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Yamaha MTN850-A 2017 Service Manual Download Page 356

ABS (ANTI-LOCK BRAKE SYSTEM)

..........................................................8-117

CIRCUIT DIAGRAM ...............................................................................8-117
ABS COMPONENTS CHART ................................................................8-119
ABS COUPLER LOCATION CHART .....................................................8-121
MAINTENANCE OF THE ABS ECU ......................................................8-123
ABS TROUBLESHOOTING OUTLINE...................................................8-123
BASIC INSTRUCTIONS FOR TROUBLESHOOTING ...........................8-124
BASIC PROCESS FOR TROUBLESHOOTING ....................................8-125
[A] CHECKING THE ABS WARNING LIGHT.........................................8-126
[A-1] ONLY THE ABS WARNING LIGHT FAILS TO COME ON............8-126
[A-2] THE ABS WARNING LIGHT AND OTHER INDICATOR 

LIGHTS FAIL TO COME ON.................................................................8-126

[A-3] THE ABS WARNING LIGHT COMES ON .....................................8-126
[A-4] ONLY THE ABS ECU FAILS TO COMMUNICATE .......................8-127
[A-5] ABS ECU AND FI ECU FAIL TO COMMUNICATE .......................8-127
[B-1] MALFUNCTION ARE CURRENTLY DETECTED .........................8-127
[B-2] DIAGNOSIS USING THE FAULT CODES ....................................8-127
[B-3] DELETING THE FAULT CODES...................................................8-147
[C-1] FINAL CHECK ...............................................................................8-147

ELECTRICAL COMPONENTS

.....................................................................8-149

CHECKING THE SWITCHES ................................................................8-153
CHECKING THE BULBS AND BULB SOCKETS ..................................8-156
CHECKING THE FUSES .......................................................................8-156
REPLACING THE ECU (Engine Control Unit) .......................................8-157
CHECKING AND CHARGING THE BATTERY......................................8-158
CHECKING THE RELAYS .....................................................................8-161
CHECKING THE TURN SIGNAL/HAZARD RELAY...............................8-162
CHECKING THE RELAY UNIT (DIODE) ...............................................8-163
CHECKING THE IGNITION COILS........................................................8-163
CHECKING THE IGNITION SPARK GAP..............................................8-164
CHECKING THE CRANKSHAFT POSITION SENSOR.........................8-164
CHECKING THE LEAN ANGLE SENSOR.............................................8-165
CHECKING THE STARTER MOTOR OPERATION ..............................8-165
CHECKING THE STATOR COIL ...........................................................8-166
CHECKING THE RECTIFIER/REGULATOR .........................................8-166
CHECKING THE HORN.........................................................................8-167
CHECKING THE ENGINE OIL LEVEL SWITCH ...................................8-167
CHECKING THE FUEL SENDER ..........................................................8-168
CHECKING THE FUEL METER/FUEL LEVEL WARNING LIGHT ........8-168
CHECKING THE OIL LEVEL WARNING LIGHT ...................................8-169
CHECKING THE RADIATOR FAN MOTOR ..........................................8-169
CHECKING THE COOLANT TEMPERATURE SENSOR......................8-169
CHECKING THE THROTTLE POSITION SENSOR ..............................8-170
CHECKING THE ACCELERATOR POSITION SENSOR ......................8-170
CHECKING THE THROTTLE SERVO MOTOR ....................................8-171
CHECKING THE AIR INDUCTION SYSTEM SOLENOID .....................8-171
CHECKING THE INTAKE AIR PRESSURE SENSOR ..........................8-172
CHECKING THE INTAKE AIR TEMPERATURE SENSOR ...................8-172
CHECKING THE GEAR POSITION SWITCH........................................8-173
CHECKING THE FUEL INJECTORS.....................................................8-174

Summary of Contents for MTN850-A 2017

Page 1: ...2017 SERVICE MANUAL MTN850 A MTN850 AH BS2 28197 E0 ...

Page 2: ......

Page 3: ...A MTN850 AH SERVICE MANUAL 2016 by Yamaha Motor Co Ltd First edition November 2016 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited ...

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

Page 5: ...C 2 3 O2 sensor coupler bracket 1 1 r e v o c h c t u l C 4 1 t e k s a g r e v o c h c t u l C 5 2 n i p l e w o D 6 1 p a c r e l l i f l i O 7 1 2 3 4 5 6 7 6 6 12 N m 1 2 kgf m 8 7 lb ft 12 N m 1 2 kgf m 8 7 lb ft 12 N m 1 2 kgf m 8 7 lb ft 1 5 N m 0 15 kgf m 1 1 lb ft 7 N m 0 7 kgf m 5 1 lb ft CLUTCH 5 43 8 Remove Clutch boss nut Conical spring washer Washer Clutch boss Thrust plate Clutch ho...

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

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

Page 8: ......

Page 9: ...CS Traction Control System 1 4 INSTRUMENT FUNCTIONS 1 8 IMPORTANT INFORMATION 1 13 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 13 REPLACEMENT PARTS 1 13 GASKETS OIL SEALS AND O RINGS 1 13 LOCK WASHERS PLATES AND COTTER PINS 1 13 BEARINGS AND OIL SEALS 1 13 CIRCLIPS 1 14 RUBBER PARTS 1 14 BASIC SERVICE INFORMATION 1 15 QUICK FASTENERS 1 15 ELECTRICAL SYSTEM 1 16 SPECIAL TOOLS 1 20 ...

Page 10: ...30002 VEHICLE 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 This information will be needed to order spare parts 1 1 ...

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

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

Page 13: ... to the difference between the wheel speeds If the slip ping exceeds the preset value the ECU controls the slipping using integrated control of the ignition timing fuel cut off and throttle valve opening of the YCC T system The traction control system can be set to one of two operation modes or turned off TCS Traction control system layout 1 2 3 6 7 8 9 10 4 5 1 Traction control system indicator l...

Page 14: ... throttle valve opening of the YCC T system so that the amount of slip is less than the preset value The traction control system indicator light in the meter assembly flashes when the traction control system has activated 1 A B D G E H F 5 C A 4 3 2 1 Front wheel sensor 2 Rear wheel sensor 3 ABS ECU 4 Traction control system switch 5 ECU A Signal conversion B Slip amount calculation C Exceeds pres...

Page 15: ...he vehicle stopped push this switch up for two seconds to turn the system off Push down to turn the system on The indicator light flashes when traction control has engaged You may notice slight changes in engine and exhaust sounds when the system has engaged When the traction control system has been set to OFF the indicator light will come on TCS OFF TCS OFF turns the traction control system off T...

Page 16: ...rn key back to ON 3 The indicator light should turn off and the system be enabled 4 Check the vehicle and turn off the warning light TIP If the indicator light or the warning light remains on after resetting check the fuel injection sys tem Refer to FUEL INJECTION SYSTEM on page 8 33 Quick shift system The quick shift system QS allows for full throttle clutch lever less electronically assisted ups...

Page 17: ...r to display the clock turn the key to ON before using the SELECT and RESET buttons to adjust the multi function meter To switch the speedometer and multi function displays between kilometers and miles press the SELECT button for one second Speedometer The speedometer shows the vehicle s traveling speed Tachometer The tachometer allows the rider to monitor the engine speed and keep it within the i...

Page 18: ...he last segment starts flashing refuel as soon as possible TIP If a problem is detected in the electrical circuit the fuel level segments and will flash repeat edly Check the electrical circuit Refer to CHECKING THE FUEL METER FUEL LEVEL WARNING LIGHT on page 8 168 Eco indicator This indicator comes on when the vehicle is be ing operated in an environmentally friendly fuel efficient manner The ind...

Page 19: ... mode AVE_ _ _ km L or AVE_ _ _ L 100 km coolant temperature mode C air intake temperature mode Air_ _ C odometer mode ODO and tripmeter modes TRIP 1 and TRIP 2 in the following order km L or L 100 km AVE_ _ _ km L or AVE_ _ _ L 100 km C Air_ _ C ODO TRIP 1 TRIP 2 When the display units have been set to miles km L L 100 km or MPG AVE_ _ _ km L AVE_ _ _ L 100 km or AVE_ _ _ MPG C Air_ _ C ODO TRIP ...

Page 20: ...AVE_ _ _ L 100 km or AVE_ _ _ MPG when the display units have been set to miles AVE_ _ _ km L The average distance that can be traveled on 1 0 L of fuel is shown AVE_ _ _ L 100 km The average amount of fuel necessary to travel 100 km is shown AVE_ _ _ MPG The average distance that can be traveled on 1 0 Imp gal of fuel is shown To switch between the average fuel consump tion display settings push ...

Page 21: ... engine performance system This model has three mode selections STD A and B WARNING EWA18440 Do not change the drive mode while the vehi cle is moving With the throttle grip closed push this switch to change the drive mode in the following order STD A B STD TIP Make sure you understand each drive mode before operating the drive mode switch The current drive mode is shown in the drive mode display ...

Page 22: ...m any source of fire EAS30007 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace ments Use oil and grease recommended by Yamaha for all lubrication jobs Other brands may be similar in function and appearance but inferior in quality EAS30008 GASKETS OIL SEALS AND O RINGS 1 When overhauling the engine replace all gaskets seals and O rings All gasket surfac es oil seal lips and O rings m...

Page 23: ... CIRCLIPS Before reassembly check all circlips carefully and replace damaged or distorted circlips Al ways replace piston pin clips after one use When installing a circlip 1 make sure the sharp edged corner 2 is positioned opposite the thrust 3 that the circlip receives EAS30012 RUBBER PARTS Check rubber parts for deterioration during in spection Some of the rubber parts are sensitive to gasoline ...

Page 24: ...ener push its pin so that it protrudes from the fastener head then insert the fastener into the part to be secured and push the pin a in with a screwdriver Make sure that the pin is flush with the fastener s head Screw type 1 Remove Quick fastener TIP To remove the quick fastener loosen the screw with a screwdriver then pull the fastener out 2 Install Quick fastener TIP To install the quick fasten...

Page 25: ...uld be gener ated which is extremely dangerous TIP If a battery lead is difficult to disconnect due to rust on the battery terminal remove the rust us ing hot water NOTICE ECA16760 Be sure to connect the battery leads to the correct battery terminals Reversing the bat tery lead connections could damage the electrical components NOTICE ECA16771 When connecting the battery leads to the battery be su...

Page 26: ...city Therefore never touch the terminals and be sure to keep the contacts clean TIP When resetting the ECU by turning the main switch to OFF be sure to wait approximately 5 seconds before turning the main switch back to ON Checking the electrical system TIP Before checking the electrical system make sure that the battery voltage is at least 12 V NOTICE ECA14371 Never insert the tester probes into ...

Page 27: ...the coupler lock hold both sections of the cou pler securely and then disconnect the cou pler There are many types of coupler locks therefore be sure to check the type of cou pler lock before disconnecting the coupler NOTICE ECA16790 When disconnecting a connector do not pull the leads Hold both sections of the connec tor securely and then disconnect the con nector 2 Check Lead Coupler Connector M...

Page 28: ...IP The resistance values shown were obtained at the standard measuring temperature of 20 C 68 F If the measuring temperature is not 20 C 68 F the specified measuring conditions will be shown Digital circuit tester CD732 90890 03243 Model 88 Multimeter with tachom eter YU A1927 Digital circuit tester CD732 90890 03243 Model 88 Multimeter with tachom eter YU A1927 Intake air temperature sensor re si...

Page 29: ... use part number starting with YM YU or ACC For others use part number starting with 90890 Tool name Tool No Illustration Reference pages Digital circuit tester CD732 90890 03243 Model 88 Multimeter with tachometer YU A1927 1 19 5 36 8 155 8 156 8 157 8 161 8 162 8 163 8 164 8 165 8 166 8 167 8 168 8 169 8 170 8 171 8 172 8 173 8 174 Yamaha diagnostic tool USB 90890 03250 3 4 3 11 4 54 4 56 8 36 8...

Page 30: ...3 Exhaust flange nut wrench YU A9472 3 20 4 73 Oil filter wrench 90890 01426 Oil filter wrench YU 38411 3 25 Pressure gauge 90890 03153 Pressure gauge YU 03153 3 26 7 11 Oil pressure adapter H 90890 03139 3 26 Fork spring compressor 90890 01441 Fork spring compressor YM 01441 4 64 4 69 Tool name Tool No Illustration Reference pages YU 44456 ...

Page 31: ...890 01442 Adjustable fork seal driver 36 46 mm YM 01442 4 67 4 68 Rod puller 90890 01437 Universal damping rod bleeding tool set YM A8703 4 68 4 69 Rod puller attachment M10 long 90890 01578 Universal damping rod bleeding tool set YM A8703 4 68 4 69 Ring nut wrench 90890 01268 Spanner wrench YU 01268 4 73 Tool name Tool No Illustration Reference pages YM A8703 90890 01578 YM A8703 ...

Page 32: ...er YU 33223 5 1 Extension 90890 04136 5 1 Pivot shaft wrench 90890 01485 Frame mount insert wrench YM 01485 5 7 Pivot shaft wrench 90890 01518 Frame spanner socket YM 01518 5 7 5 8 Pivot shaft wrench adapter 90890 01476 5 7 5 8 Camshaft wrench 90890 04162 Camshaft wrench YM 04162 5 12 5 14 Tool name Tool No Illustration Reference pages 90890 03081 YU 33223 ...

Page 33: ...Valve guide remover 4 5 mm YM 04116 5 25 Valve guide installer ø4 5 90890 04117 Valve guide installer 4 5 mm YM 04117 5 25 Valve guide reamer ø4 5 90890 04118 Valve guide reamer 4 5 mm YM 04118 5 25 Sheave holder 90890 01701 Primary clutch holder YS 01880 A 5 31 5 32 Flywheel puller 90890 01362 Heavy duty puller YU 33270 B 5 31 Yamaha bond No 1215 90890 85505 Three bond No 1215 5 33 5 58 Tool name...

Page 34: ...2 5 46 Piston pin puller set 90890 01304 Piston pin puller YU 01304 5 62 Piston installing tool 90890 04161 Piston installing tool YM 04161 5 69 Radiator cap tester 90890 01325 Mityvac cooling system tester kit YU 24460 A 6 2 Tool name Tool No Illustration Reference pages YU 01304 YU 24460 A ...

Page 35: ...ing driver 90890 04058 Middle drive bearing installer 40 50 mm YM 04058 6 11 Fuel injector pressure adapter 90890 03210 Fuel injector pressure adapter YU 03210 7 11 Fuel pressure adapter 90890 03176 Fuel pressure adapter YM 03176 7 11 OBD GST Leadwire kit 90890 03249 8 36 Ignition checker 90890 06754 Oppama pet 4000 spark checker YM 34487 8 164 Tool name Tool No Illustration Reference pages YU 339...

Page 36: ...ness lean angle sensor 6P 90890 03209 Test harness lean angle sensor 6P YU 03209 8 165 Test harness S pressure sensor 3P 90890 03207 Test harness S pressure sensor 3P YU 03207 8 172 Tool name Tool No Illustration Reference pages ...

Page 37: ...HTENING TORQUES 2 12 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 12 ENGINE TIGHTENING TORQUES 2 13 CHASSIS TIGHTENING TORQUES 2 13 LUBRICATION POINTS AND LUBRICANT TYPES 2 15 ENGINE 2 15 CHASSIS 2 16 LUBRICATION SYSTEM CHART AND DIAGRAMS 2 19 ENGINE OIL LUBRICATION CHART 2 19 LUBRICATION DIAGRAMS 2 21 COOLING SYSTEM DIAGRAMS 2 31 CABLE ROUTING 2 35 ...

Page 38: ...850 A_RUS Dimensions Overall length 2075 mm 81 7 in Overall width 815 mm 32 1 in Overall height 1120 mm 44 1 in Seat height 820 mm 32 3 in Wheelbase 1440 mm 56 7 in Ground clearance 135 mm 5 31 in Minimum turning radius 3 0 m 9 84 ft Weight Curb weight 193 kg 425 lb Loading Maximum load 174 kg 384 lb Riding capacity 2 person ...

Page 39: ...E SAE viscosity grades 10W 40 Recommended engine oil grade API service SG type or higher JASO standard MA Lubrication system Wet sump Engine oil quantity Oil change 2 40 L 2 54 US qt 2 11 Imp qt With oil filter removal 2 70 L 2 85 US qt 2 38 Imp qt Quantity disassembled 3 40 L 3 59 US qt 2 99 Imp qt Oil filter Oil filter type Cartridge Oil pump Inner rotor to outer rotor tip clearance Less than 0 ...

Page 40: ... Valve clearance cold Intake 0 11 0 20 mm 0 0043 0 0079 in Exhaust 0 26 0 30 mm 0 0102 0 0118 in Valve dimensions Valve seat contact width intake 0 90 1 10 mm 0 0354 0 0433 in Limit 1 60 mm 0 06 in Valve seat contact width exhaust 1 10 1 30 mm 0 0433 0 0512 in Limit 1 80 mm 0 07 in Valve stem diameter intake 4 475 4 490 mm 0 1762 0 1768 in Limit 4 445 mm 0 1750 in Valve stem diameter exhaust 4 460...

Page 41: ... mm 0 0059 0 0098 in End gap limit 0 50 mm 0 0197 in Ring side clearance 0 030 0 065 mm 0 0012 0 0026 in Side clearance limit 0 115 mm 0 0045 in 2nd ring Ring type Taper End gap installed 0 30 0 45 mm 0 0118 0 0177 in End gap limit 0 80 mm 0 0315 in Ring side clearance 0 020 0 055 mm 0 0008 0 0022 in Side clearance limit 0 115 mm 0 0045 in Connecting rod Oil clearance 0 027 0 051 mm 0 0011 0 0020 ...

Page 42: ... 0 10 mm 0 004 in Clutch spring free length 45 23 mm 1 78 in Limit 42 97 mm 1 69 in Spring quantity 3 pcs Drivetrain Primary reduction ratio 1 681 79 47 Transmission type Constant mesh 6 speed Gear ratio 1st 2 667 40 15 2nd 2 000 38 19 3rd 1 619 34 21 4th 1 381 29 21 5th 1 190 25 21 6th 1 037 28 27 Main axle runout limit 0 08 mm 0 0032 in Drive axle runout limit 0 08 mm 0 0032 in Secondary reducti...

Page 43: ... sampling point Sampling port on the exhaust pipe To be measured Coolant temperature Temperature 90 110 C 194 230 F CO 1 5 3 5 Difference in vacuum pressure between the cylinders 1 3 kPa 10 mmHg 0 4 inHg Fuel line pressure at idle 300 390 kPa 3 0 3 9 kgf cm 43 5 56 6 psi Throttle grip free play 3 0 5 0 mm 0 12 0 20 in Air induction system Solenoid resistance 20 24 ...

Page 44: ...ZR17M C 73W Manufacturer model BRIDGESTONE S20R Manufacturer model DUNLOP D214 Tire air pressure measured on cold tires 1 person Front 250 kPa 2 50 kgf cm 36 psi Rear 290 kPa 2 90 kgf cm 42 psi 2 persons Front 250 kPa 2 50 kgf cm 36 psi Rear 290 kPa 2 90 kgf cm 42 psi Front brake Type Hydraulic dual disc brake Disc outside diameter thickness 298 0 4 5 mm 11 73 0 18 in Brake disc thickness limit 4 ...

Page 45: ... 62 US oz 16 29 Imp oz Level left 148 mm 5 8 in Level right 148 mm 5 8 in Spring preload Adjusting system Mechanical adjustable type Adjustment value Soft 19 0 mm 0 75 in Adjustment value STD 16 0 mm 0 63 in Adjustment value Hard 4 0 mm 0 16 in Rebound damping Adjusting system Mechanical adjustable type Unit for adjustment Click Adjustment value from the start position Soft 11 Adjustment value fro...

Page 46: ...Unit for adjustment Turn Adjustment value from the start position Soft 3 Adjustment value from the start position STD 1 1 2 Adjustment value from the start position Hard 0 Drive chain Size DID525V10 Chain type Sealed type Number of links 110 Drive chain slack Maintenance stand 5 0 15 0 mm 0 20 0 59 in Drive chain slack Sidestand 5 0 15 0 mm 0 20 0 59 in 15 link length limit 239 3 mm 9 42 in ...

Page 47: ...utput 14 0 V 415 W at 5000 r min Stator coil resistance 0 152 0 228 Rectifier regulator Regulator type Three phase Regulated voltage DC 14 3 14 7 V Rectifier capacity DC 50 0 A Battery Model YTZ10S Voltage capacity 12 V 8 6 Ah 10 HR Bulb wattage Headlight LED Brake tail light LED Front turn signal light 10 0 W Rear turn signal light 10 0 W Auxiliary light LED License plate light LED Meter lighting...

Page 48: ...kshaft position sensor resistance 228 342 Intake air temperature sensor resistance 5400 6600 at 0 C 5400 6600 at 32 F Intake air temperature sensor resistance 290 390 at 80 C 290 390 at 176 F Coolant temperature sensor resistance 2512 2777 at 20 C 2512 2777 at 68 F Coolant temperature sensor resistance 210 221 at 100 C 210 221 at 212 F Fuse s Main fuse 50 0 A Headlight fuse 10 0 A Signaling system...

Page 49: ...l To avoid warpage tight en multi fastener assemblies in a crisscross pat tern and progressive stages until the specified tightening torque is reached Unless otherwise specified tightening torque specifications re quire clean dry threads Components should be at room temperature A Distance between flats B Outside thread diameter A nut B bolt General tightening torques N m kgf m lb ft 10 mm 6 mm 6 0...

Page 50: ... 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 43 N m 4 3 kgf m 31 lb ft Item Thread size Q ty Tightening torque Remarks Front wheel axle M16 1 65 N m 6 5 kgf m 47 lb ft Front wheel axle pinch bolt M8 1 23 N m 2 3 kgf m 17 lb ft Rear wheel sprocket nut M10 6 80 N m 8 0 kgf m 58 lb ft Rear wheel axle nut M18 1 150 N m 15 kgf m 108 lb ft Rear br...

Page 51: ...o approximately 52 N m 5 2 kgf m 38 lb ft with a torque wrench then loosen the lower ring nut completely 2 Tighten the lower ring nut to 18 N m 1 8 kgf m 13 lb ft Drive sprocket nut M22 1 95 N m 9 5 kgf m 69 lb ft Stake Item Thread size Q ty Tightening torque Remarks E ...

Page 52: ...st Crankshaft big ends Piston surfaces Piston pins Connecting rod bolts Crankshaft journals Balancer shaft journals Generator rotor assembly Water pump impeller shaft Oil pump rotors inner and outer Oil pump assembly Oil filter cartridge union bolt Oil nozzle O rings or Main gallery bolt O ring or Oil cooler sub gallery O ring or Drive axle sub gallery O ring or Balancer journal bolt O rings Idler...

Page 53: ...n point Lubricant Steering bearings seal lip and ball race lip Tube guide throttle grip inner surface and throttle cables Brake lever pivot bolt and metal to metal moving parts Clutch lever pivot bolt metal to metal moving parts and clutch cable end Swingarm collar outer surface oil seal lip Pivot shaft Swingarm pivot bush outer surface oil seal lip Swingarm pivot thrust cover inner surface Relay ...

Page 54: ...LUBRICANT TYPES 2 17 Rear wheel drive hub oil seal Rear wheel drive hub mating surface Brake caliper piston seal Master cylinder inside Brake caliper piston dust seal Brake caliper bolts Lubrication point Lubricant LS LS S S ...

Page 55: ...LUBRICATION POINTS AND LUBRICANT TYPES 2 18 ...

Page 56: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 19 EAS20019 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS30020 ENGINE OIL LUBRICATION CHART 1 3 4 5 11 12 13 13 14 15 16 17 13 7 8 9 10 10 10 10 6 2 ...

Page 57: ...Oil pump 3 Relief valve 4 Oil cooler 5 Oil filter cartridge 6 Main gallery 7 Drive axle 8 Main axle 9 Shift fork upper 10 Mission shower 11 Crankshaft 12 AC magneto 13 Oil nozzle 14 Balancer shaft 15 Timing chain tensioner 16 Intake camshaft 17 Exhaust camshaft ...

Page 58: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 21 EAS30021 LUBRICATION DIAGRAMS 1 2 3 4 ...

Page 59: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 22 1 Oil level switch 2 Oil filter cartridge union bolt 3 Oil filter cartridge 4 Crankshaft ...

Page 60: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 23 4 7 7 8 9 5 6 2 3 1 ...

Page 61: ...BRICATION SYSTEM CHART AND DIAGRAMS 2 24 1 Timing chain tensioner 2 Intake camshaft 3 Exhaust camshaft 4 Balancer shaft 5 Crankshaft 6 Oil cooler 7 Oil strainer 8 Oil drain bolt 9 Oil pump driven sprocket ...

Page 62: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 25 4 5 6 2 3 1 ...

Page 63: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 26 1 Oil cooler 2 Oil filter cartridge 3 Oil level switch 4 Oil strainer 5 Oil pump 6 Main gallery bolt ...

Page 64: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 27 6 5 3 2 7 4 1 ...

Page 65: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 28 1 Balancer shaft 2 Crankshaft 3 Main axle 4 Shift fork guide bar shift fork C side 5 Drive axle 6 Sub gallery bolt 7 Shift fork ...

Page 66: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 29 9 8 7 6 3 3 2 5 4 1 ...

Page 67: ...30 1 Cylinder head 2 Exhaust camshaft 3 Intake camshaft 4 Oil passage to the timing chain tensioner 5 Oil passage to the cylinder head 6 Oil passage to the clutch chamber 7 Oil return passage from the cylinder head 8 Crankshaft 9 Main gallery ...

Page 68: ...COOLING SYSTEM DIAGRAMS 2 31 EAS20020 COOLING SYSTEM DIAGRAMS 1 1 2 3 ...

Page 69: ...COOLING SYSTEM DIAGRAMS 2 32 1 Water pump 2 Thermostat 3 Radiator ...

Page 70: ...COOLING SYSTEM DIAGRAMS 2 33 1 2 3 4 5 6 ...

Page 71: ...COOLING SYSTEM DIAGRAMS 2 34 1 Water jacket 2 Thermostat 3 Radiator 4 Water pump 5 Oil cooler 6 Coolant reservoir ...

Page 72: ...CABLE ROUTING 2 35 EAS20021 CABLE ROUTING Handlebar top view ...

Page 73: ...nstalling the rubber cover silicone water or soapy water may be applied to the inside of the rubber cover B Connect the front brake light switch connec tor onto the front brake light switch C Detailed drawing of around the front brake master cylinder D Straight line parallel to the front brake master cylinder reservoir cap E 3 13 F Center of the metal fitting for the front brake hose ...

Page 74: ...CABLE ROUTING 2 37 Handlebar front view ...

Page 75: ...nto the hole in the stay 1 D The L type terminal of the horn should face to the outside of the vehicle E Insert the clamp of the wire harness into the hole in the bracket F Install along the side of the master cylinder Point the claws downward and make sure the damper faces toward the master cylinder and clamp G Route the throttle cable and front brake hose between the handle crown and the bracket...

Page 76: ...CABLE ROUTING 2 39 Radiator front side view and right side view ...

Page 77: ...or inlet hose so that the tip of the hose contacts the rib of the water jacket joint H Install the radiator inlet hose with its yellow paint mark facing downward I Point the hose clamp installation bolt upward J Install the radiator inlet hose up to the base of the bend in the radiator pipe K Install the radiator inlet hose with its white paint mark facing inward L Install the radiator hose up to ...

Page 78: ...CABLE ROUTING 2 41 Fuel tank left and bottom view ...

Page 79: ...the clip so that the end is on the paint mark Do not put it on the clip spool guard Point the end to the rear and store it inside to the fuel hose C Align the fuel pump positioning to the inner panel marking visual guide during installa tion D Insert the fuel tank breather hose up to the section where the fuel tank pipe increases in diameter Install it so that the yellow paint mark faces the rearw...

Page 80: ...CABLE ROUTING 2 43 Canister top view and left side view ...

Page 81: ...white paint mark on the hose upward D Point the end of the clip downward E Install the canister with its stamped mark fac ing upward F The tip of the clip and the yellow paint mark on the hose should face backward Position the hose so that its paint mark is visible from the rear of the vehicle Within 45 G Insert the hose up to the section where the fuel tank pipe increases in diameter H Atmosphere...

Page 82: ...CABLE ROUTING 2 45 Air filter case and throttle body top view and left side view ...

Page 83: ...ip touches the pipe of the cylinder head Install the breather hose on the white paint mark side to the engine Install the breather hose so that the white paint mark is in the rear of the vehicle and parallel to the cylinder head mating surfaces Install the clip so that the end is in the rear of the vehicle and parallel to the cylinder head mating surfaces C Install the ECU harness by storing it in...

Page 84: ...CABLE ROUTING 2 47 Air cut off valve left side view ...

Page 85: ...ve so that the tip of the hose contacts the air filter case B Insert the protrusion on the radiator fan cover into the hole in the air cut off valve holder C Point the end of the clip for the air induction system hose air cut off valve to reed valve cover 2 3 forward D Point the end of the clip for the air induction system hose air filter case to air cut off valve to the left E 45 F Point the end ...

Page 86: ...CABLE ROUTING 2 49 Frame and engine right side view ...

Page 87: ...ten the O2 sensor lead with the clamp and then install it on the bracket H Route the O2 sensor lead and the rear brake light switch lead through the bracket guide I Route the rear brake light switch lead outside brake fluid reservoir hose J It does not matter whether the O2 sensor lead or the rear brake light switch lead is on top bottom in the area shown in the illustration K Insert the clamp so ...

Page 88: ...CABLE ROUTING 2 51 Frame right side view ...

Page 89: ...er H Route the front turn signal light lead right between the ribs on holder 2 and the fuse box I Insert the headlight coupler in the claws on the front panel J Route the handlebar switch lead right through the inside of the guide of holder 2 K Insert the fuse box into holder 2 L The clamp position should be 0 20 mm 0 0 79 in from the end of the coolant reservoir hose protector M After routing the...

Page 90: ...CABLE ROUTING 2 53 Frame left side view a ...

Page 91: ...ch lead left into the hole in stay 1 H Hook the handlebar switch lead left to the holder I Route the front turn signal light lead left between the handlebar switch lead left and stay 1 J Route the front turn signal light lead left between the frame and stay 1 K Route the wire harness under the vehicle along the throttle cable L The horizontal direction of the clamp does not matter M Insert the cla...

Page 92: ...CABLE ROUTING 2 55 Frame and engine left side view ...

Page 93: ...ble B Place the stator coil assembly lead so that bare copper wires do not protrude from the boots C Fasten the main switch coupler to the coupler cover with the clamp D The positions for the leads on the immobilizer unit side do not matter regarding the main switch lead E Route the front wheel sensor lead rear side of the vehicle respect to the main switch lead F Install the clamp to the hole in ...

Page 94: ...CABLE ROUTING 2 57 Frame and engine left side view ...

Page 95: ...through the notch in bracket 1 F Route the shift switch lead through the inside of the vehicle along the brake hose and drain hose G Route the drain hose through the inside of the vehicle along the brake hose H Clamp the shift switch lead to the shift switch Clamp at the positioning tape of the shift switch lead Make sure the clamp is engaged by 1 or more notches The orientation of the clamp openi...

Page 96: ...CABLE ROUTING 2 59 Frame top view ...

Page 97: ...n fasten it with tape B Insert the clamp into the fuel rail hole C Fold back the injector lead 1 by the coupler and then fasten it with tape D Connect the sub lead to the injector 2 cou pler Fasten the injector coupler on the wire harness side with tape E For the air cut off valve lead ignition coil lead 3 and fuel injector lead 3 it does not mat ter which is routed above the others F Route the co...

Page 98: ...CABLE ROUTING 2 61 Frame top view ...

Page 99: ...ugh the inside of the vehicle along the brake hose B Secure the end of the clamp to the rounded corners of the battery box C Route the rear wheel sensor lead and license plate light lead through the right side of the vehicle along the brake hose D Route the shift switch coupler under the license plate light lead E Clamp the protector of the brake hose and shift switch lead F The rear end of the cl...

Page 100: ...CABLE ROUTING 2 63 Frame top view ...

Page 101: ... the turn sig nal hazard relay in the battery box D Install the rubber bracket of the relay unit in the battery box E Install the clamp into the hole in the battery box F After connecting the license plate light con nector store the turn signal light coupler left right furthest to the bottom of the vehi cle After connecting the other couplers store them below the tail brake light lead G Route the ...

Page 102: ...CABLE ROUTING 2 65 Front brake right side view and left side view ...

Page 103: ...ard direction D Inside of the vehicle E Insert the clamp securely F Make sure the clamp is engaged by 3 or more notches Engage the claws so that they face toward the rear side of the vehicle G Insert the clamp into the T stud of the bracket H Route the front wheel sensor lead in front of the vehicle along the brake hose I Route the front wheel sensor lead in front of the vehicle along the brake ho...

Page 104: ...CABLE ROUTING 2 67 Rear brake ...

Page 105: ...ng the direction in the illustration E Do not clamp the rear wheel sensor lead F Fasten the protector of the brake hose with the clamp Install the mating section on the top of the vehicle G Make sure to install the clamp all the way in the swingarm assembly H Install the rear wheel sensor lead so that it facing outward I Install the brake pipe so that it aligned with the cutout in the caliper J Pl...

Page 106: ...CABLE ROUTING 2 69 Hydraulic unit top view and left side view ...

Page 107: ...Bracket A Make sure to insert the ABS ECU coupler all the way in B Install the brake hose front brake master cyl inder to hydraulic unit so that the protrusion contact to the brake hose hydraulic unit to front brake calipers C In the plug hole install the brake hose rear brake master cylinder to hydraulic unit the brake hose hydraulic unit to rear brake cali per and rear wheel sensor lead D 28 34 ...

Page 108: ...CABLE ROUTING 2 71 ...

Page 109: ...ISC BRAKE 3 13 CHECKING THE FRONT BRAKE PADS 3 14 ADJUSTING THE REAR DISC BRAKE 3 14 CHECKING THE REAR BRAKE PADS 3 15 CHECKING THE FRONT BRAKE HOSES 3 15 CHECKING THE REAR BRAKE HOSE 3 15 BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS 3 15 CHECKING THE WHEELS 3 16 CHECKING THE TIRES 3 16 CHECKING THE WHEEL BEARINGS 3 18 CHECKING THE SWINGARM OPERATION 3 18 LUBRICATING THE SWINGARM PIVOT 3 18 DRIVE CHAIN...

Page 110: ...LEVEL 3 26 CHECKING THE COOLING SYSTEM 3 27 CHANGING THE COOLANT 3 27 CHECKING THE FRONT BRAKE LIGHT SWITCH 3 29 ADJUSTING THE REAR BRAKE LIGHT SWITCH 3 29 CHECKING AND LUBRICATING THE CABLES 3 29 CHECKING THE THROTTLE GRIP 3 29 CHECKING AND CHARGING THE BATTERY 3 30 CHECKING THE FUSES 3 30 ADJUSTING THE HEADLIGHT BEAMS 3 30 ...

Page 111: ...HE EMISSION CONTROL SYSTEM EAS30615 GENERAL MAINTENANCE AND LUBRICATION CHART NO ITEM CHECK OR MAINTENANCE JOB ODOMETER READING ANNUAL CHECK 1000 km 600 mi 10000km 6000 mi 20000 km 12000 mi 30000 km 18000 mi 40000 km 24000 mi 1 Fuel line Check fuel hoses for cracks or damage Replace if necessary 2 Spark plugs Check condition Adjust gap and clean Replace 3 Valve clearance Check and adjust Every 400...

Page 112: ...ghly Every 1000 km 600 mi and after washing the motorcycle riding in the rain or riding in wet areas 13 Steering bearings Check bearing assemblies for looseness Moderately repack with lith ium soap based grease 14 Chassis fasteners Make sure that all nuts bolts and screws are properly tight ened 15 Brake lever pivot shaft Lubricate with silicone grease 16 Brake pedal pivot shaft Lubricate with lit...

Page 113: ...3 Rear suspension relay arm and connecting arm pivoting points Check operation 24 Engine oil Change warm engine before draining Check oil level and vehicle for oil leakage 25 Engine oil filter cartridge Replace 26 Cooling system Check coolant level and vehi cle for coolant leakage Change Every 3 years 27 Front and rear brake switches Check operation 28 Moving parts and cables Lubricate 29 Throttle...

Page 114: ...information about using the Yamaha diagnostic tool refer to the operation manual that is included with the tool 5 Install Rider seat Refer to GENERAL CHASSIS 1 on page 4 1 EAS30619 CHECKING THE FUEL LINE The following procedure applies to all of the fuel drain and breather hoses 1 Remove Air scoop Refer to GENERAL CHASSIS 1 on page 4 1 Rider seat Refer to GENERAL CHASSIS 1 on page 4 1 Fuel tank co...

Page 115: ...lor is medium to light tan 5 Clean Spark plug with a spark plug cleaner or wire brush 6 Measure Spark plug gap a with a wire thickness gauge Out of specification Regap 7 Install Spark plugs Ignition coils TIP Before installing the spark plug clean the spark plug and gasket surface 8 Install Air cut off valve Refer to AIR INDUCTION SYSTEM on page 7 15 Air filter case Refer to GENERAL CHASSIS 2 on p...

Page 116: ... Valve clearance Out of specification Adjust a Turn the crankshaft counterclockwise b When piston 1 is at TDC on the compres sion stroke align the TDC mark a on the generator rotor with the generator rotor cover mark b TIP TDC on the compression stroke can be found when the camshaft lobes are turned away from each other c Measure the valve clearance with a thickness gauge 1 TIP If the valve cleara...

Page 117: ...ween the speci fied valve clearance and the measured valve clearance Example Specified valve clearance 0 11 0 20 mm 0 004 0 008 in Measured valve clearance 0 25 mm 0 010 in 0 25 mm 0 010 in 0 20 mm 0 008 in 0 05 mm 0 002 in c Check the thickness of the current valve pad TIP The thickness a of each valve pad is marked in hundredths of millimeters on the side that touch es the valve lifter Example I...

Page 118: ...a tion repeat all of the valve clearance adjust ment steps until the specified clearance is obtained 7 Install All removed parts TIP For installation reverse the removal procedure EAS31017 CHECKING THE ENGINE IDLING SPEED TIP Prior to checking the engine idling speed the throttle body synchronization should be adjusted properly the air filter element should be clean and the engine should have adeq...

Page 119: ... tank Refer to FUEL TANK on page 7 1 6 Check Throttle body synchronization a Start the engine warm it up for several min utes and then let it run at the specified en gine idling speed b Check the vacuum pressure If out of specification Adjust the throttle body synchronization Adjusting the throttle body synchronization 1 Adjust Throttle body synchronization a Start the engine warm it up for severa...

Page 120: ...ank Refer to FUEL TANK on page 7 1 Fuel tank cover Refer to GENERAL CHASSIS 1 on page 4 1 Rider seat Refer to GENERAL CHASSIS 1 on page 4 1 Air scoop Refer to GENERAL CHASSIS 1 on page 4 1 5 Adjust Throttle grip free play Refer to CHECKING THE THROTTLE GRIP on page 3 29 EAS30798 CHECKING THE THROTTLE BODY JOINTS 1 Remove Throttle bodies Refer to THROTTLE BODIES on page 7 5 2 Check Throttle body jo...

Page 121: ...AD BREATHER HOSE 1 Remove Air filter case Refer to GENERAL CHASSIS 2 on page 4 7 2 Check Cylinder head breather hose 1 Cracks damage Replace Loose connection Connect properly NOTICE ECA14920 Make sure the cylinder head breather hose is routed correctly 3 Install Air filter case Refer to GENERAL CHASSIS 2 on page 4 7 EAS30628 REPLACING THE AIR FILTER ELEMENT 1 Remove Air scoop Refer to GENERAL CHAS...

Page 122: ...r to GENERAL CHASSIS 1 on page 4 1 Air scoop Refer to GENERAL CHASSIS 1 on page 4 1 EAS30629 ADJUSTING THE CLUTCH LEVER FREE PLAY 1 Check Clutch lever free play a Out of specification Adjust 2 Adjust Clutch lever free play Handlebar side a Turn the adjusting bolt 1 in direction a or b until the specified clutch lever free play is obtained TIP If the specified clutch lever free play cannot be obtai...

Page 123: ...and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake performance When refilling be careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock NOTICE ECA13540 Brake fluid may d...

Page 124: ...all of the brake pads 1 Operate the brake 2 Check Front brake pad Wear indicators 1 almost touch the brake disc Replace the brake pads as a set Refer to FRONT BRAKE on page 4 25 EAS30631 ADJUSTING THE REAR DISC BRAKE 1 Adjust Brake pedal position a Loosen the locknut 1 b Turn the adjusting bolt 2 in direction a or b until the specified brake pedal position is obtained WARNING EWA13070 After adjust...

Page 125: ...hicle upright and apply the rear brake several times 4 Check Brake hose Brake fluid leakage Replace the damaged hose Refer to REAR BRAKE on page 4 37 EAS30893 BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS WARNING EWA14000 Always bleed the brake system when the brake related parts are removed NOTICE ECA18050 Bleed the brake system in the following or der 1st step Front brake calipers 2nd step Rear brake ...

Page 126: ...TION TESTS on page 4 54 NOTICE ECA17061 Make sure that the main switch is turned to OFF before checking the operation of the hydraulic unit k After operating the ABS repeat steps e to i and then fill the brake master cylinder reser voir or brake fluid reservoir to the proper level with the specified brake fluid l Tighten the bleed screw to specification m Fill the brake master cylinder reservoir o...

Page 127: ...ire combination other than one approved by Yamaha is used on this vehicle WARNING EWA13210 New tires have a relatively low grip on the road surface until they have been slightly worn Therefore approximately 100 km should be traveled at normal speed before any high speed riding is done TIP For tires with a direction of rotation mark 1 Install the tire with the mark pointing in the di rection of whe...

Page 128: ...rload the engine and other vital parts and one that is too loose can skip and damage the swing arm or cause an accident Therefore keep the drive chain slack within the specified lim its 1 Shift the transmission into the neutral posi tion 2 Check Drive chain slack a Out of specification Adjust NOTICE ECA20870 Improper drive chain slack will overload the engine as well as other vital parts of the mo...

Page 129: ...bricant that is suitable for O ring chains Do not use any other lubricants on the drive chain since they may contain solvents that could damage the O rings EAS30645 CHECKING AND ADJUSTING THE STEERING HEAD 1 Stand the vehicle on a level surface WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over TIP Place the vehicle on a maintenance stand so that the front ...

Page 130: ...page 4 58 EAS30646 LUBRICATING THE STEERING HEAD 1 Lubricate Upper bearing Lower bearing Bearing race EAS31186 CHECKING THE CHASSIS FASTENERS Make sure that all nuts bolts and screws are properly tightened Refer to CHASSIS TIGHTENING TORQUES on page 2 13 EAS30804 LUBRICATING THE BRAKE LEVER Lubricate the pivoting point and metal to metal moving parts of the lever EAS30805 LUBRICATING THE CLUTCH LE...

Page 131: ...ter tube Replace the oil seal 3 Hold the vehicle upright and apply the front brake 4 Check Front fork operation Push down hard on the handlebar several times and check if the front fork rebounds smoothly Rough movement Repair Refer to FRONT FORK on page 4 62 EAS30806 ADJUSTING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs WARNING EWA13120 Securely support the v...

Page 132: ...ing mechanism and to modify the specifications as necessary Compression damping left side only NOTICE ECA13590 Never go beyond the maximum or minimum adjustment positions 1 Adjust Compression damping a Turn the adjusting screw 1 in direction a or b Spring preload Minimum 19 0 mm 0 75 in Standard 16 0 mm 0 63 in Maximum 4 0 mm 0 16 in Direction a Rebound damping is increased sus pension is harder D...

Page 133: ... adjustment positions 1 Adjust Rebound damping a Turn the adjusting screw 1 in direction a or b TIP To obtain a precise adjustment it is advisable to check the actual total number of turns of the damping force adjusting mechanism This ad justment range may not exactly match the spec ifications listed due to small differences in Direction a Spring preload is increased suspen sion is harder Directio...

Page 134: ...uld cause clutch slippage Therefore do not add any chemical additives or use engine oils with a grade of CD or higher and do not use oils labeled ENERGY CONSERVING II Do not allow foreign materials to enter the crankcase TIP Before checking the engine oil level wait a few minutes until the oil has settled 4 Start the engine warm it up for several min utes and then turn it off 5 Check the engine oi...

Page 135: ...ral min utes and then turn it off 10 Check Engine for engine oil leaks 11 Check Engine oil level Refer to CHECKING THE ENGINE OIL LEVEL on page 3 24 EAS30810 MEASURING THE ENGINE OIL PRESSURE 1 Check Engine oil level Below the minimum level mark a Add the recommended engine oil to the proper level 2 Start the engine warm it up for several min utes and then turn it off NOTICE ECA13410 When the engi...

Page 136: ...vel NOTICE ECA21281 Adding water instead of coolant dilutes the antifreeze concentration of the coolant If water is used instead of coolant check and if necessary correct the antifreeze concentration of the coolant Use only distilled water However if dis tilled water is not available soft water may be used 3 Start the engine warm it up for several min utes and then turn it off Pressure gauge 90890...

Page 137: ...ap bolt 1 Radiator cap 2 Radiator cap stopper 3 WARNING EWA13030 A hot radiator is under pressure Therefore do not remove the radiator cap when the en gine is hot Scalding hot fluid and steam may be blown out which could cause serious in jury When the engine has cooled open the radiator cap as follows Place a thick rag or a towel over the radiator cap and slowly turn the radiator cap counter clock...

Page 138: ...ntifreeze concentration of the coolant Use only distilled water However if dis tilled water is not available soft water may be used If coolant comes into contact with painted surfaces immediately wash them with wa ter Do not mix different types of antifreeze 10 Install Radiator cap stopper Radiator cap Radiator cap bolt 11 Fill Coolant reservoir with the recommended coolant to the maxi mum level m...

Page 139: ...ode and interfere with its movement Re place damaged outer cable and inner cables as soon as possible 1 Check Outer cable Damage Replace 2 Check Cable operation Rough movement Lubricate TIP Hold the cable end upright and pour a few drops of lubricant into the cable sheath or use a suit able lubricating device EAS30815 CHECKING THE THROTTLE GRIP 1 Check Throttle cables Damage deterioration Replace ...

Page 140: ... to CHECKING AND CHARGING THE BATTERY on page 8 158 EAS30662 CHECKING THE FUSES Refer to CHECKING THE FUSES on page 8 156 EAS30664 ADJUSTING THE HEADLIGHT BEAMS 1 Adjust Headlight beam vertically TIP To adjust the headlight beam vertically insert a phillips screwdriver into the hole a and turn the adjusting screw a Turn the adjusting screw 1 in direction b or c 2 Adjust Headlight beam horizontally...

Page 141: ...PERIODIC MAINTENANCE 3 31 a Turn the adjusting screw 1 in direction b or c Direction b Headlight beam moves to the right Direction c Headlight beam moves to the left a b c 1 1 b c ...

Page 142: ...PERIODIC MAINTENANCE 3 32 ...

Page 143: ... REPLACING THE REAR WHEEL SPROCKET 4 21 ASSEMBLING THE REAR WHEEL 4 21 MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR 4 22 ADJUSTING THE REAR WHEEL STATIC BALANCE 4 22 INSTALLING THE REAR WHEEL REAR BRAKE DISC 4 22 FRONT BRAKE 4 25 INTRODUCTION 4 30 CHECKING THE FRONT BRAKE DISCS 4 30 REPLACING THE FRONT BRAKE PADS 4 31 REMOVING THE FRONT BRAKE CALIPERS 4 32 DISASSEMBLING THE FRONT BRAKE CA...

Page 144: ...NDLEBAR 4 58 REMOVING THE HANDLEBAR 4 59 CHECKING THE HANDLEBAR 4 59 INSTALLING THE HANDLEBAR 4 59 FRONT FORK 4 62 REMOVING THE FRONT FORK LEGS 4 64 DISASSEMBLING THE FRONT FORK LEGS 4 64 CHECKING THE FRONT FORK LEGS 4 65 ASSEMBLING THE FRONT FORK LEGS 4 66 INSTALLING THE FRONT FORK LEGS 4 70 STEERING HEAD 4 71 REMOVING THE LOWER BRACKET 4 73 CHECKING THE STEERING HEAD 4 73 INSTALLING THE STEERING...

Page 145: ...G THE DRIVE CHAIN 4 83 CHECKING THE DRIVE CHAIN 4 83 CHECKING THE DRIVE SPROCKET 4 84 CHECKING THE REAR WHEEL SPROCKET 4 84 CHECKING THE REAR WHEEL DRIVE HUB 4 84 INSTALLING THE DRIVE CHAIN 4 85 ADJUSTING THE SHIFT PEDAL 4 86 ...

Page 146: ...IS 1 Removing the seat and battery Order Job Parts 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 Spacer 1 1 2 3 3 4 5 6 2 2 N m 0 22 kgf m 1 6 lb ft ...

Page 147: ...Seat bracket 1 4 Rear turn signal light coupler 2 Disconnect 5 Tail brake light coupler 1 Disconnect 6 Lower tail cover 1 7 Tail brake light 1 8 Rear turn signal assembly 1 6 2 3 7 4 1 4 0 N m 0 40 kgf m 2 9 lb ft 4 0 N m 0 40 kgf m 2 9 lb ft 1 5 N m 0 15 kgf m 1 1 lb ft 1 5 N m 0 15 kgf m 1 1 lb ft 1 5 N m 0 15 kgf m 1 1 lb ft 7 N m 0 7 kgf m 5 1 lb ft 7 N m 0 7 kgf m 5 1 lb ft 8 4 4 5 ...

Page 148: ...s to remove Q ty Remarks 1 Headlight unit cover 1 2 Headlight coupler 1 Disconnect 3 Meter assembly coupler 1 Disconnect 4 Meter assembly 1 5 Headlight bracket 1 6 Headlight assembly 1 4 1 3 2 2 5 6 1 5 N m 0 15 kgf m 1 1 lb ft 5 N m 0 5 kgf m 3 6 lb ft 7 N m 0 7 kgf m 5 1 lb ft ...

Page 149: ... 5 Fuel tank mole right 1 6 Radiator cover left 1 7 Radiator cover right 1 8 Turn signal light coupler left 1 Disconnect 9 Front side panel left 1 10 Turn signal light coupler right 1 Disconnect 11 Front side panel right 1 1 2 7 9 3 4 5 5 1 5 N m 0 15 kgf m 1 1 lb ft 1 5 N m 0 15 kgf m 1 1 lb ft 1 5 N m 0 15 kgf m 1 1 lb ft 7 N m 0 7 kgf m 5 1 lb ft 7 N m 0 7 kgf m 5 1 lb ft 10 11 6 8 ...

Page 150: ...scoop into the hole d b Install the air scoop bolt and quick fastener and then tighten the bolts to specification 2 Install Air scoop right 1 a Insert the projection a on the air scoop into the grommet b and insert the projection c on the air scoop into the hole d b Install the air scoop bolt and quick fastener and then tighten the bolts to specification EAS31334 INSTALLING THE FUEL TANK MOLES 1 I...

Page 151: ...GENERAL CHASSIS 1 4 6 2 Install Fuel tank mole right 1 a Install the hole a in the fuel tank mole onto the projection b on the air scoop stay 1 a b ...

Page 152: ...IS 1 on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 1 ECU Engine Control Unit 1 2 ECU coupler 2 Disconnect 3 Air filter case cover 1 4 Air filter element 1 5 Air filter case joint clamp screw 3 Loosen 6 Air induction system hose 1 Disconnect 7 Cylinder head breather hose 1 Disconnect 8 Air filter case 1 1 2 3 4 5 6 7 8 3 3 10 7 N m 0 7 kgf m 5 1 lb ft 1 6 N m 0 16 kgf m 1 2 lb ft 2 8 N m 0 2...

Page 153: ... 2 2 Front wheel sensor bracket 1 3 Front wheel sensor 1 4 Wheel axle pinch bolt 1 Loosen 5 Wheel axle 1 6 Front wheel 1 7 Collar 2 8 Front brake disc 2 1 6 7 8 8 1 5 5 7 5 LT LT 2 4 3 7 N m 0 7 kgf m 5 1 lb ft 18 N m 1 8 kgf m 13 lb ft 18 N m 1 8 kgf m 13 lb ft 23 N m 2 3 kgf m 17 lb ft 35 N m 3 5 kgf m 25 lb ft 65 N m 6 5 kgf m 47 lb ft ...

Page 154: ...FRONT WHEEL 4 9 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 A 1 2 3 4 2 3 3 LT 8 N m 0 8 kgf m 5 8 lb ft ...

Page 155: ...or 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 Wheel axle Front wheel EAS31149 DISASSEMBLING THE FRONT WHEEL NOTICE ECA21340 Do not drop the wheel sensor rotor or sub ject it to shocks If any solvent gets on the wheel sensor ro tor wipe it off immediately 1 Remove Oil seals Wh...

Page 156: ... wipe it off immediately 1 Install Wheel bearings Oil seals a Install the new wheel bearing right side NOTICE ECA18110 Do not contact the wheel bearing inner race 1 or balls 2 Contact should be made only with the outer race 3 TIP Use a socket 4 that matches the diameter of the wheel bearing outer race b Install the spacer c Install the new wheel bearing left side TIP Place a suitable washer 1 betw...

Page 157: ...c screwdrivers etc away from the front wheel sensor or front wheel sensor rotor Do not drop or shock the wheel sensor or the wheel sensor rotor 1 Check Front wheel sensor 1 Cracks bends distortion Replace Iron powder dust Clean 2 Check Front wheel sensor rotor 1 Cracks damage scratches Replace the front wheel sensor rotor Iron powder dust solvent Clean TIP The wheel sensor rotor is installed on th...

Page 158: ...ot TIP Place the front wheel on a suitable balancing stand a Spin the front wheel b When the front wheel stops put an X1 mark at the bottom of the wheel c Turn the front wheel 90 so that the X1 mark is positioned as shown d Release the front wheel e When the wheel stops put an X2 mark at the bottom of the wheel f Repeat steps c through e several times until all the marks come to rest at the same s...

Page 159: ...ern 2 Check Front brake discs Refer to CHECKING THE FRONT BRAKE DISCS on page 4 30 3 Lubricate Oil seal lips 4 Install Collars Front wheel Wheel axle 5 Tighten Wheel axle Wheel axle pinch bolt NOTICE ECA19760 Before tightening the wheel axle push down hard on the handlebars several times and check if the front fork rebounds smoothly TIP Check that wheel axle end a is flush with front fork surface ...

Page 160: ...ng LOC TITE on the mounting surface of the rotor deformation caused by an impact during ser vice and caught foreign materials If there is any defective part repair or replace the de fective part TIP Measure the distance between the front wheel sensor rotor and front wheel sensor in several places in one rotation of the front wheel Do not turn the front wheel while the thickness gauge is installed ...

Page 161: ...t 2 Loosen 3 Adjusting bolt 2 Loosen 4 Cover 1 5 License plate coupler 1 Disconnect 6 Washer 1 7 Wheel axle nut 1 8 Chain puller assembly 1 9 Wheel axle 1 10 Adjusting block 1 11 Rear wheel 1 12 Brake caliper bracket 1 16 N m 1 6 kgf m 12 lb ft 16 N m 1 6 kgf m 12 lb ft 150 N m 15 kgf m 108 lb ft 7 N m 0 7 kgf m 5 1 lb ft 7 N m 0 7 kgf m 5 1 lb ft 1 12 11 5 6 8 7 2 3 2 3 5 10 9 4 ...

Page 162: ...Order Job Parts to remove Q ty Remarks 1 License plate bracket 1 2 Mudguard 1 3 Cover 1 4 Fender stay 1 5 Chain puller 1 7 N m 0 7 kgf m 5 1 lb ft 10 N m 1 0 kgf m 7 2 lb ft 10 N m 1 0 kgf m 7 2 lb ft 22 N m 2 2 kgf m 16 lb ft 3 4 5 2 1 LT LT LT ...

Page 163: ...ve Q ty Remarks 1 Rear brake disc 1 2 Bracket 1 3 Rear wheel sprocket 1 4 Collar 1 5 Collar 1 6 Oil seal 1 7 Bearing 1 8 Rear wheel drive hub 1 9 Collar 1 10 Rear wheel drive hub damper 6 11 Rear wheel 1 1 2 3 3 4 5 7 8 9 10 11 5 6 LT 6 30 N m 3 0 kgf m 22 lb ft 80 N m 8 0 kgf m 58 lb ft ...

Page 164: ...HEEL 4 19 Disassembling the rear wheel Order Job Parts to remove Q ty Remarks 1 Rear wheel sensor rotor 1 2 Oil seal 1 3 Wheel bearing 1 4 Spacer 1 5 Wheel bearing 1 A 1 3 4 LT 2 3 5 8 N m 0 8 kgf m 5 8 lb ft ...

Page 165: ... caliper Be sure not to contact the sensor electrode to any metal part when removing the rear wheel sensor from the rear brake caliper bracket 3 Loosen Locknuts 1 Adjusting bolts 2 4 Remove Wheel axle nut 1 Washer Chain puller assembly Wheel axle 2 Rear wheel Brake caliper bracket NOTICE ECA21400 Be sure to remove the rear wheel sensor be fore removing the brake caliper bracket oth erwise the sens...

Page 166: ...ear Replace the drive sprocket the rear wheel sprocket and the drive chain as a set Bent teeth Replace the drive sprocket the rear wheel sprocket and the drive chain as a set 2 Replace Rear wheel sprocket a Remove the rear wheel sprocket nuts and the rear wheel sprocket b Clean the rear wheel drive hub with a clean cloth especially the surfaces that contact the sprocket c Install the new rear whee...

Page 167: ...NSOR AND SENSOR ROTOR on page 4 12 EAS30164 ADJUSTING THE REAR WHEEL STATIC BALANCE TIP After replacing the tire wheel or both the rear wheel static balance should be adjusted Adjust the rear wheel static balance with the brake disc and rear wheel drive hub installed 1 Adjust Rear wheel static balance Refer to ADJUSTING THE FRONT WHEEL STATIC BALANCE on page 4 13 EAS31157 INSTALLING THE REAR WHEEL...

Page 168: ...ing the rear wheel sensor check the rear wheel sensor lead for twists 9 Measure Distance a between the wheel sensor rotor 1 and rear wheel sensor 2 Out of specification Check the wheel bear ing for looseness and the rear wheel sensor and sensor rotor installation conditions warpage caused by overtorque wrong in stallation direction rotor decentering LOC TITE on the mounting surface of the rotor de...

Page 169: ...sor rotor and rear wheel sensor in several places in one rotation of the rear wheel Do not turn the rear wheel while the thickness gauge is installed This may damage the rear wheel sen sor rotor and the rear wheel sensor Distance a between the wheel sensor rotor and rear wheel sen sor 0 7 1 4 mm 0 03 0 06 in Thickness gauge 90890 03180 Feeler gauge set YU 26900 9 1 2 a ...

Page 170: ...ty Remarks The following procedure applies to both of the front brake calipers 1 Brake pad clip 2 2 Brake pad pin 1 3 Brake pad spring 1 4 Brake pad 2 5 Front brake caliper 1 6 Bleed screw 1 7 Bleed screw 1 Right brake caliper side 1 2 3 4 5 6 7 5 N m 0 5 kgf m 3 6 lb ft 35 N m 3 5 kgf m 25 lb ft ...

Page 171: ... diaphragm holder 1 3 Brake master cylinder reservoir diaphragm 1 4 Brake lever 1 5 Front brake light switch lead connector 2 Disconnect 6 Front brake light switch 1 7 Brake hose union bolt 1 8 Brake hose gasket 2 9 Brake hose 1 10 Front brake master cylinder holder 1 11 Front brake master cylinder assembly 1 1 2 3 4 5 6 7 8 9 10 11 S S 1 0 N m 0 10 kgf m 0 72 lb ft 1 5 N m 0 15 kgf m 1 1 lb ft 6 ...

Page 172: ...FRONT BRAKE 4 27 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 ...

Page 173: ... procedure applies to both of the front brake calipers Brake fluid Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS on page 3 15 1 Brake hose union bolt 1 2 Brake hose gasket 1 3 Brake hose 2 4 Brake hose gasket 2 5 Front brake caliper 1 1 2 3 4 5 35 N m 3 5 kgf m 25 lb ft 30 N m 3 0 kgf m 22 lb ft ...

Page 174: ...he front brake calipers 1 Brake pad clip 2 2 Brake pad pin 1 3 Brake pad spring 1 4 Brake pad 2 5 Brake caliper piston 4 6 Brake caliper piston dust seal 4 7 Brake caliper piston seal 4 8 Bleed screw 1 9 Bleed screw 1 Right brake caliper side 1 2 3 4 5 6 6 7 5 6 6 7 7 7 8 9 S S BF S BF S 5 N m 0 5 kgf m 3 6 lb ft 5 N m 0 5 kgf m 3 6 lb ft ...

Page 175: ... Remove Front wheel Refer to FRONT WHEEL on page 4 8 2 Check Front brake disc Damage galling Replace 3 Measure Brake disc runout Out of specification Correct the brake disc runout or replace the brake disc a Place the vehicle on a maintenance stand so that the front wheel is elevated b Before measuring the brake disc runout turn the handlebar to the left or right to ensure that the front wheel is ...

Page 176: ... disconnect the brake hose or disassem ble the brake caliper 1 Remove Brake pad clips 1 Brake pad pin 2 Brake pad spring 3 2 Remove Brake pads 1 3 Measure Brake pad wear limit a Out of specification Replace the brake pads as a set 4 Remove Brake caliper bolts 5 Install Brake pads Brake pad spring TIP Always install new brake pads and new brake pad spring as a set a Connect a clear plastic hose 1 t...

Page 177: ...ake lever operation Soft or spongy feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS on page 3 15 EAS30724 REMOVING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers TIP Before removing the brake caliper drain the brake fluid from the entire brake system 1 Remove Brake hose union bolts 1 Brake hose gaskets 2 Brake hoses 3 TIP Put ...

Page 178: ...e the brake caliper pistons Brake caliper cylinders 2 Scratches wear Replace the brake caliper assembly Brake caliper body 3 Cracks damage Replace the brake caliper assembly Brake fluid delivery passages brake caliper body Obstruction Blow out with compressed air WARNING EWA13611 Whenever a brake caliper is disassembled replace the brake caliper piston dust seals and brake caliper piston seals EAS...

Page 179: ...WARNING EWA13090 Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake performance When refilling be careful that water does not enter the brake fluid reservoi...

Page 180: ... brake master cylinder body Obstruction Blow out with compressed air 2 Check Brake master cylinder kit Damage scratches wear Replace 3 Check Brake master cylinder reservoir 1 Brake master cylinder reservoir diaphragm holder 2 Cracks damage Replace Brake master cylinder reservoir diaphragm 3 Damage wear Replace 4 Check Brake hoses Cracks damage wear Replace EAS30181 ASSEMBLING THE FRONT BRAKE MASTE...

Page 181: ...WARNING EWA13540 Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake performance When refilling be careful that water does not enter the brake master cylinde...

Page 182: ... 1 Screw plug 1 2 Brake pad retaining bolt 1 3 Rear brake caliper 1 4 Brake pad 2 5 Brake pad shim 2 6 Brake pad insulator 2 7 Brake pad spring 1 8 Bleed screw 1 LT S S S S 2 5 N m 0 25 kgf m 1 8 lb ft 5 N m 0 5 kgf m 3 6 lb ft 17 N m 1 7 kgf m 12 lb ft 22 N m 2 2 kgf m 16 lb ft 27 N m 2 7 kgf m 20 lb ft ...

Page 183: ...e fluid 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 holder 1 6 Brake fluid reservoir hose 1 7 Brake hose union bolt 1 8 Brake hose gasket 2 9 Brake hose 1 10 Rear brake light switch coupler 1 Disconnect 11 Footrest assembly right 1 12 Brake pedal 1 1 2 3 4 5 6 7 8 9 10 11 12 LT 3 8 N m 0 38 kgf m 2...

Page 184: ... Parts to remove Q ty Remarks 13 Rear brake master cylinder assembly 1 14 Rear brake light switch 1 13 14 LT 3 8 N m 0 38 kgf m 2 8 lb ft 23 N m 2 3 kgf m 17 lb ft 30 N m 3 0 kgf m 22 lb ft 30 N m 3 0 kgf m 22 lb ft 55 N m 5 5 kgf m 40 lb ft 110 N m 11 kgf m 80 lb ft ...

Page 185: ...ling the rear brake master cylinder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder yoke 1 2 Brake master cylinder kit 1 3 Hose joint 1 4 Bushing 1 5 Brake master cylinder body 1 S BF BF 18 N m 1 8 kgf m 13 lb ft ...

Page 186: ...emove Q ty Remarks Brake fluid Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS on page 3 15 1 Brake hose union bolt 1 2 Brake hose gasket 2 3 Brake hose 1 4 Rear brake caliper 1 LT S S 22 N m 2 2 kgf m 16 lb ft 27 N m 2 7 kgf m 20 lb ft 30 N m 3 0 kgf m 22 lb ft ...

Page 187: ... 1 2 Brake pad retaining bolt 1 3 Brake pad 2 4 Brake pad shim 2 5 Brake pad insulator 2 6 Brake pad spring 1 7 Brake caliper piston 1 8 Brake caliper piston dust seal 1 9 Brake caliper piston seal 1 10 Bleed screw 1 S S S BF 2 5 N m 0 25 kgf m 1 8 lb ft 5 N m 0 5 kgf m 3 6 lb ft 17 N m 1 7 kgf m 12 lb ft ...

Page 188: ...sure Brake disc runout Out of specification Correct the brake disc runout or replace the brake disc Refer to CHECKING THE FRONT BRAKE DISCS on page 4 30 4 Measure Brake disc thickness Measure the brake disc thickness at a few dif ferent locations Out of specification Replace Refer to CHECKING THE FRONT BRAKE DISCS on page 4 30 5 Adjust Brake disc runout Refer to CHECKING THE FRONT BRAKE DISCS on p...

Page 189: ...o contact the brake pads Remove any excess grease 4 Install Rear brake caliper Brake pad retaining bolts Screw plug 5 Check Brake fluid level Below the minimum level mark a Add the specified brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 13 6 Check Brake pedal operation Soft or spongy feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM AB...

Page 190: ...e caliper piston dust seal and brake caliper piston seal EAS30188 CHECKING THE REAR BRAKE CALIPER 1 Check Brake caliper piston 1 Rust scratches wear Replace the brake caliper piston Brake caliper cylinder 2 Scratches wear Replace the brake caliper assembly Brake caliper body 3 Cracks damage Replace the brake caliper assembly Brake fluid delivery passages brake caliper body Obstruction Blow out wit...

Page 191: ...ets Brake hose 2 Brake hose union bolt 3 WARNING EWA13531 Proper brake hose routing is essential to in sure safe vehicle operation NOTICE ECA19080 When installing the brake hose onto the brake caliper 1 make sure the brake pipe a passes between the projections b on the brake caliper 2 Remove Rear brake caliper 3 Install Brake pad insulators Brake pad shims onto the brake pads Brake pad spring into...

Page 192: ...l 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 13 7 Check Brake pedal operation Soft or spongy feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS on page 3 15 EAS30193 REMOVING THE REAR BRAKE MASTER CYLINDER 1 Remove Brake hose union bolt 1 Brake hose gaskets 2 Brake hose 3 TIP To co...

Page 193: ...akage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake performance When refilling be careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock NOTICE ECA13540 Brake fluid...

Page 194: ...gle sensor coupler 1 Disconnect 2 Fuel tank bracket assembly 1 3 ABS ECU coupler 1 Disconnect 4 Brake hose union bolt Gasket 1 2 5 Rear brake hose hydraulic unit to rear brake caliper 1 Disconnect 6 Brake hose union bolt Gasket 1 2 7 Rear brake hose rear brake master cylinder to hydraulic unit 1 Disconnect 8 Brake hose union bolt Gasket 1 2 9 Front brake hose hydraulic unit to front brake caliper ...

Page 195: ...11 Front brake hose front brake master cylinder to hydraulic unit 1 Disconnect 12 Bracket 1 13 Rear brake hose bracket 1 14 Hydraulic unit bracket 1 15 Hydraulic unit 1 10 11 12 13 14 15 LT 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 11 N m 1 1 kgf m 8 0 lb ft 30 N m 3 0 kgf m 22 lb ft 30 N m 3 0 kgf m 22 lb ft ...

Page 196: ... Rear wheel sensor 5 Rear wheel sensor rotor 6 Front wheel sensor 7 Front wheel sensor rotor 8 ABS warning light 9 Fuse box 1 10 Rear brake hose hydraulic unit to rear brake caliper 11 Front brake hose front brake master cylinder to hydraulic unit 12 Front brake hose hydraulic unit to front brake caliper 13 Rear brake hose rear brake master cylinder to hydraulic unit ...

Page 197: ...connect ABS ECU coupler 1 TIP Pull the lock lever a of the ABS ECU coupler in the direction of the arrow shown and then dis connect the coupler 2 Remove Brake hoses TIP Do not operate the brake lever and brake pedal while removing the brake hoses NOTICE ECA18251 When removing the brake hoses cover the area around the hydraulic unit assembly to catch any spilt brake fluid Do not allow the brake flu...

Page 198: ...k lever a of the coupler in the direction of the arrow shown Make sure that the ABS ECU coupler is con nected in the correct position as shown in illus tration A 5 Fill Brake master cylinder reservoir Brake fluid reservoir with the specified amount of the specified brake fluid WARNING EWA13090 Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing ...

Page 199: ...firmation WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over TIP For the brake line routing confirmation use the diagnosis of function of the Yamaha diagnostic tool Before performing the brake line routing confir mation make sure that no malfunctions have been detected in the ABS ECU and that the wheels are not rotating 1 Place the vehicle on a maintenance ...

Page 200: ...e brake lever or brake pedal check that the brake hoses and brake pipes are connected cor rectly to the hydraulic unit assembly 10 If the operation of the hydraulic unit is normal delete all of the fault codes ABS reaction force confirmation WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over TIP For the ABS reaction force confirmation use the diagnosis of f...

Page 201: ... The brake lever and brake pedal are not being operated 9 A reaction force pulsating action is generated in the brake lever 1 and continues for a few seconds TIP The reaction force pulsating action consists of quick pulses Be sure to continue operating the brake lever and brake pedal even after the pulsating action has stopped ON and OFF on the tool screen indicate when the brakes are being applie...

Page 202: ...he pulse is hardly felt in either the brake lever or brake pedal check that the brake hoses and brake pipes are connected cor rectly to the hydraulic unit assembly 12 Turn the main switch to OFF 13 Remove the Yamaha diagnostic tool from the Yamaha diagnostic tool coupler and then in stall the protective cap 14 Turn the main switch to ON 15 Set the start engine stop switch to 16 Check for brake flu...

Page 203: ...ip 1 10 Clutch switch coupler 1 Disconnect 11 Handlebar switch left 1 12 Handlebar grip 1 13 Clutch cable 1 Disconnect 14 Clutch lever holder 1 15 Upper handlebar holder 2 16 Handlebar 1 17 Lower handlebar holder 2 1 2 4 5 6 7 8 9 10 11 12 13 14 15 16 8 1 3 17 1 8 N m 0 18 kgf m 1 3 lb ft 1 8 N m 0 18 kgf m 1 3 lb ft 11 N m 1 1 kgf m 8 0 lb ft 10 N m 1 0 kgf m 7 2 lb ft 40 N m 4 0 kgf m 29 lb ft 3...

Page 204: ...y weaken it EAS30205 INSTALLING THE HANDLEBAR 1 Stand the vehicle on a level surface WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over 2 Install Lower handlebar holders temporarily Handlebar 1 Upper handlebar holders 2 NOTICE ECA19130 First tighten the bolts on the front side of the upper handlebar holder and then on the rear side Turn the handlebar all th...

Page 205: ...enter of slit on the clutch lever holder with the punch mark a on the handlebar 8 Install Handlebar grip 1 Grip end 2 a Apply a thin coat of rubber adhesive onto the end of the handlebar left b Side the handlebar grip over the end of the handlebar left c Wipe off any excess rubber adhesive with a clean rag WARNING EWA13700 Do not touch the handlebar grip until the rub ber adhesive has fully dried ...

Page 206: ...lebar 10 Adjust Throttle grip free play Refer to CHECKING THE THROTTLE GRIP on page 3 29 11 Adjust Clutch lever free play Refer to ADJUSTING THE CLUTCH LEVER FREE PLAY on page 3 12 Handlebar switch screw 1 8 N m 0 18 kgf m 1 3 lb ft Throttle grip free play 3 0 5 0 mm 0 12 0 20 in Clutch lever free play 10 0 15 0 mm 0 39 0 59 in T R a b ...

Page 207: ...oth of the front fork legs Front wheel Refer to FRONT WHEEL on page 4 8 1 Front fender 1 2 Upper bracket pinch bolt 1 Loosen 3 Cap bolt 1 Loosen 4 Lower bracket pinch bolt 2 Loosen 5 Front fork leg 1 1 2 3 4 5 10 N m 1 0 kgf m 7 2 lb ft 10 N m 1 0 kgf m 7 2 lb ft 26 N m 2 6 kgf m 19 lb ft 23 N m 2 3 kgf m 17 lb ft 23 N m 2 3 kgf m 17 lb ft ...

Page 208: ...r 1 5 Fork spring 1 6 Locknut 1 7 Damper adjusting rod 1 8 Dust seal 1 9 Oil seal clip 1 10 Outer tube 1 11 Oil seal 1 12 Washer 1 13 Outer tube bushing 1 14 Inner tube bushing 1 15 Damper rod assembly bolt 1 16 Copper washer 1 17 Damper rod assembly 1 18 Inner tube 1 19 Wheel axle pinch bolt 1 Left side only LT 19 15 N m 1 5 kgf m 11 lb ft 23 N m 2 3 kgf m 17 lb ft 23 N m 2 3 kgf m 17 lb ft ...

Page 209: ... Cap bolt 2 Lower bracket pinch bolts 3 WARNING EWA13640 Before loosening the upper and lower brack et pinch bolts support the front fork leg 4 Remove Front fork leg EAS30207 DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Remove Cap bolt 1 from the damper rod assembly Washer 2 Spacer 3 Locknut 4 a Press down on the spacer with the fork spring com...

Page 210: ...ced 5 Remove Damper rod assembly bolt Damper rod assembly TIP While holding the damper rod with the damper rod holder 1 loosen the damper rod assembly bolt EAS30208 CHECKING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Check Inner tube 1 Outer tube 2 Bends damage scratches Replace WARNING EWA13650 Do not attempt to straighten a bent inner tube as this may da...

Page 211: ...nt of the fork oil it may cause poor handling and a loss of stability TIP When assembling the front fork leg be sure to replace the following parts Inner tube bushing Outer tube bushing Oil seal Oil seal clip Dust seal Copper washer O ring Before assembling the front fork leg make sure all of the components are clean 1 Install Damper rod assembly 1 NOTICE ECA19120 Allow the damper rod assembly to ...

Page 212: ... front fork leg with a plastic bag to protect the oil seal during installation 5 Install Outer tube to the inner tube 6 Install Outer tube bushing 1 Washer 2 with the fork seal driver 3 7 Install Oil seal 1 with the fork seal driver 2 8 Install Oil seal clip 1 TIP Adjust the oil seal clip so that it fits into the outer tube s groove 9 Install Dust seal 1 with the fork seal driver 2 Fork seal drive...

Page 213: ...oil may spurt out 13 Before measuring the fork oil level wait ten minutes until the oil has settled and the air bubbles have dispersed TIP Be sure to bleed the front fork leg of any residual air 14 Measure Front fork leg oil level a from the top of the outer tube with the outer tube fully compressed and without the fork spring Out of specification Correct Fork seal driver 90890 01442 Adjustable fo...

Page 214: ...acer with the fork spring compressor 1 h Pull up the rod puller and install the rod holder 2 between the locknut 3 and the spacer 4 TIP Use the side of the rod holder that is marked B i Remove the rod puller and rod puller attach ment j Position the locknut 3 as distance b k Set the cap bolt distance c to specification New 1 2 5 3 6 4 Rod puller 90890 01437 Universal damping rod bleeding tool set ...

Page 215: ...ower bracket pinch bolts EAS30210 INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Install Front fork leg Temporarily tighten the upper and lower bracket pinch bolts TIP Make sure the outer tube is flush with the top of the upper bracket 2 Tighten Lower bracket pinch bolts 1 Cap bolt 2 Upper bracket pinch bolt 3 WARNING EWA13680 Make sure the brake ho...

Page 216: ...1 on page 4 1 Handlebar Refer to HANDLEBAR on page 4 58 Front fork legs Refer to FRONT FORK on page 4 62 1 Protector 1 2 Rivet 1 3 Coupler cover assembly 1 4 Clamp 1 5 Main switch coupler 2 Disconnect 6 Immobilizer coupler 1 Disconnect 7 Horn lead connector 2 Disconnect 8 Horn 1 9 Front brake hose 1 10 Headlight stay 1 11 Horn bracket 1 FWD 7 9 10 11 8 1 2 3 4 5 6 7 N m 0 7 kgf m 5 1 lb ft 7 N m 0...

Page 217: ...Lock washer 1 16 Upper ring nut 1 17 Rubber washer 1 18 Lower ring nut 1 19 Lower bracket 1 20 Bearing cover 1 21 Lower bearing dust seal 1 22 Upper bearing 1 23 Lower bearing 1 FWD 15 14 19 12 23 22 21 13 16 17 18 20 7 N m 0 7 kgf m 5 1 lb ft 7 N m 0 7 kgf m 5 1 lb ft 110 N m 11 kgf m 80 lb ft 1st 2nd 52 N m 5 2 kgf m 38 lb ft 18 N m 1 8 kgf m 13 lb ft ...

Page 218: ...Wash Bearing Bearing race 2 Check Bearing 1 Bearing race 2 Damage pitting Replace the bearings and bearing races as a set 3 Replace Bearing Bearing race a Remove the bearing races from the steering head pipe 1 with a long rod 2 and hammer b Remove the bearing race 3 from the lower bracket with a floor chisel 4 and hammer c Install a new dust seal and new bearing rac es NOTICE ECA14270 If the beari...

Page 219: ... 2 Upper ring nut 3 Lock washer 4 Refer to CHECKING AND ADJUSTING THE STEERING HEAD on page 3 19 3 Install Upper bracket Steering stem nut TIP Temporarily tighten the steering stem nut 4 Install Front fork legs Refer to FRONT FORK on page 4 62 TIP Temporarily tighten the upper and lower bracket pinch bolts 5 Tighten Steering stem nut Recommended lubricant Lithium soap based grease Steering stem nu...

Page 220: ...to ENGINE REMOVAL on page 5 3 1 Connecting arm lower nut Bolt 1 1 2 Relay arm nut Collar Bolt 1 1 1 3 Rear shock absorber assembly upper nut Washer Bolt 1 1 1 4 Rear shock absorber assembly upper nut Washer Bolt 1 2 1 5 Rear shock absorber assembly 1 6 Connecting arm upper nut Bolt 1 1 7 Connecting arm 2 8 Relay arm 1 9 Collar Oil seal Bearing 1 2 2 10 Collar Oil seal Bearing 2 4 2 4 1 2 3 4 5 6 7...

Page 221: ...s end as shown WARNING EWA13760 Wear eye protection to prevent eye damage from released gas or metal chips EAS30219 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 1 Stand the vehicle on a level surface WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over TIP Place the vehicle on a maintenance stand so that the rear wheel is elevated 2 Remove Connecting arm lower n...

Page 222: ...embly upper nut Relay arm bolt Relay arm nut Connecting arm lower bolt Connecting arm lower nut TIP Install the rear shock absorber assembly upper bolt relay arm bolt and connecting arm lower bolt from the left When installing the rear shock absorber as sembly lift up the swingarm Install the rear shock absorber assembly with the rebound damping adjusting screw facing the left side of the vehicle ...

Page 223: ...REAR SHOCK ABSORBER ASSEMBLY 4 78 Rear shock absorber assembly nut upper 44 N m 4 4 kgf m 32 lb ft Relay arm nut 61 N m 6 1 kgf m 44 lb ft Connecting arm lower nut 55 N m 5 5 kgf m 40 lb ft T R ...

Page 224: ...er to CHAIN DRIVE on page 4 82 1 Connecting arm lower nut 1 2 Connecting arm lower bolt 1 3 Pivot shaft nut 1 4 Pivot shaft 1 5 Washer 1 6 Swingarm 1 7 Drive chain guard 1 8 Drive chain guide 1 9 Bracket 1 10 Rear fender 1 11 Dust cover 4 12 Collar 3 13 Oil seal 4 14 Bearing 4 15 Washer 1 1 2 3 4 5 6 7 8 9 11 13 10 13 12 11 12 13 13 11 12 14 14 14 15 LT 7 N m 0 7 kgf m 5 1 lb ft 7 N m 0 7 kgf m 5 ...

Page 225: ...e to side If the swingarm has side to side play check the collars bearings and dust covers c Check the swingarm vertical movement B by moving the swingarm up and down If the swingarm vertical movement is not smooth or if there is binding check the pivot shaft collars bearings and dust covers 4 Remove Drive chain Refer to REMOVING THE DRIVE CHAIN on page 4 83 Swingarm EAS30227 CHECKING THE SWINGARM...

Page 226: ...Rear wheel Refer to REAR SHOCK ABSORBER AS SEMBLY on page 4 75 and REAR WHEEL on page 4 16 5 Adjust Drive chain slack Refer to DRIVE CHAIN SLACK on page 3 18 Recommended lubricant Lithium soap based grease Installed depth a 2 0 mm 0 08 in Installed depth b 9 0 mm 0 35 in Installed depth c 0 5 1 5 mm 0 02 0 06 in Installed depth d 7 0 mm 0 28 in Installed depth e 1 5 2 5 mm 0 06 0 10 in 1 1 4 4 3 3...

Page 227: ...3 Shift switch 1 4 Shift rod 1 5 Shift arm 1 6 Shift rod joint 1 7 Drive sprocket cover 1 8 Drive chain guide 1 9 Drive sprocket nut 1 10 Washer 1 11 Drive sprocket 1 12 Drive chain 1 2 2 2 5 3 4 8 6 7 12 11 10 9 E 1 LT E 7 N m 0 7 kgf m 5 1 lb ft 8 N m 0 8 kgf m 5 8 lb ft 10 N m 1 0 kgf m 7 2 lb ft 14 N m 1 4 kgf m 10 lb ft 95 N m 9 5 kgf m 69 lb ft ...

Page 228: ...th 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 15 link section length a of the 15 link section of the drive chain using the fol lowing formula Drive chain 15 link section length a length b between pin inner sides length c between pin outer sides 2 TIP When measuring a 15 link section of the drive chain make sure that th...

Page 229: ...Check O rings 1 Damage Replace the drive chain Drive chain rollers 2 Damage wear Replace the drive chain Drive chain side plates 3 Damage wear cracks Replace the drive chain 5 Lubricate Drive chain EAS30231 CHECKING THE DRIVE SPROCKET 1 Check Drive sprocket More than 1 4 tooth a wear Replace the drive sprocket the rear wheel sprocket and the drive chain as a set Bent teeth Replace the drive sprock...

Page 230: ...side of the connecting link 3 and inside of the connecting plate 1 is 14 1 14 3 mm 0 555 0 562 in 2 Lubricate Drive chain 3 Install Drive sprocket Washer 1 Drive sprocket nut 2 TIP While applying the rear brake tighten the drive sprocket nut Install washer 1 with the OUT mark a fac ing out Stake the drive sprocket nut 2 at cutouts b in the drive axle 4 Install Shift arm 1 TIP Before installing mak...

Page 231: ...ive chain slack within the specified lim its EAS31729 ADJUSTING THE SHIFT PEDAL TIP The shift pedal position is determined by the in stalled shift rod length 1 Measure Installed shift rod length a Incorrect Adjust 2 Adjust Installed shift rod length a Loosen both locknuts 1 b Turn the shift rod 2 in direction a or b to obtain the correct shift pedal position Shift rod joint bolt 10 N m 1 0 kgf m 7...

Page 232: ...ocknuts TIP Be sure to place the shift rod joints in parallel The allowable twist of the shift rod joints is 5 d Make sure the installed shift rod length is within specification Shift rod locknut 7 N m 0 7 kgf m 5 1 lb ft 1 2 1 b a T R ...

Page 233: ...EAD 5 20 INSTALLING THE CYLINDER HEAD 5 21 VALVES AND VALVE SPRINGS 5 22 REMOVING THE VALVES 5 23 CHECKING THE VALVES AND VALVE GUIDES 5 23 CHECKING THE VALVE SEATS 5 25 CHECKING THE VALVE SPRINGS 5 26 CHECKING THE VALVE LIFTERS 5 27 INSTALLING THE VALVES 5 27 GENERATOR AND STARTER CLUTCH 5 29 REMOVING THE GENERATOR 5 31 REMOVING THE STARTER CLUTCH 5 31 CHECKING THE STARTER CLUTCH 5 31 INSTALLING ...

Page 234: ... PAN 5 56 CHECKING THE OIL STRAINER 5 56 INSTALLING THE OIL PAN 5 56 CRANKCASE 5 57 DISASSEMBLING THE CRANKCASE 5 58 CHECKING THE CRANKCASE 5 58 ASSEMBLING THE CRANKCASE 5 58 CONNECTING RODS AND PISTONS 5 61 REMOVING THE CONNECTING RODS AND PISTONS 5 62 CHECKING THE CYLINDER AND PISTON 5 62 CHECKING THE PISTON RINGS 5 63 CHECKING THE PISTON PIN 5 64 CHECKING THE CONNECTING RODS 5 64 INSTALLING THE...

Page 235: ...CHECKING THE SHIFT DRUM ASSEMBLY 5 82 CHECKING THE TRANSMISSION 5 82 ASSEMBLING THE MAIN AXLE AND DRIVE AXLE 5 82 INSTALLING THE TRANSMISSION 5 83 ...

Page 236: ... in the spark plug wells to prevent it from falling into the cylinders 4 Install Compression gauge 1 Extension 2 5 Measure Compression pressure Out of specification Refer to steps c and d a Set the main switch to ON b With the throttle wide open crank the engine until the reading on the compression gauge stabilizes WARNING EWA17100 To prevent sparking the plug remove all ig nition coil couplers an...

Page 237: ...o FUEL TANK on page 7 1 Fuel tank cover Refer to GENERAL CHASSIS 1 on page 4 1 Rider seat Refer to GENERAL CHASSIS 1 on page 4 1 Air scoop Refer to GENERAL CHASSIS 1 on page 4 1 Compression pressure with oil applied into the cylinder Reading Diagnosis Higher than without oil Piston ring s wear or damage Repair Same as without oil Piston valves cylinder head gasket possibly defective Repair Spark p...

Page 238: ...o remove Q ty Remarks 1 O2 sensor coupler bracket 1 2 O2 sensor coupler 1 Disconnect 3 Muffler assembly 1 4 Exhaust gasket 3 5 Muffler protector 1 1 2 3 4 5 6 10 N m 1 0 kgf m 7 2 lb ft 10 N m 1 0 kgf m 7 2 lb ft 12 N m 1 2 kgf m 8 7 lb ft 20 N m 2 0 kgf m 14 lb ft 20 N m 2 0 kgf m 14 lb ft LT LT LT ...

Page 239: ...ROTTLE BODIES on page 7 5 Fuel rail Refer to THROTTLE BODIES on page 7 5 Front side panel Refer to GENERAL CHASSIS 1 on page 4 1 Radiator Refer to RADIATOR on page 6 1 Air cut off valve Refer to AIR INDUCTION SYSTEM on page 7 15 Footrest assembly right Refer to REAR BRAKE on page 4 37 Shift rod Drive sprocket Refer to CHAIN DRIVE on page 4 82 1 Clutch cable 1 Disconnect 2 Starter motor lead 1 Disc...

Page 240: ...ob Parts to remove Q ty Remarks 6 Oil level switch coupler 1 Disconnect 7 Gear position switch coupler 2 Disconnect 8 Crankshaft position sensor coupler 1 Disconnect 9 Stator coil coupler 1 Disconnect 8 7 6 9 7 N m 0 7 kgf m 5 1 lb ft 12 N m 1 2 kgf m 8 7 lb ft ...

Page 241: ...eft front upper side 1 1 1 4 Adapter bolt left 1 5 Engine mounting bolt rear lower side Engine mounting nut rear lower side 1 1 6 Engine mounting bolt rear upper side Engine mounting nut rear upper side 1 1 7 Engine 1 8 Engine mounting adjust bolt 3 1 2 3 4 5 6 7 8 8 8 3 5 6 3 7 N m 0 7 kgf m 5 1 lb ft 7 N m 0 7 kgf m 5 1 lb ft 12 N m 1 2 kgf m 8 7 lb ft 12 N m 1 2 kgf m 8 7 lb ft 45 N m 4 5 kgf m...

Page 242: ... 4 Install Adapter bolt left 5 temporarily tighten 5 Install Engine mounting bolt left front upper side 6 Engine mounting bolt left front lower side 7 Engine mounting bolt right front lower side 8 TIP Temporarily tighten the engine mounting bolts 6 8 6 Tighten Engine mounting adjust bolt front 1 TIP Tighten the engine mounting adjust bolt to specification with the pivot shaft wrench Make sure that...

Page 243: ...ngine mounting bolt right front upper side 10 Engine mounting bolt left front upper side 6 Engine mounting bolt left front lower side 7 Engine mounting bolt right front lower side 8 12 Tighten Adapter bolt left 5 Adapter bolt right 9 Engine mounting adjust bolt rear 7 N m 0 7 kgf m 5 1 lb ft Pivot shaft wrench 90890 01518 Frame spanner socket YM 01518 Pivot shaft wrench adapter 90890 01476 Engine ...

Page 244: ...page 7 1 Air filter case Refer to GENERAL CHASSIS 2 on page 4 7 Front side panel Refer to GENERAL CHASSIS 1 on page 4 1 Radiator Refer to RADIATOR on page 6 1 Air cut off valve Refer to AIR INDUCTION SYSTEM on page 7 15 1 Ignition coil coupler 3 Disconnect 2 Ignition coil 3 3 Spark plug 3 4 Cylinder head cover 1 5 Cylinder head cover gasket 1 6 Timing chain guide top side 1 1 2 3 4 5 6 3 2 2 S S S...

Page 245: ...asket 1 5 Intake camshaft cap 1 6 Exhaust camshaft cap 1 7 Camshaft cap 1 8 Intake camshaft 1 9 Exhaust camshaft 1 10 Intake camshaft sprocket 1 11 Exhaust camshaft sprocket 1 12 Timing chain bolt 1 13 Dowel pin 1 14 Timing chain guide intake side 1 15 Timing chain 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 E E LT 8 M 8 E 4 4 S 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 l...

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

Page 247: ...pins and camshaft caps TIP Tighten the camshaft cap bolts in stages and in a crisscross pattern working from the inner caps out Do not turn the camshaft when measuring the camshaft journal to camshaft cap clearance with the Plastigauge d Remove the camshaft caps and then mea sure the width of the Plastigauge 2 Camshaft wrench 90890 04162 Camshaft wrench YM 04162 Camshaft lobe dimensions Lobe heigh...

Page 248: ... CHAIN GUIDES The following procedure applies to all of the camshaft sprockets and timing chain guides 1 Check Timing chain guide intake side 1 Timing chain guide top side 2 Damage wear Replace the defective part s EAS30266 CHECKING THE TIMING CHAIN TENSIONER 1 Check Timing chain tensioner Cracks damage rough movement Re place a Lightly press the timing chain tensioner rod into the timing chain te...

Page 249: ...urn the crankshaft counterclockwise b When piston 1 is at BTDC125 align the mark a on the generator rotor with the gen erator rotor cover mark b 3 Install Intake camshaft sprocket 1 Exhaust camshaft sprocket 2 TIP Install the camshaft projection a at the posi tion shown in the illustration Tighten the camshaft sprocket bolt with the camshaft wrench 3 4 Install Exhaust camshaft 1 Intake camshaft 2 ...

Page 250: ...bolts with the engine oil The camshaft cap bolts must be tightened evenly or damage to the cylinder head camshaft caps and camshafts will result Do not turn the crankshaft when installing the camshaft to avoid damage or improper valve timing 7 Tighten Camshaft cap bolts 1 TIP Tighten the camshaft cap bolts in stages and in a crisscross pattern working from the inner caps out NOTICE ECA17430 Lubric...

Page 251: ... cylinder block TIP Face the section a of the gasket inward c Tighten the timing chain tensioner bolts to the specified torque d Screw the hexagon wrench by hand until the timing chain tensioner rod touches the timing chain guide and then tighten 1 4 turn by tool TIP The timing chain tensioner rod is extended by turning the hexagon wrench clockwise e Remove the hexagon wrench and check the timing ...

Page 252: ...ANCE on page 3 5 13 Install Timing mark accessing bolt 1 Crankshaft end cover 2 14 Install Timing chain guide top side Cylinder head cover gasket 1 Cylinder head cover TIP Apply Three Bond No 1541C onto the mating surfaces of the cylinder head cover and cylin der head cover gasket After installing the cylinder head cover gasket 1 to the cylinder head cover cut off the a section 15 Install Spark pl...

Page 253: ...CAMSHAFTS 5 18 TIP Install the ignition coils 1 in the direction shown in the illustration 1 ...

Page 254: ...n page 5 9 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 Timing chain guide exhaust side 1 1 2 3 4 5 8 E 4 10 N m 1 0 kgf m 7 2 lb ft 10 N m 1 0 kgf m 7 2 lb ft 1st 3rd 2nd 17 N m 1 7 kgf m 12 lb ft Specified angle 120 20 N m 2 0 kgf m 14 lb ft 30 N m 3 0 kgf m 22 lb ft 16 N m 1 6 kgf m 12 lb ft ...

Page 255: ... TIP Do not use a sharp instrument to avoid damag ing or scratching Spark plug bore threads Valve seats 2 Check Cylinder head Damage scratches Replace Cylinder head water jacket Mineral deposits rust Eliminate 3 Measure Cylinder head warpage Out of specification Resurface the cylinder head a Place a straightedge 1 and a thickness gauge 2 across the cylinder head b Measure the warpage c If the limi...

Page 256: ...olts 1 8 Cylinder head bolts 9 12 Following the tightening order loosen the bolt one by one and then retighten it to the specific torque and the specific angle TIP Tighten the cylinder head bolts 1 8 in the tightening sequence as shown and torque them in 3 stages 4 Install Exhaust camshaft Intake camshaft Refer to INSTALLING THE CAMSHAFTS on page 5 14 Cylinder head bolt 1 8 1st 20 N m 2 0 kgf m 14...

Page 257: ... 12 4 Intake valve spring retainer 6 5 Intake valve spring 6 6 Intake valve 6 7 Intake valve stem seal 6 8 Intake valve spring seat 6 9 Intake valve guide 6 10 Exhaust valve lifter 6 11 Exhaust valve pad 6 12 Exhaust valve cotter 12 13 Exhaust valve spring retainer 6 14 Exhaust valve spring 6 15 Exhaust valve 6 16 Exhaust valve stem seal 6 17 Exhaust valve spring seat 6 18 Exhaust valve guide 6 1 ...

Page 258: ...lean solvent a into the intake and exhaust ports b Check that the valves properly seal TIP There should be no leakage at the valve seat 1 3 Remove Valve cotters TIP Remove the valve cotters by compressing the valve spring with the valve spring compressor 1 and the valve spring compressor attachment 2 4 Remove Valve spring retainer 1 Valve spring 2 Valve 3 Valve stem seal 4 Valve spring seat 5 TIP ...

Page 259: ... 2 and valve guide remover 1 c After installing the valve guide bore the valve guide with the valve guide reamer 3 to ob tain the proper valve stem to valve guide clearance TIP After replacing the valve guide reface the valve seat Valve stem to valve guide clearance Valve guide inside diameter a Valve stem diameter b Valve stem to valve guide clear ance intake 0 010 0 037 mm 0 0004 0 0015 in Limit...

Page 260: ... 3 Measure Valve seat contact width a Out of specification Replace the cylinder head a Apply blue layout fluid b onto the valve face b Install the valve into the cylinder head c Press the valve through the valve guide and onto the valve seat to make a clear impres sion d Measure the valve seat contact width TIP Where the valve seat and valve face contacted one another the blue layout fluid will ha...

Page 261: ...th be tween your hands e Apply a fine lapping compound to the valve face and repeat the above steps f After every lapping procedure be sure to clean off all of the lapping compound from the valve face and valve seat g Apply blue layout fluid b onto the valve face h Install the valve into the cylinder head i Press the valve through the valve guide and onto the valve seat to make a clear impres sion...

Page 262: ...ocedure applies to all of the valves and related components 1 Deburr Valve stem end with an oil stone 2 Lubricate Valve stem 1 Valve stem seal 2 with the recommended lubricant 3 Install Valve spring seat 1 Valve stem seal 2 Valve 3 Valve spring 4 Valve spring retainer 5 into the cylinder head TIP Make sure each valve is installed in its original place Install the valve springs with the larger pitc...

Page 263: ...could damage the valve 6 Lubricate Valve pad with the recommended lubricant Valve lifter with the recommended lubricant 7 Install Valve pad Valve lifter TIP The valve lifter must move smoothly when ro tated with a finger Each valve lifter and valve pad must be rein stalled in its original position b Smaller pitch Valve spring compressor 90890 04019 Valve spring compressor YM 04019 Valve spring com...

Page 264: ...e 6 8 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 24 1 Stator coil coupler 1 Disconnect 2 Crankshaft position sensor coupler 1 Disconnect 3 Holder fuel tank overflow hose 1 4 Generator cover 1 5 Generator cover gasket 1 6 Dowel pin 2 7 Stator coil lead holder 1 8 Stator coil assembly stator coil crankshaft posi tion sensor 1 1 2 3 5 6 7 8 E E E E 3 LT 6 6 3 LT LT LT 4 10 N m 1 0 kg...

Page 265: ...lutch idle gear shaft 1 14 Starter clutch idle gear 1 15 Crankshaft end cover 1 16 Timing mark accessing bolt 1 17 Water pump outlet pipe 1 9 12 15 16 17 E E 13 14 E 10 11 E 3 LT 6 3 LT LT LT 10 N m 1 0 kgf m 7 2 lb ft 10 N m 1 0 kgf m 7 2 lb ft 32 N m 3 2 kgf m 23 lb ft 75 N m 7 5 kgf m 54 lb ft 15 N m 1 5 kgf m 11 lb ft 12 N m 1 2 kgf m 8 7 lb ft 12 N m 1 2 kgf m 8 7 lb ft 12 N m 1 2 kgf m 8 7 l...

Page 266: ...nerator rotor EAS30868 REMOVING THE STARTER CLUTCH 1 Remove Starter clutch bolts Starter clutch TIP While holding the generator rotor 1 with the sheave holder 2 loosen the starter clutch bolts EAS30869 CHECKING THE STARTER CLUTCH 1 Check Starter clutch rollers Damage wear Replace 2 Check Starter clutch idle gear Starter clutch gear Burrs chips roughness wear Replace the defective part s 3 Check St...

Page 267: ...ave holder 3 tighten the starter clutch bolts EAS30872 INSTALLING THE GENERATOR 1 Install Woodruff key Generator rotor Washer Generator rotor bolt TIP Clean the tapered portion of the crankshaft and the generator rotor hub When installing the generator rotor make sure the woodruff key is properly seated in the key way of the crankshaft Lubricate the washer with engine oil Lubricate the generator r...

Page 268: ...ator cover bolts in stages and in a crisscross pattern 5 Connect Stator coil coupler Crankshaft position sensor coupler TIP To route the stator coil lead refer to CABLE ROUTING on page 2 35 Yamaha bond No 1215 90890 85505 Three bond No 1215 Generator cover bolt 1 12 N m 1 2 kgf m 8 7 lb ft LOCTITE Generator cover bolt 2 12 N m 1 2 kgf m 8 7 lb ft New T R 1 2 2 2 ...

Page 269: ...1 Air scoop Fuel tank cover Refer to GENERAL CHASSIS 2 on page 4 7 Fuel tank Refer to FUEL TANK on page 7 1 Air filter case Refer to GENERAL CHASSIS 2 on page 4 7 Throttle bodies Refer to THROTTLE BODIES on page 7 5 1 Starter motor lead 1 Disconnect 2 Negative battery lead 1 Disconnect 3 Starter motor 1 1 2 3 12 N m 1 2 kgf m 8 7 lb ft 7 N m 0 7 kgf m 5 1 lb ft ...

Page 270: ...er motor Order Job Parts to remove Q ty Remarks 1 O ring 1 2 Starter motor front cover 1 3 Starter motor yoke 1 4 Armature assembly 1 5 Gasket 2 6 Brush holder set 1 7 Starter motor rear cover 1 5 N m 0 5 kgf m 3 6 lb ft 11 N m 1 1 kgf m 8 0 lb ft ...

Page 271: ...asure 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 overall length a Out of specification Replace the brush holder set 5 Measure Brush spring force Out of specification Replace the brush holder set Mica undercut depth 0 70 mm 0 03 in Digital circuit tester CD732 90890 03243 Model 88 Multimete...

Page 272: ...on 2 Install Starter motor rear cover 1 Starter motor yoke 2 Starter motor front cover 3 TIP Align the match marks a on the starter motor yoke with the match marks b on the front and rear cover EAS30327 INSTALLING THE STARTER MOTOR 1 Install Starter motor 1 Negative battery lead 2 Starter motor bolts 3 TIP Install the negative battery lead as shown in the illustration 2 Connect Starter motor lead ...

Page 273: ...NG THE ENGINE OIL on page 3 24 1 Clutch cable 1 Disconnect 2 Cover 1 3 O2 sensor coupler bracket 1 4 Clutch cover 1 5 Clutch cover gasket 1 6 Dowel pin 2 7 Oil filler cap 1 1 2 3 4 5 6 7 6 6 12 N m 1 2 kgf m 8 7 lb ft 12 N m 1 2 kgf m 8 7 lb ft 12 N m 1 2 kgf m 8 7 lb ft 1 5 N m 0 15 kgf m 1 1 lb ft 7 N m 0 7 kgf m 5 1 lb ft ...

Page 274: ...te 1 Install the clutch cover damper plate with its folded up side facing upward 2 Clutch cover damper 1 3 Circlip 1 4 Pull lever 1 5 Pull lever spring 1 6 Circlip 1 7 Pull lever shaft 1 8 Oil seal 1 9 Bearing 1 10 Bearing 1 3 4 5 6 7 8 9 10 E 1 2 LT LT 10 N m 1 0 kgf m 7 2 lb ft 10 N m 1 0 kgf m 7 2 lb ft ...

Page 275: ...late 1 3 Inside diameter 126 mm 4 96 in 8 Clutch plate 1 1 Inside diameter 116 mm 4 57 in 9 Clutch plate 2 7 Inside diameter 105 mm 4 13 in 10 Friction plate 2 6 Inside diameter 119 mm 4 69 in 11 Clutch damper spring 1 12 Clutch damper spring seat 1 13 Clutch boss nut 1 14 Conical spring washer 1 15 Washer 1 16 Clutch boss 1 1 2 3 4 7 7 10 8 9 E 5 6 11 12 13 14 15 16 LT E E E 11 12 10 N m 1 0 kgf ...

Page 276: ...b Parts to remove Q ty Remarks 17 Thrust plate 1 18 Clutch housing 1 19 Oil pump drive chain 1 20 Bearing 1 21 Spacer 1 22 Thrust plate 1 23 Thrust plate 1 E 17 18 19 20 21 22 23 LT E E E 10 N m 1 0 kgf m 7 2 lb ft 125 N m 12 5 kgf m 90 lb ft ...

Page 277: ...3 Remove Clutch spring bolts 1 Pressure plate 1 2 Clutch springs Pressure plate 2 3 Pull rod 4 4 Remove Friction plates 1 1 5 Remove Clutch plate 1 1 Clutch plates 2 Friction plates 2 Clutch damper spring Clutch damper spring seat 6 Straighten the clutch boss nut rib a 7 Loosen Clutch boss nut 1 TIP While holding the clutch boss 2 with the univer sal clutch holder 3 loosen the clutch boss nut 1 2 ...

Page 278: ...f the clutch plates 1 Check Clutch plate 1 2 Damage Replace the clutch plates as a set 2 Measure Clutch plate 1 2 thickness with a surface plate and thickness gauge 1 Out of specification Replace the clutch plates as a set 3 Measure Assembly width a of the friction plates and clutch plates Friction plate 1 thickness 2 92 3 08 mm 0 115 0 121 in Wear limit 2 82 mm 0 111 in Friction plate 2 thickness...

Page 279: ...clutch plate 2 EAS30351 CHECKING THE CLUTCH SPRINGS The following procedure applies to all of the clutch springs 1 Check Clutch spring Damage Replace the clutch springs as a set 2 Measure Clutch spring free length a Out of specification Replace the clutch springs as a set EAS30352 CHECKING THE CLUTCH HOUSING 1 Check Clutch housing dogs Damage pitting wear Deburr the clutch housing dogs or replace ...

Page 280: ...amage wear Replace EAS30356 CHECKING THE PRIMARY DRIVE GEAR 1 Check Primary drive gear Damage wear Replace the crankshaft and clutch housing as a set Excessive noise during operation Replace the crankshaft and clutch housing as a set EAS30357 CHECKING THE PRIMARY DRIVEN GEAR 1 Check Primary driven gear 1 Damage wear Replace the clutch housing and crankshaft as a set Excessive noise during operatio...

Page 281: ...ighten the clutch boss nut Stake the clutch boss nut at cutouts b in the main axle 3 Install Clutch damper spring seat Clutch damper spring Friction plates 1 Clutch plates 2 Friction plates 2 Clutch plate 1 TIP First install a friction plate and then alternate between a clutch plate and a friction plate Install the last friction plate 1 offset from the other friction plates 2 making sure to align ...

Page 282: ...ng to ward lower side When installing the pull lever push the pull le ver and check that the punch mark a on the pull lever aligns with the mark b on the clutch cover Make sure that the pull rod teeth and pull lever shaft pinion gear are engaged 7 Connect Clutch cable 1 TIP For the clutch cable 1 turn the nut 2 in fully and then adjust the length a by using the nut 3 so that the cable length is 47...

Page 283: ...CLUTCH 5 48 8 Adjust Clutch lever free play Refer to ADJUSTING THE CLUTCH LEVER FREE PLAY on page 3 12 Clutch lever free play 10 0 15 0 mm 0 39 0 59 in 1 2 3 a b c ...

Page 284: ...to CLUTCH on page 5 38 Shift arm Refer to CHAIN DRIVE on page 4 82 1 Circlip 1 2 Washer 1 3 Shift shaft 1 4 Washer 1 5 Circlip 1 6 Washer 1 7 Stopper lever 1 8 Stopper lever spring 1 9 Collar 1 10 Shift shaft spring 1 11 Shift shaft spring stopper 1 12 Oil seal 1 13 Bearing 1 3 4 5 6 7 8 9 10 11 LT E E 1 2 12 13 E E 22 N m 2 2 kgf m 16 lb ft ...

Page 285: ...hift shaft assembly Stopper lever spring 2 TIP Hook the end of the shift shaft spring 3 onto the shift shaft spring stopper 1 Hook the ends of the stopper lever spring 2 onto the stopper lever 4 and the crankcase boss 5 Mesh the stopper lever with the shift drum seg ment assembly 2 Install Bearing Oil seal Washer 1 Circlip 2 TIP Lubricate the oil seal lips with lithium soap based grease Lubricate ...

Page 286: ...oving the oil pump Order Job Parts to remove Q ty Remarks Clutch cover Refer to CLUTCH on page 5 38 1 Oil pump driven sprocket 1 2 Oil pump assembly 1 1 2 LT 10 N m 1 0 kgf m 7 2 lb ft 10 N m 1 0 kgf m 7 2 lb ft 15 N m 1 5 kgf m 11 lb ft ...

Page 287: ... Remarks 1 Oil pump cover 1 2 Oil pump shaft 1 3 Pin 1 4 Oil pump inner rotor 1 5 Oil pump outer rotor 1 6 Circlip 1 Hold down the washer when removing the circlip 7 Washer 1 8 Spring 1 9 Relief valve 1 10 Dowel pin 2 E 1 2 3 4 5 6 7 8 9 10 10 3 8 N m 0 38 kgf m 2 8 lb ft ...

Page 288: ...efec tive part s 2 Measure Inner rotor to outer rotor tip clearance a Outer rotor to oil pump housing clearance b Out of specification Replace the defective part s 3 Check Oil pump operation Rough movement Repeat steps 1 and 2 or replace the defective part s EAS30338 CHECKING THE RELIEF VALVE 1 Check Relief valve 1 Spring 2 Damage wear Replace the oil pump as sembly 1 2 Inner rotor to outer rotor ...

Page 289: ...3 INSTALLING THE OIL PUMP 1 Install Oil pump 1 Oil pump bolts 2 Oil pump driven sprocket 3 NOTICE ECA20940 After installing the oil pump drive chain and driven sprocket make sure the oil pump turns smoothly TIP 1RC mark of the oil pump driven sprocket is in stalled at oil pump side Install the oil pump drive chain onto the oil pump driven sprocket Recommended lubricant Engine oil Oil pump cover sc...

Page 290: ...Refer to FUEL TANK on page 7 1 Muffler assembly Refer to ENGINE REMOVAL on page 5 3 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 24 1 Oil level switch coupler 1 Disconnect 2 Oil level switch lead holder 1 3 Oil level switch 1 4 O2 sensor lead holder 1 5 Oil pan 1 6 Oil pan gasket 1 7 Oil strainer 1 1 2 3 4 5 6 7 LT 13 LT 10 N m 1 0 kgf m 7 2 lb ft 10 N m 1 0 kgf m 7 2 lb ft 43 N m 4...

Page 291: ... Replace Contaminants Clean with solvent EAS31070 INSTALLING THE OIL PAN 1 Install Oil pan gasket Oil pan 1 Oil level switch 2 Engine oil drain bolt 3 WARNING EWA12820 Always use new copper washers TIP Tighten the oil pan bolts in stages and in a crisscross pattern Lubricate the oil level switch O ring with lithi um soap based grease Oil pan bolt 10 N m 1 0 kgf m 7 2 lb ft Oil level switch bolt 10...

Page 292: ...rainer Refer to OIL PAN on page 5 55 1 Oil filter cartridge 1 2 Oil filter cartridge union bolt 1 3 Gear position switch 1 4 Clutch cable holder 1 5 Lower crankcase 1 6 Dowel pin 3 1 2 3 4 5 6 6 6 2 2 4 2 11 6 E E E E LT E LT 4 0 N m 0 40 kgf m 2 9 lb ft 10 N m 1 0 kgf m 7 2 lb ft 10 N m 1 0 kgf m 7 2 lb ft 12 N m 1 2 kgf m 8 7 lb ft 17 N m 1 7 kgf m 12 lb ft 24 N m 2 4 kgf m 17 lb ft 24 N m 2 4 k...

Page 293: ... shaft journal bearing from the lower crankcase TIP Identify the position of each part very carefully so that it can be reinstalled in its original place EAS30390 CHECKING THE CRANKCASE 1 Thoroughly wash the crankcase halves in a mild solvent 2 Thoroughly clean all the gasket surfaces and crankcase mating surfaces 3 Check Crankcase Cracks damage Replace Oil delivery passages Obstruction Blow out w...

Page 294: ...14 M6 85 mm 3 35 in bolt 18 M6 65 mm 2 56 in bolts 15 16 M6 65 mm 2 56 in bolt 26 M6 50 mm 1 97 in bolts 17 19 21 23 25 27 30 M6 40 mm 1 57 in bolt 22 7 Tighten Crankcase bolts 1 8 Following the tightening order loosen the bolt one by one and then retighten it to the specific torque WARNING EWA16610 If the bolt is tightened more than the speci fied angle do not loosen the bolt and then re tighten ...

Page 295: ...Tighten the bolts in the tightening sequence cast on the crankcase Crankcase bolts 9 14 24 N m 2 4 kgf m 17 lb ft Crankcase bolts 15 30 10 N m 1 0 kgf m 7 2 lb ft 8 1 2 3 4 5 6 7 8 T R 22 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 ...

Page 296: ...ve Q ty Remarks Lower crankcase Refer to CRANKCASE on page 5 57 1 Connecting rod cap 3 2 Big end lower bearing 3 3 Piston pin clip 6 4 Piston pin 3 5 Piston 3 6 Connecting rod 3 7 Big end upper bearing 3 8 Top ring 3 9 2nd ring 3 10 Oil ring 3 E 1 2 3 4 6 7 8 9 10 M M E E 3 E 5 1st 2nd 20 N m 2 0 kgf m 14 lb ft Specified angle 175 185 ...

Page 297: ...in out TIP For reference during installation put identifica tion marks on the piston crown Before removing the piston pin deburr the pis ton pin clip groove and the piston pin bore ar ea If both areas are deburred and the piston pin is still difficult to remove remove it with the piston pin puller set 4 3 Remove Top ring 2nd ring Oil ring TIP When removing a piston ring open the end gap with your ...

Page 298: ... set TIP Before measuring the piston ring side clearance eliminate any carbon deposits from the piston ring grooves and piston rings 2 Install Piston ring into the cylinder TIP Use the piston crown to level the piston ring near bottom of cylinder a where cylinder wear is lowest 3 Measure Piston ring end gap Bore 78 000 78 010 mm 3 0709 3 0713 in Wear limit 78 060 mm 3 0732 in C maximum of D1 D2 D3...

Page 299: ...e clearance Out of specification Replace the piston pin and piston as a set EAS30750 CHECKING THE CONNECTING RODS 1 Measure Crankshaft pin to big end bearing clearance Out of specification Replace the big end bearings Top ring End gap installed 0 15 0 25 mm 0 0059 0 0098 in End gap limit 0 50 mm 0 0197 in 2nd ring End gap installed 0 30 0 45 mm 0 0118 0 0177 in End gap limit 0 80 mm 0 0315 in b Up...

Page 300: ...bricate the bolt threads and seats with molybdenum disulfide oil Make sure that the projection a on the con necting rod cap faces the same direction as the Y mark b on the connecting rod After installing the big end bearing assemble the connecting rod and connecting rod cap without installing them onto the crankshaft TIP Install by carrying out the following procedures in order to assemble in the ...

Page 301: ...he specified angle j After the installation check that the section shown a is flush with each other by touching the surface k Remove the connecting rod and big end bearings l Measure the compressed Plastigauge width on the crankshaft pin If the crankshaft pin to big end bearing clearance is out of specification select replacement big end bearings 2 Select Big end bearings P1 P3 TIP The numbers A s...

Page 302: ...ghten the connecting rod bolts using the plastic region tightening angle method Al ways install new bolts TIP Install by carrying out the following procedures in order to assemble in the most suitable condition a Replace the connecting rod bolts with new ones b Clean the connecting rod bolts and lubricate the bolt threads and seats with molybdenum disulfide oil c After installing the big end beari...

Page 303: ...ers a face up 4 Install Piston 1 onto the respective connecting rod 2 Piston pin 3 Piston pin clips 4 TIP Apply engine oil onto the piston pin Make sure that the Y mark a on the connect ing rod faces left when the punch mark b on the piston is pointing up as shown Install the piston pin clips so that the clip ends are 3 mm 0 12 in c or more from the cutout in the piston Reinstall each piston into ...

Page 304: ...the connecting rods face towards the left side of the crank shaft Make sure that the projection b on the con necting rod cap faces the same direction as the Y mark a on the connecting rod Apply Molybdenum disulfide oil to the bolt threads and seats 10 Tighten Connecting rod bolts 1 TIP Tighten the connecting rod bolts using the fol lowing procedure a Tighten the connecting rod bolts with a torque ...

Page 305: ...re again NOTICE ECA20890 Do not use a torque wrench to tighten the bolt to the specified angle d After the installation check that the section shown a is flush with each other by touching the surface WARNING EWA17120 If the connecting rod and cap are not flush with each other remove the connecting rod bolts and big end bearing and restart from step 1 In this case make sure to replace the connectin...

Page 306: ...Lower crankcase Refer to CRANKCASE on page 5 57 Connecting rod Refer to REMOVING THE CONNECTING RODS AND PISTONS on page 5 62 1 Balancer shaft 1 2 Balancer shaft journal lower bearing 2 3 Balancer shaft journal upper bearing 2 4 Crankshaft 1 5 Crankshaft journal lower bearing 4 6 Crankshaft journal upper bearing 4 7 Oil nozzle 3 1 2 3 4 5 6 7 E 2 3 E 7 E E ...

Page 307: ...pin surfaces Bearing surfaces Scratches wear Replace the crankshaft 3 Measure Crankshaft journal to crankshaft journal bearing clearance Out of specification Replace the crank shaft journal bearings NOTICE ECA13920 Do not interchange the crankshaft journal bearings To obtain the correct crankshaft journal to crankshaft journal bearing clear ance and prevent engine damage the crank shaft journal be...

Page 308: ...crank shaft journal lower bearings h Measure the compressed Plastigauge width a on each crankshaft journal If the crankshaft journal to crankshaft jour nal bearing clearance is out of specification select replacement crankshaft journal bear ings 4 Select Crankshaft journal bearings J1 J4 TIP The numbers A stamped into the crankshaft web and the numbers B stamped into the lower crankcase are used t...

Page 309: ...e the balancer shaft journal bearings must be installed in their original positions a Clean the balancer shaft journal bearings balancer shaft journals and bearing portions of the crankcase b Place the upper crankcase upside down on a bench c Install the balancer shaft journal upper bear ings 1 and the balancer shaft into the upper crankcase TIP Align the projections a on the balancer shaft journa...

Page 310: ...ncer shaft jour nal bearing clearance is out of specification select replacement balancer shaft journal bearings 4 Select Balancer shaft journal bearing J1 J2 TIP The numbers A stamped into the balancer shaft web and the numbers B stamped into the lower crankcase are used to determine the replacement balancer shaft journal bearing siz es J1 J2 refer to the bearings shown in the bal ancer shaft and...

Page 311: ...THE BALANCER ASSEMBLY 1 Install Balancer shaft journal upper bearings into the upper crankcase Balancer shaft journal lower bearings into the lower crankcase TIP Align the projections a on the balancer shaft journal bearings 1 with the notches b in the crankcases Be sure to install each balancer shaft journal bearing in its original place 2 Install Balancer shaft TIP Install by aligning the cranks...

Page 312: ...SE on page 5 57 1 Drive axle assembly 1 2 Oil seal 1 3 Bearing 1 4 Washer 1 5 Shift drum retainer 2 6 Shift fork guide bar 2 7 Shift fork L 1 8 Shift fork R 1 9 Shift drum assembly 1 10 Shift fork C 1 11 Main axle assembly 1 12 Bearing 1 1 2 3 4 5 6 7 8 9 10 11 E LT LT LT E E E E E 5 6 LT E 12 10 N m 1 0 kgf m 7 2 lb ft 10 N m 1 0 kgf m 7 2 lb ft 12 N m 1 2 kgf m 8 7 lb ft ...

Page 313: ... pinion gear 1 2 Toothed lock washer 1 3 Toothed lock washer retainer 1 4 6th pinion gear 1 5 Collar 1 6 Washer 1 7 Circlip 1 8 3rd pinion gear 1 9 Circlip 1 10 Washer 1 11 5th pinion gear 1 12 Collar 1 13 Bearing housing 1 14 Bearing 1 15 Main axle 1 9 10 12 15 13 14 7 8 6 5 4 3 2 1 11 E M M M M M M ...

Page 314: ...lar 1 5 5th wheel gear 1 6 Circlip 1 7 Washer 1 8 3rd wheel gear 1 9 Collar 1 10 Toothed lock washer 1 11 Toothed lock washer retainer 1 12 4th wheel gear 1 13 Collar 1 14 Washer 1 15 Circlip 1 16 6th wheel gear 1 17 Circlip 1 18 Washer 1 19 Collar 1 20 2nd wheel gear 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 M M E M E M M M M M M ...

Page 315: ...TRANSMISSION 5 80 Disassembling the drive axle assembly Order Job Parts to remove Q ty Remarks 21 Collar 1 22 Bearing 1 23 Circlip 1 24 Drive axle 1 21 M M E M E 22 23 24 M M M M M M ...

Page 316: ...ontinue tightening the bolts until the main axle assembly comes free from the upper crankcase 3 Remove Bearing 1 EAS30431 CHECKING THE SHIFT FORKS The following procedure applies to all of the shift forks 1 Check Shift fork cam follower 1 Shift fork pawl 2 Bends damage scoring wear Replace the shift fork 2 Check Shift fork guide bar Roll the shift fork guide bar on a flat surface Bends Replace WAR...

Page 317: ...of specification Replace the drive axle 3 Check Transmission gears Blue discoloration pitting wear Replace the defective gear s Transmission gear dogs Cracks damage rounded edges Replace the defective gear s 4 Check Transmission gear engagement each pinion gear to its respective wheel gear Incorrect Reassemble the transmission axle assemblies 5 Check Transmission gear movement Rough movement Repla...

Page 318: ...ve a in the axle align the projection on the retainer with an axle spline and then install the toothed lock washer Be sure to align the projection on the toothed lock washer that is between the alignment marks b with the alignment mark c on the re tainer EAS30438 INSTALLING THE TRANSMISSION 1 Install Bearing 1 TIP Face the seal side of bearing to the outside 2 Install Main axle assembly 1 Bearing ...

Page 319: ... Shift drum retainers 3 Bearing Oil seal Circlip 4 Drive axle assembly 5 TIP Install shift fork R into the groove a in the 5th wheel gear and shift fork L into the groove b in the 6th wheel gear on the drive axle Install the shift drum retainer with its OUT mark c facing outward Touch the protrusion d on the shift fork guide bar to the side of the shift drum retainer Make sure that the drive axle ...

Page 320: ...TRANSMISSION 5 85 ...

Page 321: ...G THE RADIATOR 6 2 OIL COOLER 6 4 CHECKING THE OIL COOLER 6 5 INSTALLING THE OIL COOLER 6 5 THERMOSTAT 6 6 CHECKING THE THERMOSTAT 6 7 INSTALLING THE THERMOSTAT ASSEMBLY 6 7 WATER PUMP 6 8 DISASSEMBLING THE WATER PUMP 6 10 CHECKING THE WATER PUMP 6 10 ASSEMBLING THE WATER PUMP 6 10 ...

Page 322: ...lant reservoir cover 1 3 Coolant reservoir 1 4 Coolant reservoir cap 1 5 Radiator cap 1 6 Radiator fan motor coupler 1 Disconnect 7 Radiator hose cylinder head to radiator 1 Disconnect 8 Radiator inlet hose 1 Disconnect 9 Radiator outlet hose 1 Disconnect 10 Radiator 1 11 Radiator fan cover 1 12 Radiator fan 1 13 Radiator stay 1 1 2 3 4 5 6 7 8 9 10 LT 11 12 13 0 5 N m 0 05 kgf m 0 36 lb ft 9 N m ...

Page 323: ...Replace Malfunction Check and repair Refer to COOLING SYSTEM on page 8 29 EAS30440 INSTALLING THE RADIATOR 1 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 27 2 Check Cooling system Leaks Repair or replace any faulty part a Attach the radiator cap tester 1 and radiator cap tester adapter 2 to the radiator b Apply 122 7 kPa 1 23 kgf...

Page 324: ...TOR 6 3 pressure c Measure the indicated pressure with the gauge 3 Measure Radiator cap valve opening pressure Below the specified pressure Replace the radiator cap Refer to CHECKING THE RADIATOR on page 6 2 ...

Page 325: ...r assembly Refer to ENGINE REMOVAL on page 5 3 Coolant Drain Refer to CHANGING THE COOLANT on page 3 27 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 24 1 Radiator inlet hose 1 2 Oil cooler inlet hose 1 3 Oil cooler outlet hose 1 4 Oil cooler 1 5 Water jacket joint 1 LT 1 2 3 4 5 10 N m 1 0 kgf m 7 2 lb ft 10 N m 1 0 kgf m 7 2 lb ft LT LT ...

Page 326: ...p based grease to the O ring Make sure the O ring is positioned properly 3 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 27 Crankcase with the specified amount of the recom mended engine oil Refer to CHANGING THE ENGINE OIL on page 3 24 4 Check Cooling system Leaks Repair or replace any faulty part Refer to INSTALLING THE RADIATOR...

Page 327: ...ts to remove Q ty Remarks Muffler assembly Refer to ENGINE REMOVAL on page 5 3 Coolant Drain Refer to CHANGING THE COOLANT on page 3 27 1 Radiator outlet hose 1 2 Water pump inlet hose 1 3 Oil cooler outlet hose 1 Disconnect 4 Thermostat assembly 1 1 2 3 4 10 N m 1 0 kgf m 7 2 lb ft ...

Page 328: ...y 2 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 27 3 Check Cooling system Leaks Repair or replace any faulty part Refer to INSTALLING THE RADIATOR on page 6 2 4 Measure Radiator cap valve opening pressure Below the specified pressure Replace the radiator cap Refer to CHECKING THE RADIATOR on page 6 2 1 ...

Page 329: ...6 WATER PUMP Removing the water pump Order Job Parts to remove Q ty Remarks Coolant Drain Refer to CHANGING THE COOLANT on page 3 27 1 Water pump inlet hose 1 Disconnect 2 Water pump assembly 1 1 2 12 N m 1 2 kgf m 8 7 lb ft ...

Page 330: ...r Job Parts to remove Q ty Remarks 1 Water pump housing cover 1 2 O ring 1 3 Circlip 1 4 Water pump driven gear 1 5 Pin 1 6 Washer 1 7 Impeller shaft 1 8 Mechanical seal 1 9 Bearing 1 10 Oil seal 1 E E 1 2 3 4 5 6 7 8 9 10 10 N m 1 0 kgf m 7 2 lb ft ...

Page 331: ...EAS30447 CHECKING THE WATER PUMP 1 Check Water pump housing cover 1 Impeller shaft 2 Cracks damage wear Replace Water pump housing 3 Cracks damage wear Replace the water pump assembly 2 Check Bearing Rough movement Replace 3 Check Water pump inlet hose Cracks damage wear Replace EAS30448 ASSEMBLING THE WATER PUMP 1 Install Oil seal 1 Bearing 2 into the water pump housing 3 TIP Install the oil seal...

Page 332: ... the mechanical seal is dirty clean it 4 Measure Impeller shaft tilt Out of specification Repeat steps 3 and 4 NOTICE ECA20340 Make sure the mechanical seal impeller side is flush with the impeller Mechanical seal installer 90890 04078 Water pump seal installer YM 33221 A Middle driven shaft bearing driver 90890 04058 Middle drive bearing installer 40 50 mm YM 04058 2 Water pump housing 3 Mechanic...

Page 333: ...FUEL HOSE FUEL RAIL SIDE 7 8 REMOVING THE INJECTORS 7 8 CHECKING THE INJECTORS 7 8 CHECKING AND CLEANING THE THROTTLE BODIES 7 8 REPLACING THE THROTTLE BODIES 7 10 INSTALLING THE INJECTORS 7 10 CHECKING THE INJECTOR PRESSURE 7 10 CHECKING THE FUEL PRESSURE 7 11 INSTALLING THE FUEL HOSE FUEL RAIL SIDE 7 12 ADJUSTING THE THROTTLE POSITION SENSOR 7 12 ADJUSTING THE ACCELERATOR POSITION SENSOR 7 13 AI...

Page 334: ... 2 Fuel pump coupler 1 Disconnect 3 Fuel tank breather hose 1 Disconnect 4 Fuel tank drain hose 1 Disconnect 5 Fuel tank 1 6 Fuel pump bracket 1 7 Fuel pump 1 8 Fuel pump gasket 1 9 Wire harness assembly left 1 10 Air scoop stay left 1 11 Wire harness assembly right 1 12 Air scoop stay right 1 1 2 3 4 5 5 6 7 8 9 10 11 12 2 4 2 2 2 2 2 2 4 0 N m 0 40 kgf m 2 9 lb ft 7 N m 0 7 kgf m 5 1 lb ft 7 N m...

Page 335: ... 1 Air scoop Fuel tank cover Refer to GENERAL CHASSIS 2 on page 4 7 Fuel tank Refer to FUEL TANK on page 7 1 1 Canister purge hose hose joint to canister 1 2 Fuel tank breather hose fuel tank to canister 1 3 Canister holder 1 4 Canister 1 5 Canister breather hose 1 6 Canister bracket 1 1 2 3 4 5 6 7 N m 0 7 kgf m 5 1 lb ft ...

Page 336: ...tion b slide the fuel hose connector cover in direction c and then remove the hose from the fuel pump Before removing the hose place a few rags in the area under where it will be removed It is prohibited to wear the cotton work gloves or equivalent coverings 4 Remove Fuel tank TIP Do not set the fuel tank down so that the instal lation surface of the fuel pump is directly under the tank Be sure to...

Page 337: ...the proper tight ening sequence as shown EAS30457 INSTALLING THE FUEL TANK 1 Connect Fuel hose fuel tank side NOTICE ECA17500 When installing the fuel hose make sure that it is securely connected and that the fuel hose connector cover on the fuel hose is in the correct position otherwise the fuel hose will not be properly installed TIP Install the fuel hose onto the fuel pump secure ly and slide t...

Page 338: ...ose 1 2 Intake air pressure sensor 1 coupler 1 Disconnect 3 Intake air pressure sensor 2 coupler 1 Disconnect 4 Accelerator position sensor coupler 1 Disconnect 5 Throttle servo motor coupler 1 Disconnect 6 Throttle position sensor coupler 1 Disconnect 7 Throttle cable accelerator cable 1 Disconnect Black 8 Throttle cable decelerator cable 1 Disconnect 9 Throttle body joint clamp screw 6 Loosen 10...

Page 339: ...gative pressure hose 6 2 Hose joint 2 3 Canister purge hose 4 4 Hose joint 2 5 Intake air pressure sensor 2 1 6 Intake air pressure sensor 1 1 7 Throttle position sensor 1 8 Accelerator position sensor 1 1 1 1 3 5 6 7 8 3 3 4 2 3 5 N m 0 35 kgf m 2 5 lb ft 3 5 N m 0 35 kgf m 2 5 lb ft ...

Page 340: ...hrottle bodies Throttle body joint Refer to THROTTLE BODIES on page 7 5 1 Fuel rail 1 2 Injector 3 3 Injector coupler 2 Disconnect 4 Injector lead 1 5 Injector lead coupler 1 Disconnect 6 Wire harness 1 7 Adapter 1 3 5 6 1 4 2 3 2 7 5 N m 0 5 kgf m 3 6 lb ft 12 N m 1 2 kgf m 8 7 lb ft ...

Page 341: ...ted area free of combustible materials Make sure that there is no smoking or use of electric tools in the vicinity of the injectors Be careful when disconnecting the fuel hose Any remaining pressure in the fuel hose may cause the fuel to spray out Place a container or rag under the hose to catch any fuel that spills Always clean up any spilt fuel immediately Turn the main switch to OFF and discon ...

Page 342: ...gs a c Hold the throttle valves in the open position WARNING EWA15940 When cleaning the throttle bodies be careful not to injure yourself on the throttle valves or other components of the throttle bodies NOTICE ECA20380 Do not open the throttle valves by supply ing electrical power to the throttle bodies Do not use tools to open the throttle valves or to keep them in the open position Do not open ...

Page 343: ... Place the vehicle on a maintenance stand so that the rear wheel is elevated 6 Check Engine idling speed Start the engine warm it up and then mea sure the engine idling speed EAS30480 INSTALLING THE INJECTORS NOTICE ECA21550 Always use new O rings When installing the injectors do not allow any foreign material to enter or adhere to the injectors fuel rails or O rings Be careful not to twist or pin...

Page 344: ... THE FUEL PRESSURE 1 Check Fuel pressure a Remove the rider seat air scoop and fuel tank cover Refer to GENERAL CHASSIS 1 on page 4 1 b Remove the fuel tank bolt and hold up the fuel tank c Disconnect the fuel hose 1 from the fuel pump Refer to REMOVING THE FUEL TANK on page 7 3 WARNING EWA17320 Cover fuel hose connections with a cloth when disconnecting them Residual pres sure in the fuel lines c...

Page 345: ...on sensor to strong shocks If the throttle position sensor is dropped replace it 1 Check Throttle position sensor Refer to CHECKING THE THROTTLE PO SITION SENSOR on page 8 170 2 Adjust Throttle position sensor angle TIP Before adjusting the throttle position sensor the throttle bodies must be removed a Temporary tighten the throttle position sensor screws b Check that the throttle valves are fully...

Page 346: ...tic code number 14 is selected g Turn the throttle grip to the fully closed posi tion h Adjust the position of the accelerator position sensor angle so that 12 22 can appear in the Yamaha diagnostic tool screen i After adjusting the accelerator position sen sor angle tighten the accelerator position sensor bolts 2 j Turn the throttle grip to the fully open position k Check the Yamaha diagnostic to...

Page 347: ...THROTTLE BODIES 7 14 r If the Yamaha diagnostic tool screen values are not within the specified ranges after re peating steps f to p several times replace the accelerator position sensor ...

Page 348: ...AIR INDUCTION SYSTEM 7 15 EAS20071 AIR INDUCTION SYSTEM 1 2 3 2 3 4 4 ...

Page 349: ...AIR INDUCTION SYSTEM 7 16 1 Air filter case 2 Air induction system hose air filter case to air cut off valve 3 Air cut off valve 4 Air induction system hose air cut off valve to reed valve cover ...

Page 350: ...l Refer to GENERAL CHASSIS 1 on page 4 1 Radiator Refer to RADIATOR on page 6 1 1 Air cut off valve coupler 1 Disconnect 2 Air induction system hose air cut off valve to reed valve cover 1 3 Air induction system hose air cut off valve to reed valve cover 1 4 Air induction system hose air filter case to air cut off valve 1 5 Air cut off valve 1 6 Air cut off valve holder 1 7 Reed valve cover 1 8 Re...

Page 351: ...EM 7 18 Removing the air cut off valve assembly and reed valves Order Job Parts to remove Q ty Remarks 11 Reed valve assembly 2 1 12 Reed valve plate 2 LT 11 LT LT 12 10 N m 1 0 kgf m 7 2 lb ft 10 N m 1 0 kgf m 7 2 lb ft ...

Page 352: ...mperature is below the specified value the air cut off valve remains open and allows the air to flow into the exhaust pipe until the temperature becomes higher than the specified value 1 Check Hoses Loose connections Connect properly Cracks damage Replace 2 Check Reed valve Reed valve stopper Reed valve seat Cracks damage Replace the reed valve assembly 3 Measure Reed valve bending limit a Out of ...

Page 353: ... that the open side turns to the exhaust side of the en gine Install the reed valve assembly 2 so that the open side turns to the intake side of the engine 3 Install Reed valve cover A Reed valve assembly 1 B Reed valve assembly 2 C Exhaust side Reed valve cover bolt 10 N m 1 0 kgf m 7 2 lb ft LOCTITE 1 c d d A C B C T R ...

Page 354: ...AIR INDUCTION SYSTEM 7 21 ...

Page 355: ...NG 8 19 SIGNALING SYSTEM 8 21 CIRCUIT DIAGRAM 8 21 TROUBLESHOOTING 8 23 COOLING SYSTEM 8 29 CIRCUIT DIAGRAM 8 29 TROUBLESHOOTING 8 31 FUEL INJECTION SYSTEM 8 33 CIRCUIT DIAGRAM 8 33 ECU SELF DIAGNOSTIC FUNCTION 8 35 TROUBLESHOOTING METHOD 8 35 YAMAHA DIAGNOSTIC TOOL 8 36 TROUBLESHOOTING DETAILS FAULT CODE 8 37 FUEL PUMP SYSTEM 8 105 CIRCUIT DIAGRAM 8 105 TROUBLESHOOTING 8 107 IMMOBILIZER SYSTEM 8 ...

Page 356: ...ne Control Unit 8 157 CHECKING AND CHARGING THE BATTERY 8 158 CHECKING THE RELAYS 8 161 CHECKING THE TURN SIGNAL HAZARD RELAY 8 162 CHECKING THE RELAY UNIT DIODE 8 163 CHECKING THE IGNITION COILS 8 163 CHECKING THE IGNITION SPARK GAP 8 164 CHECKING THE CRANKSHAFT POSITION SENSOR 8 164 CHECKING THE LEAN ANGLE SENSOR 8 165 CHECKING THE STARTER MOTOR OPERATION 8 165 CHECKING THE STATOR COIL 8 166 CHE...

Page 357: ......

Page 358: ...IGNITION SYSTEM 8 1 EAS20072 IGNITION SYSTEM EAS30490 CIRCUIT DIAGRAM ...

Page 359: ...nector 24 Joint coupler 25 Relay unit 30 ECU Engine Control Unit 31 Ignition coil 1 32 Ignition coil 2 33 Ignition coil 3 34 Spark plug 40 Crankshaft position sensor 45 Lean angle sensor 70 Gear position switch 73 Sidestand switch 74 Handlebar switch right 76 Start engine stop switch A Wire harness D Negative battery sub wire harness ...

Page 360: ...sition switch neutral circuit and sidestand switch are set to OFF thereby preventing the spark plugs from producing a spark However the engine continues to run under the following con ditions The transmission is in gear the neutral circuit of the gear position switch is open and the sidestand is up the sidestand switch circuit is closed The transmission is in neutral the neutral circuit of the gea...

Page 361: ...y 2 Main fuse 3 Main switch 4 Ignition fuse 5 Start engine stop switch 6 Ignition coil 7 Spark plug 8 ECU Engine Control Unit 9 Sidestand switch 10 Relay unit diode 11 Gear position switch neutral circuit 12 Battery negative lead ...

Page 362: ...OK 3 Check the spark plugs Refer to CHECKING THE SPARK PLUGS on page 3 5 NG Re gap or replace the spark plugs OK 4 Check the ignition spark gap Refer to CHECKING THE IGNI TION SPARK GAP on page 8 164 OK Ignition system is OK NG 5 Check the ignition coils Refer to CHECKING THE IGNI TION COILS on page 8 163 NG Replace the ignition coils OK 6 Check the crankshaft position sen sor Refer to CHECKING TH...

Page 363: ...OK 11 Check the relay unit diode Refer to CHECKING THE RELAY UNIT DIODE on page 8 163 NG Replace the relay unit OK 12 Check the lean angle sensor Refer to CHECKING THE LEAN ANGLE SENSOR on page 8 165 NG Replace the lean angle sensor OK 13 Check the entire ignition system s wiring Refer to CIRCUIT DIAGRAM on page 8 1 NG Properly connect or repair the ignition sys tem s wiring OK Replace the ECU Ref...

Page 364: ...ELECTRIC STARTING SYSTEM 8 7 EAS20073 ELECTRIC STARTING SYSTEM EAS30493 CIRCUIT DIAGRAM ...

Page 365: ...system fuse 21 Starter relay 22 Starter motor 23 Joint connector 24 Joint coupler 25 Relay unit 26 Starting circuit cut off relay 70 Gear position switch 73 Sidestand switch 74 Handlebar switch right 76 Start engine stop switch 81 Handlebar switch left 82 Clutch switch A Wire harness D Negative battery sub wire harness ...

Page 366: ...losed The clutch lever is pulled to the handlebar the clutch switch is closed and the sidestand is up the sidestand switch is closed The starting circuit cut off relay prevents the starter motor from operating when neither of these condi tions has been met In this instance the starting circuit cut off relay is open so current cannot reach the starter motor When at least one of the above conditions...

Page 367: ...IS UP AND THE CLUTCH LEVER IS PULLED TO THE HAN DLEBAR 1 Battery 2 Main fuse 3 Main switch 4 Ignition fuse 5 Start engine stop switch 6 Starting circuit cut off relay 7 Diode 8 Clutch switch 9 Sidestand switch 10 Gear position switch neutral circuit 11 Diode 12 Starter relay 13 Starter motor ...

Page 368: ...n Refer to CHECKING THE START ER MOTOR OPERATION on page 8 165 OK Starter motor is OK Perform the electric starting system troubleshooting starting with step 5 NG 4 Check the starter motor Refer to CHECKING THE START ER MOTOR on page 5 36 NG Repair or replace the starter motor OK 5 Check the relay unit starting circuit cut off relay Refer to CHECKING THE RE LAYS on page 8 161 NG Replace the relay ...

Page 369: ...Replace the sidestand switch OK 11 Check the clutch switch Refer to CHECKING THE SWITCHES on page 8 153 NG Replace the clutch switch OK 12 Check the start engine stop switch Refer to CHECKING THE SWITCHES on page 8 153 NG Replace the handlebar switch right OK 13 Check the entire starting system s wiring Refer to CIRCUIT DIAGRAM on page 8 7 NG Properly connect or repair the starting sys tem s wirin...

Page 370: ...CHARGING SYSTEM 8 13 EAS20074 CHARGING SYSTEM EAS30496 CIRCUIT DIAGRAM ...

Page 371: ...CHARGING SYSTEM 8 14 1 AC magneto 2 Rectifier regulator 4 Main fuse 18 Battery 19 Engine ground A Wire harness D Negative battery sub wire harness ...

Page 372: ...E BATTERY on page 8 158 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 8 166 NG Replace the stator coil assembly OK 4 Check the rectifier regulator Refer to CHECKING THE RECTI FIER REGULATOR on page 8 166 NG Replace the rectifier regulator OK 5 Check the entire charging system s wiring Refer to CIRCUIT DIAGRAM on...

Page 373: ...CHARGING SYSTEM 8 16 ...

Page 374: ...LIGHTING SYSTEM 8 17 EAS20075 LIGHTING SYSTEM EAS30498 CIRCUIT DIAGRAM ...

Page 375: ...gine Control Unit 53 Meter assembly 56 Meter light 57 High beam indicator light 81 Handlebar switch left 86 Pass switch 87 Dimmer switch 93 Headlight assembly 94 Headlight control unit 95 Headlight high beam 96 Headlight low beam 97 Auxiliary light 98 License plate light 99 Tail brake light A Wire harness D Negative battery sub wire harness E Sub wire harness License plate light ...

Page 376: ...Check the fuses Main headlight ignition and signal ing system Refer to CHECKING THE FUSES on page 8 156 NG Replace the fuse s OK 3 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 158 NG Clean the battery terminals Recharge or replace the battery OK 4 Check the main switch Refer to CHECKING THE SWITCHES on page 8 153 NG Replace the main switch immobilizer unit OK 5 Check the ...

Page 377: ...g system s wiring Refer to CIRCUIT DIAGRAM on page 8 17 NG Properly connect or repair the lighting sys tem s wiring OK Replace the ECU meter assembly headlight assembly or tail brake light Refer to REPLACING THE ECU Engine Control Unit on page 8 157 ...

Page 378: ...SIGNALING SYSTEM 8 21 EAS20076 SIGNALING SYSTEM EAS30500 CIRCUIT DIAGRAM ...

Page 379: ...e trouble warning light 63 Coolant temperature warning light 65 Quick shift indicator light 66 Turn signal indicator light left 67 Turn signal indicator light right 69 Oil level switch 70 Gear position switch 71 Fuel sender 74 Handlebar switch right 77 Hazard switch 78 Front brake light switch 79 Rear brake light switch 80 Turn signal hazard relay 81 Handlebar switch left 84 Horn switch 85 Turn si...

Page 380: ...ghting Refer to CHECKING THE FUSES on page 8 156 NG Replace the fuse s OK 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 158 NG Clean the battery terminals Recharge or replace the battery OK 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 153 NG Replace the main switch immobilizer unit OK 4 Check the entire signaling system s wiring Refer to CIRCUIT DIAGR...

Page 381: ...ar brake light switch OK 3 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 8 21 NG Properly connect or repair the signaling system s wiring OK This circuit is OK 1 Check the turn signal light bulb and socket Refer to CHECKING THE BULBS AND BULB SOCKETS on page 8 156 NG Replace the turn signal light bulb s sock et s or both OK 2 Check the turn signal switch Refer to CHEC...

Page 382: ...OK 2 Check the relay unit diode Refer to CHECKING THE RELAY UNIT DIODE on page 8 163 NG Replace the relay unit OK 3 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 8 21 NG Properly connect or repair the signaling system s wiring OK Replace the meter assembly 1 Check the oil level switch Refer to CHECKING THE SWITCHES on page 8 153 NG Replace the oil level switch OK 2 Ch...

Page 383: ... sure that the QS is effective Check whether the QS icon is dis played at the top of the meter NG Activate the QS Set the QS to a setting other than OFF OK 4 Check that the shift switch coupler is connected NG Connect the shift switch coupler OK 5 Check the shift switch Refer to DIAGNOSTIC CODE SENSOR OPERATION TABLE on page 9 13 and CHECKING THE SWITCHES on page 8 153 NG Replace the shift switch ...

Page 384: ...HE REAR WHEEL SENSOR AND SENSOR ROTOR on page 4 22 NG Replace the rear wheel sensor OK 2 Check the entire wheel sensor wir ing Refer to TIP NG Properly connect or repair the wheel sen sor wiring OK Replace the hydraulic unit assembly ECU meter assembly Refer to REPLACING THE ECU Engine Control Unit on page 8 157 1 Check the coolant temperature sen sor Refer to CHECKING THE COOL ANT TEMPERATURE SEN...

Page 385: ...SIGNALING SYSTEM 8 28 ...

Page 386: ...COOLING SYSTEM 8 29 EAS20077 COOLING SYSTEM EAS30502 CIRCUIT DIAGRAM ...

Page 387: ...tion fuse 18 Battery 19 Engine ground 23 Joint connector 24 Joint coupler 30 ECU Engine Control Unit 42 Coolant temperature sensor 100 Radiator fan motor relay 101 Radiator fan motor A Wire harness C Sub wire harness Coolant temperature sen sor D Negative battery sub wire harness ...

Page 388: ...r to CHECKING THE SWITCHES on page 8 153 NG Replace the main switch immobilizer unit OK 4 Check the radiator fan motor Refer to CHECKING THE RADIA TOR FAN MOTOR on page 8 169 NG Replace the radiator fan motor s OK 5 Check the radiator fan motor relay Refer to CHECKING THE RE LAYS on page 8 161 NG Replace the radiator fan motor relay OK 6 Check the coolant temperature sen sor Refer to CHECKING THE ...

Page 389: ...COOLING SYSTEM 8 32 ...

Page 390: ...FUEL INJECTION SYSTEM 8 33 EAS20078 FUEL INJECTION SYSTEM EAS30504 CIRCUIT DIAGRAM ...

Page 391: ...t temperature sensor 43 Intake air pressure sensor 1 44 Intake air pressure sensor 2 45 Lean angle sensor 47 Rear wheel sensor 48 ABS ECU electronic control unit 49 Throttle servo motor 50 Accelerator position sensor 51 Throttle position sensor 52 Yamaha diagnostic tool coupler 53 Meter assembly 59 Multi function meter 62 Engine trouble warning light 64 Traction control system indicator light 70 G...

Page 392: ...gine to continue operating or stop operating depending on the conditions EAS30506 TROUBLESHOOTING METHOD The engine operation is not normal and the engine trouble warning light comes on 1 Check Fault code number a Check the fault code numbers that have a condition of Detected using the Yamaha diagnostic tool b Identify the faulty system with the fault code number c Identify the probable cause of t...

Page 393: ...eth ods By connecting the adapter interface which is connected to the USB port of a computer to a vehicle s ECU using the communication cable you can display information that is necessary for identifying mal functions and for maintenance to display on the computer The displayed information includes the sen sor output data and information recorded in the ECU 01 Throttle position sensor signal 1 thr...

Page 394: ...e 9 5 Diagnosis of malfunction Fault codes recorded on the ECU are read and the contents are dis played The freeze frame data FFD is the operation data when a malfunction was detected This data can be used to identify when the malfunction occurred and check the engine conditions and running conditions when it occurred Diagnosis of function Check the operation of the output value of each sensor and...

Page 395: ...2 first If fault code numbers P0030 and P0223 are both indicated take the actions specified for fault code number P0223 first If fault code numbers P0030 and P2135 are both indicated take the actions specified for fault code number P2135 first Crankshaft position sensor Intake air temperature sensor Fuel injector 1 O2 sensor Fuel injector 2 Lean angle sensor Fuel injector 3 ABS ECU electronic cont...

Page 396: ...n of the fault code using the mal function mode of the Yamaha diagnostic tool Condition is Recovered Go to item 6 and finish the service Condition is Detected Start the engine and then check the condition of the fault code Condition is Recovered Go to item 6 and finish the service Condition is Detected Go to item 3 TIP For this check also set the start engine stop switch to ON 3 Wire harness conti...

Page 397: ...tem P0107 Intake air pressure sensor 1 ground short circuit detected P0108 Intake air pressure sensor 1 open or power short circuit detected Fail safe system Able to start engine Able to drive vehicle Diagnostic code No 03 Tool display Displays the intake air pressure 1 Procedure Operate the throttle while pushing the side of the start engine stop switch If the display value changes the performanc...

Page 398: ...to ON and then check the condition of the fault code using the mal function mode of the Yamaha diagnostic tool Condition is Recovered Go to item 7 and finish the service Condition is Detected Go to item 4 3 1 1 Intake air pressure sensor 1 2 ECU 3 Sensor input lead 4 Sensor output lead 5 Sensor ground lead 3 2 Disconnect the ECU coupler from the ECU Disconnect the intake air pressure sensor 1 coup...

Page 399: ...uity replace the wire harness 3 6 For P0108 Open circuit Between intake air pressure sensor 1 coupler and ECU coupler black blue black blue If there is no continuity replace the wire harness 3 7 Disconnect the couplers from the parts that are connected to the ECU Refer to Parts connected to the ECU on page 8 38 Fault code No P0107 P0108 Item P0107 Intake air pressure sensor 1 ground short circuit ...

Page 400: ...level Approx 101 kPa 757 6 mmHg 29 8 inHg 1000 m 3300 ft above sea level Approx 90 kPa 675 1 mmHg 26 6 inHg 2000 m 6700 ft above sea level Approx 80 kPa 600 0 mmHg 23 6 inHg 3000 m 9800 ft above sea level Approx 70 kPa 525 0 mmHg 20 7 inHg When engine is cranking Make sure that the indication value changes The value does not change when engine is cranking Check the intake air pressure sensor 1 Rep...

Page 401: ... coupler securely or replace the wire harness Turn the main switch to ON and then check the condition of the fault code using the mal function mode of the Yamaha diagnostic tool Condition is Recovered Go to item 7 and finish the service Condition is Detected Go to item 2 2 Connection of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken ...

Page 402: ...take air temperature sensor coupler and ground brown white ground If there is continuity replace the wire harness 3 4 For P0113 Open circuit Between intake air temperature sensor coupler and ECU coupler brown white brown white If there is no continuity replace the wire harness Fault code No P0112 P0113 Item P0112 Intake air temperature sensor ground short circuit detected P0113 Intake air temperat...

Page 403: ...fault code using the mal function mode of the Yamaha diagnostic tool Condition is Recovered Go to item 7 and finish the service Condition is Detected Go to item 5 5 Defective intake air tempera ture sensor Execute the diagnostic mode Code No 05 When engine is cold Displayed temperature is close to the ambient temperature The displayed temperature is not close to the ambient temper ature Check the ...

Page 404: ...of service com pletion 1 Connection of coolant tempera ture sensor coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the coupler securely or replace the wire harness Turn the main switch to ON and then check the condition of the fault code using the mal function mode ...

Page 405: ...er from the ECU Disconnect the coolant temperature sensor coupler from the coolant temperature sensor 3 3 For P0117 Ground short circuit Between wire harness coupler ECU side and ground green white ground Between sub wire harness coupler coolant temperature sensor side and ground green white ground If there is continuity replace the wire harness and or sub wire harness A Wire harness coupler White...

Page 406: ...rness coupler ECU side and ECU coupler black blue black blue Between sub wire harness coupler coolant temperature sensor side and coolant temperature sen sor coupler black blue black blue If there is no continuity replace the wire harness and or sub wire harness A Wire harness coupler ECU side B Sub wire harness coupler coolant temperature sensor side 3 6 Disconnect the couplers from the parts tha...

Page 407: ...nt temperature sensor Execute the diagnostic mode Code No 06 When engine is cold Displayed temperature is close to the ambient temperature The displayed temperature is not close to the ambient temper ature Check the coolant tem perature sensor Replace if defective Refer to CHECKING THE COOLANT TEMPERATURE SENSOR on page 8 169 Turn the main switch to ON and then check the condition of the fault cod...

Page 408: ...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 condition of the pins Improperly connected Con nect the coupler securely or replace the wire harness Turn the main switch to ON and then check the condition of the fault code using the mal function mod...

Page 409: ...een throttle position sensor coupler and ground white ground If there is continuity replace the wire harness Fault code No P0122 P0123 P0222 P0223 P2135 Item P0122 Throttle position sensor ground short circuit detected P0123 Throttle position sensor open or power short circuit detected P0222 Throttle position sensor ground short circuit detected P0223 Throttle position sensor open or power short c...

Page 410: ...ess 3 6 For P0223 Open circuit Between throttle position sensor coupler and ECU coupler black black If there is no continuity replace the wire harness Fault code No P0122 P0123 P0222 P0223 P2135 Item P0122 Throttle position sensor ground short circuit detected P0123 Throttle position sensor open or power short circuit detected P0222 Throttle position sensor ground short circuit detected P0223 Thro...

Page 411: ... Refer to Parts connected to the ECU on page 8 38 3 10 For P0122 P0123 Short circuit Between throttle position sensor output terminal white a of ECU coupler and any other ECU cou pler terminal b If there is continuity replace the wire harness Fault code No P0122 P0123 P0222 P0223 P2135 Item P0122 Throttle position sensor ground short circuit detected P0123 Throttle position sensor open or power sh...

Page 412: ... service Condition is Detected Go to item 5 5 Throttle position sensor resis tance Measure the throttle position sensor resistance black blue blue Refer to CHECKING THE THROTTLE POSITION SEN SOR on page 8 170 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 ...

Page 413: ... Condition is Detected Go to item 7 7 Malfunction in ECU Replace the ECU Refer to REPLACING THE ECU Engine Control Unit on page 8 157 Service is finished 8 Delete the fault code and check that the engine trouble warning light goes off Confirm that the fault code has a condition of Recovered using the Yamaha diagnostic tool and then delete the fault code Fault code No P0132 Item O2 sensor short cir...

Page 414: ...e fault code using the mal function mode of the Yamaha diagnostic tool Condition is Recovered Go to item 7 and finish the service Condition is Detected Go to item 4 4 Wire harness continuity Open or short circuit Properly connect or replace the wire har ness Between O2 sensor coupler and joint connector black blue black blue Between joint connector and ECU coupler black blue black blue Between O2 ...

Page 415: ...njector 1 Measure the fuel injector resis tance Replace if out of specification Refer to CHECKING THE FUEL INJECTORS on page 8 174 Execute the diagnostic mode Code No 36 Operating sound Go to item 6 No operating sound Go to item 3 3 Connection of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pi...

Page 416: ...eplace if out of specification Refer to CHECKING THE FUEL INJECTORS on page 8 174 Execute the diagnostic mode Code No 37 Operating sound Go to item 7 No operating sound Go to item 3 3 Connection of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the coupler secu...

Page 417: ... for the operating sound Item Probable cause of malfunc tion and check Maintenance job Confirmation of service com pletion 1 Connection of fuel injector 3 coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the coupler securely or replace the wire harness Execute the di...

Page 418: ...Tool display Procedure Item Probable cause of malfunc tion and check Maintenance job Confirmation of service com pletion 1 Connection of crankshaft posi tion sensor coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the coupler securely or replace the wire harness Cran...

Page 419: ...rank the engine and then check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item 7 and finish the service Condition is Detected Go to item 5 5 Defective crankshaft position sensor Check the crankshaft position sensor Refer to CHECKING THE CRANKSHAFT POSITION SENSOR on page 8 164 Replace if defective Crank the engine and then ...

Page 420: ... Detected Go to item 2 2 Connection of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the coupler securely or replace the wire harness Start the engine and let it idle for approximately 5 seconds Check the condition of the fault code using the malfunction mode ...

Page 421: ...il safe system Able to start engine depending on the number of faulty cylinders Able to drive vehicle depending on the number of faulty cylinders Diagnostic code No 31 Actuation Actuates the cylinder 2 ignition coil five times at one second intervals The check indicator on the Yamaha diagnostic tool screen comes on each time the ignition coil is actuated Procedure Check that a spark is generated f...

Page 422: ...oseness or pinch ing Improperly installed ignition coil Reinstall or replace the igni tion coil Start the engine and let it idle for approximately 5 seconds Check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item 7 and finish the service Condition is Detected Go to item 5 5 Defective cylinder 2 ignition coil Measure the prima...

Page 423: ...ted Go to item 2 2 Connection of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the coupler securely or replace the wire harness Start the engine and let it idle for approximately 5 seconds Check the condition of the fault code using the malfunction mode of the...

Page 424: ...vice is finished 7 Delete the fault code and check that the engine trouble warning light goes off Confirm that the fault code has a condition of Recovered using the Yamaha diagnostic tool and then delete the fault code Fault code No P0500 P1500 Item A Rear wheel sensor no normal signals are received from the rear wheel sensor B Neutral switch open or short circuit is detected C Clutch switch open ...

Page 425: ...hat the indicated value increases Value increases Go to item A 8 Value does not increase Go to item A 3 A 3 Connection of ABS ECU cou pler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the coupler securely or replace the wire harness Execute the diagnostic mode Code No 07...

Page 426: ...l by hand and check that the indicated value increases Value increases Go to item A 8 Value does not increase Go to item A 7 A 7 Malfunction in ABS ECU Replace the ABS ECU Go to item A 8 A 8 Delete the fault code and check that the engine trouble warning light goes off Turn the main switch to ON and then rotate the rear wheel by hand Start the engine and input the vehicle speed signals by operat i...

Page 427: ... check that the indicated value increases Value does not increase Go to item A 2 for the rear wheel sensor Fault code No P1500 detected Execute the diagnostic mode Code No 21 When the transmission is in neutral ON When the transmission is in gear with the clutch lever released OFF Incorrect indication Go to item B 2 When the transmission is in gear with the clutch lever squeezed and the sidestand ...

Page 428: ...nit Replace if defective Refer to CHECKING THE RELAY UNIT DIODE on page 8 163 Execute the diagnostic mode Code No 21 When the transmission is in neutral ON When the transmission is in gear with the clutch lever released OFF Correct indication Go to item B 9 Incorrect indication Go to item B 6 B 6 Defective neutral switch Check the neutral switch Replace if defective Refer to CHECKING THE SWITCHES ...

Page 429: ...eel sensor no normal signals are received from the rear wheel sensor B Neutral switch open or short circuit is detected C Clutch switch open or short circuit is detected Fail safe system Able to start engine Able to drive vehicle Diagnostic code No 21 Tool display Clutch switch ON when the clutch lever is squeezed with the transmission in gear and when the sidestand is retracted OFF when the clutc...

Page 430: ...nsmission in gear and when the sidestand is retracted OFF When the clutch lever is squeezed with the transmission in gear and when the sidestand is retracted ON Correct indication Go to item C 8 Incorrect indication Go to item C 3 C 3 Connection of clutch switch cou pler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condit...

Page 431: ...ack yellow black red black red Execute the diagnostic mode Code No 21 When the clutch lever is released with the transmission in gear and when the sidestand is retracted OFF When the clutch lever is squeezed with the transmission in gear and when the sidestand is retracted ON Correct indication Go to item C 8 Incorrect indication Go to item C 6 C 6 Defective clutch switch Check the clutch switch R...

Page 432: ...ation of service com pletion 1 Malfunction in charging system Check the charging system Refer to CHARGING SYSTEM on page 8 13 Defective rectifier regulator or AC magneto Replace Defective connection in the charging system circuit Prop erly connect or replace the wire harness Start the engine and let it idle for approximately 5 seconds Check the condition of the fault code using the malfunction mod...

Page 433: ...M fault code number an error is detected while reading or writing on EEPROM Fail safe system Able Unable to start engine Able Unable to drive vehicle Diagnostic code No 60 Tool display 00 No malfunctions detected If the self diagnosis fault code P062F is indi cated the ECU is defective 01 03 CO adjustment value If more than one cylinder is defective the display alternates every two seconds to show...

Page 434: ...Change the CO concentration of cylinder 3 and rewrite in EEPROM Refer to ADJUSTING THE EXHAUST GAS VOLUME on page 3 11 After this adjustment is made turn the main switch to OFF Set the main switch to ON and then check the condition of the fault code using the mal function mode of the Yamaha diagnostic tool Condition is Recovered Go to item 7 and finish the service Condition is Detected Repeat item...

Page 435: ...unction mode of the Yamaha diagnostic tool Condition is Recovered Go to item 8 and finish the service Condition is Detected Go to item 3 3 Check the electronic throttle valve fuse Blown fuse Replace the elec tronic throttle valve fuse 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...

Page 436: ...voltage Approximately 12 0 Procedure Set the start engine stop switch to and then compare the actually measured battery voltage with the tool display value If the actually mea sured battery voltage is low recharge the battery 50 Actuation Actuates the relay unit five times at one second intervals The check indicator on the Yamaha diagnostic tool screen come on each time the relay is actuated Proce...

Page 437: ...o to item 7 and finish the service Condition is Detected Go to item 4 4 Defective relay unit Execute the diagnostic mode Code No 50 No operating sound Replace the relay unit Start the engine and let it idle for approximately 5 seconds Check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item 7 and finish the service Condition i...

Page 438: ...is indicated 0 m above sea level Approx 101 kPa 757 6 mmHg 29 8 inHg 3000 m 9800 ft above sea level Approx 70 kPa 525 0 mmHg 20 7 inHg Displayed value is incorrect Check the intake air pressure sensor 1 Replace if defective Refer to CHECKING THE INTAKE AIR PRESSURE SEN SOR on page 8 172 Turn the main switch to ON and then check the condition of the fault code using the mal function mode of the Yam...

Page 439: ... the operating sound Item Probable cause of malfunc tion and check Maintenance job Confirmation of service com pletion 1 Connection of air induction sys tem solenoid coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the coupler securely or replace the wire harness Tur...

Page 440: ...red white red white Turn the main switch to ON and then check the condition of the fault code using the mal function mode of the Yamaha diagnostic tool Condition is Recovered Go to item 6 and finish the service Condition is Detected Start the engine and check the status of the fault code Condition is Recovered Go to item 6 and finish the service Condition is Detected Go to item 4 TIP Check that th...

Page 441: ... using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item 7 and finish the service Condition is Detected Go to item 2 2 Connection of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the coupler securely or replace the wire harne...

Page 442: ...n in ECU Replace the ECU Refer to REPLACING THE ECU Engine Control Unit on page 8 157 Service is finished 7 Delete the fault code and check that the engine trouble warning light goes off Confirm that the fault code has a condition of Recovered using the Yamaha diagnostic tool and then delete the fault code Fault code No P1602 Item Malfunction in ECU internal circuit malfunction of ECU power cut of...

Page 443: ...ler Open or short circuit Replace the wire harness Between starter relay and ECU coupler red red Turn the main switch to ON and then check the condition of the fault code using the mal function mode of the Yamaha diagnostic tool Condition is Recovered Go to item 7 and finish the service Condition is Detected Go to item 5 5 Wire harness continuity between starter relay and bat tery Open or short ci...

Page 444: ...OFF and then back to ON Check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item 6 and finish the service Condition is Detected Go to item 2 2 Connection of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly conn...

Page 445: ... short circuit Between lean angle sensor coupler and ground yellow green ground If there is continuity replace the wire harness 3 4 For P1605 Open circuit Between lean angle sensor coupler and ECU coupler blue blue If there is no continuity replace the wire harness Fault code No P1604 P1605 Item P1604 Lean angle sensor ground short circuit detected P1605 Lean angle sensor open or power short circu...

Page 446: ... 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 38 3 8 For P1604 P1605 Short circuit Between lean angle sensor output terminal yellow green a of ECU coupler and any other ECU coupler terminal b If there is continuity replace the wire harness Fault code No P1604 P1605 Item P1604 Lean angle...

Page 447: ... stop switch If the display value changes the performance is OK Item Probable cause of malfunc tion and check Maintenance job Confirmation of service com pletion 1 Connection of Intake air pres sure sensor 2 coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the couple...

Page 448: ... 3 Sensor input lead 4 Sensor output lead 5 Sensor ground lead 3 2 Disconnect the ECU coupler from the ECU Disconnect the Intake air pressure sensor 2 coupler from the Intake air pressure sensor 2 3 3 For P1606 Ground short circuit Between Intake air pressure sensor 2 coupler and ground pink white ground If there is continuity replace the wire harness Fault code No P1606 P1607 Item P1606 Intake ai...

Page 449: ...ntinuity replace the wire harness 3 6 For P1607 Open circuit Between Intake air pressure sensor 2 coupler and ECU coupler black blue black blue If there is no continuity replace the wire harness 3 7 Disconnect the couplers from the parts that are connected to the ECU Refer to Parts connected to the ECU on page 8 38 Fault code No P1606 P1607 Item P1606 Intake air pressure sensor 2 ground short circ...

Page 450: ...ea level Approx 101 kPa 757 6 mmHg 29 8 inHg 1000 m 3300 ft above sea level Approx 90 kPa 675 1 mmHg 26 6 inHg 2000 m 6700 ft above sea level Approx 80 kPa 600 0 mmHg 23 6 inHg 3000 m 9800 ft above sea level Approx 70 kPa 525 0 mmHg 20 7 inHg When engine is cranking Make sure that the indication value changes The value does not change when engine is cranking Check the Intake air pressure sensor 2 ...

Page 451: ...sed position 97 107 fully open position Procedure Check with throttle grip in fully closed position Check with throttle grip in fully open position 15 Tool display Accelerator position sensor signal 2 10 24 fully closed position 95 109 fully open position Procedure Check with throttle grip in fully closed position Check with throttle grip in fully open position Item Probable cause of malfunc tion ...

Page 452: ...ault 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 4 3 1 1 Accelerator position sensor 2 ECU 3 Sensor input lead 4 Sensor output lead 1 5 Sensor output lead 2 6 Sensor ground lead 3 2 Disconnect the ECU coupler from the ECU Disconnect the accelerator position sensor coupler from the acceler...

Page 453: ...5 For P2127 Ground short circuit Between accelerator position sensor coupler and ground black ground If there is continuity replace the wire harness Fault code No P2122 P2123 P2127 P2128 P2138 Item P2122 Accelerator position sensor open or ground short circuit detected P2123 Accelerator position sensor power short circuit detected P2127 Accelerator position sensor ground short circuit detected P21...

Page 454: ...coupler and ECU coupler black blue black blue If there is no continuity replace the wire harness 3 9 Disconnect the couplers from the parts that are connected to the ECU Refer to Parts connected to the ECU on page 8 38 Fault code No P2122 P2123 P2127 P2128 P2138 Item P2122 Accelerator position sensor open or ground short circuit detected P2123 Accelerator position sensor power short circuit detect...

Page 455: ...on mode of the Yamaha diagnostic tool Condition is Recovered Go to item 8 and finish the service Condition is Detected Go to item 5 5 Accelerator position sensor resistance Measure the accelerator posi tion sensor resistance black blue blue Refer to CHECKING THE ACCELERATOR POSITION SENSOR on page 8 170 Turn the main switch to ON and then check the condition of the fault code using the mal functio...

Page 456: ...ine Control Unit on page 8 157 Service is finished 8 Delete the fault code and check that the engine trouble warning light goes off Confirm that the fault code has a condition of Recovered using the Yamaha diagnostic tool and then delete the fault code Fault code No P2158 Item Front wheel sensor no normal signals are received from the front wheel sensor Fail safe system Able to start engine Able t...

Page 457: ...ns Improperly connected Con nect the coupler securely or replace the wire harness Execute the diagnostic mode Code No 16 Rotate the front wheel by hand and check that the indicated value increases Value increases Go to item 9 and finish the service Value does not increase Go to item 4 4 Connection of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins b...

Page 458: ...ervice Value does not increase Go to item 8 8 Malfunction in ABS ECU Replace the ABS ECU Go to item 9 9 Delete the fault code and check that the engine trouble warning light goes off Turn the main switch to ON and then rotate the front wheel by hand Start the engine and input the vehicle speed signals by operat ing the vehicle at 20 to 30 km h 12 to 19 mph Confirm that the fault code has a conditi...

Page 459: ...king condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the coupler securely or replace the wire harness Start the engine and let it idle for approximately 10 seconds Check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item...

Page 460: ...ult code which has a condition of Detected 7 Malfunction in ECU Replace the ECU Refer to REPLACING THE ECU Engine Control Unit on page 8 157 Service is finished 8 Delete the fault code and check that the engine trouble warning light goes off Confirm that the fault code has a condition of Recovered using the Yamaha diagnostic tool and then delete the fault code Event code No U0155 or Err Item Multi...

Page 461: ...en white light green white Turn the main switch to ON and then check the condition of the fault code using the mal function mode of the Yamaha diagnostic tool Condition is Recovered Go to item 6 and finish the service Condition is Detected Go to item 4 4 Defective meter assembly Replace the meter assembly Turn the main switch to ON and then check the condition of the fault code using the mal funct...

Page 462: ...FUEL PUMP SYSTEM 8 105 EAS20081 FUEL PUMP SYSTEM EAS30513 CIRCUIT DIAGRAM ...

Page 463: ... Battery 19 Engine ground 20 Fuel injection system fuse 23 Joint connector 24 Joint coupler 25 Relay unit 27 Fuel pump relay 30 ECU Engine Control Unit 72 Fuel pump 74 Handlebar switch right 76 Start engine stop switch A Wire harness D Negative battery sub wire harness ...

Page 464: ...he main switch Refer to CHECKING THE SWITCHES on page 8 153 NG Replace the main switch immobilizer unit OK 4 Check the start engine stop switch Refer to CHECKING THE SWITCHES on page 8 153 NG Replace the handlebar switch right OK 5 Check the relay unit fuel pump re lay Refer to CHECKING THE RE LAYS on page 8 161 NG Replace the relay unit OK 6 Check the fuel pump Refer to CHECKING THE FUEL PUMP OPE...

Page 465: ...FUEL PUMP SYSTEM 8 108 ...

Page 466: ...IMMOBILIZER SYSTEM 8 109 EAS20084 IMMOBILIZER SYSTEM EAS30519 CIRCUIT DIAGRAM ...

Page 467: ...use 13 Ignition fuse 18 Battery 19 Engine ground 23 Joint connector 24 Joint coupler 28 Immobilizer unit 30 ECU Engine Control Unit 53 Meter assembly 54 Immobilizer system indicator light 59 Multi function meter A Wire harness D Negative battery sub wire harness ...

Page 468: ...s lost regis tering new codes in the standard keys is impossible The standard keys can still be used to start the vehicle However if code re registering is required e g if a new standard key is made or all keys are lost the entire immobilizer system must be replaced Therefore it is highly rec ommended to use either standard key for driving and to keep the code re registering key in a safe place Do...

Page 469: ...the ignition key to OFF 30 seconds later the indicator light will start flashing continuously in the standby flashing mode pattern for up to 24 hours After that time the indicator light will stop flashing but the immobilizer system is still enabled Standby mode Parts to be replaced Key registration requirement Main switch immobilizer unit Standard key ECU Acces sory lock and key Main switch Immobi...

Page 470: ...ile the indicator light is flashing turn the main switch to OFF remove the key and within 5 sec onds insert the second standard key to be registered into the main switch TIP If he immobilizer system indicator light stops flashing 5 seconds after the first standard key is registered the registration mode is deactivated If this occurs the second standard key cannot be registered and steps 2 to 4 nee...

Page 471: ...ain switch OFF c LED on d LED off e Less than 5 0 s f Code re registering key g Remaining standard key h Registration mode A If the immobilizer system indicator light stops flashing 5 seconds after the first standard key is registered the second standard key cannot be registered ...

Page 472: ...DIAGRAM on page 8 109 NG Properly connect or repair the immobilizer system wiring OK Check the condition of the each im mobilizer system circuits Refer to SELF DIAGNOSIS FAULT CODE INDICATION on page 8 115 Fault code Part Symptom Cause Action 51 IMMOBILIZER UNIT Code cannot be trans mitted between the key and the immobi lizer unit 1 Radio wave interfer ence caused by objects around the keys and an...

Page 473: ...ch Noise interference or dis connected lead cable 1 Interference due to radio wave noise 2 Disconnected commu nication harness 3 Immobilizer unit mal function 4 ECU failure The ECU or immobi lizer unit was replaced with a used unit from another vehicle 1 Register the code re registering key 2 Check the wire harness and con nector 3 Replace the main switch immobi lizer unit 4 Replace the ECU Refer ...

Page 474: ...ABS ANTI LOCK BRAKE SYSTEM 8 117 EAS20085 ABS ANTI LOCK BRAKE SYSTEM EAS30843 CIRCUIT DIAGRAM ...

Page 475: ...pler 25 Relay unit 26 Starting circuit cut off relay 30 ECU Engine Control Unit 46 Front wheel sensor 47 Rear wheel sensor 48 ABS ECU electronic control unit 52 Yamaha diagnostic tool coupler 53 Meter assembly 59 Multi function meter 68 ABS warning light 74 Handlebar switch right 76 Start engine stop switch 78 Front brake light switch 79 Rear brake light switch A Wire harness D Negative battery su...

Page 476: ...ABS ANTI LOCK BRAKE SYSTEM 8 119 EAS30525 ABS COMPONENTS CHART 1 2 3 4 5 6 7 8 9 1 ...

Page 477: ...RAKE SYSTEM 8 120 1 Hydraulic unit assembly 2 Fuse box 2 3 Yamaha diagnostic tool coupler 4 Rear wheel sensor 5 Rear wheel sensor rotor 6 Front wheel sensor 7 Front wheel sensor rotor 8 ABS warning light 9 Fuse box 1 ...

Page 478: ...ABS ANTI LOCK BRAKE SYSTEM 8 121 EAS30844 ABS COUPLER LOCATION CHART 1 2 3 4 5 ...

Page 479: ...ABS ANTI LOCK BRAKE SYSTEM 8 122 1 Meter assembly coupler 2 Rear wheel sensor coupler 3 ABS ECU coupler 4 Yamaha diagnostic tool coupler 5 Front wheel sensor coupler ...

Page 480: ...a diagnostic tool For information about using the Yamaha diagnostic tool refer to B 2 DIAG NOSIS USING THE FAULT CODES on page 8 127 For troubleshooting items other than the following items follow the normal service method WARNING EWA16710 When maintenance or checks have been performed on components related to the ABS be sure to perform a final check before delivering the vehicle to the customer T...

Page 481: ...ng them to shocks or pulling on them with too much force since the ABS components are precisely adjusted The ABS ECU and hydraulic unit are united assemblies and cannot be disassembled The malfunction history is stored in the memory of the ABS ECU Delete the fault codes when the ser vice is finished This is because the past fault codes will be displayed again if another malfunction occurs EAS30529...

Page 482: ... of the final checks completed normally Finished Yes No A Turn the main switch to ON and check the ABS warning light Fails to come on Comes on The ABS ECU fuse is blown The ABS ECU coupler is disconnected The wire harness is defective The hydraulic unit assembly is defective The connection with the Yamaha diagnostic tool is defective The wire harness is defective Cannot communicate Can communicate...

Page 483: ...bly If the ABS warning light comes on the ABS ECU is defective Replace the hydraulic unit assembly EAS30533 A 2 THE ABS WARNING LIGHT AND OTHER INDICATOR LIGHTS FAIL TO COME ON 1 Main switch Check the main switch for continuity Refer to CHECKING THE SWITCHES on page 8 153 If there is no continuity replace the main switch immobilizer unit 2 Battery Check the condition of the battery Refer to CHECKI...

Page 484: ...n light green white terminal of the ABS ECU coupler and light green white terminal of the Yamaha diagnostic tool coupler CANL 4 ABS ECU malfunction Replace the hydraulic unit assembly EAS31164 A 5 ABS ECU AND FI ECU FAIL TO COMMUNICATE 1 Yamaha diagnostic tool Check that the Yamaha diagnostic tool is properly connected 2 Wire harness Open circuit in the wire harness between the ABS ECU coupler and...

Page 485: ...veling Foreign material adhered around the front wheel sen sor Incorrect installation of the front wheel Defective sensor rotor or incorrect installation of the rotor Defective front wheel sen sor or incorrect installation of the sensor 12 Rear wheel sensor intermit tent pulses or no pulses Rear wheel sensor signal is not received properly Pulses are not received or are received intermittently whi...

Page 486: ...r short circuit in the wire harness between the rear wheel sensor and the hydraulic unit assembly Defective rear wheel sen sor or hydraulic unit assembly 17 45 Front wheel sensor missing pulses Front wheel sensor signal is not received properly Miss ing pulses are detected in the signal while the vehicle is traveling Foreign material adhered around the front wheel sen sor Incorrect installation of...

Page 487: ... supply circuit Short circuit is detected in the solenoid power supply circuit in the hydraulic unit assembly Defective hydraulic unit assembly 33 Hydraulic unit assembly abnormal ABS motor power supply Power is not supplied to the motor circuit in the hydraulic unit assembly Blown ABS motor fuse Defective coupler between the battery and the hydrau lic unit assembly Open or short circuit in the wi...

Page 488: ...sensor rotor or incorrect installation of the rotor Defective rear wheel sen sor or incorrect installation of the sensor 51 52 Vehicle system power sup ply voltage of ABS ECU power supply is high for fault code No 51 Vehicle system power sup ply voltage of wheel sen sor power supply is high for fault code No 52 Power voltage supplied to the ABS ECU in the hydraulic unit assembly is too high for fa...

Page 489: ...re har ness between the rear wheel sensor and the hydraulic unit assembly Defective rear wheel sen sor Defective hydraulic unit assembly Fault code No 11 25 Item Front wheel sensor intermittent pulses or no pulses Symptom Front wheel sensor signal is not received properly Pulses are not received or are received intermittently while the vehicle is travel ing Order Item components and probable cause...

Page 490: ...r wheel sensor or incorrect installation of the sensor Check the wheel sensor for damage and the installed condition of the sensor Repair or replace the wheel sensor if necessary Refer to MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR on page 4 22 Fault code No 13 26 Item Front wheel sensor abnormal pulse period Symptom Front wheel sensor signal is not received properly The pulse period is ...

Page 491: ...tortion and bends Refer to CHECKING THE REAR WHEEL on page 4 21 3 Defective sensor rotor or incorrect instal lation of the rotor Check the surface of the sensor rotor for damage Replace the sensor rotor if there is visible damage Refer to MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR on page 4 22 4 Defective rear wheel sensor or incorrect installation of the sensor Check the wheel sensor f...

Page 492: ... 7 Wheel sensor 3 Defective front wheel sensor or hydraulic unit assembly If the above items were performed and no malfunctions were found the wheel sensor or hydraulic unit assembly is defective Replace the wheel sensor or hydraulic unit assembly Refer to FRONT WHEEL on page 4 8 and ABS ANTI LOCK BRAKE SYSTEM on page 4 49 Fault code No 16 Item Rear wheel sensor open or short circuit Symptom Open ...

Page 493: ...r or hydraulic unit assembly If the above items were performed and no malfunctions were found the wheel sensor or hydraulic unit assembly is defective Replace the wheel sensor or hydraulic unit assembly Refer to REAR WHEEL on page 4 16 and ABS ANTI LOCK BRAKE SYSTEM on page 4 49 Fault code No 17 45 Item Front wheel sensor missing pulses Symptom Front wheel sensor signal is not received properly Mi...

Page 494: ...Fault code No 18 46 Item Rear wheel sensor missing pulses Symptom Rear wheel sensor signal is not received properly Missing pulses are detected in the signal while the vehicle is traveling Order Item components and probable cause Check or maintenance job 1 Foreign material adhered around the rear wheel sensor Check the surface of the sensor rotor and wheel sensor for foreign material such as metal...

Page 495: ...em tail brake light or brake light switch and the hydraulic unit assembly Check 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 3 Open or short circuit in the wire harness between the signaling system tail brake light or brake light switch and the hydrau lic unit assembly Between ABS EC...

Page 496: ...rder Item components and probable cause Check or maintenance job 1 Defective hydraulic unit assembly Replace the hydraulic unit assembly Refer to ABS ANTI LOCK BRAKE SYSTEM on page 4 49 Fault code No 33 Item Hydraulic unit assembly abnormal ABS motor power supply Symptom Power is not supplied to the motor circuit in the hydraulic unit assembly Order Item components and probable cause Check or main...

Page 497: ...o ABS ANTI LOCK BRAKE SYSTEM on page 4 49 Fault code No 41 Item Front wheel ABS intermittent wheel speed pulses or incorrect depressurization Symptom Pulses from the front wheel sensor are received intermittently while the vehicle is traveling Front wheel will not recover from the locking tendency even though the signal is transmitted from the ABS ECU to reduce the hydraulic pressure Order Item co...

Page 498: ...r wheel sensor for fault code No 42 Check the components for looseness distortion and bends Refer to CHECKING THE REAR WHEEL on page 4 21 2 Incorrect rotation of the rear wheel Check that there is no brake disc drag on the wheel and make sure that it rotates smoothly Refer to CHECKING THE REAR WHEEL on page 4 21 3 Rear brake dragging Check that the brake fluid pressure is correctly transmit ted to...

Page 499: ...of the sensor Repair or replace the wheel sensor if necessary Refer to MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR on page 4 12 Fault code No 44 Item Rear wheel sensor missing pulses Symptom Rear wheel sensor signal is not received properly Missing pulses are detected in the signal while the vehicle is traveling Order Item components and probable cause Check or maintenance job 1 Foreign...

Page 500: ...fer to CHARGING SYSTEM on page 8 13 Fault code No 53 Item Vehicle system power supply voltage of ABS ECU power supply is low Symptom Power voltage supplied to the ABS ECU in the hydraulic unit assem bly is too low Order Item components and probable cause Check or maintenance job 1 Defective battery Recharge or replace the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 158 2 Defective...

Page 501: ... before disconnecting or connecting a coupler 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 starter relay coupler ABS motor fuse red blue red blue Between ABS ECU coupler and ABS solenoid fuse red white red white 4 Defective charging system Check the charging system Refer to C...

Page 502: ...to the front wheel sensor is too low Order Item components and probable cause Check or maintenance job 1 Short circuit in the wire harness between the front wheel sensor and the hydraulic unit assembly Check that there is no short circuit between the white terminal 1 and the black terminal 2 Check that there is no short circuit between the black yellow terminal 3 and the white terminal 1 If there ...

Page 503: ...en the white terminal 1 and the black terminal 2 Check that there is no short circuit between the black yellow terminal 3 and the white terminal 1 If there is a short circuit the wire harness is defective Replace the wire harness 4 ABS ECU 5 Wheel sensor 2 Defective rear wheel sensor Check that there is no short circuit between the black terminal 1 and the white terminal 2 If there is a short circ...

Page 504: ...RAKE DISCS on page 4 14 and IN STALLING THE REAR WHEEL REAR BRAKE DISC on page 4 22 3 Perform brake line routing confirmation Refer to HYDRAULIC UNIT OPERATION TESTS on page 4 54 If it does not have reaction force properly the brake hose is not properly routed or connected 4 Delete the fault codes Refer to B 3 DELETING THE FAULT CODES on page 8 147 5 Checking the ABS warning light Refer to CHECKIN...

Page 505: ...ck for continuity between green red terminal of the ABS ECU coupler and green red terminal of the meter assembly coupler Malfunction in the meter assembly circuit Malfunction in the ABS warning light circuit in the hydraulic unit assembly ...

Page 506: ...ELECTRICAL COMPONENTS 8 149 EAS20089 ELECTRICAL COMPONENTS ...

Page 507: ...ic unit assembly 5 Battery 6 Fuse box 2 7 Main fuse 8 Fuel injection system fuse 9 Starter relay 10 Rectifier regulator 11 Rear wheel sensor 12 Rear brake light switch 13 Gear position switch 14 Sidestand switch 15 O2 sensor 16 Oil level switch 17 Front wheel sensor 18 Ignition coil 19 Radiator fan motor 20 Horn ...

Page 508: ...ELECTRICAL COMPONENTS 8 151 ...

Page 509: ...relay 6 Turn signal hazard relay 7 Relay unit 8 Shift switch 9 Stator coil 10 Crankshaft position sensor 11 Coolant temperature sensor 12 Throttle servo motor 13 Accelerator position sensor 14 Throttle position sensor 15 Intake air pressure sensor 1 16 Intake air pressure sensor 2 17 Injector 18 Air induction system solenoid 19 Fuse box 1 ...

Page 510: ...ELECTRICAL COMPONENTS 8 153 EAS30549 CHECKING THE SWITCHES 2 1 3 4 5 6 7 8 13 14 15 9 11 12 10 ...

Page 511: ... signal switch 4 Horn switch 5 Traction control system switch 6 Clutch switch 7 Oil level switch 8 Sidestand switch 9 Hazard switch 10 Start engine stop switch 11 Drive mode switch 12 Front brake light switch 13 Main switch 14 Rear brake light switch 15 Shift switch ...

Page 512: ...en checking for continuity switch back and forth between the switch positions a few times The switches and their terminal connections are illustrated as in the following example of the main switch The switch positions a are shown in the far left column and the switch lead colors b are shown in the top row The continuity i e a closed circuit between switch terminals at a given switch position is in...

Page 513: ...terminal 2 and check the continuity b If either of the readings indicate no continuity replace the bulb Checking the condition of the bulb sockets The following procedure applies to all of the bulb sockets 1 Check Bulb socket for continuity with the digital circuit tester No continuity Replace TIP Check each bulb socket for continuity in the same manner as described in the bulb section however not...

Page 514: ...he lighting and ignition systems to malfunction and could possibly cause a fire 4 Install Rider seat Refer to GENERAL CHASSIS 1 on page 4 1 EAS31006 REPLACING THE ECU Engine Control Unit 1 Turn the main switch to OFF 2 Replace the ECU Engine Control Unit 3 Clean the throttle bodies and reset the ISC idle speed control learning value Digital circuit tester CD732 90890 03243 Model 88 Multimeter with...

Page 515: ...balance between cells will not be maintained and battery performance will deteriorate Charging time charging amperage and charging voltage for a VRLA Valve Regu lated Lead Acid battery are different from those of conventional batteries The VRLA Valve Regulated Lead Acid battery should be charged according to the appropriate charging method If the battery is over charged the electrolyte level will ...

Page 516: ...re in full contact with the battery terminal and that they are not shorted A corroded bat tery charger lead clip may generate heat in the contact area and a weak clip spring may cause sparks If the battery becomes hot to the touch at any time during the charging process dis connect the battery charger and let the bat tery cool before reconnecting it Hot batteries can explode As shown in the follow...

Page 517: ...r to charging TIP Voltage should be measured 30 minutes after the engine is stopped b Connect a charger and ammeter to the bat tery and start charging c Make sure that the current is higher than the standard charging current written on the bat tery TIP If the current is lower than the standard charging current written on the battery this type of battery charger cannot charge the VRLA Valve Regu la...

Page 518: ...ification Replace Starter relay Relay unit starting circuit cut off relay Relay unit fuel pump relay Digital circuit tester CD732 90890 03243 Model 88 Multimeter with tachom eter YU A1927 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Relay operation Continuity between 3 and 4 1 Positive battery terminal 2 Negative battery terminal 3 Positiv...

Page 519: ...ion Replace a Connect the digital circuit tester DC V to the turn signal hazard relay terminal as shown b Turn the main switch to ON c Measure the turn signal hazard relay output voltage 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 Turn signal hazard relay input voltage DC 12 V Digital circuit tester CD732...

Page 520: ...chom eter YU A1927 Continuity Positive tester probe sky blue 1 Negative tester probe black yellow 2 No continuity Positive tester probe black yellow 2 Negative tester probe sky blue 1 Continuity Positive tester probe sky blue 1 Negative tester probe black red 3 No continuity Positive tester probe black red 3 Negative tester probe sky blue 1 Continuity Positive tester probe sky blue 1 Negative test...

Page 521: ...re the ignition spark gap a e Crank the engine by pushing the side of the start engine stop switch and gradually in crease the spark gap until a misfire occurs EAS30560 CHECKING THE CRANKSHAFT POSITION SENSOR 1 Disconnect Crankshaft position sensor coupler from the wire harness 2 Check Crankshaft position sensor resistance Out of specification Replace the crank shaft position sensor a Connect the ...

Page 522: ...4 Refer to TROUBLESHOOTING on page 8 11 a Connect the positive battery terminal 1 and starter motor lead 2 with a jumper lead 3 WARNING EWA13810 A wire that is used as a jumper lead must have at least the same capacity of the bat tery lead otherwise the jumper lead may burn This check is likely to produce sparks therefore make sure no flammable gas or Digital circuit tester CD732 90890 03243 Model...

Page 523: ...gine tachometer to the ignition coil of cylinder 1 b Connect the digital circuit tester AC V to the rectifier regulator coupler as shown Stator coil resistance 0 152 0 228 Digital circuit tester CD732 90890 03243 Model 88 Multimeter with tachom eter YU A1927 Positive tester probe white 1 Negative tester probe white 2 Positive tester probe white 1 Negative tester probe white 3 Positive tester probe...

Page 524: ...isconnect the horn leads from the horn ter minals b Connect the digital circuit tester to the horn terminals c Measure the horn resistance 2 Check Horn sound Faulty sound Replace EAS30846 CHECKING THE ENGINE OIL LEVEL SWITCH 1 Drain Engine oil 2 Remove Oil level switch from the oil pan 3 Check Oil level switch resistance Regulated voltage DC 14 3 14 7 V Digital circuit tester CD732 90890 03243 Mod...

Page 525: ...gnosis de vice for the fuel level detection circuit 1 Check Fuel meter fuel level warning light 1 Turn the main switch to ON Oil level switch Oil level switch resistance maxi mum level position 484 0 536 0 Oil level switch resistance mini mum level position 114 0 126 0 Digital circuit tester CD732 90890 03243 Model 88 Multimeter with tachom eter YU A1927 Minimum level position A Positive tester pr...

Page 526: ... CHECKING THE RADIATOR FAN MOTOR 1 Check Radiator fan motor Faulty rough movement Replace a Disconnect the radiator fan motor coupler from the wire harness b Connect the battery DC 12 V as shown c Measure the radiator fan motor movement EAS30578 CHECKING THE COOLANT TEMPERATURE SENSOR 1 Remove Coolant temperature sensor Refer to CYLINDER HEAD on page 5 19 WARNING EWA14130 Handle the coolant temper...

Page 527: ...l circuit tester to the throttle position sensor terminals as shown b Measure the throttle position sensor maxi mum resistance 3 Install Throttle position sensor TIP When installing the throttle position sensor ad just its angle properly Refer to ADJUSTING THE THROTTLE POSITION SENSOR on page 7 12 EAS30582 CHECKING THE ACCELERATOR POSITION SENSOR 1 Remove Accelerator position sensor from the throt...

Page 528: ...tle servo motor TIP Do not use old batteries to operate the throttle servo motor EAS30587 CHECKING THE AIR INDUCTION SYSTEM SOLENOID 1 Check Air induction system solenoid resistance Out of specification Replace a Remove the air induction system solenoid coupler from the air induction system sole noid b Connect the digital circuit tester to the air induction system solenoid terminal as shown Digita...

Page 529: ...erature sensor with special care Never subject the intake air temperature sensor to strong shocks If the intake air temperature sensor is dropped replace it 2 Check Intake air temperature sensor resistance Out of specification Replace a Connect the digital circuit tester to the in Intake air pressure sensor output voltage 3 57 3 71 V at 101 3 kPa Digital circuit tester CD732 90890 03243 Model 88 M...

Page 530: ...itch Digital circuit tester CD732 90890 03243 Model 88 Multimeter with tachom eter YU A1927 Digital circuit tester CD732 90890 03243 Model 88 Multimeter with tachom eter YU A1927 3 1 2 Result Neutral position Continuity Positive tester probe sky blue 1 Negative tester probe Sensor terminal a 1st position Continuity Positive tester probe white 2 Negative tester probe Sensor terminal b 2nd position ...

Page 531: ...ance Out of specification Replace the fuel injec tor a Disconnect the fuel injector coupler from the fuel injector b Connect the digital circuit tester to the fuel injector coupler as shown c Measure the fuel injector resistance Resistance 12 0 Digital circuit tester CD732 90890 03243 Model 88 Multimeter with tachom eter YU A1927 Positive tester probe Injector terminal 1 Negative tester probe Inje...

Page 532: ...ELECTRICAL COMPONENTS 8 175 ...

Page 533: ... PERFORMANCE 9 3 FAULTY FRONT FORK LEGS 9 3 UNSTABLE HANDLING 9 3 FAULTY LIGHTING OR SIGNALING SYSTEM 9 3 TROUBLESHOOTING AT THE ABS WARNING LIGHT 9 4 SELF DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE 9 5 SELF DIAGNOSTIC FUNCTION TABLE FOR FUEL INJECTION SYSTEM 9 5 SELF DIAGNOSTIC FUNCTION TABLE FOR IMMOBILIZER SYSTEM 9 13 COMMUNICATION ERROR WITH THE METER 9 13 DIAGNOSTIC CODE SENSOR OPERATION T...

Page 534: ...or contaminated fuel Sucked in air Electrical system 1 Battery Discharged battery Faulty battery 2 Fuse s Blown damaged or incorrect fuse Improperly installed fuse 3 Spark plug s Incorrect spark plug gap Incorrect spark plug heat range Fouled spark plug Worn or damaged electrode Worn or damaged insulator 4 Ignition coil s Cracked or broken ignition coil body Broken or shorted primary or secondary ...

Page 535: ...opper lever Shift forks Worn shift fork Shift drum Incorrect axial play Worn shift drum groove Transmission Worn gear dog EAS30849 FAULTY CLUTCH Clutch slips 1 Clutch Improperly assembled clutch Improperly adjusted clutch cable Loose or fatigued clutch spring Worn friction plate Worn clutch plate 2 Engine oil Incorrect oil level Incorrect oil viscosity low Deteriorated oil Clutch drags 1 Clutch Un...

Page 536: ... tube bushing Bent or damaged damper rod Incorrect oil viscosity Incorrect oil level EAS30611 UNSTABLE HANDLING Handlebar Bent or improperly installed handlebar Steering head components Improperly installed upper bracket Improperly installed lower bracket improperly tightened ring nut Bent steering stem Damaged ball bearing or bearing race Front fork leg s Uneven oil levels both front fork legs Un...

Page 537: ...lay Faulty main switch Faulty turn signal switch Incorrect turn signal bulb Turn signal remains lit Faulty meter assembly Faulty turn signal hazard relay Burnt out turn signal bulb Turn signal blinks quickly Faulty meter assembly Incorrect turn signal bulb Faulty turn signal hazard relay Burnt out turn signal bulb Horn does not sound Damaged or faulty horn Faulty main switch Faulty horn switch Fau...

Page 538: ...sure sensor 1 and ECU Open or short cir cuit in wire harness between intake air pressure sensor 1 and ECU Defective intake air pressure sensor 1 Malfunction in ECU Engine idling speed is unstable Engine response is poor Loss of engine power Increased exhaust emissions Intake air pressure difference is fixed to 0 kPa N is fixed Fuel is not cut off due to the intake air pres sure difference Intake a...

Page 539: ...tected P0223 Throttle posi tion sensor open or power short circuit detected P2135 Throttle posi tion sensor output voltage deviation error P0122 P0222 Low voltage of the throttle position sensor circuit 0 25 V or less P0123 P0223 High voltage of the throttle position sensor circuit 4 75 V or more P2135 Difference in output voltage 1 and output voltage 2 of the throttle position sen sor Defective c...

Page 540: ...ire harness between injector and ECU Defective injector Malfunction in ECU Improperly installed injector Loss of engine power Engine is difficult to start Engine cannot be started Engine stops Engine idling speed is unstable Increased exhaust emissions O2 feedback is not carried out Air induction system solenoid is turned on all the time air induc tion system air cut off ISC feedback is not carrie...

Page 541: ...cir cuit in wire harness between ABS unit and ECU Open or short cir cuit in wire harness between neutral switch and ECU Open or short cir cuit in wire harness between clutch switch and ECU Defective rear wheel sensor Defective neutral switch Defective clutch switch Improper adjust ment of clutch lever Malfunction in ECU Vehicle speed is not displayed on the meter Engine stalls when the vehicle is ...

Page 542: ...ons Engine cannot be started or is difficult to start Engine idling speed is unstable OBD memory value is not correct CO adjustment value for the faulty cylinder 0 default value ISC learning values Default values OBD memory value is initialized Initialization of O2 feedback learning value P0638 YCC T drive system malfunction detected Defective coupler between throttle servo motor and ECU Open or s...

Page 543: ...dback is not carried out ISC feedback is not carried out ISC learning is not carried out P1400 Air induction system solenoid open or short circuit detected Open or short cir cuit in wire harness Disconnected cou pler Defective air induc tion system sole noid Defective air induc tion system sole noid controller malfunction in ECU Increased exhaust emissions Electric current in air induction system ...

Page 544: ...nnot be started P1606 P1607 P1606 Intake air pressure sensor 2 ground short circuit detected P1607 Intake air pressure sensor 2 open or power short circuit detected P1606 Low voltage of the intake air pres sure sensor 2 circuit 0 5 V or less P1607 High voltage of the intake air pres sure sensor 2 circuit 4 8 V or more Defective coupler between intake air pressure sensor 2 and ECU Open or short cir...

Page 545: ...r ator opening tran sientcontrol is not carried out Accelerator opening is fixed 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 P2158 Front wheel sensor no normal signals are received from the front wheel sensor Open or short cir cuit in wire harnes...

Page 546: ...diagnostic tool Err multi function meter dis play CAN communication error with the meter Communication between the ECU and the meter is not possi ble Defective meter cou pler and ECU cou pler Open or short cir cuit in the wire har ness between the meter and the ECU Defective meter Defective ECU Defective meter dis play Traction control does not work Grip warmer output OFF is fixed MAP changeover S...

Page 547: ...m voltage Approximately 12 0 Set the start engine stop switch to and then com pare the actually measured battery voltage with the tool display value If the actually measured battery voltage is low recharge the battery 13 Throttle position sensor sig nal 2 Fully closed position 9 23 Check with throttle valves fully closed Fully open position 94 108 Check with throttle valves fully open 14 Accelerat...

Page 548: ...ault code No P062F If more than one item is defective the displays alternates every two sec onds to show all the detected numbers 01 03 Cylinder adjustment value If more than one cylinder is defective the display alter nates every 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 ...

Page 549: ...second intervals The check indicator on the Yamaha diagnostic tool screen come on each time the ignition coil is actuated Check that a spark is gener ated five times Connect an ignition checker 32 Cylinder 3 ignition coil Actuates the cylinder 3 igni tion coil five times at one second intervals The check indicator on the Yamaha diagnostic tool screen come on each time the ignition coil is actuated...

Page 550: ... sound 50 Relay unit Actuates the relay unit five times at one second inter vals The check indicator on the Yamaha diagnostic tool screen come on each time the relay is actuated Check that the relay unit is actuated five times by listen ing for the operating sound 51 Radiator fan motor relay Actuates the radiator fan motor relay five times at five second intervals The check indicator on the Yamaha...

Page 551: ...ke air pressure sensor 2 Same as for fault code number P1606 and P1607 Perform the checks and maintenance jobs for fault code number P1606 and P1607 203 Lean angle sen sor Brief abnormality detected in the lean angle sensor Same as for fault code number P1604 and P1605 Perform the checks and maintenance jobs for fault code number P1604 and P1605 207 Accelerator posi tion sensor Brief abnormality d...

Page 552: ...ed clutch cable Malfunction in the fuel injection system Dirty or worn spark plug Malfunction in the bat tery Malfunction in ECU If a fault code is occurring respond to that first Rarely code 243 occurs even when the system is functioning properly 244 Poor start ing inability to start Poor starting inability to start detected No gasoline Malfunction in the fuel injection system Dirty or worn spark...

Page 553: ...ht does not come on Service is finished Engine trouble warning light comes on Go to item 2 2 Installed condition of lean angle sensor Check the installed direction and condition of the sensor Turn the main switch to ON then to OFF and then back to ON Engine trouble warning light does not come on Service is finished Engine trouble warning light comes on Go to item 3 3 Defective lean angle sensor Ex...

Page 554: ...riod of time Item Probable cause of malfunc tion and check Maintenance job Confirmation of service com pletion 1 Allow to idle for a long period of time Turn the main switch to OFF Check whether it is possible to start the engine Able to start the engine Ser vice is finished Unable to start the engine Go to item 2 2 Malfunction in ECU Replace the ECU Refer to REPLACING THE ECU Engine Control Unit ...

Page 555: ...ight 55 Neutral indicator light 56 Meter light 57 High beam indicator light 58 Tachometer 59 Multi function meter 60 Oil level warning light 61 Fuel level indicator 62 Engine trouble warning light 63 Coolant temperature warning light 64 Traction control system indica tor light 65 Quick shift indicator light 66 Turn signal indicator light left 67 Turn signal indicator light right 68 ABS warning lig...

Page 556: ...own Yellow G B Green Black G R Green Red G W Green White G Y Green Yellow Gy G Gray Green Gy R Gray Red L B Blue Black L R Blue Red L W Blue White L Y Blue Yellow Lg L Light green Blue Lg W Light green White O G Orange Green P B Pink Black P W Pink White R B Red Black R G Red Green R L Red Blue R W Red White Sb W Sky blue White W G White Green W L White Blue W R White Red W Y White Yellow Y B Yell...

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Page 559: ...17 WIRING DIAGRAM MTN850 A MTN850 AH 2017 SCHÉMA DE CÂBLAGE MTN850 A MTN850 AH 2017 SCHALTPLAN MTN850 A MTN850 AH 2017 SCHEMA ELETTRICO MTN850 A MTN850 AH 2017 DIAGRAMA ELÉCTRICO BS2 28197 E0_W D indd 1 2016 11 01 17 54 45 ...

Page 560: ...17 WIRING DIAGRAM MTN850 A MTN850 AH 2017 SCHÉMA DE CÂBLAGE MTN850 A MTN850 AH 2017 SCHALTPLAN MTN850 A MTN850 AH 2017 SCHEMA ELETTRICO MTN850 A MTN850 AH 2017 DIAGRAMA ELÉCTRICO BS2 28197 E0_W D indd 2 2016 11 01 17 54 45 ...

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