check the condition of the fault code using the mal...

Page 510: ...ximately 5 seconds Check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item 7 and finish the service Condition is Detected Go to item 2 2 Connection of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected...

Page 511: ...and finish the service Condition is Detected Go to item 6 6 Malfunction in ECU Replace the ECU Refer to REPLACING THE ECU Engine Control Unit on page 8 194 Service is finished 7 Delete the fault code and check that the engine trouble warning light goes off Confirm that the fault code has a condition of Recovered using the Yamaha diagnostic tool and then delete the fault code Fault code No P0916 P0...

Page 512: ... replace the wire harness Turn the main switch to ON and then check the condition of the fault code using the mal function mode of the Yamaha diagnostic tool Condition is Recovered Go to item 7 and finish the service Condition is Detected Go to item 3 3 Wire harness continuity Open or short circuit Replace the wire harness Turn the main switch to ON and then check the condition of the fault code u...

Page 513: ... gear position sensor coupler and ECU coupler blue blue If there is no continuity replace the wire harness 3 5 For P0916 Open circuit Between gear position sensor coupler and ECU coupler green white green white If there is no continuity replace the wire harness Fault code No P0916 P0917 Item P0916 Gear position sensor open or ground short circuit detected P0917 Gear position sensor power short cir...

Page 514: ...Turn the main switch to ON and then check the condition of the fault code using the mal function mode of the Yamaha diagnostic tool Condition is Recovered Go to item 7 and finish the service Condition is Detected Go to item 5 5 Display of each gear position on the meter Make sure that the position of each gear is correctly displayed on the meter If incorrect Replace the gear position sensor Turn t...

Page 515: ...m Probable cause of malfunction and check Maintenance job Confirmation of service com pletion 1 Connection of air induction sys tem solenoid coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the coupler securely or replace the wire harness Turn the main switch to ON a...

Page 516: ... fuse red white red white Turn the main switch to ON and then check the condition of the fault code using the mal function mode of the Yamaha diagnostic tool Condition is Recovered Go to item 6 and finish the service Condition is Detected Start the engine and check the status of the fault code Condition is Recovered Go to item 6 and finish the service Condition is Detected Go to item 4 TIP Check t...

Page 517: ...de using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item 7 and finish the service Condition is Detected Go to item 2 2 Connection of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the coupler securely or replace the wire har...

Page 518: ...on in ECU Replace the ECU Refer to REPLACING THE ECU Engine Control Unit on page 8 194 Service is finished 7 Delete the fault code and check that the engine trouble warning light goes off Confirm that the fault code has a condition of Recovered using the Yamaha diagnostic tool and then delete the fault code Fault code No P1602 Item Malfunction in ECU internal circuit malfunction of ECU power cut o...

Page 519: ...red Between fuse box 1 backup fuse and ECU coupler red green red green Turn the main switch to ON and then check the condition of the fault code using the mal function mode of the Yamaha diagnostic tool Condition is Recovered Go to item 7 and finish the service Condition is Detected Go to item 5 5 Wire harness continuity between main switch and ECU coupler Open or short circuit Replace the wire ha...

Page 520: ...OFF and then back to ON Check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item 6 and finish the service Condition is Detected Go to item 2 2 Connection of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly conn...

Page 521: ...4 Ground short circuit Between lean angle sensor coupler and ground yellow green ground If there is continuity replace the wire harness 3 4 For P1605 Open circuit Between lean angle sensor coupler and ECU coupler blue blue If there is no continuity replace the wire harness Fault code No P1604 P1605 Item P1604 Lean angle sensor ground short circuit detected P1605 Lean angle sensor open or power sho...

Page 522: ... no continuity replace the wire harness 3 7 Disconnect the couplers from the parts that are connected to the ECU Refer to Parts connected to the ECU on page 8 37 3 8 For P1604 P1605 Short circuit Between lean angle sensor output terminal yellow green a of ECU coupler and any other ECU coupler terminal b If there is continuity replace the wire harness Fault code No P1604 P1605 Item P1604 Lean angle...

Page 523: ...elerator position sensor open or ground short circuit detected P2123 Accelerator position sensor power short circuit detected P2127 Accelerator position sensor ground short circuit detected P2128 Accelerator position sensor open or power short circuit detected P2138 Accelerator position sensor output voltage deviation error Fail safe system Able Unable to start engine Able Unable to drive vehicle ...

Page 524: ...securely or replace the wire harness Turn the main switch to ON and then check the condition of the fault code using the mal function mode of the Yamaha diagnostic tool Condition is Recovered Go to item 7 and finish the service Condition is Detected Go to item 3 3 Wire harness continuity Open or short circuit Replace the wire harness Turn the main switch to ON and then check the condition of the f...

Page 525: ... accelerator position sensor coupler and ground white ground If there is continuity replace the wire harness Fault code No P2122 P2123 P2127 P2128 P2138 Item P2122 Accelerator position sensor open or ground short circuit detected P2123 Accelerator position sensor power short circuit detected P2127 Accelerator position sensor ground short circuit detected P2128 Accelerator position sensor open or p...

Page 526: ... 6 For P2128 Open circuit Between accelerator position sensor coupler and ECU coupler black black If there is no continuity replace the wire harness Fault code No P2122 P2123 P2127 P2128 P2138 Item P2122 Accelerator position sensor open or ground short circuit detected P2123 Accelerator position sensor power short circuit detected P2127 Accelerator position sensor ground short circuit detected P21...

Page 527: ...r to Parts connected to the ECU on page 8 37 3 10 For P2122 P2123 Short circuit Between accelerator position sensor output terminal white a of ECU coupler and any other ECU coupler terminal b If there is continuity replace the wire harness Fault code No P2122 P2123 P2127 P2128 P2138 Item P2122 Accelerator position sensor open or ground short circuit detected P2123 Accelerator position sensor power...

Page 528: ...lly open A value of 97 106 is indicated Check accelerator position sen sor signal 2 Execute the diagnostic mode Code No 15 When the throttle grip is fully closed A value of 10 24 is indicated When the throttle grip is fully open A value of 94 109 is indicated An indicated value is out of the specified range Replace the accelerator position sensor Turn the main switch to ON and then check the condi...

Page 529: ...m the following procedure Execute the diagnostic mode Code No 16 Rotate the front wheel by hand and check that the indicated value increases Value increases Go to item 9 and finish the service Value does not increase Go to item 2 2 Connection of front wheel sen sor coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking cond...

Page 530: ...ontinuity Open or short circuit Replace the wire harness Between front wheel sensor coupler and ABS ECU coupler black black white white Between ABS ECU coupler and ECU coupler white green white green Execute the diagnostic mode Code No 16 Rotate the front wheel by hand and check that the indicated value increases Value increases Go to item 9 and finish the service Value does not increase Go to ite...

Page 531: ...ion of Detected Fault code No P2195 Item O2 sensor 1 open circuit detected Fail safe system Able to start engine Able to drive vehicle Diagnostic code No Tool display Procedure Item Probable cause of malfunc tion and check Maintenance job Confirmation of service com pletion 1 Installed condition of O2 sensor 1 Check for looseness or pinch ing Improperly installed sensor Reinstall or replace the se...

Page 532: ...ondition is Detected Go to item 4 Also delete this fault code which has a condition of Detected 4 Wire harness continuity Open or short circuit Replace the wire harness Between O2 sensor 1 coupler and ECU coupler gray green gray green pink black pink black Between O2 sensor 1 coupler and joint connector black blue black blue Between O2 sensor 1 coupler and joint coupler red white red white Between...

Page 533: ...check that the engine trouble warning light goes off Confirm that the fault code has a condition of Recovered using the Yamaha diagnostic tool and then delete the fault code Fault code No P2197 Item O2 sensor 2 open circuit detected Fail safe system Able to start engine Able to drive vehicle Diagnostic code No Tool display Procedure Item Probable cause of malfunc tion and check Maintenance job Con...

Page 534: ...ndition is Detected Go to item 4 Also delete this fault code which has a condition of Detected 4 Wire harness continuity Open or short circuit Replace the wire harness Between O2 sensor 2 coupler and ECU coupler gray yellow gray yellow pink white pink white Between O2 sensor 2 coupler and joint connector black blue black blue Between O2 sensor 2 coupler and joint coupler red white red white Betwee...

Page 535: ... Item P2228 Atmospheric pressure sensor ground short circuit detected P2229 Atmospheric pressure sensor open or power short circuit detected Fail safe system Able to start engine Able to drive vehicle Diagnostic code No 02 Tool display Displays the atmospheric pressure Procedure Compare the actually measured atmospheric pressure with the tool dis play value Item Probable cause of malfunc tion and ...

Page 536: ...ch to ON and then check the condition of the fault code using the mal function mode of the Yamaha diagnostic tool Condition is Recovered Go to item 7 and finish the service Condition is Detected Go to item 4 3 1 1 Atmospheric pressure sensor 2 ECU 3 Sensor input lead 4 Sensor output lead 5 Sensor ground lead 3 2 Disconnect the ECU coupler from the ECU Disconnect the atmospheric pressure sensor cou...

Page 537: ...y replace the wire harness 3 6 For P2229 Open circuit Between atmospheric pressure sensor coupler and ECU coupler black blue black blue If there is no continuity replace the wire harness 3 7 Disconnect the couplers from the parts that are connected to the ECU Refer to Parts connected to the ECU on page 8 37 Fault code No P2228 P2229 Item P2228 Atmospheric pressure sensor ground short circuit detec...

Page 538: ... 757 6 mmHg 29 8 inHg 1000 m 3300 ft above sea level Approx 90 kPa 675 1 mmHg 26 6 inHg 2000 m 6700 ft above sea level Approx 80 kPa 600 0 mmHg 23 6 inHg 3000 m 9800 ft above sea level Approx 70 kPa 525 0 mmHg 20 7 inHg Displayed value is incorrect Replace the atmospheric pres sure sensor Turn the main switch to ON and then check the condition of the fault code using the mal function mode of the Y...

Page 539: ...place the wire harness Turn the main switch to ON and then check the condition of the fault code using the mal function mode of the Yamaha diagnostic tool Condition is Recovered Go to item 6 and finish the service Condition is Detected Go to item 3 3 Wire harness continuity Open or short circuit Replace the wire harness Between meter assembly cou pler and joint coupler blue black blue black blue w...

Page 540: ...CRUISE CONTROL SYSTEM 8 123 EAS20087 CRUISE CONTROL SYSTEM EAS30544 CIRCUIT DIAGRAM ...

Page 541: ...30 Clutch switch 31 Front brake light switch 32 Rear brake light switch 41 Joint connector 42 Joint coupler 54 ECU Engine Control Unit 73 Yamaha diagnostic tool coupler 74 Meter assembly 80 Multi function meter 86 Cruise control system indicator light 87 Cruise control setting indicator light 92 Handlebar switch left 93 Cruise control power switch 94 Cruise control setting switch 110 Brake light r...

Page 542: ...CRUISE CONTROL SYSTEM 8 125 EAS30666 CRUISE CONTROL CIRCUIT OPERATION 20 19 18 17 16 15 14 13 12 11 10 7 6 3 2 1 9 8 5 4 ...

Page 543: ...ake light fuse 9 Cruise control power switch 10 Cruise control setting switch 11 Grip cancel switch 12 Front brake light switch 13 Rear brake light switch 14 Clutch switch 15 Brake light relay 16 Tail brake light 17 ECU Engine Control Unit 18 Multi function meter 19 Cruise control system indicator light 20 Cruise control setting indicator light ...

Page 544: ...ly and assembly EAS30668 BASIC PROCESS FOR TROUBLESHOOTING A C 2 B 3 B 2 B 1 C 1 Comes on Fails to come on Flashes No No Push the cruise control power switch and check the cruise control system indicator light Fault code number is not displayed Explain the conditions for automatically deactivating the cruise control system to the customer Finished Is there automatic deactivation history for the cr...

Page 545: ...ndicator light come on B 2 EAS30670 B 1 DIAGNOSIS USING THE FAULT CODES 1 Information for the fault codes from the cruise control system is contained in the following table Re fer to this table for troubleshooting Fault code table Fault code No P056C Fault code No Symptom Check point P056C No normal signals from the switch are received by the ECU Wire harness ECU coupler and front or rear brake li...

Page 546: ...hen check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item A 10 and finish the ser vice Condition is Detected Go to item A 4 A 4 Connection of main switch cou pler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connect...

Page 547: ...ler and battery black black Turn the main switch to ON Operate the brake lever and then check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item A 10 and finish the ser vice Condition is Detected Go to item A 8 A 8 Defective front brake light switch Replace the front brake light switch Turn the main switch to ON Operate the br...

Page 548: ... ON Operate the brake pedal and then check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item B 10 and finish the ser vice Condition is Detected Go to item B 3 B 3 Connection of brake light relay coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking co...

Page 549: ...wire harness Between battery and main switch coupler red red Between main switch coupler and rear brake switch brown blue green yellow Between rear brake light switch coupler and brake light relay coupler light green black light green black Between brake light relay cou pler and ECU coupler light green black light green black Between brake light relay cou pler and battery black black Turn the main...

Page 550: ...tting switch RES is pushed ON When the cruise control setting switch is released OFF Malfunction Go to item A 2 Execute the diagnostic mode Code 81 When the cruise control setting switch SET is pushed ON When the cruise control setting switch is released OFF Malfunction Go to item B 2 for the cruise control setting switch SET A 2 Connection of left handlebar switch coupler Check the locking condit...

Page 551: ...red Go to item A 9 and finish the ser vice Condition is Detected Go to item A 5 A 5 Check the fuse main fuse ignition fuse cruise control fuse Abnormality Replace the fuse main fuse ignition fuse cruise control fuse Turn the main switch to ON Push and release the RES side of the cruise control setting switch and then check the con dition of the fault code using the malfunction mode of the Yamaha d...

Page 552: ...goes off Confirm that the fault code has a condition of Recovered using the Yamaha diagnostic tool and then delete the fault code Fault code No P0564 Item A Cruise control setting switch RES open or short circuit is detected B Cruise control setting switch SET open or short circuit is detected Fail safe system Able to start engine Able to drive vehicle Diagnostic code No 80 81 Tool display ON when...

Page 553: ...cou pler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the coupler securely or replace the wire harness Turn the main switch to ON Push and release the SET side of the cruise control setting switch and then check the con dition of the fault code using the malfunction mode...

Page 554: ... then check the con dition of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item B 9 and finish the ser vice Condition is Detected Go to item B 7 B 7 Defective cruise control setting switch Replace the left handlebar switch Turn the main switch to ON Push the RES side and SET side of the cruise con trol setting switch and then check the condit...

Page 555: ...plain the automatic deactivation function of the cruise control system to the customer and explain that this is not a malfunction EAS30674 C 1 DELETING THE FAULT CODES 1 Delete the fault code using the malfunction of the Yamaha diagnostic tool and check that the engine trouble warning light goes off EAS30675 C 2 FINAL CHECK 1 Check the brake lever and brake pedal operation 2 Check the rear brake l...

Page 556: ...FUEL PUMP SYSTEM 8 139 EAS20081 FUEL PUMP SYSTEM EAS30513 CIRCUIT DIAGRAM ...

Page 557: ...ain fuse 7 Fuel injection system fuse 9 Backup fuse 12 Ignition fuse 18 Battery 19 Engine ground 27 Relay unit 29 Fuel pump relay 33 Handlebar switch right 35 Start engine stop switch 40 Fuel pump 41 Joint connector 54 ECU Engine Control Unit ...

Page 558: ...the battery OK 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 191 NG Replace the main switch OK 4 Check the start engine stop switch Refer to CHECKING THE SWITCHES on page 8 191 NG Replace the right handlebar switch OK 5 Check the relay unit fuel pump re lay Refer to CHECKING THE RE LAYS on page 8 198 NG Replace the relay unit OK 6 Check the fuel pump Refer to CHECKING THE FUEL P...

Page 559: ...FUEL PUMP SYSTEM 8 142 ...

Page 560: ...IMMOBILIZER SYSTEM 8 143 EAS20084 IMMOBILIZER SYSTEM EAS30519 CIRCUIT DIAGRAM ...

Page 561: ...Main switch 4 Main fuse 9 Backup fuse 12 Ignition fuse 18 Battery 19 Engine ground 25 Immobilizer unit 41 Joint connector 54 ECU Engine Control Unit 74 Meter assembly 75 Immobilizer system indicator light 80 Multi function meter ...

Page 562: ...s lost regis tering new codes in the standard keys is impossible The standard keys can still be used to start the vehicle However if code re registering is required e g if a new standard key is made or all keys are lost the entire immobilizer system must be replaced Therefore it is highly rec ommended to use either standard key for driving and to keep the code re registering key in a safe place Do...

Page 563: ... the ignition key to OFF 30 seconds later the indicator light will start flashing continuously in the standby flashing mode pattern for up to 24 hours After that time the indicator light will stop flashing but the immobilizer system is still enabled Standby mode Parts to be replaced Key registration requirement Main switch immobilizer unit Standard key ECU Accessory lock and key Main switch Immobi...

Page 564: ...ile the indicator light is flashing turn the main switch to OFF remove the key and within 5 sec onds insert the second standard key to be registered into the main switch TIP If he immobilizer system indicator light stops flashing 5 seconds after the first standard key is registered the registration mode is deactivated If this occurs the second standard key cannot be registered and steps 2 to 4 nee...

Page 565: ...ain switch OFF c LED on d LED off e Less than 5 0 s f Code re registering key g Remaining standard key h Registration mode A If the immobilizer system indicator light stops flashing 5 seconds after the first standard key is registered the second standard key cannot be registered ...

Page 566: ...HECKING AND CHARGING THE BATTERY on page 8 195 NG Clean the battery terminals Recharge or replace the battery OK 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 191 NG Replace the main switch immobilizer unit OK 4 Check the entire immobilizer sys tem wiring Refer to CIRCUIT DIAGRAM on page 8 143 NG Properly connect or repair the immobilizer system wiring OK Check the condition of ...

Page 567: ...dard key 53 IMMOBILIZER UNIT Codes cannot be transmitted between the ECU and the immobilizer unit Noise interference or dis connected lead cable 1 Interference due to radio wave noise 2 Disconnected commu nication harness 3 Immobilizer unit mal function 4 ECU malfunction 1 Check the wire harness and con nector 2 Replace the main switch immobi lizer unit 3 Replace the ECU Refer to REPLACING THE ECU...

Page 568: ...5 sec ON and 0 5 sec OFF Example Fault code 52 56 ECU Unidentified code is received Noise interference or dis connected lead cable 1 Check the wire harness and con nector 2 Replace the main switch immobi lizer unit 3 Replace the ECU Refer to REPLACING THE ECU Engine Control Unit on page 8 194 Fault code Part Symptom Cause Action a Light on b Light off ...

Page 569: ...IMMOBILIZER SYSTEM 8 152 ...

Page 570: ...ABS Anti lock Brake System 8 153 EAS20085 ABS Anti lock Brake System EAS30843 CIRCUIT DIAGRAM ...

Page 571: ...und 20 ABS motor fuse 23 Brake light fuse 31 Front brake light switch 32 Rear brake light switch 41 Joint connector 42 Joint coupler 54 ECU Engine Control Unit 68 Front wheel sensor 69 Rear wheel sensor 70 ABS ECU Electronic Control Unit 73 Yamaha diagnostic tool coupler 74 Meter assembly 80 Multi function meter 90 ABS warning light 108 Tail brake light 110 Brake light relay ...

Page 572: ...ABS Anti lock Brake System 8 155 EAS30525 ABS COMPONENTS CHART 1 5 6 7 10 9 8 12 1 2 3 4 11 ...

Page 573: ...ssembly 2 ABS solenoid fuse 3 ABS ECU fuse 4 ABS warning light 5 Front wheel sensor rotor 6 Front wheel sensor 7 Front brake caliper 8 Rear wheel sensor 9 Rear wheel sensor rotor 10 Rear brake caliper 11 ABS motor fuse 12 Yamaha diagnostic tool coupler ...

Page 574: ...ABS Anti lock Brake System 8 157 EAS30844 ABS COUPLER LOCATION CHART 2 1 4 3 5 ...

Page 575: ...ABS Anti lock Brake System 8 158 1 Meter assembly coupler 2 Front wheel sensor coupler 3 Yamaha diagnostic tool coupler 4 ABS ECU coupler 5 Rear wheel sensor coupler ...

Page 576: ...n page 8 163 For troubleshooting items other than the following items follow the normal service method WARNING EWA16710 When maintenance or checks have been performed on components related to the ABS be sure to perform a final check before delivering the vehicle to the customer TIP To final check refer to C 1 FINAL CHECK on page 8 178 ABS operation when the ABS warning light comes on 1 The ABS war...

Page 577: ...ydraulic unit are united assemblies and cannot be disassembled The malfunction history is stored in the memory of the ABS ECU Delete the fault codes when the ser vice is finished This is because the past fault codes will be displayed again if another malfunction occurs EAS30529 BASIC INSTRUCTIONS FOR TROUBLESHOOTING WARNING EWA17420 Perform the troubleshooting A B C in order Be sure to follow the ...

Page 578: ...completed normally Finished Yes No A Turn the main switch to ON and check the ABS warning light Fails to come on Comes on The ABS ECU fuse is blown The ABS ECU coupler is disconnected The ABS solenoid fuse is blown The wire harness is defective The hydraulic unit assembly is defective The connection with the Yamaha diagnostic tool is defective The battery voltage is low Cannot communicate Can comm...

Page 579: ...meter assembly If the ABS warning light comes on the ABS ECU is defective Replace the hydraulic unit assembly EAS30533 A 2 THE ABS WARNING LIGHT AND OTHER INDICATOR LIGHTS FAIL TO COME ON 1 Main switch Check the main switch for continuity Refer to CHECKING THE SWITCHES on page 8 191 If there is no continuity replace the main switch 2 Battery Check the condition of the battery Refer to CHECKING AND...

Page 580: ...minal of the Yamaha diagnostic tool coupler CANL 4 ABS ECU malfunction Replace the hydraulic unit assembly EAS31164 A 5 ABS ECU AND FI ECU FAIL TO COMMUNICATE 1 Yamaha diagnostic tool Check that the Yamaha diagnostic tool is properly connected 2 Wire harness Open circuit in the wire harness between the ABS ECU coupler and the Yamaha diagnostic tool cou pler Check for continuity between blue white ...

Page 581: ...t wheel Defective sensor rotor or incorrect installation of the rotor Defective front wheel sen sor or incorrect installation of the sensor 12 Rear wheel sensor intermit tent pulses or no pulses Rear wheel sensor signal is not received properly Pulses are not received or are received intermittently while the vehicle is traveling Foreign material adhered around the rear wheel sen sor Incorrect inst...

Page 582: ...and the hydraulic unit assembly Defective rear wheel sen sor or hydraulic unit assembly 21 Hydraulic unit assembly defective solenoid drive cir cuit Solenoid drive circuit in the hydraulic unit assembly is open or short circuited Defective hydraulic unit assembly 31 Hydraulic unit assembly defective ABS solenoid power circuit Power is not supplied to the solenoid circuit in the hydraulic unit asse...

Page 583: ...fective sensor rotor or incorrect installation of the rotor Defective front wheel sen sor or incorrect installation of the sensor 44 46 Rear wheel sensor missing pulses Rear wheel sensor signal is not received properly Miss ing pulses are detected in the signal while the vehicle is traveling Foreign material adhered around the rear wheel sen sor Incorrect installation of the rear wheel Defective s...

Page 584: ...ydraulic unit assembly Fault code No 11 Item Front wheel sensor intermittent pulses or no pulses Symptom Front wheel sensor signal is not received properly Pulses are not received or are received intermittently while the vehicle is travel ing Order Item components and probable cause Check or maintenance job 1 Foreign material adhered around the front wheel sensor Check the surface of the sensor ro...

Page 585: ...d condition of the sensor Repair or replace the wheel sensor if necessary Refer to MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR on page 4 37 Fault code No 13 26 Item Front wheel sensor abnormal pulse period Symptom Front wheel sensor signal is not received properly The pulse period is abnormal while the vehicle is traveling Order Item components and probable cause Check or maintenance job...

Page 586: ...eel sensor if necessary 2 Incorrect installation of the rear wheel Check the components for looseness distortion and bends Refer to CHECKING THE REAR WHEEL on page 4 35 3 Defective sensor rotor or incorrect instal lation of the rotor Check the surface of the sensor rotor for damage Replace the sensor rotor if there is visible damage Refer to MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR on...

Page 587: ...7 Wheel sensor 3 Defective front wheel sensor or hydraulic unit assembly If the above items were performed and no malfunctions were found the wheel sensor or hydraulic unit assembly is defective Replace the wheel sensor or hydraulic unit assembly Refer to FRONT WHEEL on page 4 22 and ABS Anti lock Brake System on page 4 65 Fault code No 16 Item Rear wheel sensor open or short circuit Symptom Open ...

Page 588: ...re is short circuit the wire harness is defective Replace the wire harness 6 ABS ECU 7 Wheel sensor 3 Defective rear wheel sensor or hydraulic unit assembly If the above items were performed and no malfunctions were found the wheel sensor or hydraulic unit assembly is defective Replace the wheel sensor or hydraulic unit assembly Refer to REAR WHEEL on page 4 31 and ABS Anti lock Brake System on pa...

Page 589: ...eplace the hydraulic unit assembly Refer to ABS Anti lock Brake System on page 4 65 Fault code No 33 Item Hydraulic unit assembly abnormal ABS motor power supply Symptom Power is not supplied to the motor circuit in the hydraulic unit assembly Order Item components and probable cause Check or maintenance job 1 Blown ABS motor fuse Check the ABS motor fuse If the ABS motor fuse is blown replace the...

Page 590: ...ed from the ABS ECU to reduce the hydraulic pressure Order Item components and probable cause Check or maintenance job 1 Incorrect installation of the front wheel sensor Check the components for looseness distortion and bends Refer to CHECKING THE FRONT WHEEL on page 4 24 2 Incorrect rotation of the front wheel Check that there is no brake disc drag on the front wheel and make sure that it rotates...

Page 591: ...ctive hydraulic unit assembly If the above items were performed and no malfunctions were found replace the hydraulic unit assembly Refer to ABS Anti lock Brake System on page 4 65 Fault code No 43 45 Item Front wheel sensor missing pulses Symptom Front wheel sensor signal is not received properly Missing pulses are detected in the signal while the vehicle is traveling Order Item components and pro...

Page 592: ... THE REAR WHEEL on page 4 35 3 Defective sensor rotor or incorrect instal lation of the rotor Check the surface of the sensor rotor for damage Replace the sensor rotor if there is visible damage Refer to MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR on page 4 37 4 Defective rear wheel sensor or incorrect installation of the sensor Check the wheel sensor for damage and the installed conditi...

Page 593: ...pler 3 Open or short circuit in the wire harness between the battery and the hydraulic unit assembly Replace if there is an open or short circuit Between ABS ECU coupler and ABS ECU fuse red black red black 4 Defective charging system Check the charging system Refer to CHARGING SYSTEM on page 8 13 Fault code No 55 Item Hydraulic unit assembly defective ABS ECU Symptom Abnormal data is detected in ...

Page 594: ...k the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the cou pler securely TIP Turn the main switch to OFF before disconnecting or connecting a coupler 4 Open or short circuit in the wire harness between the battery and the hydraulic unit assembly Replace if there is an open or short circuit Between ABS ECU cou...

Page 595: ...age 4 28 and INSTALLING THE REAR WHEEL DISC BRAKE on page 4 37 3 Perform brake line routing confirmation Refer to HYDRAULIC UNIT OPERATION TEST on page 4 70 If it does not have reaction force properly the brake hose is not properly routed or connected 4 Delete the fault codes Refer to B 3 DELETING THE FAULT CODES on page 8 178 5 Checking the ABS warning light Refer to CHECKING THE ABS WARNING LIGH...

Page 596: ...d the meter assembly Check for continuity between green orange terminal of the ABS ECU coupler and green orange ter minal of the meter assembly coupler Malfunction in the meter assembly circuit Malfunction in the ABS warning light circuit in the hydraulic unit assembly ...

Page 597: ...ABS Anti lock Brake System 8 180 ...

Page 598: ...STEERING DAMPER SYSTEM 8 181 EAS20259 STEERING DAMPER SYSTEM EAS32036 CIRCUIT DIAGRAM ...

Page 599: ... Backup fuse 12 Ignition fuse 18 Battery 19 Engine ground 41 Joint connector 42 Joint coupler 54 ECU Engine Control Unit 71 Steering damper solenoid 73 Yamaha diagnostic tool coupler 74 Meter assembly 76 Steering damper warning light 80 Multi function meter ...

Page 600: ...cause of the malfunction Refer to TROUBLESHOOTING DETAILS STEERING DAMPER FAULT CODE on page 8 183 and SELF DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE on page 9 5 3 Perform the reinstatement action for the fuel injection system Refer to Confirmation of service completion in the appropriate table in TROUBLESHOOTING DE TAILS STEERING DAMPER FAULT CODE on page 8 183 TIP Turning the main switch to ...

Page 601: ...upler and check the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the coupler securely or replace the wire harness Turn the main switch to ON and then check the condition of the fault code using the mal function mode of the Yamaha diagnostic tool Condition is Recovered Go to item 6 and finish the service Condition is Detected Go to item 3 3 Wire harn...

Page 602: ...d check that the engine trouble warning light goes off Confirm that the fault code has a condition of Recovered using the Yamaha diagnostic tool and then delete the fault code Fault code No C1000 Item Steering damper solenoid open or short circuit detected ...

Page 603: ...STEERING DAMPER SYSTEM 8 186 ...

Page 604: ...ELECTRICAL COMPONENTS 8 187 EAS20089 ELECTRICAL COMPONENTS 4 2 1 5 6 7 8 9 10 11 12 13 14 15 17 18 19 20 21 22 23 3 16 ...

Page 605: ... sensor 7 Injector 8 Throttle position sensor 9 Fuel pump 10 Battery 11 Lean angle sensor 12 EXUP servo motor 13 Hydraulic unit assembly 14 Shift switch OPTION 15 Stator coil 16 Crankshaft position sensor 17 ECU Engine Control Unit 18 Radiator fan motor 19 Horn 20 Steering damper solenoid 21 Headlight control unit 22 Auxiliary DC jack 23 Main switch immobilizer unit ...

Page 606: ...ELECTRICAL COMPONENTS 8 189 1 2 3 4 5 6 7 8 9 10 12 13 14 15 16 17 18 19 20 22 23 24 11 21 ...

Page 607: ... light relay 9 Starter relay 10 Rectifier regulator 11 Rear wheel sensor 12 Rear brake light switch 13 Gear position sensor 14 Sidestand switch 15 O2 sensor 16 Oil pressure switch 17 Cylinder identification sensor 18 Front wheel sensor 19 Air induction system solenoid 20 Radiator fan motor relay 21 Fuse box Brake light fuse 22 Fuse box Cruise control fuse 23 Fuse box 2 24 Fuse box 1 ...

Page 608: ...ELECTRICAL COMPONENTS 8 191 EAS30549 CHECKING THE SWITCHES 2 1 3 4 6 5 7 8 9 10 13 12 14 15 16 17 18 11 ...

Page 609: ... 4 Horn switch 5 Select switch 6 Traction control system switch 7 Turn signal switch 8 Grip cancel switch 9 Sidestand switch 10 Shift switch OPTION 11 Main switch 12 Mode switch 13 Start engine stop switch 14 Hazard switch 15 Clutch switch 16 Front brake light switch 17 Rear brake light switch 18 Neutral switch ...

Page 610: ...e 1 range When checking for continuity switch back and forth between the switch positions a few times The switches and their terminal connections are illustrated as in the following example of the main switch The switch positions a are shown in the far left column and the switch lead colors b are shown in the top row The continuity i e a closed circuit between switch terminals at a given switch po...

Page 611: ...al system cause the lighting and ignition systems to malfunction and could possibly cause a fire 4 Install Air scoop left Rider seat Refer to GENERAL CHASSIS 1 on page 4 1 EAS31006 REPLACING THE ECU Engine Control Unit 1 Turn the main switch to OFF 2 Replace the ECU Engine Control Unit 3 Clean the throttle bodies and reset the ISC Idle Speed Control learning value Refer to CHECKING AND CLEANING TH...

Page 612: ...ve Regu lated Lead Acid battery are different from those of conventional batteries The VRLA Valve Regulated Lead Acid battery should be charged according to the appropriate charging method If the battery is over charged the electrolyte level will drop con siderably Therefore take special care when charging the battery NOTICE ECA22960 Use only the specified genuine YAMAHA bat tery Using a different...

Page 613: ...re in full contact with the battery terminal and that they are not shorted A corroded bat tery charger lead clip may generate heat in the contact area and a weak clip spring may cause sparks If the battery becomes hot to the touch at any time during the charging process dis connect the battery charger and let the bat tery cool before reconnecting it Hot batteries can explode As shown in the follow...

Page 614: ... Voltage should be measured 30 minutes after the engine is stopped b Connect a charger and ammeter to the bat tery and start charging c Make sure that the current is higher than the standard charging current written on the bat tery TIP If the current is lower than the standard charging current written on the battery this type of battery charger cannot charge the VRLA Valve Regu lated Lead Acid bat...

Page 615: ...log pocket tester YU 03112 C 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Relay operation Continuity between 3 and 4 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe L W R W R W 1 2 3 4 Br W L W R W R L L WR W L B L Y Sb B Y Sb W L W L W Result Continuity between 3 and 4 1 Positive bat...

Page 616: ...Lg B L R Y B 4 Continuity Positive tester probe sky blue 1 Negative tester probe black yellow 2 No continuity Positive tester probe black yellow 2 Negative tester probe sky blue 1 Continuity Positive tester probe sky blue 1 Negative tester probe blue yellow 3 No continuity Positive tester probe blue yellow 3 Negative tester probe sky blue 1 Continuity Positive tester probe sky blue 1 Negative test...

Page 617: ...E IGNITION SPARK GAP 1 Check Ignition spark gap Out of specification Perform the ignition system troubleshooting starting with step 5 Refer to TROUBLESHOOTING on page 8 4 TIP If the ignition spark gap is within specification the ignition system circuit is operating normally a Remove the ignition coil from the spark plug b Connect the ignition checker 1 as shown Primary coil resistance 1 19 1 61 Po...

Page 618: ...om the fuel tank bracket 2 Check Lean angle sensor output voltage Out of specification Replace a Connect the test harness lean angle sensor 6P 1 to the lean angle sensor and wire harness as shown b Connect the pocket tester DC 20 V to the test harness lean angle sensor 6P 2 Ignition coil Crankshaft position sensor resis tance 189 231 Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positi...

Page 619: ... no flammable gas or fluid is in the vicinity b Check the starter motor operation EAS30566 CHECKING THE STATOR COIL 1 Disconnect Stator coil coupler from the wire harness 2 Check Stator coil resistance Out of specification Replace the stator coil a Connect the digital circuit tester to the stator coil coupler as shown b Measure the stator coil resistance EAS30680 CHECKING THE RECTIFIER REGULATOR 1...

Page 620: ...r from the fuel pump 2 Remove Fuel tank 3 Remove Fuel pump from the fuel tank 4 Check Fuel sender resistance Out of specification Replace the fuel pump assembly a Connect the pocket tester 10 100 to the fuel sender terminals as shown Rectifier regulator input voltage above 14 V at 5000 r min Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe white 1 Negative tester pro...

Page 621: ...ADIATOR FAN MOTORS 1 Check Radiator fan motor Faulty rough movement Replace a Disconnect the radiator fan motor coupler from the wire harness b Connect the battery DC 12 V as shown c Measure the radiator fan motor movement EAS30578 CHECKING THE COOLANT TEMPERATURE SENSOR 1 Remove Coolant temperature sensor Refer to CYLINDER HEAD on page 5 23 WARNING EWA14130 Handle the coolant temperature sensor w...

Page 622: ...fer to GENERAL CHASSIS 3 on page 4 20 2 Check Throttle valve operation Throttle valves do not fully close Replace the throttle bodies a Connect two C size batteries to the throttle servo motor terminals 1 as shown NOTICE ECA17660 Do not use a 12 V battery to operate the throt tle servo motor TIP Do not use old batteries to operate the throttle servo motor Coolant temperature sensor re sistance 251...

Page 623: ...rness speed sensor 3P 1 to the rear speed sensor coupler and wire harness as shown b Connect the pocket tester DC 20 V to the test harness speed sensor 3P c Turn the main switch to ON d Rotate the crankshaft e Measure the voltage With each full rotation of the crankshaft the voltage reading should cycle from 0 8 V to 4 8 V to 0 8 V to 4 8 V EAS30594 CHECKING THE INTAKE AIR TEMPERATURE SENSOR 1 Rem...

Page 624: ...8 CHECKING THE STEERING DAMPER SOLENOID 1 Remove Air scoop right Refer to GENERAL CHASSIS 1 on page 4 1 2 Check Steering damper solenoid resistance Out of specification Replace the steering damper assembly a Disconnect the steering damper lead coupler from wire harness b Connect the pocket tester 10 to the steering damper lead coupler c Measure the steering damper solenoid resis tance EAS30681 CHE...

Page 625: ...ector coupler from the fuel injector b Connect the pocket tester 10 to the fuel injector coupler as shown c Measure the fuel injector resistance Resistance 12 0 Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe Injector terminal 1 Negative tester probe Injector terminal 2 ...

Page 626: ...ELECTRICAL COMPONENTS 8 209 ...

Page 627: ...ORK LEGS 9 3 UNSTABLE HANDLING 9 3 FAULTY LIGHTING OR SIGNALING SYSTEM 9 3 TROUBLESHOOTING AT THE ABS WARNING LIGHT 9 4 SELF DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE 9 5 SELF DIAGNOSTIC FUNCTION TABLE FOR FUEL INJECTION SYSTEM 9 5 SELF DIAGNOSTIC FUNCTION TABLE FOR STEERING DAMPER SYSTEM 9 15 SELF DIAGNOSTIC FUNCTION TABLE FOR IMMOBILIZER SYSTEM 9 16 COMMUNICATION ERROR WITH THE METER 9 16 DI...

Page 628: ...ed or contaminated fuel Sucked in air Electrical system 1 Battery Discharged battery Faulty battery 2 Fuse s Blown damaged or incorrect fuse Improperly installed fuse 3 Spark plug s Incorrect spark plug gap Incorrect spark plug heat range Fouled spark plug Worn or damaged electrode Worn or damaged insulator 4 Ignition coil s Cracked or broken ignition coil body Broken or shorted primary or seconda...

Page 629: ...rned stopper lever Shift forks Worn shift fork Shift drum Incorrect axial play Worn shift drum groove Transmission Worn gear dog EAS30849 FAULTY CLUTCH Clutch slips 1 Clutch Improperly assembled clutch Improperly adjusted clutch cable Loose or fatigued clutch spring Worn friction plate Worn clutch plate 2 Engine oil Incorrect oil level Incorrect oil viscosity low Deteriorated oil Clutch drags 1 Cl...

Page 630: ...rect oil level EAS30611 UNSTABLE HANDLING Handlebar Bent or improperly installed handlebar Steering head components Improperly installed upper bracket Improperly installed lower bracket improperly tightened ring nut Bent steering stem Damaged ball bearing or bearing race Front fork leg s Uneven oil levels both front fork legs Unevenly tensioned fork spring both front fork legs Broken fork spring B...

Page 631: ...y Faulty meter assembly Faulty main switch Faulty turn signal switch Turn signal remains lit Faulty meter assembly Turn signal blinks quickly Faulty meter assembly Horn does not sound Damaged or faulty horn Faulty main switch Faulty horn switch Faulty battery Blown damaged or incorrect fuse Faulty wire harness EAS30848 TROUBLESHOOTING AT THE ABS WARNING LIGHT Refer to BASIC PROCESS FOR TROUBLE SHO...

Page 632: ...alfunction in ECU Broken or discon nected lead in O2 sensor 2 heater When the O2 sensor 2 does not operate because the exhaust temperature is low Increased exhaust emissions Fuel learning cannot be carried out Display only If the O2 sensor 2 does not operate O2 feedback is not carried out Cruise control system cannot be operated P0069 Intake air pressure sensor or atmo spheric pressure sen sor Whe...

Page 633: ...ried out ISC feedback is not carried out ISC learning is not carried out Cruise control system cannot be operated P0112 P0113 P0112 Intake air temperature sensor ground short circuit detected P0113 Intake air temperature sensor open or power short circuit detected P0112 Low voltage of the intake air tem perature sensor circuit 0 1 V or less P0113 High voltage of the intake air tem perature sensor ...

Page 634: ...nsor ground short circuit detected P0223 Throttle posi tion sensor open or power short circuit detected P2135 Throttle posi tion sensor output voltage deviation error P0122 P0222 Low voltage of the throttle position sensor circuit 0 25 V or less P0123 P0223 High voltage of the throttle position sensor circuit 4 75 V or more P2135 Difference in output voltage 1 and output voltage 2 of the throttle ...

Page 635: ...ECU Increased exhaust emissions O2 feedback is not carried out O2 feedback learning is not carried out Air induction system solenoid is turned on all the time air induc tion system air cut off Cruise control system cannot be operated P0201 P0202 P0203 P0204 P0201 Fuel injector 1 malfunction in fuel injector 1 P0202 Fuel injector 2 malfunction in fuel injector 2 P0203 Fuel injector 3 malfunction in...

Page 636: ...g operation Cruise control system cannot be operated P0351 P0352 P0353 P0354 P0351 Cylinder 1 ignition coil open or short circuit detected in the primary lead of the cylinder 1 igni tion coil P0352 Cylinder 2 ignition coil open or short circuit detected in the primary lead of the cylinder 2 igni tion coil P0353 Cylinder 3 ignition coil open or short circuit detected in the primary lead of the cyli...

Page 637: ...utral switch open or short circuit is detected P1500 Clutch switch open or short circuit is detected Open or short cir cuit in wire harness between rear wheel sensor and ABS unit Open or short cir cuit in wire harness between ABS unit and ECU Open or short cir cuit in wire harness between neutral switch and ECU Open or short cir cuit in wire harness between clutch switch and ECU Defective rear whe...

Page 638: ...h open or short circuit detected Open or short cir cuit in wire harness Defective cruise control setting switch Malfunction in ECU Cruise control system cannot be operated Cruise control system cannot be operated Rear brake light switch open or short circuit detected P0601 Faulty ECU memory When this malfunc tion is detected in the ECU the fault code number might not appear on the tool display Mal...

Page 639: ...is restricted ISC feedback is not carried out ISC learning is not carried out Cruise control system cannot be operated P0657 Fuel system voltage incorrect voltage sup plied to the fuel injec tor fuel pump and relay unit Open or short cir cuit in wire harness between relay unit and ECU Open circuit in wire harness between battery and ECU Defective relay unit Malfunction in ECU Engine is difficult t...

Page 640: ...not be started Engine is forcefully stopped the injector output is stopped P1602 Malfunction in ECU internal circuit mal function of ECU power cut off function Open or short cir cuit in wire harness between ECU and battery Open or short cir cuit in wire harness between ECU and main switch Blown backup fuse Malfunction in ECU Engine idling speed is unstable Engine idling speed is high Increased exh...

Page 641: ...ed to 0 O2 feedback is not carried out YCC T evacuation is activated Fuel cut is prohibited by accelerator open ing Output is restricted ISC feedback is not carried out ISC learning is not carried out Cruise control system cannot be operated P2158 Front wheel sensor no normal signals are received from the front wheel sensor Open or short cir cuit in wire harness between front wheel sensor and ECU ...

Page 642: ...r and ECU Open or short cir cuit in wire harness between atmo spheric pressure sensor and ECU Improperly installed atmospheric pres sure sensor Defective atmo spheric pressure sensor Malfunction in ECU Engine is difficult to start Increased exhaust emissions Insufficient power at high altitudes Engine idling speed is unstable N is fixed Intake air pressure difference is fixed to 0 kPa Atmospheric ...

Page 643: ...unication error with the meter Communication between the ECU and the meter is not possi ble Defective meter cou pler and ECU cou pler Open or short cir cuit in the wire har ness between the meter and the ECU Defective meter Defective ECU Defective meter dis play Traction control does not work Grip warmer output OFF is fixed MAP changeover State is fixed Traction control does not work Meter switch ...

Page 644: ...he tool display value If the actually measured battery voltage is low recharge the battery 13 Throttle position sensor sig nal 2 Fully closed position 10 24 Check with throttle valves fully closed Fully open position 94 109 Check with throttle valves fully open 14 Accelerator position sensor signal 1 Fully closed position 13 21 Check with throttle grip fully closed position Fully open position 97 ...

Page 645: ...ery two seconds to show all the detected cylin der numbers When all cylinder numbers are shown the display repeats the same process 11 Data error for ISC Idle Speed Control learning val ues 12 O2 feedback learning value 13 OBD memory value 67 ISC Idle Speed Control learning condition display ISC Idle Speed Control learning data erasure 00 ISC Idle Speed Control learning data has been erased 01 It ...

Page 646: ...witch and rear brake light switch Operate the brake lever and brake pedal Brake lever is squeezed ON Brake lever is released OFF Brake pedal is depressed ON Brake pedal is released OFF 86 Shift switch Check the switch condition by operating the shift pedal Shift pedal up position ON Other position than the shift pedal up position OFF 87 O2 feedback learning data erasure 00 O2 feedback learning dat...

Page 647: ...r 36 Injector 1 Actuates the injector 1 five times at one second inter vals The check indicator on the Yamaha diagnostic tool screen come on each time the fuel injector is actuated Check that injector 1 is actuated five times by listen ing for the operating sound 37 Injector 2 Actuates the injector 2 five times at one second inter vals The check indicator on the Yamaha diagnostic tool screen come ...

Page 648: ...s The check indicator on the Yamaha diagnostic tool screen come on each time the relay is actuated Check that the relay unit is actuated five times by listen ing for the operating sound 51 Radiator fan motor relay Actuates the radiator fan motor relay five times at five second intervals The check indicator on the Yamaha diagnostic tool screen come on each time the relay is actuated Check that the ...

Page 649: ...ke air temper ature sensor Brief abnormality detected in the intake air temperature sen sor Same as for fault code number P0112 and P0113 Perform the inspection items listed for fault code number P0112 and P0113 198 Atmospheric pressure sensor Brief abnormality detected in atmo spheric pressure sen sor Same as for fault code number P2228 and P2229 Perform the inspection items listed for fault code...

Page 650: ...unctioning 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 throttle cable Poorly adjusted clutch cable Malfunction in the fuel injection system Dirty or worn spark plug Malfunction in the bat tery Malfunction in ECU If a fault code is occurring respond to that first Rarely Code 243 o...

Page 651: ... it more than 65 degrees Item Probable cause of malfunc tion and check Maintenance job Confirmation of service com pletion 1 The vehicle has overturned Raise the vehicle upright Turn the main switch to ON then to OFF and then back to ON Engine trouble warning light does not come on Service is finished Engine trouble warning light comes on Go to item 2 2 Installed condition of lean angle sensor Che...

Page 652: ...EVENT CODE TABLE 9 25 4 Malfunction in ECU Replace the ECU Refer to REPLACING THE ECU Engine Control Unit on page 8 194 Service is finished Event code No 30 Item Latch up detected ...

Page 653: ...uction system solenoid 61 Injector 1 62 Injector 2 63 Injector 3 64 Injector 4 65 Accelerator position sensor 66 Throttle position sensor 67 Throttle servo motor 68 Front wheel sensor 69 Rear wheel sensor 70 ABS ECU Electronic Control Unit 71 Steering damper solenoid 72 Shift switch OPTION 73 Yamaha diagnostic tool cou pler 74 Meter assembly 75 Immobilizer system indicator light 76 Steering damper...

Page 654: ...e G O Green Orange G W Green White G Y Green Yellow Gy G Gray Green Gy R Gray Red Gy Y Gray Yellow 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 B Orange Black O G Orange Green O W Orange White P B Pink Black P W Pink White R B Red Black R G Red Green R L Red Blue R W Red White R Y Red Yellow Sb W Sky blue White W B W...

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Page 657: ...G 2016 WIRING DIAGRAM MTN1000 MTN1000G 2016 SCHÉMA DE CÂBLAGE MTN1000 MTN1000G 2016 SCHALTPLAN MTN1000 MTN1000G 2016 SCHEMA ELETTRICO MTN1000 MTN1000G 2016 DIAGRAMA ELÉCTRICO B67 28197 E0_WD indd 1 2016 02 15 15 04 37 ...

Page 658: ...G 2016 WIRING DIAGRAM MTN1000 MTN1000G 2016 SCHÉMA DE CÂBLAGE MTN1000 MTN1000G 2016 SCHALTPLAN MTN1000 MTN1000G 2016 SCHEMA ELETTRICO MTN1000 MTN1000G 2016 DIAGRAMA ELÉCTRICO B67 28197 E0_WD indd 2 2016 02 15 15 04 37 ...

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Yamaha MT 10 2016, Service Manual

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