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Yamaha N MAX GPD150-A 2015, Service Manual

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Yamaha N MAX GPD150-A 2015 Service Manual Download Page 190

REAR BRAKE

4-57

TIP

Put the end of the brake hose into a container 
and pump out the brake fluid carefully.

EAS30187

DISASSEMBLING THE REAR BRAKE 
CALIPER

1. Remove:

• Brake caliper piston “1”
• Brake caliper piston dust seal “2”
• Brake caliper piston seal “3”

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a. Blow compressed air into the brake hose joint 

opening “a” to force out the piston from the 
brake caliper.

WARNING

EWA13550

• Cover the brake caliper piston with a rag. 

Be careful not to get injured when the pis-
ton is expelled from the brake caliper.

• Never try to pry out the brake caliper pis-

ton.

b. Remove the brake caliper piston dust seal 

and brake caliper piston seal.

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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 with compressed air.

WARNING

EWA17070

Whenever a brake caliper is disassembled, 
replace the brake caliper piston dust seal 
and brake caliper piston seal.

2. Check:

• Brake caliper bracket 

Cracks/damage 

→

 Replace.

1

2

3

1

2

3

a

Recommended brake component replacement 

schedule

Brake pads

If necessary

Piston seal

Every two years

Piston dust seal

Every two years

Brake hose

Every four years

Brake fluid

Every two years and 
whenever the brake is 
disassembled

1

2

3

Summary of Contents for N MAX GPD150-A 2015

Page 1: ...2015 SERVICE MANUAL GPD150 A 2DP F8197 E0 ...

Page 2: ...UAL 2015 by PT Yamaha Indonesia Motor Manufacturing First edition July 2015 All rights reserved Any reproduction or unauthorized use without the written permission of PT Yamaha Indonesia Motor Manufacturing is expressly prohibited ...

Page 3: ...ations and significant 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 ...

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

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

Page 6: ......

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

Page 8: ......

Page 9: ... ABS OPERATION 1 13 ABS WARNING LIGHT AND OPERATION 1 16 INSTRUMENT FUNCTIONS 1 18 IMPORTANT INFORMATION 1 22 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 22 REPLACEMENT PARTS 1 22 GASKETS OIL SEALS AND O RINGS 1 22 LOCK WASHERS PLATES AND COTTER PINS 1 22 BEARINGS AND OIL SEALS 1 23 CIRCLIPS 1 23 RUBBER PARTS 1 23 BASIC SERVICE INFORMATION 1 24 QUICK FASTENERS 1 24 ELECTRICAL SYSTEM 1 25 SPECIAL TOO...

Page 10: ... 1 EAS20007 IDENTIFICATION EAS30002 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the frame EAS30004 ENGINE SERIAL NUMBER The engine serial number 1 is stamped into the crankcase 1 1 ...

Page 11: ...rements for the engine to deliver more performance and cleaner exhaust gases increase it becomes necessary to control the air fuel ratio in a more precise and finely tuned manner To accom modate this need this model has adopted an electronically controlled fuel injection FI system in place of the conventional carburetor system This system can achieve an optimum air fuel ratio required by the engin...

Page 12: ...d by the ECU Signals that are input from the throttle position sensor coolant temperature sensor crankshaft position sensor intake air pressure sensor intake air temperature sensor front wheel sensor and O2 sensor enable the ECU to determine the injection duration The injection timing is determined through the signals from the crankshaft posi tion sensor As a result the volume of fuel that is requ...

Page 13: ...ntain the basic maneuverability of the vehicle 3 The hydraulic unit assembly which is the main component of the ABS is centrally located on the vehicle to increase mass centralization ABS layout 1 7 8 9 10 1 2 4 3 5 6 1 Hydraulic unit assembly 2 ABS warning light 3 Front wheel sensor rotor 4 Front wheel sensor 5 Rear wheel sensor rotor 6 Rear wheel sensor 7 ABS test coupler 8 ABS control unit fuse...

Page 14: ...eed and the chassis speed Slip ratio is the value that shows the rate of wheel slippage and is defined by the following formula Slip ratio Chassis speed Wheel speed Chassis speed 100 0 There is no slipping between the wheel and the road surface The chassis speed is equal to the wheel speed 100 The wheel speed is 0 but the chassis is moving i e wheel lock Brake force and vehicle stability When the ...

Page 15: ... the hydraulic pressure is reduced it increases the hydraulic pressure point B in the following figure The hydraulic pressure is initially increased quickly and then it is increased gradually ABS operation and vehicle control If the ABS starts operating there is a tendency of the wheel to lock and the vehicle is approaching the limit of control To make the rider aware of this condition the ABS has...

Page 16: ...ncy of the wheel to lock caused by applying the brakes The ABS cannot prevent wheel lock on slippery surfaces such as ice when it is caused by engine braking even if the ABS is operating Electronic ABS features The Yamaha ABS anti lock brake system has been developed with the most advanced electronic technology The ABS control is processed with good response under various vehicle travel conditions...

Page 17: ... element in the hall IC installed in the wheel sensor generates pulses The pulse frequency which is proportional to the wheel speed is converted into a wave in the hall IC so that it can be output The ABS ECU calculates the wheel rotation speed by detecting the pulse frequency 1 2 3 4 4 7 7 5 6 8 9 9 10 11 12 13 14 6 1 Rear brake master cylinder 2 Hydraulic unit assembly 3 Front brake master cylin...

Page 18: ...ed the ABS warning light will go off when the vehicle is ridden or pushed at a speed of 7 km h 4 mi h or faster NOTICE ECA22940 If the rear wheel is raced with the vehicle on a centerstand the ABS warning light may flash or come on If this occurs turn the main switch to OFF then back to ON The ABS operation is normal if the ABS warning light goes off after the vehicle starts off If the fault codes...

Page 19: ...e electromagnetic force generated in the inlet solenoid valve varies proportionally with the duty cycle control voltage that is supplied to it Since this voltage is continuously variable the solenoid valve moves smoothly and the hydraulic pressure is adjusted linearly 1 When the brakes are operated normally the inlet solenoid valve 1 is open and the outlet solenoid valve 2 is closed The brake line...

Page 20: ...lower brake lines brake caliper side Buffer chamber The buffer chamber accumulates the brake fluid that is depressurized while the ABS is operating ABS ECU The ABS ECU is integrated with the hydraulic unit to achieve a compact and lightweight design As shown in the following block diagram the ABS ECU receives wheel sensor signals from the front and rear wheels and also receives signals from other ...

Page 21: ...mory of the ABS ECU e g a blown ABS con trol unit fuse 14 7 4 5 6 2 3 1 9 10 11 12 13 17 15 24 20 22 23 21 26 27 18 19 16 25 8 1 Battery 2 AC magneto 3 Rectifier regulator 4 Main fuse 5 ABS motor fuse 6 ABS solenoid fuse 7 Main switch 8 ABS control unit fuse 9 Signaling system fuse 10 Rear brake light switch 11 Front brake light switch 12 Tail brake light 13 ABS test coupler 14 Hydraulic unit asse...

Page 22: ...inlet solenoid valve is open and the outlet solenoid valve is closed because a control signal has not been transmitted from the ABS ECU Therefore when the brake lever is squeezed the hydraulic pressure in the brake master cylinder increases and the brake fluid is sent to the brake caliper At this time the inlet and outlet check valves of the hydraulic pump are closed As a result of eliminating the...

Page 23: ...outlet solenoid valve is open the brake fluid is sent to the buffer chamber As a result the hydraulic pressure in the brake caliper is reduced The brake fluid stored in the buffer chamber is pumped back to the brake master cylinder by the hy draulic pump linked to the ABS motor 12 13 7 6 11 3 4 5 9 8 10 1 Brake master cylinder 2 Brake light switch 3 ABS motor 4 Hydraulic pump 5 Buffer chamber 6 Ou...

Page 24: ...solenoid valve As the inlet solenoid valve opens the brake line from the brake master cylinder opens allowing the brake fluid to be sent to the brake caliper 1 Brake master cylinder 2 Brake light switch 3 ABS motor 4 Hydraulic pump 5 Buffer chamber 6 Outlet solenoid valve 7 Inlet solenoid valve 8 Brake caliper 9 Wheel sensor 10 ABS ECU 11 ABS warning light 12 Brake fluid pressure 13 Time ...

Page 25: ...is occurs turn the main switch to OFF then back to ON The ABS operation is normal if the ABS warning light goes off after the vehicle starts off The ABS operation is normal if the ABS warning light flashes Even if the ABS warning light remains on and does not go off or if it comes on after riding conven tional braking performance of the vehicle is maintained 1 Brake master cylinder 2 Brake light s...

Page 26: ...braking distance or improve the cornering perfor mance Depending on the road conditions the braking distance may be longer compared to that of vehicles not equipped with ABS Therefore ride at a safe speed and keep a safe distance be tween yourself and other vehicles The braking of the vehicle even in the worst case is principally executed when the vehicle is advancing straight ahead During a turn ...

Page 27: ...two seconds 3 When the hour digits start flashing push the RESET button to set the hours 4 Push the SELECT button and the minute digits will start flashing 5 Push the RESET button to set the minutes 6 Push the SELECT button and then release it to start the clock Fuel meter The fuel meter indicates the amount of fuel in the fuel tank The display segments of the fuel meter disappear towards E Empty ...

Page 28: ...button to switch the display between the odometer mode ODO tripmeter modes TRIP 1 and TRIP 2 oil change tripme ter mode OIL TRIP V belt replacement tripme ter mode V BELT TRIP instantaneous fuel consumption mode F ECO km L or L 100 km and average fuel consumption mode AVE F ECO km L or L 100 km in the following or der ODO TRIP 1 TRIP 2 OIL TRIP V BELT TRIP F ECO AVE F ECO ODO If the fuel level war...

Page 29: ...be shown until the vehicle has traveled 0 1 km 0 06 mi Oil change tripmeter mode The oil change tripmeter shows the distance traveled since it was last reset i e since the last oil change The oil change indicator OIL will flash at the ini tial 1000 km 600 mi then at 4000 km 2500 mi and every 4000 km thereafter to indicate that the engine oil should be changed After changing the engine oil reset th...

Page 30: ...omes on i e before the periodic V belt replacement interval has been reached the V belt replacement tripmeter must be reset for the next periodic V belt replacement to be indicated at the correct time Self diagnosis device This model is equipped with a self diagnosis de vice for various electrical circuits If a problem is detected in any of those circuits the engine trouble warning light will come...

Page 31: ... correct installation of all parts 5 Keep all parts away from 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 ...

Page 32: ...ed air because this will damage the bearing surfac es EAS30011 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 i...

Page 33: ...stener 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 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 34: ...f 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 sure to connect the positive bat tery lead first then ...

Page 35: ... 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 the cou pler terminal slots Always insert the probes from the opposite end a of the coupler tak ing care not to loosen or damage the leads NOTICE ECA16640 For waterproof ...

Page 36: ...ure 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 Moisture Dry with an air blower Rust stains Connect and disconnect sev eral times 3 Check All connections Loose connection Connect properly TIP If ...

Page 37: ...teps 1 to 3 As a quick remedy use a contact revitalizer available at most part stores 6 Check Resistance TIP The resistance values shown were obtained at the standard measuring temperature of 20 C 68 F If the measuring temperature is not 20 C 68 F the specified measuring conditions will be shown Pocket tester 90890 03112 Analog pocket tester YU 03112 C Pocket tester 90890 03112 Analog pocket teste...

Page 38: ...BASIC SERVICE INFORMATION 1 29 ...

Page 39: ...arting with YM YU or ACC For others use part numbers starting with 90890 Tool name Tool No Illustration Reference pages Pocket tester 90890 03112 Analog pocket tester YU 03112 C 1 28 1 28 8 97 8 98 8 98 8 99 8 102 8 103 8 103 8 103 8 104 8 104 8 105 8 105 8 106 8 107 8 108 8 108 Tappet adjusting tool 90890 01311 Six piece tappet set YM A5970 3 7 Yamaha diagnostic tool 90890 03231 3 7 3 8 4 65 4 67...

Page 40: ...auge 90890 03081 Engine compression tester YU 33223 5 1 Extension 90890 04136 5 1 Camshaft wrench 90890 04162 Camshaft wrench YM 04162 5 13 5 17 Yamaha bond No 1215 90890 85505 Three bond No 1215 5 16 5 64 Slide hammer bolt 90890 01085 Slide hammer bolt 8 mm YU 01083 2 5 19 Tool name Tool No Illustration Reference pages YM A9409 7 YM A5142 4 90890 03081 YU 33223 ...

Page 41: ...mpressor adapter 22 mm YM 04108 5 23 5 28 Valve guide remover ø5 90890 04097 Valve guide remover 5 0 mm YM 04097 5 24 Valve guide installer ø5 90890 04098 Valve guide installer 5 0 mm YM 04098 5 24 Valve guide reamer ø5 90890 04099 Valve guide reamer 5 0 mm YM 04099 5 24 Piston pin puller set 90890 01304 Piston pin puller YU 01304 5 30 Tool name Tool No Illustration Reference pages YU 01083 3 YU 0...

Page 42: ...38 5 38 5 42 5 42 Socket wrench 39 mm 90890 01493 5 38 5 42 Sheave spring compressor 90890 04134 Sheave spring compressor YM 04134 5 38 5 41 Sheave fixed block 90890 04135 Sheave fixed bracket YM 04135 5 38 5 41 Oil seal guide 37 mm 90890 04177 5 41 Flywheel puller 90890 01189 Flywheel puller YM 01189 5 49 Tool name Tool No Illustration Reference pages ø37 ...

Page 43: ...109 Crankcase separating tool 90890 01135 Crankcase separator YU 01135 B 5 62 Crankshaft installer pot 90890 01274 Installing pot YU 90058 5 63 Crankshaft installer bolt 90890 01275 Bolt YU 90060 5 63 Adapter M12 90890 01278 Adapter 3 YU 90063 5 63 Tool name Tool No Illustration Reference pages YU 90058 YU 90059 ...

Page 44: ...tem tester kit YU 24460 A 6 3 6 3 Radiator cap tester adapter 90890 01352 Pressure tester adapter YU 33984 6 3 Mechanical seal installer 90890 04145 6 9 Middle driven shaft bearing driver 90890 04058 Middle drive bearing installer 40 50 mm YM 04058 6 9 Tool name Tool No Illustration Reference pages YM 91044 YU 24460 A YU 33984 ø10 ø30 ...

Page 45: ... Pressure gauge 90890 03153 Pressure gauge YU 03153 7 4 Fuel pressure adapter 6 3mm 90890 03227 7 4 Ignition checker 90890 06754 Oppama pet 4000 spark checker YM 34487 8 105 Tool name Tool No Illustration Reference pages ...

Page 46: ...SPECIAL TOOLS 1 37 ...

Page 47: ...ENING TORQUES 2 11 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 11 ENGINE TIGHTENING TORQUES 2 12 CHASSIS TIGHTENING TORQUES 2 15 LUBRICATION POINTS AND LUBRICANT TYPES 2 19 ENGINE 2 19 LUBRICATION SYSTEM CHART AND DIAGRAMS 2 21 ENGINE OIL LUBRICATION CHART 2 21 LUBRICATION DIAGRAMS 2 23 COOLING SYSTEM DIAGRAMS 2 27 CABLE ROUTING 2 29 ...

Page 48: ...nsions Overall length 1955 mm 77 0 in Overall width 740 mm 29 1 in Overall height 1115 mm 43 9 in Seat height 765 mm 30 1 in Wheelbase 1350 mm 53 1 in Ground clearance 135 mm 5 31 in Minimum turning radius 2000 mm 78 7 in Weight Curb weight 127 kg 280 lb Maximum load 168 kg 370 lb ...

Page 49: ... type or higher JASO standard MA or MB Engine oil quantity Quantity disassembled 1 00 L 1 06 US qt 0 88 Imp qt Periodic oil change 0 90 L 0 95 US qt 0 79 Imp qt Final transmission oil Type Motor oil SAE 10W 30 Type SE or higher or Gear oil SEA 85W SL 3 Quantity disassembled 0 16 L 0 17 US qt 0 14 Imp qt Quantity 0 15 L 0 16 US qt 0 13 Imp qt Oil filter Oil filter type Centrifugal Oil pump Oil pump...

Page 50: ...686 mm 1 2830 1 2869 in Limit High speed 32 487 mm 1 2790 in Lobe height Exhaust 29 420 29 520 mm 1 1583 1 1622 in Limit 29 320 mm 1 1543 in Camshaft runout limit 0 030 mm 0 0012 in Rocker arm rocker arm shaft Rocker arm inside diameter 9 985 10 000 mm 0 3931 0 3937 in Limit 10 015 mm 0 3943 in Rocker arm shaft outside diameter 9 966 9 976 mm 0 3924 0 3928 in Limit 9 936 mm 0 3912 in Rocker arm to...

Page 51: ... 37 kgf 31 36 36 08 lbf Installed compression spring force exhaust 139 50 160 50 N 14 22 16 37 kgf 31 36 36 08 lbf Spring rate K1 intake 30 67 N mm 3 13 kgf mm 175 13 lbf in Spring rate K2 intake 49 28 N mm 5 03 kgf mm 281 39 lbf in Spring rate K1 exhaust 30 62 N mm 3 12 kgf mm 174 84 lbf in Spring rate K2 exhaust 39 71 N mm 4 05 kgf mm 226 74 lbf in Spring tilt intake 1 5 mm 0 06 in Spring tilt e...

Page 52: ... Big end radial clearance 0 004 0 014 mm 0 0002 0 0006 in Clutch Clutch type Dry centrifugal automatic Automatic centrifugal clutch Clutch shoe thickness 4 0 mm 0 16 in Limit 2 5 mm 0 10 in Clutch shoe spring free length 34 8 mm 1 37 in Clutch housing inside diameter 125 0 mm 4 92 in Limit 126 0 mm 4 96 in Compression spring free length 95 0 mm 3 74 in Limit 85 5 mm 3 37 in Weight outside diameter...

Page 53: ...14 7 psi Intake air temperature sensor resistance 5700 0 6300 0 Ω at 0 C 5700 0 6300 0 Ω at 32 F Coolant temperature sensor resistance 2510 2770 Ω at 20 C 2510 2770 Ω at 68 F Coolant temperature sensor resistance 210 221 Ω at 100 C 210 221 Ω at 212 F Idling condition Fuel line pressure at idling 220 300 kPa 2 2 3 0 kgf cm 31 9 43 5 psi Engine idling speed 1500 1700 r min CO Muffler tail pipe 0 0 1...

Page 54: ...turer model IRC SS 570F Wear limit front 1 0 mm 0 04 in Rear tire Type Tubeless Size 130 70 13M C 63P Manufacturer model IRC SS 560R Wear limit rear 1 0 mm 0 04 in Tire air pressure measured on cold tires Front 1 person 150 kPa 1 50 kgf cm 22 psi Rear 1 person 250 kPa 2 50 kgf cm 36 psi Front 2 persons 150 kPa 1 50 kgf cm 22 psi Rear 2 persons 250 kPa 2 50 kgf cm 36 psi Front brake Type Single dis...

Page 55: ... bearing Center to lock angle left 47 5 Center to lock angle right 47 5 Front suspension Type Telescopic fork Spring shock absorber type Coil spring oil damper Front fork travel 100 0 mm 3 94 in Fork spring free length 245 3 mm 9 66 in Limit 240 0 mm 9 45 in Spring rate K1 5 00 N mm 0 51 kgf mm 28 55 lbf in Spring rate K2 7 50 N mm 0 76 kgf mm 42 83 lbf in Spring stroke K1 0 0 68 5 mm 0 00 2 70 in...

Page 56: ...tifier regulator Regulated voltage DC 13 7 14 7 V Rectifier capacity DC 15 0 A Battery Model YTZ7V Voltage capacity 12 V 6 0 Ah Manufacturer PT YUASA Ten hour rate charging current 0 60 A Bulb voltage wattage quantity Headlight LED Auxiliary light 12 V 5 0 W 2 Tail brake light 12 V 10 0 W 1 LED Front turn signal light 12 V 10 0 W 2 Rear turn signal light 12 V 10 0 W 2 Meter lighting LED Indicator ...

Page 57: ...Horn type Plane Quantity 1 Maximum amperage 3 0 A Coil resistance 1 06 1 11 Ω Turn signal relay Relay type Condenser Built in self canceling device No Fuel sender unit Sender unit resistance full 10 0 14 0 Ω Sender unit resistance empty 267 0 273 0 Ω Fuses Main fuse 1 15 0 A Main fuse 2 7 5 A Taillight fuse 7 5 A Signaling system fuse 7 5 A ABS motor fuse 30 0 A ABS control unit fuse 7 5 A ABS sol...

Page 58: ... 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 Nm m kgf ft lbf 10 mm 6 mm 6 0 ...

Page 59: ...ug M12 1 28 Nm 2 8 m kgf 20 ft lbf Cylinder head cover breather plate bolt M5 4 4 0 Nm 0 40 m kgf 2 9 ft lbf Valve clearance adjusting screw locknut M5 4 7 Nm 0 7 m kgf 5 1 ft lbf Timing chain tensioner bolt M6 2 10 Nm 1 0 m kgf 7 2 ft lbf Yamaha bond No 1215 Timing chain guide bolt intake side M6 1 10 Nm 1 0 m kgf 7 2 ft lbf Timing chain guide stopper bolt M6 2 10 Nm 1 0 m kgf 7 2 ft lbf Coolant ...

Page 60: ... Starter motor sub wire harness bolt M5 1 3 5 Nm 0 35 m kgf 2 5 ft lbf Starter motor cover bolt M4 2 2 5 Nm 0 25 m kgf 1 8 ft lbf Brush holder screw M4 2 1 5 Nm 0 15 m kgf 1 1 ft lbf Crankcase bolt M6 11 10 Nm 1 0 m kgf 7 2 ft lbf Crankshaft position sensor holder bolt M6 2 10 Nm 1 0 m kgf 7 2 ft lbf Transmission case cover bolt M8 6 19 Nm 1 9 m kgf 14 ft lbf Final transmission oil drain bolt M8 1...

Page 61: ...TIGHTENING TORQUES 2 14 Cylinder head tightening sequence 4 2 5 3 1 6 ...

Page 62: ...3 ft lbf Front side cover screw M5 6 1 8 Nm 0 18 m kgf 1 3 ft lbf Front cowling assembly screw M5 15 M5 4 1 8 Nm 0 18 m kgf 1 3 ft lbf Front cowling assembly screw M5 11 M5 2 1 8 Nm 0 18 m kgf 1 3 ft lbf Meter assembly panel bolt M6 2 3 8 Nm 0 38 m kgf 2 8 ft lbf Footrest board and rear side cover bolt M6 2 7 Nm 0 7 m kgf 5 1 ft lbf Footrest board assembly bolt M6 4 3 8 Nm 0 38 m kgf 2 8 ft lbf Fo...

Page 63: ...0 6 m kgf 4 3 ft lbf Rear brake lever pivot nut M6 1 6 Nm 0 6 m kgf 4 3 ft lbf Front brake lever pivot bolt M6 1 6 Nm 0 6 m kgf 4 3 ft lbf Front brake lever pivot nut M6 1 6 Nm 0 6 m kgf 4 3 ft lbf Grip end bolt left M6 1 7 Nm 0 7 m kgf 5 1 ft lbf Grip end bolt right M6 1 7 Nm 0 7 m kgf 5 1 ft lbf Brake light switch screw M4 2 1 2 Nm 0 12 m kgf 0 87 ft lbf Handlebar bracket nut M10 1 63 Nm 6 3 m k...

Page 64: ...21 ft lbf Front brake hose guide bolt M6 1 7 Nm 0 7 m kgf 5 1 ft lbf Hydraulic unit assembly bolt M6 3 7 Nm 0 7 m kgf 5 1 ft lbf Front brake hose union bolt hydrau lic unit assembly side M10 2 29 Nm 2 9 m kgf 21 ft lbf Rear brake hose union bolt hydrau lic unit assembly side M10 2 29 Nm 2 9 m kgf 21 ft lbf Rectifier regulator nut M6 2 7 Nm 0 7 m kgf 5 1 ft lbf Front cowling assembly bracket M8 2 2...

Page 65: ...n the lower ring nut 16 Nm 1 6 m kgf 12 ft lbf with a torque wrench and the steering nut wrench 3 Install the rubber washer and the center ring nut 4 Finger tighten the center ring nut align the slots of both ring nuts and then install the lock washer 5 Hold the lower and center ring nuts and then tighten the upper ring nut 75 Nm 7 5 m kgf 54 ft lbf with a torque wrench and the steering nut wrench...

Page 66: ...st Rocker arm valve inner surface Camshaft sprocket Connecting rod big end face Piston pin outer surface Piston piston ring and cylinder inner surface Crank pin Cam chain sprocket inner surface Oil pump drive gear inner surface Oil pump shaft O ring fuel injector Starter wheel and bearing Starter clutch idle gear inner surface Drive axle and bearings Crankshaft threads and conical spring washer ou...

Page 67: ...LUBRICATION POINTS AND LUBRICANT TYPES 2 20 ...

Page 68: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 21 EAS20019 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS30020 ENGINE OIL LUBRICATION CHART 5 4 3 2 1 ...

Page 69: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 22 1 Oil strainer 2 Oil pump assembly 3 Crankshaft 4 Oil nozzle 5 Camshaft ...

Page 70: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 23 EAS30021 LUBRICATION DIAGRAMS 1 3 2 ...

Page 71: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 24 1 Oil strainer 2 Oil pump assembly 3 Camshaft ...

Page 72: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 25 3 2 1 4 ...

Page 73: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 26 1 Oil strainer 2 Oil pump assembly 3 Crankshaft 4 Rocker arm Valve stem end ...

Page 74: ...COOLING SYSTEM DIAGRAMS 2 27 EAS20020 COOLING SYSTEM DIAGRAMS 8 5 7 6 4 3 2 1 7 7 6 5 4 3 2 1 ...

Page 75: ...COOLING SYSTEM DIAGRAMS 2 28 1 Radiator cap 2 Coolant reservoir hose 3 Radiator 4 Radiator inlet hose 5 Radiator outlet hose 6 Thermostat assembly 7 Water pump inlet hose 8 Water pump assembly ...

Page 76: ...CABLE ROUTING 2 29 EAS20021 CABLE ROUTING Handlebar front view A B C 1 1 1 2 2 2 3 4 5 4 5 6 7 ...

Page 77: ...e master cylinder to hydraulic unit 3 Rear brake light switch lead 4 Throttle cable decelerator cable 5 Throttle cable accelerator cable 6 Front brake light switch lead 7 Lower handlebar cover A 40 44 mm 1 57 1 73 in B 5 9 mm 0 20 0 35 in C Route the throttle cables through the hole in the lower handlebar cover ...

Page 78: ...CABLE ROUTING 2 31 Handlebar left side view B A 1 1 1 1 2 2 3 4 4 3 4 3 3 4 5 5 5 6 6 6 6 6 7 7 7 9 8 8 11 10 ...

Page 79: ...andlebar switch 6 Wire harness 7 Front brake hose front brake master cylinder to hydraulic unit 8 Handlebar switch coupler right handlebar switch 9 Front brake light switch lead 10 Handlebar switch connector left handlebar switch 11 Bracket A Route the throttle cable accelerator cable to the front of the throttle cable decelerator cable B Insert the projection on the wire harness holder into the h...

Page 80: ...CABLE ROUTING 2 33 Front frame front and left side view A B C 1 2 3 3 4 4 4 5 5 15 6 7 8 9 9 9 9 10 10 10 10 11 11 11 12 12 13 14 14 15 16 17 18 18 18 18 20 19 21 22 23 19 19 19 24 ...

Page 81: ...gnal light lead front right turn signal light 16 Meter assembly 17 Front wheel sensor coupler 18 Rear brake hose rear brake master cylinder to hydraulic unit 19 Front brake hose front brake master cylinder to hydraulic unit 20 Throttle cable decelerator cable 21 Throttle cable accelerator cable 22 Seat lock cable 23 Rectifier regulator lead 24 Front turn signal light A After connecting the meter a...

Page 82: ...CABLE ROUTING 2 35 Front fork rear and right side view I H F G A B B C B C C D E F G 1 1 1 2 3 3 3 4 2 5 5 6 7 6 7 6 7 7 6 6 7 6 7 6 ...

Page 83: ...per 7 Front wheel sensor lead A Route the front brake hose hydraulic unit to front brake caliper through the guide B Position the holder within the range shown in the illustration C Route the horn lead through the holder D Connect the horn lead pink to the horn terminal E Connect the horn lead brown to the horn terminal F Inward G Outward H Forward I Rearward ...

Page 84: ...CABLE ROUTING 2 37 Frame left side view A B C C D E E 1 1 2 2 3 3 4 4 5 8 6 7 6 6 7 8 9 9 9 10 10 10 11 11 11 12 15 13 14 14 15 16 16 17 16 18 19 20 21 F G H ...

Page 85: ... test coupler lead 19 ECU lead 20 Fuse box 1 21 Fuse box 2 A White tape B Route the throttle cable accelerator cable and throttle cable decelerator cable through the guide Be sure to route the throttle cable accelerator cable above the throttle cable decelerator cable C Fasten the wire harness and negative battery lead with the plastic band D Make sure that the engine ground lead terminal contacts...

Page 86: ...CABLE ROUTING 2 39 Frame right side view A B C 1 1 2 1 2 3 4 4 5 6 6 7 7 8 8 9 9 10 12 11 12 13 13 15 14 15 16 17 18 19 20 20 21 22 23 24 ...

Page 87: ...e actuator solenoid 17 Spark plug lead 18 Water pump inlet hose 19 Thermostat assembly 20 Radiator inlet hose 21 Sidestand switch lead 22 Fuel pump lead 23 Fuel pump 24 Ignition coil lead A Route the spark plug lead between the VVA variable valve actuator solenoid and the water pump inlet hose Make sure that the spark plug lead does not contact the VVA variable valve actuator solenoid or water pum...

Page 88: ...CABLE ROUTING 2 41 Frame top view 9 A B C D 1 2 9 6 5 3 3 9 4 4 5 6 7 8 9 10 11 12 13 E ...

Page 89: ...rake light assembly lead 11 Seat lock cable 12 ABS test coupler 13 Yamaha diagnostic tool coupler A Route the seat lock cable through the hole in the frame B Install fuse box 2 completely onto the tab on the storage box C Install the protective cap onto the ABS test coupler D Route the negative battery lead through the hole in the storage box E Install fuse box 1 completely onto the tab on the sto...

Page 90: ...CABLE ROUTING 2 43 Hydraulic unit top and right side view A B C 1 1 2 2 3 3 4 5 5 6 6 7 4 ...

Page 91: ...iper 4 Rear brake hose rear brake master cylinder to hydraulic unit 5 Front brake hose front brake master cylinder to hydraulic unit 6 Front brake hose hydraulic unit to front brake caliper 7 Hydraulic unit assembly lead A Route the main switch lead through the guide B 30 C The holder may be facing in any direction ...

Page 92: ...CABLE ROUTING 2 45 Rear brake right side view A C B C D E 1 2 3 3 3 3 3 3 4 5 5 5 6 6 6 6 6 6 6 7 7 7 8 9 10 ...

Page 93: ...acket 9 Rear brake hose holder 10 AC magneto lead A Connect the coolant reservoir hose to the radiator and then fasten the hose by inserting the projection on the holder into the hole in the rear brake hose bracket and rear brake hose holder B Position the holder within the range shown in the illustration C Route the rear brake hose hydraulic unit to rear brake caliper through the guide D Upward E...

Page 94: ...CABLE ROUTING 2 47 Fuel tank right side view A B D 1 2 2 1 3 3 4 4 5 5 7 A 6 8 9 9 C ...

Page 95: ...O2 sensor lead A Install the hose completely onto the hose fitting B Position the hose clamp 3 7 mm 0 12 0 28 in from the end of the hose Point the ends of the hose clamp upward C Fasten the grommet on the fuel hose with the holder D Insert the end of the fuel tank overflow hose into the center lower cover Make sure that the end of the hose protector on the fuel tank overflow hose contacts the edg...

Page 96: ...CABLE ROUTING 2 49 Fuel tank top and bottom view A 1 B 3 B 2 C 4 ...

Page 97: ...voir breather hose 3 Coolant reservoir hose 4 Fuel hose A Install the coolant reservoir cap as shown in the illustration B Align the white paint mark on the hose with the projection on the coolant reservoir C Fasten the grommet on the fuel hose with the holder ...

Page 98: ...CABLE ROUTING 2 51 Radiator top and right side view D E B A A A H I C 1 2 7 3 4 5 6 6 B J A A J K L A 7 5 3 4 2 2 1 D E G F D E O D E G F D E N M E D N M ...

Page 99: ... 0 20 in D Upward E Downward F Forward G Rearward H Point the ends of the hose clamp to the left Make sure not to install the hose clamp on the raised portion of the hose fitting I To coolant reservoir J Face the yellow paint mark on the hose to the right K Align the yellow paint mark on the hose with the center of the thermostat assembly L Face the white paint mark on the hose upward M Outward N ...

Page 100: ...CABLE ROUTING 2 53 Air filter case top and left side view A B B B C C C C D D D F E G 1 2 1 3 3 ...

Page 101: ...lter case A Face the white paint mark on the hose upward B Point the ends of the hose clamp upward C Install the hose completely onto the hose fitting D 1 5 mm 0 04 0 20 in E 5 6 mm 0 20 0 24 in F Face the yellow paint mark on the hose outward G Point the ends of the hose clamp outward ...

Page 102: ...CABLE ROUTING 2 55 ...

Page 103: ...10 CHECKING THE FRONT BRAKE HOSES 3 11 CHECKING THE REAR BRAKE HOSES 3 11 BLEEDING THE HYDRAULIC BRAKE SYSTEM 3 12 CHECKING THE WHEELS 3 13 CHECKING THE TIRES 3 13 CHECKING THE WHEEL BEARINGS 3 14 CHECKING AND ADJUSTING THE STEERING HEAD 3 14 LUBRICATING THE STEERING HEAD 3 16 CHECKING THE CHASSIS FASTENERS 3 16 LUBRICATING THE LEVERS 3 16 CHECKING THE SIDESTAND 3 16 LUBRICATING THE SIDESTAND 3 16...

Page 104: ...CHECKING THE SWITCHES LIGHTS AND SIGNALS 3 24 ADJUSTING THE HEADLIGHT BEAM 3 24 ...

Page 105: ......

Page 106: ...CE AND LUBRICATION CHART TIP The annual checks must be performed every year except if a kilometer based maintenance is performed instead From 20000 km 12000 mi repeat the maintenance intervals starting from 4000 km 2400 mi Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools data and technical skills NO ITEM CHECK OR MAINTENANCE JOB ODOMETER READING wh...

Page 107: ...e 15 Rear brake lever pivot shaft Lubricate with silicone grease 16 Sidestand center stand Check operation Lubricate with lithium soap based grease 17 Sidestand switch Check operation 18 Front fork Check operation and for oil leakage 19 Shock absorber assemblies Check operation and shock absorbers for oil leakage 20 Engine oil Change The first 500 km 312 mi 1000 km 625 mi next every 3000 km 1875 m...

Page 108: ...nd calipers and change the brake fluid Replace the brake hoses every four years and if cracked or damaged Fuel system service Use only unleaded gasoline The use of leaded gasoline will cause severe damage to internal en gine parts such as the valves and piston rings as well as to the exhaust system Replace the fuel filler cover every two years or if cracked or damaged Check the fuel filter for clo...

Page 109: ...e contaminants Replace TIP Replace the fuel filter every 12000 km 7500 mi of operation 3 Install Fuel filter Refer to FUEL TANK on page 7 1 Center lower cover Refer to GENERAL CHASSIS 5 on page 4 12 Fuel tank cover Refer to GENERAL CHASSIS 3 on page 4 7 Front side covers Refer to GENERAL CHASSIS 2 on page 4 4 EAS30620 CHECKING THE SPARK PLUG 1 Remove Front side cover right Refer to GENERAL CHASSIS...

Page 110: ... page 4 4 EAS30622 ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves TIP Valve clearance adjustment should be made on a cold engine at room temperature When the valve clearance is to be measured or adjusted the piston must be at top dead center TDC on the compression stroke 1 Remove Battery Refer to GENERAL CHASSIS 1 on page 4 1 Front side covers Refer to GENERAL C...

Page 111: ... camshaft stopper plate c Measure the valve clearance with a thickness gauge 1 Out of specification Adjust 5 Adjust Valve clearance a Loosen the locknut 1 b Insert a thickness gauge 2 between the end of the adjusting screw and the valve tip c Turn the adjusting screw 3 in direction a or b with the tappet adjusting tool 4 until the specified valve clearance is obtained Valve clearance cold Intake 0...

Page 112: ...ication Go to next step 3 Check ISC idle speed control learning value 00 or 01 Check the intake system 02 Clean the ISC idle speed control unit and throttle body Refer to CLEANING THE ISC IDLE SPEED CONTROL UNIT AND THROTTLE BODY on page 7 12 a Connect the Yamaha diagnostic tool Use the diagnostic code number 67 Refer to SELF DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE on page 9 5 EAS30625 CHECK...

Page 113: ...k Air filter element Damage Replace TIP Replace the air filter element every 12000 km 7500 mi of operation The air filter needs more frequent service if you are riding in unusually wet or dusty areas 3 Install Air filter element Air filter case cover NOTICE ECA20480 Never operate the engine without the air filter element installed Unfiltered air will cause rapid wear of engine parts and may damage...

Page 114: ...RAL CHASSIS 2 on page 4 4 Battery Refer to GENERAL CHASSIS 1 on page 4 1 EAS31704 CLEANING THE V BELT CASE AIR FILTER ELEMENT AND CLEANING THE CHECK HOSE TIP Check the V belt case air filter check hose 1 that is located on the rear side of the V belt case If dust or water or both collects in the hose clean the hose and replace the V belt case air filter el ement 1 Remove V belt case air filter ele...

Page 115: ... not working properly Check the brake system Refer to FRONT BRAKE on page 4 36 and REAR BRAKE on page 4 49 TIP Drive on the road operate the front and rear brakes separately and check to see if the brakes are operating properly EAS30633 CHECKING THE FRONT BRAKE PADS The following procedure applies to all of the brake pads 1 Operate the brake 2 Check Front brake pad Wear indicator grooves a almost ...

Page 116: ...reser voir Water will significantly lower the boil ing point of the brake fluid and could cause vapor lock NOTICE ECA13540 Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately EAS30635 CHECKING THE FRONT BRAKE HOSES 1 Check Brake hoses 1 Cracks damage Replace 2 Check Brake hose holder Brake hose guide Loose Tighten the holder and gui...

Page 117: ...e for a few hours Repeat the bleeding procedure when the tiny bubbles in the hose have disappeared 1 Bleed ABS a Fill the brake master cylinder reservoir to the proper level with the specified brake fluid b Install the brake master cylinder diaphragm c Connect a clear plastic hose 1 tightly to the bleed screw 2 d Place the other end of the hose into a con tainer e Slowly apply the brake several ti...

Page 118: ...late WARNING EWA13181 The tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperature The tire pressure and the suspension must be adjusted according to the total weight including cargo rider passenger and ac cessories and the anticipated riding speed Operation of an overloaded vehicle could cause tire damage an accident or an injury NEVER OVERLO...

Page 119: ...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 wheel rotation Align the ...

Page 120: ...with a steering nut wrench WARNING EWA13140 Do not overtighten the lower ring nut d Check the steering head for looseness or binding by turning the front fork all the way in both directions If any binding is felt remove the lower bracket and check the upper and lower bearings Refer to STEERING HEAD on page 4 83 e Install the rubber washer f Install the center ring nut g Finger tighten the center r...

Page 121: ...KING THE CENTERSTAND 1 Check Centerstand operation Check that the centerstand moves smoothly Rough movement Repair or replace EAS30857 LUBRICATING THE CENTERSTAND Lubricate the pivoting point metal to metal mov ing parts and spring contact points of the center stand EAS30652 CHECKING THE SIDESTAND SWITCH Refer to CHECKING THE SWITCHES on page 8 95 EAS30653 CHECKING THE FRONT FORK 1 Stand the vehic...

Page 122: ...e is upright 2 Start the engine warm it up for several min utes and then turn it off 3 Remove Dipstick 1 4 Check Engine oil level The engine oil level should be between the minimum level mark a and maximum level mark b Below the minimum level mark Add the recommended engine oil to the proper level TIP Before checking the engine oil level wait a few minutes until the oil has settled Do not screw th...

Page 123: ...the gasket 7 Fill Crankcase with the specified amount of the recom mended engine oil 8 Install Dipstick 9 Start the engine warm it up for several min utes and then turn it off 10 Check Engine for engine oil leaks 11 Check Engine oil level Refer to CHECKING THE ENGINE OIL LEVEL on page 3 17 12 Remove Front side cover right Refer to GENERAL CHASSIS 2 on page 4 4 Footrest board assembly right Refer t...

Page 124: ... the antifreeze content of the coolant If water is used instead of coolant check and if nec essary correct the antifreeze concentra tion 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 4 Check Coolant level TIP Before checking the coolant level wait a few minutes unti...

Page 125: ...r cap as follows Place a thick rag or a towel over the radiator cap and slowly turn the radiator cap counter clockwise toward the detent to allow any re sidual pressure to escape When the hissing sound has stopped press down on the radi ator cap and turn it counterclockwise to re move 7 Remove Coolant drain bolt radiator side 1 along with the O ring Coolant drain bolt cylinder side 2 along with th...

Page 126: ... immediately wash them with wa ter Do not mix different types of antifreeze 12 Install Radiator cap Coolant reservoir 13 Fill Coolant reservoir with the recommended coolant to the maxi mum level mark a 14 Install Coolant reservoir cap 1 TIP Point the tab a on the coolant reservoir cap for ward 15 Start the engine warm it up for several min utes and then turn it off 16 Check Coolant level Refer to ...

Page 127: ... lithium soap based grease 8 Start the engine warm it up for several min utes and then turn it off 9 Check Final transmission oil leakage EAS31188 REPLACING THE V BELT 1 Remove Air filter case Refer to AIR FILTER CASE on page 7 7 V belt case Refer to V BELT AUTOMATIC TRANSMIS SION on page 5 34 2 Check V belt Damage wear Replace Grease oil Clean the primary and second ary pulleys Refer to V BELT AU...

Page 128: ...ter cable may cause the cable to corrode and interfere with its movement Re place damaged outer cable and inner cables as soon as possible 1 Check Outer cable Damage Replace 2 Check Cable operation Rough movement Lubricate TIP Hold the cable end upright and pour a few drops of lubricant into the cable sheath or use a suit able lubricating device EAS30861 CHECKING THE THROTTLE GRIP OPERATION 1 Chec...

Page 129: ...nsure that this does not cause the engine idling speed to change EAS30663 CHECKING THE SWITCHES LIGHTS AND SIGNALS 1 Check that all switches operate and that all lights come on Refer to INSTRUMENT AND CONTROL FUNCTIONS in Owner s manual Faulty Refer to CHECKING THE SWITCHES on page 8 95 and CHECKING THE BULBS AND BULB SOCKETS on page 8 98 EAS30664 ADJUSTING THE HEADLIGHT BEAM 1 Adjust Headlight be...

Page 130: ...PERIODIC MAINTENANCE 3 25 ...

Page 131: ... 11 INSTALLING THE REAR SIDE COVER ASSEMBLY 4 11 GENERAL CHASSIS 5 4 12 INSTALLING THE SIDESTAND 4 14 INSTALLING THE CENTER LOWER COVER 4 14 INSTALLING THE FOOTREST BOARD ASSEMBLY 4 14 INSTALLING THE BOTTOM COVER 4 14 GENERAL CHASSIS 6 4 16 REMOVING THE FRONT UPPER COWLING ASSEMBLY 4 17 INSTALLING THE FRONT UPPER COWLING ASSEMBLY 4 17 DISASSEMBLING THE FRONT UPPER COWLING ASSEMBLY 4 17 ASSEMBLING ...

Page 132: ...NT BRAKE CALIPER 4 45 INSTALLING THE FRONT BRAKE CALIPER 4 45 REMOVING THE FRONT BRAKE MASTER CYLINDER 4 46 CHECKING THE FRONT BRAKE MASTER CYLINDER 4 47 ASSEMBLING THE FRONT BRAKE MASTER CYLINDER 4 47 INSTALLING THE FRONT BRAKE MASTER CYLINDER 4 47 REAR BRAKE 4 49 INTRODUCTION 4 55 CHECKING THE REAR BRAKE DISC 4 55 REPLACING THE REAR BRAKE PADS 4 55 REMOVING THE REAR BRAKE CALIPER 4 56 DISASSEMBL...

Page 133: ... 76 REMOVING THE FRONT FORK LEGS 4 78 DISASSEMBLING THE FRONT FORK LEGS 4 78 CHECKING THE FRONT FORK LEGS 4 79 ASSEMBLING THE FRONT FORK LEGS 4 79 INSTALLING THE FRONT FORK LEGS 4 82 STEERING HEAD 4 83 REMOVING THE LOWER BRACKET 4 85 CHECKING THE STEERING HEAD 4 85 INSTALLING THE STEERING HEAD 4 85 REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM 4 88 REMOVING THE SWINGARM 4 90 MAINTENANCE OF THE REAR ...

Page 134: ...and ECU Order Job Parts to remove Q ty Remarks Seat Open 1 Battery cover 1 2 Negative battery lead 1 Disconnect 3 Positive battery lead 1 Disconnect 4 Battery 1 5 ECU coupler 1 Disconnect 6 ECU Engine Control Unit 1 7 Band 1 7 6 5 4 2 3 1 1 8 Nm 0 18 m kgf 1 3 ft Ibf T R ...

Page 135: ... storage box and then slide the cover forward b Install the battery cover screws and then tighten the screws to specification EAS31679 REMOVING THE ECU engine control unit 1 Disconnect ECU coupler 1 TIP While pushing the portion a of the ECU cou pler move the lock lever b in the direction of the arrow shown to disconnect the coupler EAS31680 INSTALLING THE ECU engine control unit 1 Connect ECU cou...

Page 136: ...GENERAL CHASSIS 1 4 3 a 1 ...

Page 137: ...ob Parts to remove Q ty Remarks 1 Grab bar 1 2 Tail brake light outer cover 1 3 Tail brake light inner cover 1 4 Front side cover left 1 5 Front side cover right 1 1 8 Nm 0 18 m kgf 1 3 ft Ibf T R 1 8 Nm 0 18 m kgf 1 3 ft Ibf T R 1 8 Nm 0 18 m kgf 1 3 ft Ibf T R 17 Nm 1 7 m kgf 12 ft Ibf T R 4 5 2 1 3 ...

Page 138: ...the projection a on the cover into the hole b in the tail brake light b Install the tail brake light outer cover screws and then tighten the screws to specification EAS31683 REMOVING THE FRONT SIDE COVER The following procedure applies to both of the front side cover 1 Remove Front side cover 1 a Remove the front side cover screws b Pull the front side cover outward to remove the projections a fro...

Page 139: ... 6 a Fit the projections a on the front side cowl ing into the grommets b b Install the front side cover screws and then tighten the screw to specification T R Front side cover screw 1 8 Nm 0 18 m kgf 1 3 ft lbf b a a 1 b ...

Page 140: ... to remove Q ty Remarks Front side covers Refer to GENERAL CHASSIS 2 on page 4 4 1 Fuel tank cap 1 2 Fuel tank cover 1 3 Center cover 1 4 Seat assembly 1 5 Owner s tool kit 1 6 Seat 1 7 Seat hinge 1 5 6 4 3 1 2 7 4 3 1 8 Nm 0 18 m kgf 1 3 ft Ibf T R 1 8 Nm 0 18 m kgf 1 3 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R ...

Page 141: ...projections c on the cover from the holes d in the leg shield EAS31686 INSTALLING THE FUEL TANK COVER 1 Install Fuel tank cover 1 a Slide the fuel tank cover forward and fit the projections a on the cover into the holes b in the leg shield b Fit the projections c on the fuel tank cover into the holes d in the storage box c Install the fuel tank cover screws and then tighten the screws to specifica...

Page 142: ...ENERAL CHASSIS 3 on page 4 7 1 Rear side cover assembly left 1 2 Center side cover left 1 3 Rear side cover left 1 4 Rear side cover assembly right 1 5 Center side cover right 1 6 Rear side cover right 1 7 Brake light coupler 1 Disconnect 8 Taillight rear turn signal coupler 1 Disconnect 8 7 1 3 3 3 2 6 5 4 7 Nm 0 7 m kgf 5 1 ft Ibf T R 1 8 Nm 0 18 m kgf 1 3 ft Ibf T R 1 8 Nm 0 18 m kgf 1 3 ft Ibf...

Page 143: ...Q ty Remarks 9 Tail brake light assembly 1 10 Starter relay 1 11 Fuse box 1 1 12 Fuse box 2 1 13 Storage box 1 14 Flap 1 9 3 3 10 14 11 13 12 7 Nm 0 7 m kgf 5 1 ft Ibf T R 1 8 Nm 0 18 m kgf 1 3 ft Ibf T R 1 8 Nm 0 18 m kgf 1 3 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R ...

Page 144: ... stor age box EAS31688 INSTALLING THE REAR SIDE COVER ASSEMBLY The following procedure applies to both of the rear side cover assembly 1 Install Rear side cover assembly 1 a Fit the projections a on the rear side cover assembly into the holes b in the storage box b Install the quick fasteners screw and bolt and then tighten the screw and bolts to spec ification 1 a b T R Rear side cover assembly s...

Page 145: ... GENERAL CHASSIS 3 on page 4 7 Storage box Refer to GENERAL CHASSIS 4 on page 4 9 1 Bottom cover 1 2 Footrest board mat left 2 3 Footrest board mat right 2 4 Footrest board assembly left 1 5 Footrest board assembly right 1 6 Center lower cover 1 7 Front lower cover left 1 8 Footrest board left 1 1 8 Nm 0 18 m kgf 1 3 ft Ibf T R 1 8 Nm 0 18 m kgf 1 3 ft Ibf T R 3 8 Nm 0 38 m kgf 2 8 ft Ibf T R 3 8 ...

Page 146: ...ks 9 Front lower cover right 1 10 Coolant reservoir cap cover 1 11 Footrest board right 1 12 Outer spring 1 13 Inner spring 1 14 Sidestand 1 1 8 Nm 0 18 m kgf 1 3 ft Ibf T R 1 8 Nm 0 18 m kgf 1 3 ft Ibf T R 3 8 Nm 0 38 m kgf 2 8 ft Ibf T R 3 8 Nm 0 38 m kgf 2 8 ft Ibf T R 24 Nm 2 4 m kgf 17 ft Ibf T R LS LS 14 11 10 9 12 13 ...

Page 147: ...ver Fit the hole b in the center lower cover over the hook c on the frame EAS31690 INSTALLING THE FOOTREST BOARD ASSEMBLY 1 Install Footrest board assembly 1 TIP Make sure that the projection a on the frame fits into the hole b in the footrest board assem bly EAS31691 INSTALLING THE BOTTOM COVER 1 Install Bottom cover 1 TIP Make sure that the projections a on the center lower cover fit into the ho...

Page 148: ...GENERAL CHASSIS 5 4 15 1 b a ...

Page 149: ...nt upper cowling 1 4 Front upper panel 1 5 Meter panel assembly 1 6 Meter assembly coupler 1 Disconnect 7 Meter assembly 1 8 Meter assembly inner panel 1 9 Meter assembly panel 1 1 8 Nm 0 18 m kgf 1 3 ft Ibf T R 1 8 Nm 0 18 m kgf 1 3 ft Ibf T R 0 4 Nm 0 04 m kgf 0 29 ft Ibf T R 1 8 Nm 0 18 m kgf 1 3 ft Ibf T R 3 8 Nm 0 38 m kgf 2 8 ft Ibf T R 1 2 3 4 6 5 7 9 8 4 3 6 4 4 ...

Page 150: ...c into the holes d in the leg shield b Install the front upper cowling assembly screw and then tighten the screw to specifi cation EAS31694 DISASSEMBLING THE FRONT UPPER COWLING ASSEMBLY 1 Disassemble Front upper cowling 1 Front upper panel 2 TIP Remove the projections a on the front upper cowling from the holes b in the front upper pan el slide the panel in the direction shown in the il lustratio...

Page 151: ...de the front upper panel in the direction shown in the illustration fit the projections a on the panel into the holes b in the front upper cowling and fit the projections c on the cowling into the holes d in the panel a 2 1 c c b d ...

Page 152: ...efer to GENERAL CHASSIS 4 on page 4 9 Center lower cover Refer to GENERAL CHASSIS 5 on page 4 12 Meter panel assembly Refer to GENERAL CHASSIS 6 on page 4 16 1 Headlight unit coupler 1 Disconnect 2 Auxiliary light coupler 1 Disconnect 3 Front turn signal light coupler left 1 Disconnect 1 8 Nm 0 18 m kgf 1 3 ft Ibf T R 1 8 Nm 0 18 m kgf 1 3 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 1 8 Nm 0 18 m kgf...

Page 153: ...ront turn signal light right 1 8 Front side cowling left 1 9 Front side panel left 1 10 Front side cowling right 1 11 Front side panel right 1 12 Front lower cowling 1 13 Headlight unit 1 1 8 Nm 0 18 m kgf 1 3 ft Ibf T R 1 8 Nm 0 18 m kgf 1 3 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 1 8 Nm 0 18 m kgf 1 3 ft Ibf T R 1 8 Nm 0 18 m kgf 1 3 ft Ibf T R 1 8 Nm 0 18 m kgf 1 3 ft Ibf T R 8 5 5 3 3 6 8 5 7...

Page 154: ...leg shield into the holes b in the front cowling assembly b Install the front cowling assembly screws and then tighten the screws to specification EAS31696 REMOVING THE FRONT SIDE COWLING The following procedure applies to both of the front side cowling 1 Remove Front side cowling 1 a Removing the front side cowling screws b Remove the projections a on the front side cowling from the holes b in th...

Page 155: ...wl ing b Install the front side cowling screws and then tighten the screws to specification EAS31698 INSTALLING THE FRONT TURN SIGNAL LIGHT The following procedure applies to both of the front turn signal light 1 Install Turn signal light 1 TIP Tighten the turn signal light screw in the proper tightening sequence as shown T R Front side cowling screw 1 8 Nm 0 18 m kgf 1 3 ft lbf T R Turn signal li...

Page 156: ...IS 2 on page 4 4 Seat assembly Refer to GENERAL CHASSIS 3 on page 4 7 Storage box Refer to GENERAL CHASSIS 4 on page 4 9 Center lower cover Refer to GENERAL CHASSIS 5 on page 4 12 Meter panel assembly Refer to GENERAL CHASSIS 6 on page 4 16 Front cowling assembly Refer to GENERAL CHASSIS 7 on page 4 19 1 Key shutter 1 2 Leg shield 1 1 2 3 5 Nm 0 35 m kgf 2 5 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T ...

Page 157: ...00 INSTALLING THE KEY SHUTTER 1 Install Key shutter 1 TIP While holding the key shutter so that it contacts the leg shield 2 tighten the key shutter screw 3 to specification T R Key shutter screw 3 5 Nm 0 35 m kgf 2 5 ft lbf 3 2 1 ...

Page 158: ...lder 1 3 Front brake caliper 1 4 Front wheel sensor 1 5 Front wheel axle nut 1 6 Front wheel axle 1 7 Collar 2 8 Front wheel 1 9 Front wheel sensor rotor 1 10 Front brake disc 1 LT LS New New LT LT New 7 Nm 0 7 m kgf 5 1 ft Ibf T R 8 Nm 0 8 m kgf 5 8 ft Ibf T R 23 Nm 2 3 m kgf 17 ft Ibf T R 35 Nm 3 5 m kgf 25 ft Ibf T R 40 Nm 4 0 m kgf 29 ft Ibf T R 3 5 1 2 4 6 7 8 7 9 10 ...

Page 159: ...FRONT WHEEL 4 26 Disassembling the front wheel Order Job Parts to remove Q ty Remarks 1 Oil seal 2 2 Wheel bearing 2 3 Spacer 1 New New New New 2 1 1 2 3 LS LS ...

Page 160: ...CA21830 Do not apply the brake lever when removing the brake caliper 3 Elevate Front wheel TIP Place the vehicle on a suitable stand so that the front wheel is elevated EAS30146 DISASSEMBLING THE FRONT WHEEL 1 Remove Oil seals Wheel bearings a Clean the surface of the front wheel hub b Remove the oil seals 1 with a flat head screwdriver TIP To prevent damaging the wheel place a rag 2 between the s...

Page 161: ...ont 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 When cleaning the wheel sensor rotor be care ful not to damage the surface o...

Page 162: ...ancing weight s 2 Find Front wheel s heavy spot TIP Place the front wheel on a suitable balancing stand a Spin the front wheel b When the front wheel stops put an X1 mark at the bottom of the wheel c Turn the front wheel 90 so that the X1 mark is positioned as shown d Release the front wheel e When the wheel stops put an X2 mark at the bottom of the wheel f Repeat steps c through e several times u...

Page 163: ...heel sensor rotor 2 NOTICE ECA21011 Do not drop the wheel sensor rotor or sub ject it to shocks If any solvent gets on the wheel sensor ro tor wipe it off immediately Replace the brake disc bolts and wheel sensor rotor bolts with new ones TIP Install the brake disc with its chamfered side a facing inward Install the front wheel sensor rotor with the stamped mark b facing away from the wheel Tighte...

Page 164: ...ensor rotor installation conditions war page caused by overtorque wrong installa tion direction rotor decentering LOCTITE on the mounting surface of the rotor defor mation caused by an impact during service and caught foreign materials If there is any defective part repair or replace the defective part TIP Measure the distance between the front wheel sensor rotor and front wheel sensor in several ...

Page 165: ...L 4 32 TIP While holding the front brake hose guide and front wheel sensor lead holder so that the por tions a of the guide and holder contact the front fork outer tube tighten the bolts to specification 1 2 a a ...

Page 166: ...ox Refer to GENERAL CHASSIS 4 on page 4 9 Muffler Refer to ENGINE REMOVAL on page 5 3 Radiator cover Refer to RADIATOR on page 6 1 Air filter case Refer to AIR FILTER CASE on page 7 7 Swingarm assembly Refer to REAR SHOCK ABSORBER AS SEMBLIES AND SWINGARM on page 4 88 1 Rear wheel 1 2 Rear wheel sensor rotor 1 3 Rear brake disc 1 LT LT LT LT LT LT New New 1 3 2 8 Nm 0 8 m kgf 5 8 ft Ibf T R 8 Nm 0...

Page 167: ... any type of magnets including mag netic pick up tools magnetic screwdrivers etc away from the rear wheel sensor rotor Do not drop or shock the wheel sensor ro tor 1 Check Rear wheel sensor rotor Refer to MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR on page 4 28 EAS30164 ADJUSTING THE REAR WHEEL STATIC BALANCE TIP After replacing the tire wheel or both the rear wheel static balance shoul...

Page 168: ...REAR WHEEL 4 35 2 Check Rear brake disc Refer to CHECKING THE REAR BRAKE DISC on page 4 55 1 a 1 b 2 ...

Page 169: ...to remove Q ty Remarks 1 Front wheel sensor lead holder 1 2 Front brake caliper 1 3 Brake pad clip 2 4 Brake pad pin 1 5 Brake pad inner 1 6 Brake pad outer 1 7 Brake pad spring 1 8 Brake caliper bleed screw 1 5 6 7 2 3 4 8 1 35 Nm 3 5 m kgf 25 ft Ibf T R 6 Nm 0 6 m kgf 4 3 ft Ibf T R ...

Page 170: ...eservoir diaphragm hold er 1 3 Brake master cylinder reservoir diaphragm 1 4 Front brake light switch connector 2 Disconnect 5 Front brake light switch 1 6 Front brake lever pivot bolt nut 1 1 7 Front brake lever 1 8 Front brake hose union bolt master cylinder side 1 9 Brake hose gasket 2 New 1 2 7 6 9 8 6 5 4 3 S 1 2 Nm 0 12 m kgf 0 87 ft Ibf T R 6 Nm 0 6 m kgf 4 3 ft Ibf T R 6 Nm 0 6 m kgf 4 3 f...

Page 171: ...master cylinder to hydraulic unit 1 Disconnect 11 Front brake master cylinder holder 1 12 Front brake master cylinder assembly 1 12 10 11 New S 1 2 Nm 0 12 m kgf 0 87 ft Ibf T R 6 Nm 0 6 m kgf 4 3 ft Ibf T R 6 Nm 0 6 m kgf 4 3 ft Ibf T R 29 Nm 2 9 m kgf 21 ft Ibf T R 1 5 Nm 0 15 m kgf 1 1 ft Ibf T R 11 Nm 1 1 m kgf 8 0 ft Ibf T R ...

Page 172: ...FRONT BRAKE 4 39 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 New 1 2 BF BF S ...

Page 173: ...EDING THE HYDRAULIC BRAKE SYSTEM on page 3 12 1 Front brake hose union bolt brake caliper side 1 2 Brake hose gasket 2 3 Front brake hose hydraulic unit to front brake caliper 1 Disconnect 4 Front wheel sensor lead holder 1 5 Front brake caliper 1 5 1 3 2 4 New 29 Nm 2 9 m kgf 21 ft Ibf T R 35 Nm 3 5 m kgf 25 ft Ibf T R ...

Page 174: ... pad pin 1 3 Brake pad inner 1 4 Brake pad outer 1 5 Brake pad spring 1 6 Front brake caliper bracket 1 7 Brake caliper piston 1 8 Brake caliper piston dust seal 1 9 Brake caliper piston seal 1 10 Brake caliper bleed screw 1 11 Brake caliper body 1 11 10 9 5 1 2 3 6 New 8 7 New 4 BF S S S 6 Nm 0 6 m kgf 4 3 ft Ibf T R S ...

Page 175: ...page 4 25 2 Check Brake disc Damage galling Replace 3 Measure Brake disc runout Out of specification Correct the brake disc runout or replace the brake disc a Place the vehicle on a suitable stand so that the front wheel is elevated b Before measuring the front brake disc runout turn the handlebar to the left or right to ensure that the front wheel is stationary c Remove the brake caliper d Hold t...

Page 176: ...s a set 2 Install Brake pad spring 1 Brake pads TIP Always install new brake pads and new brake pad spring as a set a Connect a clear plastic hose 1 tightly to the bleed screw 2 Put the other end of the hose into an open container b Loosen the bleed screw and push the brake caliper piston into the brake caliper with your finger c Tighten the bleed screw d Install new brake pad spring and new brake...

Page 177: ...ling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 12 EAS31328 REMOVING THE FRONT BRAKE CALIPER TIP Before removing the brake caliper drain the brake fluid from the entire brake system 1 Remove Brake hose union bolt 1 Brake hose gaskets 2 Front brake hose 3 TIP Put the end of the brake hose into a container and pump out the brake fluid carefully EAS30172 DISASSEMBL...

Page 178: ... THE FRONT BRAKE CALIPER WARNING EWA13621 Before installation all internal brake com ponents should be cleaned and lubricated with clean or new brake fluid Never use solvents on internal brake com ponents as they will cause the brake caliper piston dust seals and brake caliper piston seals to swell and distort Whenever a brake caliper is disassembled replace the brake caliper piston dust seals and...

Page 179: ...er reser voir Water will significantly lower the boil ing point of the brake fluid and could cause vapor lock NOTICE ECA13540 Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 5 Bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 12 6 Check Brake fluid level Below the minimum level mark a Add the specified br...

Page 180: ...solvents on internal brake com ponents EAS30182 INSTALLING THE FRONT BRAKE MASTER CYLINDER 1 Install Brake master cylinder Brake master cylinder holder 1 TIP Install the brake master cylinder holder with the UP mark a facing up Align the edge b of the brake master cylinder holder with the edge c of the stay on the han dlebar as shown in the illustration First tighten the upper bolt then the lower ...

Page 181: ...rformance When refilling be careful that water does not enter the brake master cylinder reser voir Water will significantly lower the boil ing point of the brake fluid and could cause vapor lock NOTICE ECA13540 Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 4 Bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on pa...

Page 182: ...s Order Job Parts to remove Q ty Remarks 1 Rear brake caliper 1 2 Brake pad clip 2 3 Brake pad pin 1 4 Brake pad inner 1 5 Brake pad outer 1 6 Brake pad spring 1 7 Brake caliper bleed screw 1 35 Nm 3 5 m kgf 25 ft Ibf T R 6 Nm 0 6 m kgf 4 3 ft Ibf T R 4 6 7 1 3 2 5 ...

Page 183: ...reservoir diaphragm hold er 1 3 Brake master cylinder reservoir diaphragm 1 4 Rear brake light switch connector 2 Disconnect 5 Rear brake light switch 1 6 Rear brake lever pivot bolt nut 1 1 7 Rear brake lever 1 8 Rear brake hose union bolt master cylinder side 1 9 Brake hose gasket 2 1 2 Nm 0 12 m kgf 0 87 ft Ibf T R 1 5 Nm 0 15 m kgf 1 1 ft Ibf T R 6 Nm 0 6 m kgf 4 3 ft Ibf T R 11 Nm 1 1 m kgf 8...

Page 184: ...aster cylinder to hydraulic unit 1 Disconnect 11 Rear brake master cylinder holder 1 12 Rear brake master cylinder assembly 1 1 2 Nm 0 12 m kgf 0 87 ft Ibf T R 1 5 Nm 0 15 m kgf 1 1 ft Ibf T R 6 Nm 0 6 m kgf 4 3 ft Ibf T R 11 Nm 1 1 m kgf 8 0 ft Ibf T R 29 Nm 2 9 m kgf 21 ft Ibf T R 6 Nm 0 6 m kgf 4 3 ft Ibf T R S 11 10 12 New ...

Page 185: ...REAR BRAKE 4 52 Disassembling the rear brake master cylinder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder kit 1 2 Brake master cylinder body 1 S BF BF New 1 2 ...

Page 186: ... Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 12 1 Rear brake hose union bolt brake caliper side 1 2 Brake hose gasket 2 3 Rear brake hose hydraulic unit to rear brake caliper 1 Disconnect 4 Rear brake caliper 1 29 Nm 2 9 m kgf 21 ft Ibf T R 35 Nm 3 5 m kgf 25 ft Ibf T R New 4 3 1 2 ...

Page 187: ...ake pad pin 1 3 Brake pad inner 1 4 Brake pad outer 1 5 Brake pad spring 1 6 Brake caliper bracket 1 7 Brake caliper piston 1 8 Brake caliper piston dust seal 1 9 Brake caliper piston seal 1 10 Brake caliper bleed screw 1 11 Brake caliper body 1 6 Nm 0 6 m kgf 4 3 ft Ibf T R S S S New New BF 6 7 8 9 10 2 1 11 5 3 4 ...

Page 188: ... REAR WHEEL on page 4 33 2 Check Brake disc Damage galling Replace 3 Measure Brake disc runout Out of specification Correct the brake disc runout or replace the brake disc Refer to CHECKING THE FRONT BRAKE DISC on page 4 42 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 DISC on page 4 42 5...

Page 189: ...tall Brake pad pin Brake pad clips Rear brake caliper Rear brake caliper bolts 4 Check Brake fluid level Below the minimum level mark a Add the specified brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 10 5 Check Brake lever operation Soft or spongy feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 12 EAS30186 REMOVING THE REAR...

Page 190: ...iston 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 with compressed air WARNING EWA17070 Whenever a b...

Page 191: ...rake master cylinder reservoir with the specified amount of the specified brake fluid WARNING EWA13540 Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake pe...

Page 192: ... compressed air 2 Check Brake master cylinder kit Damage scratches wear Replace 3 Check Brake master cylinder reservoir 1 Brake master cylinder reservoir cap Brake master cylinder reservoir diaphragm holder 2 Brake master cylinder reservoir diaphragm 3 Damage wear Replace 4 Check Brake hose Cracks damage wear Replace EAS30195 ASSEMBLING THE REAR BRAKE MASTER CYLINDER WARNING EWA13520 Before instal...

Page 193: ...eakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake performance When refilling be careful that water does not enter the brake master cylinder reser voir Water will significantly lower the boil ing point of the brake fluid and could cause vapor lock NOTICE ECA1354...

Page 194: ...4 4 Front upper cowling assembly Refer to GENERAL CHASSIS 6 on page 4 16 1 ABS ECU coupler 1 Disconnect 2 Front brake hose union bolt hydraulic unit as sembly side 2 3 Rear brake hose union bolt hydraulic unit as sembly side 2 4 Brake hose gasket 8 5 Front brake hose hydraulic unit to front brake caliper 1 Disconnect 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 29 Nm 2 9 m kgf 21 ft...

Page 195: ...er to hydraulic unit 1 Disconnect 7 Rear brake hose rear brake master cylinder to hydraulic unit 1 Disconnect 8 Rear brake hose hydraulic unit to rear brake caliper 1 Disconnect 9 Hydraulic unit assembly 1 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 29 Nm 2 9 m kgf 21 ft Ibf T R 29 Nm 2 9 m kgf 21 ft Ibf T R New New New New New 6 9 7 8 ...

Page 196: ...ecified torque and bleed the brake system 1 Disconnect ABS ECU coupler 1 TIP While pushing the portion a of the ABS ECU coupler move the lock lever b in the direction of the arrow shown to disconnect the coupler 2 Remove Brake hoses TIP Do not operate the brake levers while removing the brake hoses NOTICE ECA14530 When removing the brake hoses cover the area around the hydraulic unit to catch any ...

Page 197: ...nd then tighten the brake hose union bolts to specification 4 Connect ABS ECU coupler 1 TIP Connect the ABS ECU coupler and then push the lock 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 spe...

Page 198: ...llowing two methods Brake line routing confirmation this test checks the function of the ABS after the sys tem was disassembled adjusted or serviced ABS reaction force confirmation this test gen erates the same reaction force pulsating action that is generated in the front brake lever and rear brake lever when the ABS is front activat ed Brake line routing confirmation WARNING EWA13120 Securely su...

Page 199: ...rakes are being applied and released respectively NOTICE ECA22080 Check that the pulse is felt in the front brake lever rear brake lever and again in the front brake lever in this order If the pulse is felt in the rear brake lever be fore it is felt in the front brake lever check that the brake hoses and brake pipes are connected correctly to the hydraulic unit assembly If the pulse is hardly felt...

Page 200: ...taneously TIP The hydraulic unit operates 1 second after the front brake lever and rear brake lever are oper ated simultaneously and continues for approx imately 5 seconds The operation of the hydraulic unit can be con firmed using the indicator On The hydraulic unit is operating Flashing The conditions for operating the hy draulic unit have not been met Off The front brake lever and rear brake le...

Page 201: ...ver and again in the front brake lever in this order If the pulse is felt in the rear brake lever be fore it is felt in the front brake lever check that the brake hoses and brake pipes are connected correctly to the hydraulic unit assembly If the pulse is hardly felt in either the front brake lever or rear brake lever check that the brake hoses and brake pipes are con nected correctly to the hydra...

Page 202: ...r Order Job Parts to remove Q ty Remarks 1 Rearview mirror 2 2 Upper handlebar cover assembly 1 3 Upper handlebar panel 1 4 Upper handlebar cover 1 1 8 Nm 0 18 m kgf 1 3 ft Ibf T R 1 8 Nm 0 18 m kgf 1 3 ft Ibf T R 22 Nm 2 2 m kgf 16 ft Ibf T R 22 Nm 2 2 m kgf 16 ft Ibf T R 2 3 1 1 4 ...

Page 203: ... Handlebar switch right 1 7 Throttle cable 2 Disconnect 8 Throttle grip 1 9 Handlebar weight right 1 10 Grip end left 1 11 Handlebar grip 1 S S LS LS LS LS 1 8 Nm 0 18 m kgf 1 3 ft Ibf T R 2 3 Nm 0 23 m kgf 1 7 ft Ibf T R 2 3 Nm 0 23 m kgf 1 7 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 11 Nm 1 1 m kgf 8 0 ft Ibf T R 11 Nm 1 1 m kgf 8 0 ft Ibf T R 21 Nm 2 1 m kgf 15 ft I...

Page 204: ...7 Handlebar switch left 1 18 Handlebar weight left 1 19 Lower handlebar cover 1 20 Upper handlebar holder 2 21 Handlebar 1 22 Lower handlebar holder 2 S S LS LS LS LS 1 8 Nm 0 18 m kgf 1 3 ft Ibf T R 2 3 Nm 0 23 m kgf 1 7 ft Ibf T R 2 3 Nm 0 23 m kgf 1 7 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 11 Nm 1 1 m kgf 8 0 ft Ibf T R 11 Nm 1 1 m kgf 8 0 ft Ibf T R 21 Nm 2 1 m ...

Page 205: ...end TIP While holding the grip end loosen the grip end bolt 3 Remove Handlebar grip 1 TIP Blow compressed air between the handlebar and the handlebar grip and gradually push the grip off the handlebar EAS30204 CHECKING THE HANDLEBAR 1 Check Handlebar Bends cracks damage Replace WARNING EWA13690 Do not attempt to straighten a bent handle bar as this may dangerously weaken it EAS30205 INSTALLING THE...

Page 206: ... the stay on the han dlebar as shown in the illustration First tighten the upper bolt then the lower bolt 6 Install Handlebar grip 1 Grip end left 2 a Apply a thin coat of a rubber adhesive to the left end of the handlebar b Slide the handlebar grip over the left end of the handlebar TIP Make sure that the distance a between the end of the left handlebar switch and the end of the handlebar grip is...

Page 207: ...p with a thin coat of lith ium soap based grease Align the projection a on the right handlebar switch with the hole b in the handlebar Align the projection c on the grip end with the slot d in the handlebar weight There should be 1 0 3 0 mm 0 04 0 12 in of clearance e between the throttle grip and the grip end 9 Install Front brake master cylinder Front brake master cylinder holder 1 T R Grip end ...

Page 208: ...andlebar cover EAS31623 INSTALLING THE UPPER HANDLEBAR COVER ASSEMBLY 1 Install Upper handlebar cover assembly 1 a Fit the projections a on the upper handlebar cover into the slots b in the lower handlebar cover TIP There should be 2 0 4 0 mm 0 08 0 16 in of clearance c between the upper handlebar cov er assembly and the right handlebar switch 2 and between the cover assembly and the left handleba...

Page 209: ...ove Q ty Remarks The following procedure applies to both of the front fork legs Front wheel Refer to FRONT WHEEL on page 4 25 1 Front fender 1 2 Lower bracket pinch bolt 2 3 Front fork leg 1 1 3 2 2 8 Nm 0 8 m kgf 5 8 ft Ibf T R 8 Nm 0 8 m kgf 5 8 ft Ibf T R 53 Nm 5 3 m kgf 38 ft Ibf T R ...

Page 210: ...rk cap clip 1 2 Front fork cap 1 3 O ring 1 4 Fork spring 1 5 Dust seal 1 6 Oil seal clip 1 7 Front fork damper rod bolt 1 8 Copper washer 1 9 Oil flow stopper 1 10 Damper rod 1 11 Rebound spring 1 12 Damper rod ring 1 13 Inner tube 1 14 Oil seal 1 15 Outer tube 1 LT LS New New New New New New 23 Nm 2 3 m kgf 17 ft Ibf T R 8 3 14 2 5 6 4 7 13 10 11 15 9 12 1 LS ...

Page 211: ...he front fork leg has a very sophisticated internal construction which are particular ly sensitive to foreign material When disassembling and assembling the front fork leg do not allow any foreign ma terial to enter the front fork 1 Remove Front fork cap clip 1 Front fork cap 2 TIP Push the front fork cap in the direction of the ar row shown in the illustration to remove the front fork cap clip 2 ...

Page 212: ...even oil levels can result in poor han dling and a loss of stability TIP When assembling the front fork leg be sure to replace the following parts Front fork cap clip 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 ring 1 Damper rod 2 Rebound spring 3 in the inner tube 4 Oil flow stopper 5 NOT...

Page 213: ...be in the outer tube 5 Install Copper washer Front fork damper rod bolt 1 TIP While holding the damper rod assembly with the hexagon bit socket 14 mm 2 and T handle 3 tighten the front fork damper rod bolt 6 Install Oil seal clip 1 TIP Adjust the oil seal clip so that it fits into the outer tube s groove Fork seal driver weight 90890 01367 Replacement hammer YM A9409 7 Fork seal driver attachment ...

Page 214: ...easuring 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 11 Measure Front fork leg oil level a from the top of the inner tube with the inner tube fully compressed and without the fork spring Out of specification Correct TIP While filling the front fork leg keep it upright After filling slow...

Page 215: ...tall Front fork leg 1 Temporarily tighten the lower bracket pinch bolts TIP Make sure the inner tube end is flush with the top of the lower bracket 3 Tighten Lower bracket pinch bolts 1 TIP Tighten the lower bracket pinch bolts to specifi cation twice Tighten the upper and lower bolts alternately starting with the upper bolts T R Lower bracket pinch bolt 53 Nm 5 3 m kgf 38 ft lbf 1 1 1 1 ...

Page 216: ...upper cowling assembly Refer to GENERAL CHASSIS 6 on page 4 16 Front wheel Refer to FRONT WHEEL on page 4 25 Handlebar Refer to HANDLEBAR on page 4 69 Front fork legs Refer to FRONT FORK on page 4 76 1 Handlebar bracket 1 2 Horn connector 2 Disconnect 3 Horn 1 4 Horn bracket 1 5 Front brake hose holder 1 LS LS LS 75 Nm 7 5 m kgf 54 ft Ibf T R 1st 38 Nm 3 8 m kgf 27 ft Ibf 2nd 16 Nm 1 6 m kgf 12 ft...

Page 217: ...ower ring nut 1 12 Lower bracket 1 13 Bearing cover 1 14 Upper bearing inner race 1 15 Upper bearing 1 16 Lower bearing 1 17 Lower bearing inner race 1 18 Dust seal 1 19 Lower bearing outer race 1 20 Upper bearing outer race 1 LS LS LS 75 Nm 7 5 m kgf 54 ft Ibf T R 1st 38 Nm 3 8 m kgf 27 ft Ibf 2nd 16 Nm 1 6 m kgf 12 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 63 Nm 6 3 ...

Page 218: ...rings and bearing races as a set 3 Replace Bearings Bearing races 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 bearing race is not installed properly the steering head pipe could be damaged TIP Always re...

Page 219: ...ket tighten the bolt to specification 4 Install Horn bracket 1 Horn 2 TIP While holding the horn bracket so that the bracket contacts the portion a of the lower bracket 3 tighten the bolt to specification While holding the horn so that the horn con tacts the portion b of the horn bracket tighten the bolt to specification 5 Install Handlebar bracket 1 TIP Align the slots a in the lower bracket with...

Page 220: ...STEERING HEAD 4 87 1 a b ...

Page 221: ...e box Refer to GENERAL CHASSIS 4 on page 4 9 Muffler Refer to ENGINE REMOVAL on page 5 3 Radiator cover Refer to RADIATOR on page 6 1 Air filter case Refer to AIR FILTER CASE on page 7 7 1 Rear wheel axle nut 1 2 Rear brake hose holder rear side 1 3 Rear wheel sensor 1 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 21 Nm 2 1 m kgf 15 ft Ibf T R 21 Nm 2 1 ...

Page 222: ...r brake hose guide 1 8 Spacer 1 9 Bearing retaining plate 1 10 Oil seal 2 11 Bearing 1 12 Swingarm 1 13 Collar 1 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 21 Nm 2 1 m kgf 15 ft Ibf T R 21 Nm 2 1 m kgf 15 ft Ibf T R 35 Nm 3 5 m kgf 25 ft Ibf T R 57 Nm 5 7 m kgf 41 ft Ibf T R 125 Nm 12 5 m kgf 90 ft lbf T R 16 Nm 1 6 m kgf 12 ft Ibf T R LS LS LS New Ne...

Page 223: ...o not attempt to disassemble it If faulty replace with a new one Keep any type of magnets including mag netic pick up tools magnetic screwdrivers etc away from the rear wheel sensor Do not drop or shock the wheel sensor 1 Check Rear wheel sensor Refer to MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR on page 4 28 2 Check Rear wheel sensor rotor Refer to MAINTENANCE OF THE FRONT WHEEL SENSO...

Page 224: ...garm mounting bolt lower side 4 TIP Tighten the rear wheel axle nut 2 then the swingarm mounting bolts 3 4 5 Install Rear shock absorber assemblies TIP Tighten the rear shock absorber assembly nuts and bolts temporarily and then tighten them to specification 6 Measure TIP Measure the distance a only if the wheel bear ings wheel sensor rotor or both were replaced Distance a between the wheel sensor...

Page 225: ...l sensor lead refer to CABLE ROUTING on page 2 29 8 Install Rear brake hose holder rear side 1 TIP Fit the projection a on the rear brake hose hold er into the hole b in the swingarm Distance a between the wheel sensor rotor and swingarm edge of the wheel sensor installation hole 18 92 19 60 mm 0 74 0 77 in T R Rear wheel sensor bolt 7 Nm 0 7 m kgf 5 1 ft lbf T R Rear brake hose holder bolt rear s...

Page 226: ...REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM 4 93 ...

Page 227: ...HE CYLINDER HEAD 5 15 CAMSHAFT 5 18 REMOVING THE CAMSHAFT 5 19 CHECKING THE CAMSHAFT 5 19 CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS 5 20 INSTALLING THE CAMSHAFT AND ROCKER ARMS 5 20 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 INSTALLING THE VALVES 5 27 CYLINDER AND PISTON 5 29 RE...

Page 228: ... 5 40 INSTALLING THE PRIMARY SHEAVE V BELT AND SECONDARY SHEAVE 5 41 STARTER CLUTCH 5 44 CHECKING THE STARTER WHEEL 5 46 CHECKING THE STARTER CLUTCH 5 46 CHECKING THE TIMING CHAIN 5 46 CHECKING THE TIMING CHAIN GUIDE INTAKE SIDE 5 46 INSTALLING THE STARTER CLUTCH 5 46 AC MAGNETO 5 47 REMOVING THE AC MAGNETO 5 49 INSTALLING THE AC MAGNETO 5 49 ELECTRIC STARTER 5 50 CHECKING THE STARTER MOTOR 5 52 A...

Page 229: ...ING THE CRANKSHAFT ASSEMBLY 5 62 CHECKING THE CRANKSHAFT ASSEMBLY 5 62 CHECKING THE CRANKCASE 5 63 CHECKING THE BEARING 5 63 CHECKING THE OIL PUMP DRIVE GEAR 5 63 INSTALLING THE CRANKSHAFT 5 63 ASSEMBLING THE CRANKCASE 5 64 INSTALLING THE CENTERSTAND 5 64 ...

Page 230: ...ank the engine until the reading on the compression gauge stabilizes WARNING EWA12960 To prevent sparking ground the spark plug lead before cranking the engine c If the compression pressure is above the maximum specification check the cylinder head valve surfaces and piston crown for carbon deposits Carbon deposits Eliminate d If the compression pressure is below the min imum specification pour a ...

Page 231: ...ench 2 does not contact the portion b of the spark plug 9 Connect Spark plug cap TIP To route the spark plug lead refer to CON NECTING THE LEADS on page 5 8 10 Install Footrest board assembly right Refer to GENERAL CHASSIS 5 on page 4 12 Front side cover right Refer to GENERAL CHASSIS 2 on page 4 4 a b 2 1 ...

Page 232: ...arts to remove Q ty Remarks 1 Muffler protector 1 2 Muffler 1 3 Exhaust gasket 1 1 2 3 New LT LT 15 Nm 1 5 m kgf 11 ft Ibf T R 53 Nm 5 3 m kgf 38 ft Ibf T R 53 Nm 5 3 m kgf 38 ft Ibf T R 53 Nm 5 3 m kgf 38 ft Ibf T R 8 Nm 0 8 m kgf 5 8 ft Ibf T R 8 Nm 0 8 m kgf 5 8 ft Ibf T R ...

Page 233: ...SIS 2 on page 4 4 Fuel tank cover Refer to GENERAL CHASSIS 3 on page 4 7 Storage box Refer to GENERAL CHASSIS 4 on page 4 9 Center lower cover Refer to GENERAL CHASSIS 5 on page 4 12 Air filter case Refer to AIR FILTER CASE on page 7 7 V belt case air duct Refer to V BELT AUTOMATIC TRANSMIS SION on page 5 34 Fuel injector Refer to FUEL INJECTOR on page 7 5 Throttle body Refer to THROTTLE BODY on p...

Page 234: ...age 4 88 1 VVA variable valve actuator solenoid coupler 1 Disconnect 2 Crankshaft position sensor coupler 1 Disconnect 3 AC magneto lead coupler 1 Disconnect 4 O2 sensor coupler 1 Disconnect 5 Spark plug cap 1 Disconnect 6 Coolant temperature sensor coupler 1 Disconnect 7 Starter motor sub wire harness coupler 1 Disconnect 8 Engine ground lead 1 Disconnect 2 1 3 4 5 6 7 8 7 Nm 0 7 m kgf 5 1 ft Ibf...

Page 235: ...ide 1 1 5 Engine mounting nut bolt front left side 1 1 6 Engine mounting nut bolt front right side 1 1 7 Engine bracket 1 8 Damper 2 9 Spacer 1 10 Stopper 1 11 Collar 2 1 1 4 4 8 2 7 6 6 11 2 3 10 11 5 8 9 5 21 Nm 2 1 m kgf 15 ft Ibf T R 52 Nm 5 2 m kgf 38 ft Ibf T R 68 Nm 6 8 m kgf 49 ft Ibf T R 68 Nm 6 8 m kgf 49 ft Ibf T R 16 Nm 1 6 m kgf 12 ft Ibf T R 21 Nm 2 1 m kgf 15 ft Ibf T R ...

Page 236: ...ten Engine mounting nut rear side 6 Install Engine bracket bolt nut 10 TIP Do not fully tighten the nut 7 Install Rear shock absorber assemblies 11 TIP Tighten the rear shock absorber assembly nuts and bolts temporarily and then tighten them to specification 8 Tighten Engine bracket nut TIP Before tightening the engine bracket nut place the vehicle on the centerstand so that the rear wheel is elev...

Page 237: ...e actuator solenoid 2 and the water pump inlet hose 3 Make sure that the spark plug lead does not contact the VVA vari able valve actuator solenoid or water pump inlet hose EAS31588 INSTALLING THE MUFFLER 1 Install Exhaust gaskets 1 to the cylinder head TIP Install the exhaust gasket with its projections a facing toward the cylinder head T R Engine ground lead bolt 7 Nm 0 7 m kgf 5 1 ft lbf 2 3 11...

Page 238: ...NT on page 3 19 Muffler Refer to ENGINE REMOVAL on page 5 3 Radiator Refer to RADIATOR on page 6 1 Thermostat assembly Refer to THERMOSTAT on page 6 5 Water pump Refer to WATER PUMP on page 6 7 Fuel tank Refer to FUEL TANK on page 7 1 LT LS M M New New New New New New New New New 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf...

Page 239: ...connect 4 O2 sensor 1 TIP Remove the O2 sensor only when neces sary 5 Coolant temperature sensor coupler 1 Disconnect LT LS M M New New New New New New New New New 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 4 0 Nm 0 40 m kgf 2 9 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 13 Nm 1 3 m kgf 9 4...

Page 240: ...holder 1 12 Cylinder head breather hose 1 13 Cylinder head cover 1 14 Cylinder head cover gasket 1 15 Dowel pin 2 LT LS M M New New New New New New New New New 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 4 0 Nm 0 40 m kgf 2 9 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 13 Nm 1 3 m kgf 9 4 ft ...

Page 241: ...24 Decompression cam 1 25 Cylinder head 1 26 Cylinder head gasket 1 27 Dowel pin 2 28 Engine oil check bolt 1 LT LS M M New New New New New New New New New 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 4 0 Nm 0 40 m kgf 2 9 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 13 Nm 1 3 m kgf 9 4 ft Ibf ...

Page 242: ...olts and nuts in the proper se quence as shown Loosen each bolt and nuts 1 2 of a turn at a time After all of the bolts and nuts are fully loosened remove them EAS30277 CHECKING THE CYLINDER HEAD 1 Eliminate Combustion chamber carbon deposits with a rounded scraper TIP Do not use a sharp instrument to avoid damag ing or scratching Spark plug bore threads Valve seats 2 Check Cylinder head Damage sc...

Page 243: ...nd crank shaft as a set EAS30279 CHECKING THE TIMING CHAIN TENSIONER 1 Check Timing chain tensioner Cracks damage Replace a Remove the timing chain tensioner plug b While lightly pressing the timing chain ten sioner rod by hand turn the tensioner rod ful ly clockwise with a thin screwdriver 1 c While holding the timing chain tensioner rod in place with your hand turn the screwdriver counterclockwi...

Page 244: ...them in two stages 2 Install Decompression cam 1 Camshaft sprocket 2 Timing chain Camshaft sprocket bolt a Turn the crankshaft clockwise b Align the I mark a on the AC magneto rotor with the match mark b on the right crank case c Install the decompression cam d Install the timing chain onto the camshaft sprocket then the camshaft sprocket onto the camshaft and then finger tighten the camshaft spro...

Page 245: ...the gasket are protruding in the directions shown in the illustration Apply Yamaha bond No 1215 to the threads of the timing chain tensioner bolts d Turn the timing chain tensioner rod counter clockwise with a thin screwdriver 1 make sure it releases and then install the timing chain tensioner plug 4 Turn Crankshaft several turns clockwise 5 Check I mark a Make sure the I mark a on the AC magne to...

Page 246: ...seal 1 into the cylinder head cover 2 TIP Install the oil seal so that it is facing in the direc tion shown in the illustration Press the oil seal into the cylinder head cover using a suitable di ameter socket 3 9 Install VVA variable valve actuator solenoid 1 TIP While holding the VVA variable valve actuator solenoid so that it is contacting the cylinder head cover 2 tighten the bolts to specific...

Page 247: ...embly 1 4 Bearing 1 5 Rocker arm shaft 2 6 Exhaust rocker arm 1 7 Adjusting screw exhaust side 2 8 Plate 1 9 Spring 1 10 Intake rocker arm 1 1 11 Intake rocker arm stopper pin 1 12 Spring 1 13 Intake rocker arm 2 1 14 Adjusting screw intake side 2 5 5 4 3 8 2 14 14 1 6 11 12 13 9 7 2 7 2 10 E E E E M M M M M M M M New New 7 Nm 0 7 m kgf 5 1 ft Ibf T R 8 Nm 0 8 m kgf 5 8 ft Ibf T R 7 Nm 0 7 m kgf 5...

Page 248: ...CKING THE CAMSHAFT 1 Check Camshaft lobes Blue discoloration pitting scratches Re place the camshaft 2 Measure Camshaft lobe dimensions a and b Out of specification Replace the camshaft 3 Measure Camshaft runout Out of specification Replace the camshaft Slide hammer bolt 90890 01085 Slide hammer bolt 8 mm YU 01083 2 Weight 90890 01084 Weight YU 01083 3 a 2 3 4 1 6 3 5 2 Camshaft lobe dimensions Lo...

Page 249: ...lace 4 Measure Rocker arm shaft outside diameter a Out of specification Replace 5 Calculate Rocker arm to rocker arm shaft clearance TIP Calculate the clearance by subtracting the rock er arm shaft outside diameter from the rocker arm inside diameter Out of specification Replace the defective part s EAS30270 INSTALLING THE CAMSHAFT AND ROCKER ARMS 1 Lubricate Camshaft assembly Rocker arm inside di...

Page 250: ...ration install the camshaft assembly TIP Install the camshaft with the punch mark a fac ing upward 5 Install Camshaft stopper plate TIP Before installing the camshaft stopper plate make sure that the slots a in the rocker arm shafts 2 are parallel with the edge b of the cyl inder head and that the camshaft stopper plate bolt holes in the cylinder head and rocker arm shafts are aligned Recommended ...

Page 251: ...move Q ty Remarks Cylinder head Refer to CYLINDER HEAD on page 5 9 Camshaft Rocker arms Refer to CAMSHAFT on page 5 18 1 Valve cotter 8 2 Valve spring retainer 4 3 Valve spring 4 4 Intake valve 2 5 Exhaust valve 2 6 Valve stem seal 4 7 Valve spring seat 4 8 Valve guide 4 M M M E E New New New 1 2 3 6 7 8 5 New 2 3 4 8 1 6 7 ...

Page 252: ...the valve cotters by compressing the valve spring with the valve spring compressor and the valve spring compressor attachment 2 3 Remove Valve spring retainer 1 Valve spring 2 Valve 3 Valve stem seal 4 Valve spring seat 5 TIP Identify the position of each part very carefully so that it can be reinstalled in its original place EAS30284 CHECKING THE VALVES AND VALVE GUIDES The following procedure ap...

Page 253: ...stem to valve guide clearance TIP After replacing the valve guide reface the valve seat 3 Eliminate Carbon deposits from the valve face and valve seat Valve stem to valve guide clear ance intake 0 010 0 037 mm 0 0004 0 0015 in Limit 0 080 mm 0 0032 in Valve stem to valve guide clear ance exhaust 0 025 0 052 mm 0 0010 0 0020 in Limit 0 110 mm 0 0043 in New Valve guide position 9 9 10 3 mm 0 39 0 41...

Page 254: ...place the cylinder head a Apply Blue layout fluid b onto the valve face b Install the valve into the cylinder head c Press the valve through the valve guide and onto the valve seat to make a clear impres sion d Measure the valve seat width TIP Where the valve seat and valve face contacted one another the blue layout fluid will have been removed 4 Lap Valve face Valve seat TIP After replacing the c...

Page 255: ...ress the valve through the valve guide and onto the valve seat to make a clear impres sion j Measure the valve seat width again If the valve seat width is out of specification reface and lap the valve seat EAS30286 CHECKING THE VALVE SPRINGS The following procedure applies to all of the valve springs 1 Measure Valve spring free length a Out of specification Replace the valve spring 2 Measure Compr...

Page 256: ... the recommended lubricant 5 Install Valve spring seat 1 Valve stem seal 2 Valve 3 Valve spring 4 Valve spring retainer 5 into the cylinder head TIP Make sure each valve is installed in its original place Install the valve springs with the larger pitch a facing up 6 Install Valve cotters 1 b Installed length Spring tilt intake 1 5 mm 0 06 in Spring tilt exhaust 1 5 mm 0 06 in Recommended lubricant...

Page 257: ...tachment 2 7 To secure the valve cotters onto the valve stem lightly tap the valve tip with a soft face hammer NOTICE ECA13800 Hitting the valve tip with excessive force could damage the valve Valve spring compressor 90890 04019 Valve spring compressor YM 04019 Valve spring compressor attach ment 90890 04108 Valve spring compressor adapt er 22 mm YM 04108 1 2 ...

Page 258: ...nder head Refer to CYLINDER HEAD on page 5 9 1 Timing chain guide exhaust side 1 2 Cylinder 1 3 Cylinder gasket 1 4 Dowel pin 2 5 Piston pin clip 2 6 Piston pin 1 7 Piston 1 8 Top ring 1 9 2nd ring 1 10 Oil ring 1 11 Coolant drain bolt cylinder side 1 4 4 3 2 1 9 8 10 6 5 7 5 11 E E E New New New New 10 Nm 1 0 m kgf 7 2 ft Ibf T R ...

Page 259: ...open the end gap with your fingers and lift the other side of the ring over the piston crown EAS30291 CHECKING THE CYLINDER AND PISTON 1 Check Piston wall Cylinder wall Vertical scratches Rebore or replace the cylinder and replace the piston and piston rings as a set 2 Measure Piston to cylinder clearance a Measure cylinder bore C with the cylinder bore gauge TIP Measure cylinder bore C by taking ...

Page 260: ...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 position ring near the bottom of the cylinder where the cylin der wear is lowest 3 Measure Piston ring end gap Out of specification Replace the piston ring TIP The oil ring expander spacer end gap cannot be measured If the oil ring rail gap is excessive re pla...

Page 261: ...amage wear Replace EAS30294 INSTALLING THE PISTON AND CYLINDER 1 Install Lower oil ring rail 1 Oil ring expander 2 Piston ring Top ring End gap installed 0 10 0 25 mm 0 0039 0 0098 in Limit 0 50 mm 0 0197 in 2nd ring End gap installed 0 35 0 50 mm 0 0138 0 0197 in Limit 0 85 mm 0 0335 in Oil ring End gap installed 0 20 0 70 mm 0 0079 0 0276 in a Bottom of cylinder b Upper of cylinder Piston pin ou...

Page 262: ...talling a piston pin clip make sure that the clip ends b are positioned away from the cutout c in the piston as shown in the illus tration 3 Lubricate Piston Piston rings Cylinder with the recommended lubricant 4 Offset Piston ring end gaps 5 Install Dowel pins Cylinder gasket Cylinder 1 TIP While holding the piston 2 with one hand in stall the cylinder with the other hand Pass the timing chain an...

Page 263: ... Fuel tank cover Refer to GENERAL CHASSIS 3 on page 4 7 Storage box Refer to GENERAL CHASSIS 4 on page 4 9 Air filter case Refer to AIR FILTER CASE on page 7 7 1 V belt case air filter element cover 1 2 V belt case air filter element 1 3 V belt case air filter element support 1 4 V belt case air duct 1 5 V belt case 1 New New New New 6 10 5 4 2 3 1 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 ...

Page 264: ...t case gasket cut the center portion of the gasket Before in stalling a new V belt case gasket remove the V belt Refer to Removing the V belt primary sheave and secondary sheave 7 Dowel pin 1 8 V belt case check hose 1 9 Bearing 1 New New New New 6 10 7 6 8 9 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R ...

Page 265: ... sheave nut 1 2 Conical spring washer 1 3 Washer 1 4 Primary fixed sheave 1 5 V belt 1 6 Collar 1 7 Primary sliding sheave 1 8 Primary sheave weight 6 9 Cam 1 10 Slider 3 11 Clutch housing nut 1 12 Clutch housing 1 13 Secondary sheave assembly 1 45 Nm 4 5 m kgf 33 ft Ibf T R 49 Nm 4 9 m kgf 35 ft Ibf T R LS LS 4 5 6 7 8 9 10 10 10 11 12 13 3 2 1 ...

Page 266: ... ty Remarks 1 Secondary sheave nut 1 2 Clutch carrier assembly 1 3 Compression spring 1 4 Spring seat 1 5 Guide pin 3 6 Collar 3 7 Secondary sliding sheave 1 8 O ring 2 9 Oil seal 2 10 Bearing 1 11 Circlip 1 12 Bearing 1 13 Secondary fixed sheave 1 New New New New 1 2 4 9 10 11 12 13 5 9 7 8 3 6 55 Nm 5 5 m kgf 40 ft Ibf T R ...

Page 267: ... nut at this stage TIP While holding the secondary sheave with the ro tor holding tool 2 loosen the secondary sheave nut one full turn with the socket wrench 3 EAS30312 DISASSEMBLING THE SECONDARY SHEAVE 1 Remove Secondary sheave nut 1 TIP Install the sheave spring compressor 2 and sheave fixed block 3 onto the secondary sheave as shown Then compress the spring and remove the secondary sheave nut ...

Page 268: ...a cloth 2 Measure Clutch shoe thickness a Out of specification Replace the clutch shoes and springs as a set EAS30315 CHECKING THE V BELT 1 Check V belt 1 Cracks damage wear Replace Grease oil Clean the primary and second ary sheave 2 Measure V belt width a Out of specification Replace EAS30316 CHECKING THE PRIMARY SHEAVE 1 Check Primary sliding sheave Primary fixed sheave Collar Cracks damage wea...

Page 269: ...secondary fixed and sliding sheaves as a set 3 Check Guide pin 1 Damage wear Replace the secondary fixed and sliding sheaves as a set 4 Check Spring free length Out of specification Replace the spring EAS30320 ASSEMBLING THE PRIMARY SHEAVE 1 Clean Primary fixed sheave Primary sliding sheave Primary sheave weights Cam EAS30321 ASSEMBLING THE SECONDARY SHEAVE 1 Lubricate Secondary sliding sheave inn...

Page 270: ...install the secondary sheave nut Install the secondary sheave nut 1 with its ta pered side facing the clutch carrier EAS31234 INSTALLING THE PRIMARY SHEAVE V BELT AND SECONDARY SHEAVE 1 Install Secondary sheave assembly TIP Before installing the secondary sheave assem bly check that there is no grease on the splines a of the primary drive gear If there is any grease on the splines be sure to wipe ...

Page 271: ...allow grease to come in contact with the V belt TIP Install the V belt with the printed arrow mark on the V belt facing in the direction shown in the il lustration Install the V belt onto the primary sheave side 6 Install Primary fixed sheave 1 Washer Conical spring washer 2 Primary fixed sheave nut NOTICE ECA21730 Do not allow grease to contact the primary sheave assembly TIP Apply lithium soap b...

Page 272: ...in the secondary sheave when the pulley is at its narrowest position and make sure the V belt is tight 7 Tighten Primary fixed sheave nut 1 TIP While holding the primary fixed sheave with the rotor holding tool 2 tighten the primary fixed sheave nut T R Primary fixed sheave nut 49 Nm 4 9 m kgf 35 ft lbf Rotor holding tool 90890 01235 Universal magneto and rotor holder YU 01235 2 a 1 2 1 ...

Page 273: ...o V BELT AUTOMATIC TRANSMIS SION on page 5 34 1 Starter clutch cover 1 2 Oil seal 1 3 Dowel pin 2 4 Starter clutch idle gear 1 5 Starter clutch idle gear shaft 1 6 Collar 1 7 Starter clutch 1 8 Collar 1 9 Starter wheel 1 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R New LT LT LT E LS LS New...

Page 274: ...rks 10 Circlip 1 11 Bearing 1 12 Timing chain guide stopper 1 13 Timing chain 1 14 Timing chain guide intake side 1 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R New LT LT LT E LS LS New M New New 3 14 12 13 10 11 ...

Page 275: ...A the starter clutch and the starter wheel should engage otherwise the starter clutch is faulty and must be replaced c When turning the starter wheel clockwise B it should turn freely otherwise the starter clutch is faulty and must be replaced EAS31237 CHECKING THE TIMING CHAIN 1 Check Timing chain Damage stiffness Replace the timing chain and camshaft sprocket as a set EAS31238 CHECKING THE TIMIN...

Page 276: ...S 2 on page 4 4 Fuel tank cover Refer to GENERAL CHASSIS 3 on page 4 7 Storage box Refer to GENERAL CHASSIS 4 on page 4 9 Footrest board assembly right Bottom cover Refer to GENERAL CHASSIS 5 on page 4 12 Radiator fan Refer to RADIATOR on page 6 1 1 Crankshaft position sensor coupler Stator coil assembly coupler 1 1 Disconnect 2 AC magneto rotor nut 1 LT LT LT 1 1 2 10 Nm 1 0 m kgf 7 2 ft Ibf T R ...

Page 277: ... to remove Q ty Remarks 3 AC magneto rotor 1 4 Woodruff key 1 5 Crankshaft position sensor holder 1 6 Crankshaft position sensor 1 7 Stator coil assembly 1 LT LT LT 3 5 6 4 7 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 80 Nm 8 0 m kgf 58 ft Ibf T R ...

Page 278: ...STALLING THE AC MAGNETO 1 Install Woodruff key AC magneto rotor Washer AC magneto rotor nut TIP Clean the tapered portion of the crankshaft and the AC magneto rotor hub When installing the AC magneto rotor make sure the woodruff key is properly seated in the keyway of the crankshaft 2 Tighten AC magneto rotor nut 1 TIP While holding the AC magneto rotor 2 with the rotor holding tool 3 tighten the ...

Page 279: ... starter motor Order Job Parts to remove Q ty Remarks Flap Refer to GENERAL CHASSIS 4 on page 4 9 1 Starter motor lead 1 Disconnect 2 Starter motor 1 3 Starter motor sub wire harness 1 2 3 1 10 Nm 1 0 m kgf 7 2 ft Ibf T R 3 5 Nm 0 35 m kgf 2 5 ft Ibf T R LS New ...

Page 280: ...ter motor Order Job Parts to remove Q ty Remarks 1 Starter motor front cover 1 2 Gasket 1 3 Armature assembly 1 4 Brush holder set 1 5 Starter motor rear cover 1 2 5 1 3 4 1 5 Nm 0 15 m kgf 1 1 ft Ibf T R 2 5 Nm 0 25 m kgf 1 8 ft Ibf T R New New ...

Page 281: ...ion 1 Out of specification Replace the starter motor a Measure the armature assembly resistances with the digital circuit tester b If any resistance is out of specification re place the starter motor 5 Measure Brush length a Out of specification Replace the brushes as a set 6 Measure Brush spring force Out of specification Replace the brush springs as a set Commutator diameter 17 6 mm 0 69 in Limi...

Page 282: ...r cover with the match mark b on the starter motor front cover EAS30327 INSTALLING THE STARTER MOTOR 1 Install Starter motor sub wire harness 1 to the starter motor 2 TIP Install the starter motor sub wire harness to the starter motor so that the harness is parallel to the starter motor axis a Brush spring force 3 92 5 88 N 400 600 gf 14 11 21 17 oz T R Starter motor cover bolt 2 5 Nm 0 25 m kgf 1...

Page 283: ...arks Stator coil assembly Refer to AC MAGNETO on page 5 47 1 Oil strainer cover 1 2 Spring 1 3 Oil strainer 1 4 Crankcase cover right 1 5 Gasket 1 6 Dowel pin 2 7 Oil seal 1 8 Oil pump assembly 1 3 8 6 2 1 New New New 7 4 4 5 6 LS LS 10 Nm 1 0 m kgf 7 2 ft Ibf T R 4 0 Nm 0 40 m kgf 2 9 ft Ibf T R 32 Nm 3 2 m kgf 23 ft Ibf T R ...

Page 284: ...er Job Parts to remove Q ty Remarks 1 Oil pump housing cover 1 2 Pin 1 3 Oil pump driven gear 1 4 Oil pump rotor assembly 1 5 Oil pump inner rotor 1 6 Oil pump outer rotor 1 7 Oil pump housing 1 1 0 Nm 0 10 m kgf 0 72 ft Ibf T R E 3 7 2 5 6 4 1 E ...

Page 285: ...MBLING THE OIL PUMP 1 Lubricate Inner rotor Outer rotor Oil pump shaft 2 Install Oil pump housing 1 Oil pump outer rotor 2 Oil pump inner rotor 3 Oil pump driven gear 4 Pin 5 Oil pump housing cover TIP When installing the inner rotor align the pin in the oil pump driven gear with the groove a in the inner rotor 3 Check Oil pump operation Refer to CHECKING THE OIL PUMP on page 5 56 1 Inner rotor 2 ...

Page 286: ...ELT AUTOMATIC TRANSMIS SION on page 5 34 Swingarm Refer to REAR SHOCK ABSORBER AS SEMBLIES AND SWINGARM on page 4 88 Rear wheel Refer to REAR WHEEL on page 4 33 1 Final transmission oil filler cap 1 2 Final transmission oil drain bolt 1 3 Transmission case cover 1 4 Transmission case cover gasket 1 5 Dowel pin 2 19 Nm 1 9 m kgf 14 ft Ibf T R 20 Nm 2 0 m kgf 14 ft Ibf T R New New New New New E E LS...

Page 287: ...ssembly 1 7 Primary driven gear 1 8 Main axle 1 9 Drive axle 1 10 1st wheel gear 1 11 Circlip 1 12 Primary drive gear 1 13 Oil seal 2 14 Bearing 6 19 Nm 1 9 m kgf 14 ft Ibf T R 20 Nm 2 0 m kgf 14 ft Ibf T R New New New New New E E LS LS E E E LS New LS E 13 14 10 13 14 9 11 6 14 14 14 12 8 7 6 14 ...

Page 288: ...RANSMISSION 1 Install Oil seal 1 to the transmission case cover 2 Oil seal 3 to the right crankcase 4 2 Install Circlip 1 to the drive axle 2 TIP Install the circlip with its chamfered side facing as shown 3 Install Primary driven gear 1 to the main axle 2 4 Install Transmission case cover 1 TIP Tighten the transmission case cover bolts in the proper tightening sequence as shown Installed depth a ...

Page 289: ...Refer to CYLINDER AND PISTON on page 5 29 Secondary sheave assembly Refer to V BELT AUTOMATIC TRANSMIS SION on page 5 34 Starter clutch Refer to STARTER CLUTCH on page 5 44 1 Dipstick 1 2 Engine oil drain bolt 1 3 Outer spring 1 4 Inner spring 1 5 Centerstand shaft 1 10 Nm 1 0 m kgf 7 2 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 20 Nm 2 0 m kgf 14 ft Ibf T R New New New LS LS LS LS LS E 3 4 1 5 2 8 ...

Page 290: ...ts to remove Q ty Remarks 6 Centerstand 1 7 Crankcase left 1 8 Dowel pin 2 9 Crankshaft assembly 1 10 Crankcase right 1 10 Nm 1 0 m kgf 7 2 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 20 Nm 2 0 m kgf 14 ft Ibf T R New New New LS LS LS LS LS E 6 8 7 10 8 9 8 ...

Page 291: ...P Remove the crankshaft assembly with the crankcase separating tool 2 and M6 bolts 3 Make sure that the crankcase separating tool is centered over the crankshaft assembly NOTICE ECA20630 To protect the end of the crankshaft place an appropriate sized socket between the crankcase separating tool bolt and the crankshaft Do not tap on the crankshaft EAS31242 CHECKING THE CRANKSHAFT ASSEMBLY 1 Measure...

Page 292: ...CHECKING THE OIL PUMP DRIVE GEAR 1 Check Oil pump drive gear Damage wear Replace EAS30791 INSTALLING THE CRANKSHAFT 1 Install Crankshaft assembly 1 TIP Install the crankshaft assembly with the crank shaft installer pot 2 crankshaft installer bolt 3 adapter 4 and crankshaft installer spacer 5 Hold the connecting rod at top dead center TDC with one hand while turning the nut of the crankshaft instal...

Page 293: ...roughly wipe off any sealant that protrudes from between the left crankcase and the right crankcase Tighten the crankcase bolts in stages and in a crisscross pattern EAS31247 INSTALLING THE CENTERSTAND 1 Install Centerstand 1 Inner spring 2 Outer spring 3 TIP Make sure that the hooked end a of the inner spring is positioned to the outside Make sure that the hooked end b of the outer spring is posi...

Page 294: ...CRANKSHAFT 5 65 ...

Page 295: ...3 INSTALLING THE RADIATOR 6 3 THERMOSTAT 6 5 CHECKING THE THERMOSTAT ASSEMBLY 6 6 INSTALLING THE THERMOSTAT ASSEMBLY 6 6 WATER PUMP 6 7 DISASSEMBLING THE WATER PUMP 6 9 CHECKING THE WATER PUMP 6 9 ASSEMBLING THE WATER PUMP 6 9 INSTALLING THE WATER PUMP 6 9 ...

Page 296: ... Bottom cover Refer to GENERAL CHASSIS 5 on page 4 12 1 Radiator cover 1 2 Coolant reservoir breather hose 1 3 Coolant reservoir hose 1 4 Rear brake hose bracket 1 5 Rear brake hose holder front side 1 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 1 0 Nm 0 10 m kgf 0 72 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m...

Page 297: ...outlet hose 1 9 Radiator cap 1 10 Radiator 1 11 Radiator fan case 1 12 Radiator fan 1 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 1 0 Nm 0 10 m kgf 0 72 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R New 12 3 5 4 11 6 7 8 10 9 LS ...

Page 298: ... no drop in pressure 4 Check Radiator fan Damage Replace 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 19 2 Check Cooling system Leaks Repair or replace any faulty part a Attach the radiator cap tester 1 to the radia tor b Apply 196 kPa 1 96 kg cm 27 87 psi of pressure c Measure the pressure to c...

Page 299: ...e radiator cap Refer to CHECKING THE RADIATOR on page 6 3 4 Install Rear brake hose holder front side 1 TIP Make sure that the projection a on the radiator fan case 2 fits into the hole b in the rear brake hose holder T R Rear brake hose holder bolt front side 7 Nm 0 7 m kgf 5 1 ft lbf 1 a b 2 ...

Page 300: ... COOLANT on page 3 19 Front side cover right Refer to GENERAL CHASSIS 2 on page 4 4 Footrest board assembly right Bottom cover Refer to GENERAL CHASSIS 5 on page 4 12 1 Radiator inlet hose 1 Disconnect 2 Radiator outlet hose 1 Disconnect 3 Water pump inlet hose 1 Disconnect 4 Thermostat assembly 1 9 Nm 0 9 m kgf 6 5 ft Ibf T R New 3 4 2 1 LS ...

Page 301: ...ine a at 90 C 194 F TIP If the accuracy of the thermostat is in doubt re place it A faulty thermostat could cause serious overheating or overcooling EAS30445 INSTALLING THE THERMOSTAT ASSEMBLY 1 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 19 2 Check Cooling system Leaks Repair or replace any faulty part Refer to INSTALLING THE R...

Page 302: ...ain Refer to CHANGING THE COOLANT on page 3 19 Front side cover left Refer to GENERAL CHASSIS 2 on page 4 4 Footrest board assembly left Bottom cover Refer to GENERAL CHASSIS 4 on page 4 9 1 Water pump inlet hose 1 Disconnect 2 Water pump assembly 1 3 Dowel pin 2 New LS 10 Nm 1 0 m kgf 7 2 ft Ibf T R 1 2 3 3 ...

Page 303: ...to remove Q ty Remarks 1 Water pump housing cover 1 2 Water pump housing gasket 1 3 Circlip 1 4 Impeller shaft 1 5 Water pump seal 1 6 Bearing 1 7 Water pump housing 1 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R LS New New New New 1 2 5 4 6 7 3 ...

Page 304: ...cified depth as shown in the illustra tion 2 Lubricate Water pump seal 3 Install Impeller shaft 1 Circlip TIP After installation check that the impeller shaft ro tates smoothly EAS30449 INSTALLING THE WATER PUMP 1 Install O rings 1 Water pump assembly 2 Installed depth of water pump seal 0 0 5 mm 0 0 02 in Mechanical seal installer 90890 04145 Middle driven shaft bearing driv er 90890 04058 Middle...

Page 305: ...the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 19 3 Check Cooling system Leaks Repair or replace any faulty part Refer to INSTALLING THE RADIATOR on page 6 3 4 Measure Radiator cap opening pressure Below the specified pressure Replace the radiator cap Refer to CHECKING THE RADIATOR on page 6 3 T R Water pump assembly bolt 10 Nm 1 0 m kgf 7 2 ft lbf 1 b a 2...

Page 306: ...WATER PUMP 6 11 ...

Page 307: ...UEL TANK 7 3 CHECKING THE FUEL PRESSURE 7 3 FUEL INJECTOR 7 5 REMOVING THE FUEL HOSE 7 6 CHECKING THE FUEL INJECTOR 7 6 INSTALLING THE FUEL INJECTOR 7 6 INSTALLING THE FUEL HOSE 7 6 AIR FILTER CASE 7 7 INSTALLING THE AIR FILTER CASE 7 9 THROTTLE BODY 7 10 REMOVING THE THROTTLE BODY 7 12 CHECKING THE THROTTLE BODY 7 12 CLEANING THE ISC IDLE SPEED CONTROL UNIT AND THROTTLE BODY 7 12 REPLACING THE TH...

Page 308: ...Center lower cover Refer to GENERAL CHASSIS 5 on page 4 12 1 Fuel tank cap 1 2 Fuel tank overflow tray 1 3 Fuel tank overflow hose 1 4 Fuel sender coupler 1 Disconnect 5 Fuel pump coupler 1 Disconnect 6 Fuel hose 1 Disconnect 7 Fuel tank 1 8 Fuel pump bracket 1 9 Fuel pump 1 10 Fuel pump gasket 1 11 Fuel filter 1 New 9 10 7 4 4 1 5 4 6 11 2 8 3 7 Nm 0 7 m kgf 5 1 ft Ibf T R 4 0 Nm 0 40 m kgf 2 9 f...

Page 309: ...a few rags in the area under where it will be removed 3 Remove Fuel tank EAS30451 REMOVING THE FUEL PUMP 1 Remove Fuel pump NOTICE ECA14721 Do not drop the fuel pump or give it a strong shock Do not touch the base section of the fuel sender EAS31376 REMOVING THE FUEL FILTER 1 Remove Fuel filter 1 TIP Remove the projections a on the fuel pump from the holes b in the fuel filter and slide the fuel f...

Page 310: ... the fuel tank b Install the fuel tank overflow tray and fuel tank cover 3 To install the fuel tank cover refer to GENERAL CHASSIS 3 on page 4 7 c Tighten the fuel tank bolts to specification 2 Install Fuel hose 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 ...

Page 311: ...there may be fuel remaining in it TIP Before removing the hose place a few rags in the area under where it will be removed b Connect the pressure gauge 1 and fuel pressure adapter 2 to the fuel hose 3 c Start the engine d Measure the fuel pressure Faulty Replace the fuel pump e Connect the fuel hose Refer to INSTALLING THE FUEL TANK on page 7 3 3 Install Footrest board assembly right Refer to GENE...

Page 312: ...nt side covers Refer to GENERAL CHASSIS 2 on page 4 4 Fuel tank cover Refer to GENERAL CHASSIS 3 on page 4 7 Storage box Refer to GENERAL CHASSIS 4 on page 4 9 Center lower cover Refer to GENERAL CHASSIS 5 on page 4 12 1 Fuel hose 1 2 Fuel injector coupler 1 Disconnect 3 Fuel injector 1 4 Fuel injector adaptor 1 10 Nm 1 0 m kgf 7 2 ft Ibf T R New E 1 2 3 4 ...

Page 313: ...Check Injector resistance Refer to CHECKING THE FUEL INJEC TOR on page 7 6 EAS31617 INSTALLING THE FUEL INJECTOR 1 Install Fuel injector adaptor 1 O ring 2 to the fuel injector Fuel injector 3 TIP Lubricate the O ring with engine oil Align the projection a on the fuel injector adapter with the hole b in the intake manifold Align the projection c on the fuel injector with the hole d in the fuel inj...

Page 314: ... page 4 4 Fuel tank cover Refer to GENERAL CHASSIS 3 on page 4 7 Storage box Refer to GENERAL CHASSIS 4 on page 4 9 1 Air filter case cover 1 2 Air filter case duct cover 1 3 Air filter case duct 1 4 Air filter element 1 5 Transmission case breather hose 1 1 2 Nm 0 12 m kgf 0 87 ft Ibf T R 1 2 Nm 0 12 m kgf 0 87 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 3 0 Nm 0 30 m kgf 2 2 ft Ibf T R New New 1 2...

Page 315: ...eather hose 1 Disconnect 7 Air filter case joint clamp screw 1 Loosen 8 Air filter case 1 9 Air filter check hose 1 10 Air filter case joint 1 11 Hose 1 1 2 Nm 0 12 m kgf 0 87 ft Ibf T R 1 2 Nm 0 12 m kgf 0 87 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 3 0 Nm 0 30 m kgf 2 2 ft Ibf T R New New 6 6 8 9 10 7 11 ...

Page 316: ...ing surfaces of the air filter case joint and air filter case Fit the projection a on the air filter case joint between the projections b on the air filter case 3 Install Air filter case joint clamp 1 to the air filter case joint 2 TIP Align the projection a on the air filter case joint with the slot b in the air filter case joint clamp 4 Install Air filter case duct 1 TIP Fit the projection a on ...

Page 317: ...4 7 Storage box Refer to GENERAL CHASSIS 4 on page 4 9 Center lower cover Refer to GENERAL CHASSIS 5 on page 4 12 Air filter case joint Refer to AIR FILTER CASE on page 7 7 Fuel injector Refer to FUEL INJECTOR on page 7 5 1 ISC Idle Speed Control unit coupler 1 Disconnect 2 Throttle body sensor assembly coupler 1 Disconnect 5 Nm 0 5 m kgf 3 6 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 7 Nm 0 7 m kg...

Page 318: ... cable holder 1 5 Intake manifold clamp screw 1 Loosen 6 Throttle body 1 7 Intake manifold 1 8 ISC Idle Speed Control unit holder 1 9 ISC Idle Speed Control unit 1 10 Spring 1 5 Nm 0 5 m kgf 3 6 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 3 0 Nm 0 30 m kgf 2 2 ft Ibf T R LS New New 6 10 7 8 9 3 4 5 ...

Page 319: ...valve Damage scratches wear Replace the throttle body NOTICE ECA21770 Do not adjust the stop screw 1 EAS31254 CLEANING THE ISC IDLE SPEED CONTROL UNIT AND THROTTLE BODY 1 Remove the throttle body from the vehicle TIP Before removing the throttle body disconnect the throttle cables and couplers 2 Remove Screw 1 ISC Idle Speed Control unit holder 2 ISC Idle Speed Control unit 3 NOTICE ECA21780 Becau...

Page 320: ...e engine speed could re sult Do not clean any areas other than the areas a b and c If the cleaning agent en ters the ISC unit or throttle body thorough ly wipe it off 7 Adjust the ISC unit plunger to the specified distance a from the motor assembly body 8 Install Spring O ring 1 ISC Idle Speed Control unit 2 NOTICE ECA21800 Do not use the ISC unit if it was dropped Do not allow water to enter the ...

Page 321: ...THE THROTTLE BODY on page 7 14 EAS31160 REPLACING THE THROTTLE BODY 1 Remove the throttle body from the vehicle 2 Install a new throttle body to the vehicle 3 Reset ISC learning valves Use the diagnostic code number 67 Refer to SELF DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE on page 9 5 ISC valve position Use the diagnostic code number 54 Refer to SELF DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TA...

Page 322: ...OTTLE BODY 7 15 TIP Align the projection a on the throttle body with the slot b in the intake manifold Align the projection c on the intake manifold 1 with slot d in the intake manifold clamp 2 a b 1 2 c d ...

Page 323: ...TEM 8 11 CIRCUIT DIAGRAM 8 11 TROUBLESHOOTING 8 13 LIGHTING SYSTEM 8 15 CIRCUIT DIAGRAM 8 15 TROUBLESHOOTING 8 17 SIGNALING SYSTEM 8 19 CIRCUIT DIAGRAM 8 19 TROUBLESHOOTING 8 21 FUEL INJECTION SYSTEM 8 25 CIRCUIT DIAGRAM 8 25 ECU SELF DIAGNOSTIC FUNCTION 8 27 TROUBLESHOOTING METHOD 8 27 YAMAHA DIAGNOSTIC TOOL 8 28 TROUBLESHOOTING DETAILS 8 31 FUEL PUMP SYSTEM 8 57 CIRCUIT DIAGRAM 8 57 TROUBLESHOOT...

Page 324: ...S USING THE FAULT CODES 8 69 B 3 DELETING THE FAULT CODES 8 90 C 1 FINAL CHECK 8 91 ELECTRICAL COMPONENTS 8 93 CHECKING THE SWITCHES 8 95 CHECKING THE BULBS AND BULB SOCKETS 8 98 CHECKING THE FUSES 8 99 REPLACING THE ECU engine control unit 8 99 CHECKING AND CHARGING THE BATTERY 8 99 CHECKING THE RELAYS 8 102 CHECKING THE TURN SIGNAL RELAY 8 103 CHECKING THE DIODE 8 103 CHECKING THE SPARK PLUG CAP...

Page 325: ......

Page 326: ...Br Br Br Br Br R L R L R L R B R B R B R L R W L W R B R B B Y L B W B B W W R R W P W P W Br W Br W Y Y P P L L B L B L R L R L Br W B W B W W L B Y L B L R L B B L R B W B W R B R G G L L Br Br Y B W B W Y Gy R G G B Ch Ch Gy R B L B L L Y L B Y L Y B B Y W B B Y B W B W B W B W B Y Y Y B B B B Y L Ch Dg B B B Ch G Br Ch L B Y B Y B Y B W L R B G Br Br Br Br Br Br Br Br Br L Y L B B B Br W Br W ...

Page 327: ...IGNITION SYSTEM 8 2 1 Crankshaft position sensor 3 Main fuse 1 10 Main switch 12 Battery 18 Sidestand switch 29 ECU Engine Control Unit 30 Ignition coil 31 Spark plug 52 Engine ground 53 Frame ground ...

Page 328: ... AND CHARGING THE BATTERY on page 8 99 Clean the battery terminals Recharge or replace the battery 3 Check the spark plug Refer to CHECKING THE SPARK PLUG on page 3 4 Re gap or replace the spark plug 4 Check the ignition spark gap Refer to CHECKING THE IGNI TION SPARK GAP on page 8 105 Ignition system is OK 5 Check the spark plug cap Refer to CHECKING THE SPARK PLUG CAP on page 8 104 Replace the s...

Page 329: ...e main switch 9 Check the sidestand switch Refer to CHECKING THE SWITCHES on page 8 95 Replace the sidestand switch 10 Check the entire ignition system wiring Refer to CIRCUIT DIAGRAM on page 8 1 Properly connect or replace the wire har ness Replace the ECU Refer to REPLAC ING THE ECU engine control unit on page 8 99 ...

Page 330: ...R R R Br Br Br Br Br Br R L R L R L R B R B R B R L R W L W R B R B B Y L B W B B W W R R W P W P W Br W Br W Y Y P P L L B L B L R L R L Br W B W B W W L B Y L B L R L B B L R B W B W R B R G G L L Br Br Y B W B W Y Gy R G G B Ch Ch Gy R B L B L L Y L B Y L Y B B Y W B B Y B W B W B W B W B Y Y Y B B B B Y L Ch Dg B B B Ch G Br Ch L B Y B Y B Y B W L R B G Br Br Br Br Br Br Br Br Br L Y L B B B B...

Page 331: ...stem fuse 10 Main switch 12 Battery 13 Starter relay 14 Starter motor 15 Handlebar switch right 16 Start switch 17 Diode 18 Sidestand switch 39 Rear brake light switch 40 Front brake light switch 53 Frame ground A Wire harness B Starter motor sub wire harness ...

Page 332: ...to the handlebar the front brake light switch is closed and the side stand is up the sidestand switch is closed The rear brake lever is pulled to the handlebar the rear brake light switch is closed and the sidestand is up the sidestand switch is closed 11 1 10 4 2 3 7 5 6 9 8 1 Battery 2 Main fuse 1 3 Main switch 4 Signaling system fuse 5 Rear brake light switch 6 Front brake light switch 7 Start ...

Page 333: ...GING THE BATTERY on page 8 99 Clean the battery terminals Recharge or replace the battery 3 Check the starter motor operation Refer to CHECKING THE START ER MOTOR OPERATION on page 8 106 Starter motor is OK Perform the electric starting system troubleshooting starting with step 5 4 Check the starter motor Refer to CHECKING THE START ER MOTOR on page 5 52 Repair or replace the starter motor 5 Check...

Page 334: ... to CHECKING THE SWITCHES on page 8 95 The start switch is faulty Replace the right handlebar switch 10 Check the brake light switches Front and rear Refer to CHECKING THE SWITCHES on page 8 95 Replace the brake light switch es 11 Check the entire starting system wiring Refer to CIRCUIT DIAGRAM on page 8 5 Properly connect or replace the wire har ness The starting system circuit is OK ...

Page 335: ...ELECTRIC STARTING SYSTEM 8 10 ...

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

Page 337: ...CHARGING SYSTEM 8 12 2 AC magneto 3 Main fuse 1 9 Rectifier regulator 12 Battery 53 Frame ground ...

Page 338: ...e the fuse 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 99 Clean the battery terminals Recharge or replace the battery 3 Check the stator coil Refer to CHECKING THE STATOR COIL on page 8 106 Replace the stator coil assembly 4 Check the rectifier regulator Refer to CHECKING THE RECTI FIER REGULATOR on page 8 106 Replace the rectifier regulator 5 Check the entire charging...

Page 339: ...CHARGING SYSTEM 8 14 ...

Page 340: ... Br Br Br Br Br R L R L R L R B R B R B R L R W L W R B R B B Y L B W B B W W R R W P W P W Br W Br W Y Y P P L L B L B L R L R L Br W B W B W W L B Y L B L R L B B L R B W B W R B R G G L L Br Br Y B W B W Y Gy R G G B Ch Ch Gy R B L B L L Y L B Y L Y B B Y W B B Y B W B W B W B W B Y Y Y B B B B Y L Ch Dg B B B Ch G Br Ch L B Y B Y B Y B W L R B G Br Br Br Br Br Br Br Br Br L Y L B B B Br W Br W...

Page 341: ...29 ECU Engine Control Unit 43 Handlebar switch left 44 Dimmer switch 47 Tail brake light assembly 49 Taillight 52 Engine ground 53 Frame ground 56 Headlight unit 57 Auxiliary light 58 Headlight 59 Meter assembly 60 Multi function meter 64 Meter light 67 High beam indicator light ...

Page 342: ...et s 2 Check the fuses Main 1 and taillight Refer to CHECKING THE FUS ES on page 8 99 Replace the fuse s 3 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 99 Clean the battery terminals Recharge or replace the battery 4 Check the main switch Refer to CHECKING THE SWITCHES on page 8 95 Replace the main switch 5 Check the dimmer switch Refer to CHECKING THE SWITCHES on page 8 ...

Page 343: ...LIGHTING SYSTEM 8 18 ...

Page 344: ...r Br Br Br Br Br R L R L R L R B R B R B R L R W L W R B R B B Y L B W B B W W R R W P W P W Br W Br W Y Y P P L L B L B L R L R L Br W B W B W W L B Y L B L R L B B L R B W B W R B R G G L L Br Br Y B W B W Y Gy R G G B Ch Ch Gy R B L B L L Y L B Y L Y B B Y W B B Y B W B W B W B W B Y Y Y B B B B Y L Ch Dg B B B Ch G Br Ch L B Y B Y B Y B W L R B G Br Br Br Br Br Br Br Br Br L Y L B B B Br W Br ...

Page 345: ...ht switch 40 Front brake light switch 41 Turn signal relay 42 Horn 43 Handlebar switch left 45 Horn switch 46 Turn signal switch 47 Tail brake light assembly 48 Brake light 50 Rear turn signal light left 51 Rear turn signal light right 52 Engine ground 53 Frame ground 54 Front turn signal light right 55 Front turn signal light left 59 Meter assembly 60 Multi function meter 61 Coolant temperature w...

Page 346: ...fails to sound NG OK 1 Check the fuses Main 1 taillight signaling system and ABS control unit Refer to CHECKING THE FUS ES on page 8 99 Replace the fuse s 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 99 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 95 Replace the main switch 4 Check the entir...

Page 347: ...witch Refer to CHECKING THE SWITCHES on page 8 95 Replace the rear brake light switch 3 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 8 19 Properly connect or replace the wire har ness Replace the tail brake light assembly 1 Check the turn signal light bulbs and sockets Refer to CHECKING THE BULBS AND BULB SOCKETS on page 8 98 Replace the turn signal light bulb socket o...

Page 348: ... to CHECKING THE COOL ANT TEMPERATURE SENSOR on page 8 108 Replace the coolant temperature sensor 2 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 8 19 Properly connect or replace the wire har ness Replace the meter assembly or ECU Refer to REPLACING THE ECU en gine control unit on page 8 99 1 Check the fuel sender Refer to CHECKING THE FUEL SENDER on page 8 107 Replace ...

Page 349: ... coupler Green Green Blue Blue Between ABS ECU coupler and ECU coupler White White Between ECU coupler and meter assembly coupler Yellow Blue Yellow Blue 2 Check the entire wiring Refer to TIP Properly connect or replace the wiring har ness Replace the ECU ABS ECU or meter assembly Refer to REPLACING THE ECU engine control unit on page 8 99 ...

Page 350: ...R R Br Br Br Br Br Br R L R L R L R B R B R B R L R W L W R B R B B Y L B W B B W W R R W P W P W Br W Br W Y Y P P L L B L B L R L R L Br W B W B W W L B Y L B L R L B B L R B W B W R B R G G L L Br Br Y B W B W Y Gy R G G B Ch Ch Gy R B L B L L Y L B Y L Y B B Y W B B Y B W B W B W B W B Y Y Y B B B B Y L Ch Dg B B B Ch G Br Ch L B Y B Y B Y B W L R B G Br Br Br Br Br Br Br Br Br L Y L B B B Br ...

Page 351: ...ntake air pressure sensor 25 Intake air temperature sensor 26 Throttle position sensor 27 ISC Idle Speed Control unit 28 Fuel injector 29 ECU Engine Control Unit 30 Ignition coil 31 Spark plug 32 O2 sensor 33 VVA variable valve actuator solenoid 34 Front wheel sensor 38 ABS ECU 43 Handlebar switch left 44 Dimmer switch 52 Engine ground 53 Frame ground 56 Headlight unit 58 Headlight 59 Meter assemb...

Page 352: ...n for around 2 seconds after the main switch has been set to ON and it comes on while the start switch is being pushed If the warning light does not come on under these conditions the warning light LED may be defective ECU detects an abnormal signal from a sensor If the ECU detects an abnormal signal from a sensor while the vehicle is being driven the ECU illumi nates the engine trouble warning li...

Page 353: ...ction is detected in the sensors and actuators check and repair the inner parts of the engine EAS30951 YAMAHA DIAGNOSTIC TOOL This model uses the Yamaha diagnostic tool to identify malfunctions For information about using the Yamaha diagnostic tool refer to the operation manual that is included with the tool Features of the Yamaha diagnostic tool You can use the Yamaha diagnostic tool to identify ...

Page 354: ...ts 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 Function diagnostic mode Check the operation of the output value of each sensor and actuator Inspection mode Determine whether each sensor or actuator is functioning ...

Page 355: ...list of the malfunction currently occurred are displayed 3 Code The following icons and the fault code numbers for the detected malfunctions are displayed 4 ECU The types of the control units are displayed 5 Item The item names of the detected malfunction are displayed 2 3 1 4 5 6 7 8 9 10 11 12 A B A Detected malfunction B Recovered malfunction ...

Page 356: ...d on the computer Check and ser vice the items or components that are the probable cause of the malfunction following the order given Fault code No Fault code number displayed on the computer when the engine failed to work normally Diagnostic code No Diagnostic code number to be used when the diagnostic mode is operated Refer to SELF DIAGNOS TIC FUNCTION AND DIAGNOSTIC CODE TABLE on page 9 5 Fault...

Page 357: ...ion sensor Check for looseness or pinch ing Check the gap between the crankshaft position sensor and the stator coil assembly Improperly installed sensor Reinstall or replace the sensor Refer to AC MAGNETO on page 5 47 Crank the engine Fault code number is not dis played Service is finished Fault code number is displayed Go to item 5 5 Defective crankshaft position sensor Check the crankshaft posi...

Page 358: ...ed Con nect the coupler securely or re place the wire harness Turn the main switch to ON Fault code number is not dis played Service is finished Fault code number is displayed Go to item 3 3 Wire harness continuity Open or short circuit Replace the wire harness Between throttle body sensor assembly coupler and ECU cou pler Black Blue Black Blue Pink White Pink White Blue Blue Turn the main switch ...

Page 359: ...e sure that the indication value changes The value does not change when engine is cranking Re place the throttle body if defec tive Refer to THROTTLE BODY on page 7 10 Turn the main switch to ON Fault code number is not dis played Service is finished Fault code number is displayed Go to item 6 6 Malfunction in ECU Replace the ECU Refer to REPLACING THE ECU engine control unit on page 8 99 Fault co...

Page 360: ...00 m 3300 ft above sea lev el Approx 90 kPa 675 1 mmHg 26 6 inHg 2000 m 6700 ft above sea lev el Approx 80 kPa 600 0 mmHg 23 6 inHg 3000 m 9800 ft above sea lev el 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 Re place the throttle body if defec tive Refer to THROTTLE BODY on page 7 10 Fault ...

Page 361: ...embly coupler and ECU cou pler Black Blue Black Blue Yellow Yellow Blue Blue Turn the main switch to ON Fault code number is not dis played Service is finished Fault code number is displayed Go to item 4 4 Installed condition of throttle body sensor assembly Check for looseness or pinch ing Check for looseness or pinch ing Improperly installed sensor Replace the throttle body Refer to THROTTLE BOD...

Page 362: ...ode number is displayed Go to item 2 2 Defective throttle position sen sor Execute the diagnostic mode Code No 01 When the throttle valves are ful ly closed A value of 13 21 is indicated When throttle valves are fully open A value of 92 102 is indicated An indicated value is out of the specified range Replace the throttle body Refer to THROTTLE BODY on page 7 10 Turn the main switch to ON and then...

Page 363: ...CU coupler and side stand switch coupler Blue Yellow Blue Yellow Turn the main switch to ON and then extend and retract the sidestand Fault code number is not dis played Service is finished Fault code number is displayed Go to item 4 4 Defective sidestand switch Execute the diagnostic mode Code No 20 Sidestand retracted ON Sidestand extended OFF Replace if defective Turn the main switch to ON and ...

Page 364: ...t Replace the wire harness Between coolant temperature sensor coupler and ECU cou pler Green Red Green Red Black Blue Black Blue Turn the main switch to ON Fault code number is not dis played Service is finished Fault code number is displayed Go to item 4 4 Installed condition of coolant temperature sensor Check for looseness or pinch ing Improperly installed sensor Reinstall or replace the sensor...

Page 365: ...y or re place the wire harness Turn the main switch to ON Fault code number is not dis played Service is finished Fault code number is displayed Go to item 3 3 Wire harness continuity Open or short circuit Replace the wire harness Between throttle body sensor assembly coupler and ECU cou pler Black Blue Black Blue Brown White Brown White Turn the main switch to ON Fault code number is not dis play...

Page 366: ...n of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the coupler securely or re place the wire harness Start the engine warm it up and then race it or execute the diagnostic mode Code No 62 Fault code number is not dis played Service is finished Fault code numbe...

Page 367: ...ion Procedure The ISC unit vibrates when the ISC valve operates Item Probable cause of malfunc tion and check Maintenance job Confirmation of service com pletion A 1 Locate the malfunction Execute the diagnostic mode Code No 54 Fully closes the ISC idle speed control valve and then fully opens the valve This operation takes approximately 3 seconds ISC operating sound is heard Go to item A 2 ISC op...

Page 368: ...idle speed control unit is not moving correctly Replace the ISC idle speed control unit Refer to CLEANING THE ISC IDLE SPEED CONTROL UNIT AND THROTTLE BODY on page 7 12 Start the engine and let it idle for approximately 10 seconds Fault code number is not dis played Service is finished Fault code number is displayed Go to item A 8 A 8 Malfunction in ECU Replace the ECU Refer to REPLACING THE ECU e...

Page 369: ... Replace the wire harness Between ISC idle speed con trol unit coupler and ECU cou pler Pink Pink Green Yellow Green Yellow Gray Gray Sky blue Sky blue Execute the diagnostic mode Code No 54 ISC operating sound is heard Go to item B 9 and delete the fault code ISC operating sound is not heard Go to item B 5 B 5 Installed condition of ISC idle speed control unit Check for looseness or pinch ing Imp...

Page 370: ... coupler Check that fuel injector is actuated five times by listening for the operating sound Item Probable cause of malfunc tion and check Maintenance job Confirmation of service com pletion 1 Connection of fuel injector 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 ...

Page 371: ... front wheel is rotated The number is cumulative and does not reset each time the wheel is stopped Item Probable cause of malfunc tion and check Maintenance job Confirmation of service com pletion 1 Connection of front wheel sen sor coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly conn...

Page 372: ...d delete the fault code Value does not increase Go to item 5 5 Malfunction in ECU Replace the ECU Refer to REPLACING THE ECU engine control unit on page 8 99 Execute the diagnostic mode Code No 07 Rotate the front wheel by hand and check that the indicated val ue increases Value increases Go to item 7 and delete the fault code Value does not increase Go to item 6 6 Malfunction in ABS ECU Replace t...

Page 373: ... or writing on EEPROM Fault code No 46 Item Charging voltage is abnormal Fail safe system Able to start engine Able to drive vehicle Diagnostic code No Tool display Procedure Item Probable cause of malfunc tion and check Maintenance job Confirmation of service com pletion 1 Malfunction in charging system Check the charging system Refer to CHARGING SYSTEM on page 8 11 Defective rectifier regulator ...

Page 374: ...ce the wire harness Set the main switch to ON Fault code number is not dis played Service is finished Fault code number is displayed Go to item 2 2 Connection of wire harness ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the coupler securely or re place the wi...

Page 375: ...er Check the locking condition of the coupler Disconnect the cou pler and check the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the coupler securely or re place the wire harness Set the main switch to ON Start the engine and accelerate to 6000 r min Fault code number is not dis played Service is finished Fault code number is displayed Go to item 2 ...

Page 376: ... check Maintenance job Confirmation of service com pletion 1 Connection of meter assembly coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the coupler securely or re place the wire harness Turn the main switch to ON Fault code number is not dis played Service is fini...

Page 377: ...k the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the coupler securely or re place the wire harness Turn the main switch to ON Fault code number is not dis played Service is finished Fault code number is displayed Go to item 2 2 Connection of wire harness ECU coupler Check the lo...

Page 378: ...of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the coupler securely or re place the wire harness Turn the main switch to ON Fault code number is not dis played Service is finished Fault code number is displayed Go to item 2 2 Connection of wire harness ECU coupler Check the locking condition of the c...

Page 379: ...g condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the coupler securely or re place the wire harness Turn the main switch to ON Fault code number is not dis played Service is finished Fault code number is displayed Go to item 2 2 Connection of wire harness ECU coupler Check the locking condit...

Page 380: ...t dis played Service is finished Fault code number is displayed Go to item 5 5 Malfunction in ECU Replace the ECU Refer to REPLACING THE ECU engine control unit on page 8 99 Fault code No Er 4 fault code display Item ECU engine control unit internal malfunction input signal error non registered data has been received from the meter ...

Page 381: ...FUEL INJECTION SYSTEM 8 56 ...

Page 382: ...r Br Br Br Br Br R L R L R L R B R B R B R L R W L W R B R B B Y L B W B B W W R R W P W P W Br W Br W Y Y P P L L B L B L R L R L Br W B W B W W L B Y L B L R L B B L R B W B W R B R G G L L Br Br Y B W B W Y Gy R G G B Ch Ch Gy R B L B L L Y L B Y L Y B B Y W B B Y B W B W B W B W B Y Y Y B B B B Y L Ch Dg B B B Ch G Br Ch L B Y B Y B Y B W L R B G Br Br Br Br Br Br Br Br Br L Y L B B B Br W Br ...

Page 383: ...FUEL PUMP SYSTEM 8 58 3 Main fuse 1 5 Main fuse 2 10 Main switch 12 Battery 20 Fuel pump 29 ECU Engine Control Unit 52 Engine ground 53 Frame ground ...

Page 384: ... fuse s 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 99 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 95 Replace the main switch 4 Check the fuel pump Refer to CHECKING THE FUEL PRESSURE on page 7 3 Replace the fuel pump 5 Check the entire fuel pump system wiring Refer to CIRCUIT DIAGRAM on p...

Page 385: ...FUEL PUMP SYSTEM 8 60 ...

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

Page 387: ...se 12 Battery 21 Yamaha diagnostic tool coupler 29 ECU Engine Control Unit 34 Front wheel sensor 35 Rear wheel sensor 36 Joint connector 37 ABS test coupler 38 ABS ECU 39 Rear brake light switch 40 Front brake light switch 47 Tail brake light assembly 48 Brake light 52 Engine ground 53 Frame ground 59 Meter assembly 60 Multi function meter 62 ABS warning light ...

Page 388: ...ABS ANTI LOCK BRAKE SYSTEM 8 63 EAS30844 ABS COUPLER LOCATION CHART G L Br Y L B B L R R B W B W B Y B Y B W L R B G Br Y L B B Y Ch Dg Gy B R L Br W B W W L B L R L B B W R G L Br Y Y W 1 2 3 5 4 ...

Page 389: ...ABS ANTI LOCK BRAKE SYSTEM 8 64 1 ABS ECU coupler 2 Rear wheel sensor coupler 3 ABS test coupler 4 Meter assembly coupler 5 Front wheel sensor coupler ...

Page 390: ...ha diagnostic tool For information about using the Yamaha diagnostic tool refer to B 2 DIAG NOSIS USING THE FAULT CODES on page 8 69 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 391: ...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 BA...

Page 392: ...in switch to ON and check the ABS warning light Fails to come on Comes on The ABS ECU coupler is disconnected The wire harness is defective The hydraulic unit assembly is defective The ABS solenoid fuse is blown Refer to Troubleshooting details of fault code No 31 Can communicate B 1 Check for ABS fault codes in the screen for the Execute fault diagnosis Yamaha diagnostic tool Are fault codes disp...

Page 393: ...ve Replace the meter assembly If the ABS warning light comes on the ABS ECU is defective Replace the hydraulic unit assembly EAS30964 A 2 ALL INDICATOR LIGHTS FAIL TO COME ON 1 Main switch Check the main switch for continuity Refer to CHECKING THE SWITCHES on page 8 95 If there is no continuity replace the main switch 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE ...

Page 394: ...etween Blue Black terminal of the ABS ECU coupler and Blue Black terminal of the ABS test coupler CANL 4 ABS ECU malfunction Replace the hydraulic unit assembly EAS31164 A 5 ABS ECU AND FI ECU FAIL TO COMMUNICATE Cannot connect due to a tool error 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...

Page 395: ...maha diagnostic tool Fault diagnosis mode Malfunction results are displayed in the top part of the window area 1 Recovered The item list of the malfunction detected in the past already recovered are displayed 2 Detected The item list of the malfunction currently occurred are displayed 3 Code The following icons and the fault code numbers for the detected malfunctions are displayed 1 2 3 1 4 5 6 7 ...

Page 396: ...s or no pulses Front wheel sensor signal is not received properly Puls es are not received or are re ceived intermittently while the vehicle is traveling Foreign material adhered around the 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 se...

Page 397: ...cuit is de tected in the front wheel sen sor Defective coupler between the front wheel sensor and the hydraulic unit assembly Open or short circuit in the wire harness between the front wheel sensor and the hydraulic unit assembly Defective front wheel sen sor or hydraulic unit as sembly 16 Rear wheel sensor open or short circuit Open or short circuit is de tected in the rear wheel sen sor Defecti...

Page 398: ...ght switch and the hydraulic unit as sembly Defective hydraulic unit as sembly 31 Hydraulic unit assembly ab normal ABS solenoid power supply Power is not supplied to the solenoid circuit in the hy draulic unit assembly Blown ABS solenoid fuse Defective coupler between the battery and the hydrau lic unit assembly Open or short circuit in the wire harness between the battery and the hydraulic unit ...

Page 399: ...ulses Front wheel sensor signal is not received properly Miss ing pulses are detected in the signal while the vehicle is traveling Foreign material adhered around the front wheel sen sor Incorrect installation of the front wheel Defective sensor rotor or incorrect installation of the rotor Defective front wheel sen sor or incorrect installation of the sensor 44 Rear wheel sensor missing pulses Rea...

Page 400: ...Open or short circuit in the wire harness between the battery and the hydraulic unit assembly Defective charging system Defective hydraulic unit as sembly 55 Hydraulic unit assembly de fective ABS ECU Abnormal data is detected in the hydraulic unit assembly Defective hydraulic unit as sembly 56 Hydraulic unit assembly ab normal internal power sup ply Abnormality is detected in the power supply cir...

Page 401: ...nt 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 FRONT WHEEL SENSOR AND SENSOR ROTOR on page 4 28 Fault code No 12 Item Rear wheel sensor intermittent pulses or no pulses Symptom Rear wheel sensor signal is not received properly Pulses are n...

Page 402: ...or for damage Re place the sensor rotor if there is visible damage Refer to MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR on page 4 28 4 Defective front 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 FRONT WHEEL SENSOR AND SENSOR ROT...

Page 403: ...period Symptom Rear wheel sensor signal is not received properly The pulse period is abnormal while the vehicle is traveling Order Item components and probable cause Check or maintenance job Fault code No 15 Item Front wheel sensor open or short circuit Symptom Open or short circuit is detected in the front wheel sensor Order Item components and probable cause Check or maintenance job 1 Defective ...

Page 404: ...ive Replace the wire harness 6 ABS ECU 7 Front wheel sensor 3 Defective front wheel sensor or hydraulic unit assembly If the above items were performed and no malfunctions were found the wheel sensor or hydraulic unit assembly is defective Replace the wheel sensor or hydraulic unit assembly Refer to FRONT WHEEL on page 4 25 and ABS AN TI LOCK BRAKE SYSTEM on page 4 61 Fault code No 15 Item Front w...

Page 405: ...ween the Brown terminal 4 and the Yellow terminal 5 If there is short circuit the wire harness is defective Replace the wire harness Check that there is no short circuit between the Black White terminal 3 and the Brown terminal 4 and between the Black White terminal 3 and the Yel low terminal 5 If there is short circuit the wire harness is defective Replace the wire harness 6 ABS ECU 7 Rear wheel ...

Page 406: ...OR ROTOR on page 4 28 4 Defective front 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 FRONT WHEEL SENSOR AND SENSOR ROTOR on page 4 28 Fault code No 18 46 Item Rear wheel sensor missing pulses Symptom Rear wheel sensor signal is not received...

Page 407: ...naling system 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 brake light or brake light switch and the hydraulic unit assembly Between front ...

Page 408: ...der Item components and probable cause Check or maintenance job Fault code No 32 Item Hydraulic unit assembly short circuit in ABS solenoid power supply circuit Symptom Short circuit is detected in the solenoid power supply circuit in the hy draulic unit assembly Order Item components and probable cause Check or maintenance job 1 Defective hydraulic unit assembly Replace the hydraulic unit assembl...

Page 409: ...cted in the motor power supply circuit in the hy draulic unit assembly Order Item components and probable cause Check or maintenance job 1 Defective hydraulic unit assembly Replace the hydraulic unit assembly Refer to ABS ANTI LOCK BRAKE SYSTEM on page 4 61 Fault code No 41 Item Front wheel ABS intermittent wheel speed pulses or incorrect de pressurization Symptom Pulses from the front wheel senso...

Page 410: ...l speed pulses or incorrect depres surization Symptom Pulses from the rear wheel sensor are received intermittently while the vehicle is traveling for fault code No 42 Rear wheel will not recover from the locking tendency even though the signal is transmitted from the ABS ECU to reduce the hydraulic pressure Order Item components and probable cause Check or maintenance job 1 Incorrect installation...

Page 411: ...condition 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 28 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...

Page 412: ...nnection Replace or reconnect the termi nal if necessary 3 Defective charging system Check the charging system Refer to CIRCUIT DIAGRAM on page 8 11 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 Defec...

Page 413: ...S ECU coupler and ABS motor fuse Red Blue Red Blue Between ABS ECU coupler and ABS solenoid fuse Red Red 4 Defective charging system Check the charging system Refer to CHARGING SYSTEM on page 8 11 5 Defective hydraulic unit assembly If the above items were performed and no malfunctions were found replace the hydraulic unit assembly Refer to ABS ANTI LOCK BRAKE SYSTEM on page 4 61 Fault code No 55 ...

Page 414: ...re is no short circuit between the Black White terminal 3 and the Green terminal 1 If there is a short circuit the wire harness is defective Replace the wire harness 4 ABS ECU 5 Front wheel sensor 2 Defective front wheel sensor Check that there is no short circuit between the Black terminal 1 and the White terminal 2 If there is a short circuit the wheel sensor is defective Repair or replace the w...

Page 415: ...bly Check that there is no short circuit between the Yellow terminal 1 and the Brown terminal 2 Check that there is no short circuit between the Black White terminal 3 and the Yellow terminal 1 If there is a short circuit the wire harness is defective Replace the wire harness 4 ABS ECU 5 Rear wheel sensor 2 Defective rear wheel sensor Check that there is no short circuit between the Black terminal...

Page 416: ... 4 34 3 Perform brake line routing confirmation Refer to HYDRAULIC UNIT OPERATION TESTS on page 4 65 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 90 5 Checking the ABS warning light Check that the ABS warning light goes off If the ABS warning light does not come on or if it do...

Page 417: ...ABS ANTI LOCK BRAKE SYSTEM 8 92 ...

Page 418: ...ELECTRICAL COMPONENTS 8 93 EAS20089 ELECTRICAL COMPONENTS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 16 18 19 21 20 22 23 24 25 26 27 28 29 30 31 32 15 17 ...

Page 419: ...ode 14 Ignition coil 15 Front wheel sensor 16 Fuel sender 17 Fuel pump 18 Sidestand switch 19 Spark plug 20 O2 sensor 21 Coolant temperature sensor 22 VVA variable valve actuator solenoid 23 AC magneto 24 Crankshaft position sensor 25 Rear wheel sensor 26 Starter motor 27 Throttle body sensor assembly 28 Intake air pressure sensor 29 Intake air temperature sensor 30 Throttle position sensor 31 ISC...

Page 420: ...ELECTRICAL COMPONENTS 8 95 EAS30549 CHECKING THE SWITCHES ON OFF L W B B B Dg Br W B Ch L B P B Dg Br W Ch P B Y L B R Br L W B 2 4 5 8 7 6 1 3 ...

Page 421: ...ELECTRICAL COMPONENTS 8 96 1 Rear brake light switch 2 Main switch 3 Front brake light switch 4 Start switch 5 Sidestand switch 6 Turn signal switch 7 Horn switch 8 Dimmer switch ...

Page 422: ...y set the pocket tester to 0 and to the Ω 1 range When checking for continuity switch back and forth between the switch positions a few times The switches and their terminal connections are illustrated as in the following example of the main switch The switch positions a are shown in the far left column and the switch lead colors b are shown in the top row The continuity i e a closed circuit betwe...

Page 423: ...e bulb Never pull the lead other wise it may be pulled out of the terminal in the coupler 2 Check Bulb for continuity with the pocket tester No continuity Replace TIP Before checking for continuity set the pocket tester to 0 and to the Ω 1 range a Connect the positive tester probe to terminal 1 and the negative tester probe to terminal 2 and check the continuity b Connect the positive tester probe...

Page 424: ...ting and ignition systems to malfunction and could possibly cause a fire 4 Install Battery cover Refer to GENERAL CHASSIS 1 on page 4 1 EAS31006 REPLACING THE ECU engine control unit 1 Turn the main switch to OFF 2 Replace the ECU engine control unit 3 Clean the throttle body Refer to CLEANING THE ISC IDLE SPEED CONTROL UNIT AND THROTTLE BODY on page 7 12 4 Check Engine idling speed Start the engi...

Page 425: ...rably Therefore take special care when charging the battery TIP Since VRLA Valve Regulated Lead Acid bat teries are sealed it is not possible to check the charge state of the battery by measuring the specific gravity of the electrolyte Therefore the charge of the battery has to be checked by mea suring the voltage at the battery terminals 1 Remove Battery cover Refer to GENERAL CHASSIS 1 on page 4...

Page 426: ...let the bat tery cool before reconnecting it Hot batteries can explode As shown in the following illustration the open circuit voltage of a VRLA Valve Reg ulated Lead Acid battery stabilizes about 30 minutes after charging has been com pleted Therefore wait 30 minutes after charging is completed before measuring the open circuit voltage Charging method using a variable current voltage charger a Me...

Page 427: ...e battery s charg ing voltage is 15 V TIP Set the charging time at 20 hours maximum e Measure the battery open circuit voltage after leaving the battery unused for more than 30 minutes 6 Install Battery 7 Connect Battery leads to the battery terminals NOTICE ECA13630 First connect the positive battery lead 1 and then the negative battery lead 2 8 Check Battery terminals Dirt Clean with a wire brus...

Page 428: ...the main switch to ON c Measure the turn signal relay output voltage EAS30555 CHECKING THE DIODE 1 Check Diode Out of specification Replace TIP The pocket tester and the analog pocket tester readings are shown in the following table 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 Turn signal relay input volta...

Page 429: ... of specification Replace a Disconnect the ignition coil connectors from the ignition coil terminals b Connect the pocket tester Ω 1 to the igni tion coil as shown c Measure the primary coil resistance 2 Check Secondary coil resistance Out of specification Replace Continuity Positive tester probe Blue Yellow 1 Negative tester probe Blue White 2 No continuity Positive tester probe Blue White 2 Nega...

Page 430: ... switch and gradually increase 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 stator assembly a Connect the pocket tester Ω 100 to the crankshaft position sensor coupler as shown Pocke...

Page 431: ...e starter motor operation EAS30566 CHECKING THE STATOR COIL 1 Disconnect Stator coil coupler from the wire harness 2 Check Stator coil resistance Out of specification Replace the stator coil a Connect the digital circuit tester to the stator coil coupler as shown b Measure the stator coil resistance EAS30680 CHECKING THE RECTIFIER REGULATOR 1 Check Charging voltage Out of specification Replace the...

Page 432: ... diagnosis de vice for the fuel level detection circuit 1 Check Fuel meter 1 Fuel level warning indicator 2 Turn the main switch to ON Warning light comes on for a few seconds then goes off Warning light is OK Warning light does not come on Replace the meter assembly Warning light flashes eight times then goes off for 3 seconds in a repeated cycle mal function detected in fuel sender Replace the f...

Page 433: ...terminals do not get wet c Place a thermometer 3 in the coolant d Heat the coolant or let it cool down to the specified temperatures e Measure the coolant temperature sensor re sistance 3 Install Coolant temperature sensor EAS30681 CHECKING THE FUEL INJECTOR 1 Check Fuel injector resistance Out of specification Replace the fuel injec tor a Disconnect the fuel injector coupler from fuel injector b ...

Page 434: ...enoid b Connect the digital circuit tester to the VVA solenoid terminal as shown c Measure the VVA solenoid resistance Positive tester probe Injector terminal 1 Negative tester probe Injector terminal 2 Resistance 1 8 2 2 Ω at 20 C 12 0 Ω at 68 F Digital circuit tester 90890 03174 Model 88 Multimeter with ta chometer YU A1927 Positive tester probe Solenoid terminal 1 Negative tester probe Solenoid...

Page 435: ...EATING 9 2 OVERCOOLING 9 3 POOR BRAKING PERFORMANCE 9 3 FAULTY FRONT FORK LEGS 9 3 UNSTABLE HANDLING 9 3 FAULTY LIGHTING OR SIGNALING SYSTEM 9 3 SELF DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE 9 5 SELF DIAGNOSTIC FUNCTION TABLE 9 5 COMMUNICATION ERROR WITH THE YAMAHA DIAGNOSTIC TOOL 9 5 DIAGNOSTIC CODE SENSOR OPERATION TABLE 9 6 DIAGNOSTIC CODE ACTUATOR OPERATION TABLE 9 7 EVENT CODE TABLE 9 9 ...

Page 436: ...r damaged fuel hose 2 Fuel pump Faulty fuel pump Clogged fuel pump filter 3 Throttle body Deteriorated 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 Incorrect spark plug gap Incorrect spark plug heat range Fouled spark plug Worn or damaged electrode Worn or damaged ins...

Page 437: ...e or worn clutch shoe spring 2 Clutch shoe s Damaged or worn clutch shoe 3 Primary sliding sheave Seized primary sliding sheave Poor starting performance 1 V belt Slipping V belt Oil or grease on the V belt 2 Primary sliding sheave Faulty operation 3 Clutch shoe s Bent damaged or worn clutch shoe Poor speed performance 1 V belt Slipping V belt Oil or grease on the V belt 2 Primary sheave weight s ...

Page 438: ...or damaged damper rod Incorrect oil viscosity Incorrect oil level EAS30611 UNSTABLE HANDLING 1 Handlebar Bent or improperly installed handlebar 2 Steering head components Improperly installed lower bracket improperly tightened ring nut Damaged ball bearing or bearing race 3 Front fork leg s Uneven oil levels both front fork legs Unevenly tensioned fork spring both front fork legs Broken fork sprin...

Page 439: ...gnal blinks slowly Faulty turn signal relay Faulty main switch Faulty turn signal switch Incorrect turn signal light bulb Turn signal remains lit Faulty turn signal relay Burnt out turn signal light bulb Turn signal blinks quickly Incorrect turn signal light bulb Faulty turn signal relay Burnt out turn signal light bulb Horn does not sound Damaged or faulty horn Faulty main switch Faulty horn swit...

Page 440: ...ective ISC idle speed control unit ISC operating sound is not heard 39 Fuel injector open or short circuit detected 42 Front wheel sensor no normal signals are received from the front wheel sensor 44 EEPROM fault code number an error is detected while reading or writing on EEPROM 46 Charging voltage is abnormal 50 Faulty ECU memory When this malfunction is detected in the ECU the fault code num be...

Page 441: ...actually mea sured air temperature with the computer display value 06 Coolant temperature When engine is cold Dis plays temperature closer to air temperature When engine is hot Displays current coolant temperature Compare the actually mea sured coolant temperature with the computer display value 07 Front wheel speed pulse Front wheel speed pulse 0 999 Check that the number in creases when the fron...

Page 442: ...e history click Action on the Yamaha diag nostic tool screen 67 ISC idle speed control learning condition display ISC idle speed control learning data erasure 00 ISC idle speed control learning data has been erased 01 It is not necessary to erase the ISC idle speed control learning data 02 It is necessary to erase the ISC idle speed control learning data To erase the ISC idle speed control learnin...

Page 443: ...d from the cylinder head and then connect the VVA variable valve actuator solenoid cou pler Refer to CYLINDER HEAD on page 5 9 Visually check that the VVA variable valve actuator so lenoid is actuated five times 52 Headlight relay Actuates the headlight relay five times at five second in tervals The CHECK indicator and on the Yamaha diag nostic tool screen come on each time the relay is actuat ed ...

Page 444: ...re harness between the sensor and the ECU Gray Red Gray Red Low fuel pressure Clogged fuel injector Sensor malfunction Defective ECU Defective fuel injec tion system If a fault code is indi cated perform the checks and mainte nance jobs for the fault code first Event code number 240 may be indicated even if the system is normal 241 O2 sensor Correction value re mains at lower limit Correction valu...

Page 445: ...e condition detected Empty fuel tank Defective fuel injec tion system Dirty or worn spark plug Defective battery Defective ECU If a fault code is indi cated perform the checks and mainte nance jobs for the fault code first Event code number 244 may be indicated even if the system is normal 245 Engine stall Engine stall detected Empty fuel tank Improperly adjusted throttle cable Defective fuel inje...

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Page 448: ...l relay 42 Horn 43 Handlebar switch left 44 Dimmer switch 45 Horn switch 46 Turn signal switch 47 Tail brake light assembly 48 Brake light 49 Taillight 50 Rear turn signal light left 51 Rear turn signal light right 52 Engine ground 53 Frame ground 54 Front turn signal light right 55 Front turn signal light left 56 Headlight unit 57 Auxiliary light 58 Headlight 59 Meter assembly 60 Multi function m...

Page 449: ... L R L R B R B R B R L R W L W R B R B B Y L B W B B W W R R W P W P W Br W Br W Y Y P P L L B L B L R L R L Br W B W B W W L B Y L B L R L B B L R B W B W R B R G G L L Br Br Y B W B W Y Gy R G G B Ch Ch Gy R B L B L L Y L B Y L Y B B Y W B B Y B W B W B W B W B Y Y Y B B B B Y L Ch Dg B B B Ch G Br Ch L B Y B Y B Y B W L R B G Br Br Br Br Br Br Br Br Br L Y L B B B Br W Br W G Y G Y Y Br Br Br B...

Page 450: ...A L L Gy B B B B B B B B Gy B G G Br Br Gy B 1 2 3 4 5 6 7 8 9 10 11 12 13 14 16 17 18 19 20 21 22 23 25 26 27 28 29 30 31 24 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 A B 15 ...

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