Yamaha MTN1000 2016 Service Manual Download

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ELECTRIC STARTING SYSTEM

8-12

Summary of Contents for MTN1000 2016

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

Page 2: ......

Page 3: ...00 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 expres...

Page 4: ...ificant 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...

Page 5: ...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...

Page 6: ...viceable 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 Mo...

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...

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Page 9: ...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 RING...

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 se...

Page 11: ...tem 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...

Page 12: ...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...

Page 13: ...em 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 co...

Page 14: ...e 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 contr...

Page 15: ...ancel 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 t...

Page 16: ...as 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...

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...

Page 18: ...ng 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...

Page 19: ...sing 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 sy...

Page 20: ...he 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 f...

Page 21: ...h 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...

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 TI...

Page 23: ...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...

Page 24: ...e 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 WARN...

Page 25: ...e 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...

Page 26: ...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...

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 re...

Page 28: ...m 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 ind...

Page 29: ...ious 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...

Page 30: ...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 func...

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 c...

Page 32: ...ner 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 fast...

Page 33: ...ld 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 t...

Page 34: ...ity 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 m...

Page 35: ...he 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 disconnec...

Page 36: ...izer 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...

Page 37: ...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 teste...

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 ro...

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 22 90890 01365 4 100...

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 4 5 90890 04116 Valve guide remover 4 5 mm YM 04116 5...

Page 41: ...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 0...

Page 42: ...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...

Page 43: ...ft 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 injecto...

Page 44: ...000 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...

Page 45: ...TENING 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 LU...

Page 46: ...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 turn...

Page 47: ...AE 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 W...

Page 48: ...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 s...

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 En...

Page 50: ...ss 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...

Page 51: ...3 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...

Page 52: ...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...

Page 53: ...8 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 Adjustmen...

Page 54: ...e 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...

Page 55: ...ndard 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 Mode...

Page 56: ...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 Inta...

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 specif...

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 w...

Page 59: ...t 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 th...

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 filt...

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 le...

Page 62: ...ing 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 B...

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: ...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 Exhau...

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...

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: ...l 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...

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: ...ad 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...

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...

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

Page 89: ...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 t...

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

Page 91: ...t 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 ma...

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

Page 93: ...hown 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 sta...

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

Page 95: ...and 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...

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

Page 97: ...witch 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...

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

Page 99: ...e 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 Alig...

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

Page 101: ...ward 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 st...

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 lead...

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

Page 105: ...lastic 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 sta...

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

Page 107: ...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 R...

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

Page 109: ...ocking 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 t...

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

Page 111: ...t 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...

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...

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

Page 115: ...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 project...

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...

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

Page 121: ...ssembly 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 o...

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

Page 123: ...eft 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 si...

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

Page 125: ...w 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...

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

Page 127: ...diator 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...

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

Page 129: ...ING 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 th...

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

Page 131: ...ID 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 T...

Page 132: ...OOLANT 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 CHECKI...

Page 133: ...MISSION 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 1800...

Page 134: ...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...

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 C...

Page 136: ...fter 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...

Page 137: ...rush 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...

Page 138: ...e 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...

Page 139: ...erclockwise 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 gau...

Page 140: ...equired 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...

Page 141: ...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 TAN...

Page 142: ...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 vacu...

Page 143: ...ent 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...

Page 144: ...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...

Page 145: ...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...

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 al...

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 indicat...

Page 148: ...ar 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 damag...

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...

Page 150: ...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...

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 a...

Page 152: ...re 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...

Page 153: ...ng 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...

Page 154: ...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 sm...

Page 155: ...ay 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 b...

Page 156: ...e 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 spr...

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 sl...

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 checkin...

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 s...

Page 160: ...t 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 A...

Page 161: ...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 Radia...

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 Colla...

Page 163: ...ill 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 w...

Page 164: ...t 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 l...

Page 165: ...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 t...

Page 166: ...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 th...

Page 167: ...lly 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...

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: ...ECKING 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 W...

Page 170: ...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 B...

Page 171: ...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 SWINGAR...

Page 172: ...rts 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...

Page 173: ...ng 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 to...

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 L...

Page 175: ...uard 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...

Page 176: ...el 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...

Page 177: ...ler 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...

Page 178: ...rvoir 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...

Page 179: ...ry 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 Rad...

Page 180: ...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 c...

Page 181: ...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...

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...

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: ...oupler 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 Au...

Page 185: ...ont 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...

Page 186: ...move 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...

Page 187: ...r 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 Headli...

Page 188: ...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...

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...

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 Dis...

Page 192: ...ake 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...

Page 193: ...aliper 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...

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: ...nsor 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...

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 sho...

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 d...

Page 198: ...ght 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 f...

Page 199: ...ate 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...

Page 200: ...e 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 cau...

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

Page 202: ...nsor 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 wh...

Page 203: ...heel 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...

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 kg...

Page 205: ...ed 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 ele...

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...

Page 207: ...ely 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 circumferen...

Page 208: ...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 Aft...

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...

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 wh...

Page 211: ...o 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 Ble...

Page 212: ...ke 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...

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: ...e 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...

Page 215: ...ont 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 B...

Page 216: ...emove 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...

Page 217: ...o 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...

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...

Page 219: ...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 passag...

Page 220: ...ignated 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 Mixin...

Page 221: ...ke 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 reservo...

Page 222: ...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...

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: ...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...

Page 225: ...d 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 gask...

Page 226: ...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...

Page 227: ...ing 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...

Page 228: ...y 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...

Page 229: ...rake 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 Sle...

Page 230: ...ure 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...

Page 231: ...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 flui...

Page 232: ...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 cylin...

Page 233: ...ts 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...

Page 234: ...e 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...

Page 235: ...te 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...

Page 236: ...e 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 brak...

Page 237: ...lator 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...

Page 238: ...r 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...

Page 239: ...ve 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...

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...

Page 241: ...ic 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 maintenanc...

Page 242: ...al 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...

Page 243: ...ction 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 w...

Page 244: ...ic 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 t...

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 1...

Page 246: ...b 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...

Page 247: ...his 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 Ins...

Page 248: ...ble 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 handle...

Page 249: ...he 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...

Page 250: ...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 Fro...

Page 251: ...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 r...

Page 252: ...ort 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 count...

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 f...

Page 254: ...lt 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 fil...

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 inst...

Page 256: ...ICE 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 sea...

Page 257: ...r 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...

Page 258: ...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 Inst...

Page 259: ...e 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...

Page 260: ...r 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 brac...

Page 261: ...m 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 be...

Page 262: ...ash 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 hea...

Page 263: ...l 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 u...

Page 264: ...r 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...

Page 265: ...embly 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...

Page 266: ...g 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 release...

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 SHOC...

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 R...

Page 269: ...RIVE 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...

Page 270: ...st 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...

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...

Page 272: ...NG 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...

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 sl...

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: ...rive 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...

Page 276: ...ength 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...

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 EA...

Page 278: ...e 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 r...

Page 279: ...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 i...

Page 280: ...cknuts 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...

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...

Page 282: ...VER 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 C...

Page 283: ...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...

Page 284: ...at 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 swit...

Page 285: ...er 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 CH...

Page 286: ...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 p...

Page 287: ...et 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...

Page 288: ...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 Disconn...

Page 289: ...ont 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 ad...

Page 290: ...ecification 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...

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...

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...

Page 293: ...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 neces...

Page 294: ...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...

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...

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 C...

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...

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 specif...

Page 299: ...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 T...

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 Inst...

Page 301: ...ngs 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 L...

Page 302: ...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 posi...

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...

Page 304: ...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...

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...

Page 306: ...er 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...

Page 307: ...ts 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...

Page 308: ...lt 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...

Page 309: ...linder 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...

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 In...

Page 311: ...alves 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 va...

Page 312: ...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...

Page 313: ...k 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 remo...

Page 314: ...stall 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...

Page 315: ...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...

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 mu...

Page 317: ...er 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...

Page 318: ...r 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...

Page 319: ...ver 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 R...

Page 320: ...er 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...

Page 321: ...ter 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...

Page 322: ...he 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 Pri...

Page 323: ...S 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 pa...

Page 324: ...r 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...

Page 325: ...or 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 Repl...

Page 326: ...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...

Page 327: ...age 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 Oi...

Page 328: ...il 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...

Page 329: ...ing 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...

Page 330: ...ocket 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 clear...

Page 331: ...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...

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...

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 bol...

Page 334: ...rts 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...

Page 335: ...emoving 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...

Page 336: ...te 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 nu...

Page 337: ...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...

Page 338: ...e 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 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...

Page 340: ...mage 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...

Page 341: ...ch 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 frictio...

Page 342: ...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...

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 spr...

Page 344: ...ift 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 th...

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 pres...

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...

Page 347: ...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...

Page 348: ...f 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 gaske...

Page 349: ...il 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...

Page 350: ...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 Inst...

Page 351: ...up 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 th...

Page 352: ...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...

Page 353: ...n 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...

Page 354: ...e 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 D...

Page 355: ...in 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 s...

Page 356: ...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...

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 furthe...

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 res...

Page 359: ...g 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 a...

Page 360: ...aft 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...

Page 361: ...necting 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 th...

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 jour...

Page 364: ...s 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 t...

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 r...

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...

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 bear...

Page 368: ...n 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 bea...

Page 369: ...aft 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 jou...

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 1...

Page 371: ...d 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 1...

Page 372: ...r 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...

Page 373: ...ing 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...

Page 374: ...ening 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 t...

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...

Page 376: ...iner 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 t...

Page 377: ...hift 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 for...

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

Page 379: ...G 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 ASSE...

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 i...

Page 381: ...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 teste...

Page 382: ...d 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 teste...

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...

Page 384: ...il 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...

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 pa...

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...

Page 387: ...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 t...

Page 388: ...l 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...

Page 389: ...ter 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 l...

Page 390: ...mpeller 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...

Page 391: ...al 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 dri...

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: ...UEL 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 CHECKIN...

Page 394: ...e 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...

Page 395: ...ay 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 br...

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 wil...

Page 397: ...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 c...

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 couple...

Page 399: ...rottle 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...

Page 400: ...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...

Page 401: ...l 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 p...

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 positi...

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 TH...

Page 404: ...or 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 speci...

Page 405: ...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 th...

Page 406: ...elerator 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 bodie...

Page 407: ...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 t...

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

Page 409: ...CTION 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 val...

Page 410: ...ANK 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 coupl...

Page 411: ...ut 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 R...

Page 412: ...CU 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...

Page 413: ...TALLING 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 t...

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

Page 415: ...M 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 TROUBLESHOOTI...

Page 416: ...E 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 DI...

Page 417: ...ETER 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 SOLEN...

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

Page 419: ...ndlebar 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...

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 tra...

Page 421: ...he 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...

Page 422: ...ES 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...

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

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

Page 425: ...e 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...

Page 426: ...rating 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 ha...

Page 427: ...ter 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...

Page 428: ...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...

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...

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 swit...

Page 436: ...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...

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

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

Page 439: ...t 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 fun...

Page 440: ...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...

Page 441: ...HES 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 s...

Page 442: ...em 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...

Page 443: ...ENSOR 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 O...

Page 444: ...witch 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 s...

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...

Page 448: ...K 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...

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

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

Page 451: ...ensor 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 Ignitio...

Page 452: ...ine 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 c...

Page 453: ...maha 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 posit...

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...

Page 455: ...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 numb...

Page 456: ...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 condit...

Page 457: ...050 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 condi...

Page 458: ...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 thi...

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 ma...

Page 460: ...x 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...

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...

Page 462: ...rness 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 p...

Page 463: ...y 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 Reinstal...

Page 464: ...ressure 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 Yamah...

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...

Page 466: ...ake 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 couple...

Page 467: ...ault 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 se...

Page 468: ...f 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 cond...

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...

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 th...

Page 471: ...t 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 a...

Page 472: ...tion 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 c...

Page 473: ...en 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...

Page 474: ...ss 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 P...

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 the...

Page 476: ...ully 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...

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 c...

Page 478: ...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 eng...

Page 479: ...n 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 Bet...

Page 480: ...jector 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...

Page 481: ...ctor 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 o...

Page 482: ...ector 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...

Page 483: ...tor 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 op...

Page 484: ...ect 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...

Page 485: ...bable 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...

Page 486: ...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 Defectiv...

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 Improp...

Page 488: ...l 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...

Page 489: ...seness 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...

Page 490: ...ed 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 c...

Page 491: ...l 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...

Page 492: ...ooseness 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 usin...

Page 493: ...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...

Page 494: ...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 E...

Page 495: ...ce 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 t...

Page 496: ...re 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 Di...

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 RE...

Page 498: ...ed 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 dia...

Page 499: ...pler 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 i...

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 i...

Page 501: ...it 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 clu...

Page 502: ...el 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...

Page 503: ...smission 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 Incorr...

Page 504: ...lack 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...

Page 505: ...tion 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...

Page 506: ...ode 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 detec...

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 Reco...

Page 508: ...ness 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 Cond...

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...

Page 510: ...imately 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...

Page 511: ...nd 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 a...

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 fin...

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 gr...

Page 514: ...urn 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...

Page 515: ...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 Disconnec...

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 fin...

Page 517: ...e 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 c...

Page 518: ...n 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...

Page 519: ...ed 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 too...

Page 520: ...FF 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 G...

Page 521: ...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...

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 Betwe...

Page 523: ...lerator 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 Accel...

Page 524: ...ecurely 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 ite...

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 g...

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 P21...

Page 527: ...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...

Page 528: ...ly 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...

Page 529: ...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 do...

Page 530: ...ntinuity 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 E...

Page 531: ...on 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 m...

Page 532: ...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 1 coupler and...

Page 533: ...heck 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...

Page 534: ...dition 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 E...

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...

Page 536: ...h 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...

Page 537: ...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...

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 52...

Page 539: ...lace 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...

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

Page 541: ...0 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 funct...

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: ...ke 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...

Page 544: ...y 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 indicat...

Page 545: ...dicator 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 tro...

Page 546: ...en 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...

Page 547: ...er 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 Recov...

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 Condit...

Page 549: ...ire 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 coup...

Page 550: ...ting 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...

Page 551: ...ed 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 cruis...

Page 552: ...oes 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 sh...

Page 553: ...ou 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 secure...

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...

Page 555: ...lain 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...

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

Page 557: ...in 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 J...

Page 558: ...he 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 Re...

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

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

Page 561: ...ain 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 li...

Page 562: ...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...

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 flas...

Page 564: ...le 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 in...

Page 565: ...in 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...

Page 566: ...ECKING 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...

Page 567: ...ard 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 co...

Page 568: ...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 immo...

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: ...nd 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 senso...

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: ...sembly 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...

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: ...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 b...

Page 577: ...draulic 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 pa...

Page 578: ...ompleted 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...

Page 579: ...eter 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...

Page 580: ...inal 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 Ya...

Page 581: ...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 w...

Page 582: ...nd 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 assembl...

Page 583: ...ective 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...

Page 584: ...draulic 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 inter...

Page 585: ...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 abnorma...

Page 586: ...el 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 inco...

Page 587: ...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 Replac...

Page 588: ...e 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 mal...

Page 589: ...place 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 mo...

Page 590: ...d 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 loosen...

Page 591: ...tive 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 I...

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...

Page 593: ...ler 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...

Page 594: ...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...

Page 595: ...ge 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...

Page 596: ...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 Malfunc...

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...

Page 600: ...ause 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...

Page 601: ...pler 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 ch...

Page 602: ...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...

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 sen...

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 identific...

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 sw...

Page 610: ...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...

Page 611: ...l 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 En...

Page 612: ...e 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 batte...

Page 613: ...e 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 bat...

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 c...

Page 615: ...og 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 termin...

Page 616: ...g 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 t...

Page 617: ...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...

Page 618: ...m 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 Con...

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...

Page 620: ...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 th...

Page 621: ...DIATOR 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 radiat...

Page 622: ...er 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 terminal...

Page 623: ...ness 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 cran...

Page 624: ...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 asse...

Page 625: ...ctor 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...

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

Page 627: ...RK 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 T...

Page 628: ...d 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 plu...

Page 629: ...ned 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...

Page 630: ...ect oil level EAS30611 UNSTABLE HANDLING Handlebar Bent or improperly installed handlebar Steering head components Improperly installed upper bracket Improperly installed lower bracket improperly tigh...

Page 631: ...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...

Page 632: ...lfunction 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 car...

Page 633: ...ied 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 Int...

Page 634: ...sor 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 thr...

Page 635: ...CU 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 c...

Page 636: ...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 Cyl...

Page 637: ...tral 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...

Page 638: ...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...

Page 639: ...s 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 p...

Page 640: ...ot 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 be...

Page 641: ...d 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...

Page 642: ...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...

Page 643: ...nication 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 t...

Page 644: ...e 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 Full...

Page 645: ...ry 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 feedb...

Page 646: ...itch 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...

Page 647: ...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...

Page 648: ...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...

Page 649: ...e 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...

Page 650: ...nctioning 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 adju...

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...

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: ...ction 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 sen...

Page 654: ...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 Blu...

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Page 657: ...2016 WIRING DIAGRAM MTN1000 MTN1000G 2016 SCH MA DE C BLAGE MTN1000 MTN1000G 2016 SCHALTPLAN MTN1000 MTN1000G 2016 SCHEMA ELETTRICO MTN1000 MTN1000G 2016 DIAGRAMA EL CTRICO B67 28197 E0_WD indd 1 201...

Page 658: ...2016 WIRING DIAGRAM MTN1000 MTN1000G 2016 SCH MA DE C BLAGE MTN1000 MTN1000G 2016 SCHALTPLAN MTN1000 MTN1000G 2016 SCHEMA ELETTRICO MTN1000 MTN1000G 2016 DIAGRAMA EL CTRICO B67 28197 E0_WD indd 2 201...

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Yamaha MTN1000 2016, Service Manual

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