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Yamaha Tenere 700 2020, Service Manual


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CONNECTING RODS AND PISTONS

5-66

EAS20132

CONNECTING RODS AND PISTONS

Removing the connecting rods and pistons

Order

Job/Parts to remove

Q

’

ty

Remarks

The following procedure applies to all of the 
connecting rods and pistons.

Crankcase

Separate.
Refer to “CRANKCASE” on page 5-60.

1

Connecting rod cap

1

2

Big end lower bearing

1

3

Big end upper bearing

1

4

Piston pin clip

2

5

Piston pin

1

6

Piston

1

7

Connecting rod

1

8

Top  ring

1

9

2nd ring

1

10

Oil ring

1

2

1

3

4

4

6

7

5

9

10

8

1

s

t

20 N

•

m (2.0 k

g

f

•

m, 15 lb

•

ft)

2nd

S

pecified an

g

le 1

8

0°

T.R

.

New

New

New

New

E

E

E

E

E

M

M

Summary of Contents for Tenere 700 2020

Page 1: ...2020 SERVICE MANUAL T n r 700 XTZ690 XTZ690 U BW3 F8197 E0...

Page 2: ......

Page 3: ...TIP If the contents of the manual are revised the last digit of the manual number will be increased by one This Service Manual contains information regarding periodic maintenance to the emission cont...

Page 4: ...tle 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 d...

Page 5: ...TION Serviceable with engine mounted Gear oil Filling fluid Molybdenum disulfide oil Lubricant Brake fluid Special tool Wheel bearing grease Tightening torque Lithium soap based grease Wear limit clea...

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 APPENDIX 9...

Page 8: ......

Page 9: ...1 GENERAL INFORMATION IDENTIFICATION 1 1 VEHICLE IDENTIFICATION NUMBER 1 1 MODEL LABEL 1 1 FEATURES 1 2 MULTI FUNCTION METER UNIT 1 2 SPECIAL TOOLS 1 7...

Page 10: ...ICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the steering head pipe EAS30003 MODEL LABEL The model label 1 is affixed to the frame under the seat Th...

Page 11: ...423 Be sure to stop the vehicle before making any setting changes to the multi function meter unit Changing settings while riding can distract the operator and increase the risk of an accident Speedom...

Page 12: ...ted by Clock The clock uses a 12 hour time system TIP When the main switch is turned off the clock can be viewed by pushing the top set button To set the clock 1 Turn the key to ON 2 Push the bottom s...

Page 13: ...i cally reset Push the top set button to switch the display in the following order ODO TRIP 1 TRIP 2 TRIP CD TRIP F km L or L 100 km or MPG AVE_ _ _ km L or AVE_ _ _ L 100 km or AVE_ _ _ MPG _ _ C Air...

Page 14: ...p tion unit is MPG km L The distance that can be traveled on 1 0 L of fuel under the current riding conditions is shown L 100 km The amount of fuel necessary to travel 100 km under the current riding...

Page 15: ...be displayed The temperature displayed may vary from the ambient temperature Brightness control mode The brightness level of the multi function meter unit panel can be adjusted To adjust the brightnes...

Page 16: ...e list provided below to avoid any mistakes TIP For U S A and Canada use part number starting with YM YU or ACC For others use part number starting with 90890 Tool name Tool No Illustration Reference...

Page 17: ...90890 01426 Oil filter wrench YU 38411 3 24 Pressure gauge 90890 03153 Pressure gauge YU 03153 3 26 7 12 7 13 Oil pressure adapter H 90890 03139 3 26 Fork spring compression tool 90890 01573 Fork spri...

Page 18: ...703 4 65 Rod puller attachment M10 long 90890 01578 Universal damping rod bleeding tool set YM A8703 4 65 Ring nut wrench 90890 01268 Spanner wrench YU 01268 4 70 Engine alignment tool 90890 11097 4 7...

Page 19: ...r 90890 04019 Valve spring compressor YM 04019 5 28 5 32 Valve spring compressor attachment 26 90890 01243 Valve spring compressor adapter 26 mm YM 01253 1 5 28 5 32 Valve guide remover 4 5 90890 0411...

Page 20: ...ester CD732 90890 03243 Model 88 Multimeter with tachometer YU A1927 5 40 8 130 8 131 8 132 8 133 8 133 8 133 8 134 8 135 8 135 8 136 8 137 8 137 8 137 8 138 8 139 8 139 8 140 Universal clutch holder...

Page 21: ...r kit YU 24460 A 6 4 Radiator cap tester adapter 90890 01352 Pressure tester adapter YU 33984 6 4 Mechanical seal installer 33 90890 04132 Water pump seal installer 33 YM 33221 A 6 13 Middle driven sh...

Page 22: ...ssure adapter 90890 03176 Fuel pressure adapter YM 03176 7 13 OBD GST Leadwire kit 90890 03249 8 34 Ignition checker 90890 06754 Oppama pet 4000 spark checker YM 34487 8 135 Test harness lean angle se...

Page 23: ...GENERAL SPECIFICATIONS 2 1 ENGINE SPECIFICATIONS 2 2 CHASSIS SPECIFICATIONS 2 7 ELECTRICAL SPECIFICATIONS 2 10 TIGHTENING TORQUES 2 12 ENGINE TIGHTENING TORQUES 2 12 CHASSIS TIGHTENING TORQUES 2 13 CA...

Page 24: ...0P B BW34 XTZ690_AUS Dimensions Overall length 2370 mm 93 3 in Overall width 905 mm 35 6 in Overall height 1455 mm 57 3 in Wheelbase 1595 mm 62 8 in Ground clearance 240 mm 9 45 in Minimum turning rad...

Page 25: ...ty grades 10W 40 Recommended engine oil grade API service SG type or higher JASO standard MA Lubrication system Wet sump Engine oil quantity Without oil filter cartridge replacement 2 30 L 2 43 US qt...

Page 26: ...10 35 710 mm 1 4020 1 4059 in Limit 35 510 mm 1 3980 in Lobe height Exhaust 35 710 35 810 mm 1 4059 1 4098 in Limit 35 610 mm 1 4020 in Camshaft runout limit 0 030 mm 0 0012 in Valve valve seat valve...

Page 27: ...970 mm 0 7075 in Piston pin to piston pin bore clearance 0 009 0 025 mm 0 0004 0 0010 in Piston ring Top ring End gap limit 0 50 mm 0 0197 in Ring side clearance 0 030 0 065 mm 0 0012 0 0026 in Side c...

Page 28: ...ckness 1 90 2 10 mm 0 075 0 083 in Plate quantity 6 pcs Warpage limit 0 10 mm 0 004 in Clutch spring free length 50 00 mm 1 97 in Limit 47 50 mm 1 87 in Drivetrain Primary reduction ratio 1 925 77 40...

Page 29: ...erature 85 105 C 185 221 F Engine oil temperature 60 80 C 140 176 F Intake vacuum 39 3 41 6 kPa 295 312 mmHg 11 6 12 3 inHg Difference in vacuum pressure between the cylinders 0 kPa 1 3 kPa 0 mmHg 10...

Page 30: ...SCORPION RALLY STR Tire air pressure measured on cold tires 1 person Front 220 kPa 2 20 kgf cm 32 psi Rear 250 kPa 2 50 kgf cm 36 psi 2 persons Front 220 kPa 2 20 kgf cm 32 psi Rear 250 kPa 2 50 kgf c...

Page 31: ...oz Level 85 0 mm 3 35 in Rebound damping Adjusting system Mechanical adjustable type Unit for adjustment Click Adjustment value from the start position Soft 31 Adjustment value from the start positio...

Page 32: ...nit for adjustment Click Adjustment value from the start position Soft 18 Adjustment value from the start position STD 15 Adjustment value from the start position Hard 0 Drive chain Size 525V11 Chain...

Page 33: ...Charging system Charging system AC magneto Standard output 14 0 V 29 3 A at 5000 r min Stator coil resistance 0 128 0 192 Rectifier regulator Regulator type Three phase Regulated voltage DC 14 3 14 7...

Page 34: ...228 342 Intake air temperature sensor resistance 5400 6600 at 0 C 5400 6600 at 32 F Intake air temperature sensor resistance 290 390 at 80 C 290 390 at 176 F Coolant temperature sensor resistance 2510...

Page 35: ...kgf m 9 6 lb ft Cylinder head cover bolt M6 4 10 N m 1 0 kgf m 7 4 lb ft Generator rotor bolt M12 1 70 N m 7 0 kgf m 52 lb ft Generator cover bolt M6 2 12 N m 1 2 kgf m 8 9 lb ft Generator cover bolt...

Page 36: ...f m 59 lb ft Rear wheel axle nut M18 1 105 N m 10 5 kgf m 77 lb ft Brake caliper bleed screw M8 3 10 N m 1 0 kgf m 7 4 lb ft Front brake caliper bolt M10 4 40 N m 4 0 kgf m 30 lb ft Upper handlebar ho...

Page 37: ...bolts less than 20 N m 2 0 kgf m 15 lb ft temporally 2 Tighten the upper handlebar holder bolt on the front side and then on the rear side to specified torque TIP Lower bracket pinch bolt Tighten the...

Page 38: ...CABLE ROUTING 2 15 EAS20021 CABLE ROUTING Handlebar front view A B C D E F G H E F G G H I G H E G F H G H H J J K L K M M N N O 1 2 3 2 3 4 4 5 5 6 7 7 8 9 11 9 10 11 12 12 13 14 15...

Page 39: ...th the meter assembly B Fasten the left handlebar switch lead and clutch cable with the holder Position the holder to the upper edge of the clutch cable protector C 90 100 mm 3 54 3 94 in D To meter a...

Page 40: ...2 17 Frame front right side view A C C C D E G H I L M N O P R 1 2 3 4 5 6 7 8 8 8 8 9 9 9 10 11 11 12 13 14 15 10 11 16 17 18 19 18 19 20 21 22 23 24 25 26 27 J K L M J K L M J K P O J K P O J K O P...

Page 41: ...the main switch lead outside of the bracket C Insert the projection on the coupler into the hole in the coupler holder D Insert the projection on the handlebar switch lead and main switch lead into th...

Page 42: ...ROUTING 2 19 Frame and engine right side view G H G G H G H H G G H H A B C L K M N 1 2 3 4 5 6 7 G H D E F E F 10 11 12 13 15 16 N 16 N 16 23 23 17 18 18 19 21 20 22 24 25 I J I J I J I J I J 8 9 O...

Page 43: ...verflow hose rollover valve to canister 22 Canister 23 Frame 24 O2 sensor lead 25 Oil pressure switch lead A Face the blue paint mark on the fuel tank breather hose outward B Route the sub wire harnes...

Page 44: ...L M J K L M N O P Q R S 1 2 3 4 5 6 7 5 8 8 8 34 35 8 8 8 9 10 11 12 13 13 12 2 14 15 16 17 18 2 2 2 2 19 19 22 22 19 20 20 14 14 20 20 21 19 22 20 21 22 23 24 25 26 27 19 28 29 30 31 32 33 G H L M E...

Page 45: ...ss to hydraulic unit 35 Frame A To Auxiliary DC jack B Route the wire harness through the guide on the left windshield inner panel C Route the auxiliary DC jack lead through the lower hole in the left...

Page 46: ...G H F G E H F E G H N P O E F N O F E N O E F F M U T V A Q B E G H F E G H F E G H G H J K F E G R H 1 2 3 4 5 6 7 8 7 8 7 8 8 7 8 7 7 8 9 10 11 12 13 17 14 18 18 20 20 22 17 21 21 20 21 18 21 23 23...

Page 47: ...rame E Downward F Upward G Outward H Inward I Insert the projection on the wire harness holder into the hole in the bracket J Forward K Rearward L Face the buckle of the plastic locking tie upward wit...

Page 48: ...BLE ROUTING 2 25 Frame top view D E F 1 2 3 5 4 5 6 7 9 10 11 12 13 14 15 16 17 18 19 20 8 A B C D E F J K C D I C J D I C G C D E F H I J I J 21 22 21 22 23 25 26 31 31 30 30 22 27 27 29 28 24 25 L 2...

Page 49: ...crankshaft position sensor coupler 26 Rectifier regulator coupler black 27 Frame 28 Rectifier regulator lead 29 Crankshaft position sensor coupler 30 Stator coil lead 31 Coolant reservoir hose A Faste...

Page 50: ...CABLE ROUTING 2 27 Battery and rear fender top view A E H 1 2 3 4 5 6 7 8 9 10 11 14 12 13 15 16 17 18 12 19 B C D 28 29 30 31 11 13 23 24 25 26 27 28 12 20 21 22 C D F G 32...

Page 51: ...ke light lead 23 Starter relay 24 Fuse box 2 lead 25 FI diagnostic tool connector lead 26 Fuse box 1 lead 27 Negative battery lead 28 Battery 29 Wire harness to joint coupler 30 Wire harness to relay...

Page 52: ...CABLE ROUTING 2 29 Rear brake hose right side view B C D E F H G 1 2 3 2 2 2 2 2 3 4 3 G 2 3 3 3 5 5 6 4 3 4 A J I K H J I K L M...

Page 53: ...topper on the rear brake caliper C Make sure that the pin of the brake hose contacts the stopper on the rear brake master cylinder D Fasten the rear wheel sensor lead and the brake hose with the holde...

Page 54: ...CABLE ROUTING 2 31 Front brake hose left and right side view 1 1 1 1 2 2 2 2 2 2 2 5 2 2 2 3 3 3 3 3 3 3 3 4 4 4 4 4 A B H G J K L M F N 2 2 3 3 4 4 C D E O P I Q T U V R S...

Page 55: ...lder into the hole in the radiator cover J Insert the holder into the hole in the frame Face the catch of the holder forward and then close the holder until three clicks or more are heard K Insert the...

Page 56: ...CABLE ROUTING 2 33 Hydraulic unit assembly top and left side view 1 2 3 4 3 4...

Page 57: ...Brake hose hydraulic unit to rear brake caliper 2 Brake hose rear brake master cylinder to hydraulic unit 3 Brake hose front brake master cylinder to hydraulic unit 4 Brake hose hydraulic unit to righ...

Page 58: ...CABLE ROUTING 2 35 Radiator front and right side view A B C 1 2 3 3 4 5...

Page 59: ...inlet hose Make sure not to install the hose clamp on the raised portion of the hose fitting B Align the yellow paint mark on the radiator inlet hose with the projection on the radiator pipe Install...

Page 60: ...CABLE ROUTING 2 37 Radiator left side view A B C D D F E G 1 1 2 2 3 4 5 6 6 7 5...

Page 61: ...ward B Fasten the radiator inlet hose and coolant reservoir hose at the white paint mark on each hose with the holder C Align the white paint mark on the radiator inlet hose with the projection on the...

Page 62: ...CABLE ROUTING 2 39...

Page 63: ...SES 3 14 BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS 3 14 CHECKING THE BRAKE FLUID LEVEL 3 16 CHECKING THE WHEELS 3 16 CHECKING AND TIGHTENING THE SPOKES 3 16 CHECKING THE TIRES 3 17 CHECKING THE WHEEL BE...

Page 64: ...HE FRONT BRAKE LIGHT SWITCH 3 29 ADJUSTING THE REAR BRAKE LIGHT SWITCH 3 29 CHECKING AND LUBRICATING THE CABLES 3 29 CHECKING THE THROTTLE GRIP OPERATION 3 29 CHECKING AND CHARGING THE BATTERY 3 30 CH...

Page 65: ......

Page 66: ...hould be performed by your Yamaha dealer because these items re quire special tools data and technical skills From 50000 km 30000 mi repeat the maintenance intervals starting from 10000 km 6000 mi The...

Page 67: ...000 km 600 mi and after washing the motorcycle riding in the rain or riding in wet areas 14 Steering bearings Check bearing assemblies for looseness Moderately repack with lithi um soap based grease 1...

Page 68: ...or sooner if cracked or damaged 25 Engine oil Change warm engine before draining Check oil level and vehicle for oil leakage 26 Engine oil filter cartridge Replace 27 Cooling system Check coolant lev...

Page 69: ...a diagnostic tool version 3 0 and after to perform the dynamic inspection For information about using the Yamaha diagnostic tool refer to the operation manual that is included with the tool 5 Install...

Page 70: ...e Brake hose from the holder 1 Holder 2 from the radiator cover 3 Remove Hydraulic unit bracket bolts 1 Intake air pressure sensor bolt 2 TIP Remove the hydraulic unit assembly bracket bolts 1 and int...

Page 71: ...Install Rectifier regulator Refer to ABS ANTI LOCK BRAKE SYS TEM on page 4 44 Windshield inner panel left Refer to GENERAL CHASSIS 4 on page 4 8 Fuel tank Refer to FUEL TANK on page 7 1 Fuel tank sid...

Page 72: ...rk a on the generator rotor with the slot b in the gen erator rotor cover c Measure the valve clearance with a thick ness gauge TIP If the valve clearance is incorrect record the measured reading Meas...

Page 73: ...0 0641 in The valve pad number is 163 e Round off the valve pad number according to the following table and then select the suitable valve pad TIP Refer to the following table for the available valve...

Page 74: ...e diagnostic code number 67 Refer to SELF DIAGNOSTIC FUNC TION AND DIAGNOSTIC CODE TABLE on page 9 1 b Check the ISC idle speed control leaning value EAS30797 SYNCHRONIZING THE THROTTLE BODIES TIP Bef...

Page 75: ...check the synchronization again If a bypass air screw was removed turn the screw in fully and be sure to synchronize the throttle bodies If the throttle body synchronization can not be adjusted using...

Page 76: ...tank side covers Refer to GENERAL CHASSIS 3 on page 4 5 Fuel tank Refer to FUEL TANK on page 7 1 2 Check Canister Canister purge hose Fuel tank breather overflow hoses Canister breather hose Cracks d...

Page 77: ...filter element Air duct cover NOTICE ECA14401 Never operate the engine without the air filter element installed Unfiltered air will cause rapid wear of engine parts and may damage the engine Operating...

Page 78: ...lever TIP While pushing the brake lever forward turn the adjusting dial 1 until the brake lever is in the desired position Be sure to align the setting on the adjusting dial with the arrow mark a on...

Page 79: ...efer to ADJUSTING THE REAR BRAKE LIGHT SWITCH on page 3 29 EAS30634 CHECKING THE REAR BRAKE PADS The following procedure applies to all of the brake pads 1 Operate the brake 2 Check Rear brake pad Wor...

Page 80: ...tly to the bleed screw 2 d Place the other end of the hose into a con tainer e Slowly apply the brake several times f Fully squeeze the brake lever or fully de press the brake pedal and hold it in pos...

Page 81: ...E ECA13540 Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately TIP In order to ensure a correct reading of the brake fluid level make...

Page 82: ...and of the same design No guarantee con cerning handling characteristics can be giv en if a tire combination other than one approved by Yamaha is used on this vehicle WARNING EWA13210 New tires have a...

Page 83: ...le on the sidestand WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over 2 Shift the transmission into the neutral posi tion 3 Check Drive chain slack Out of spe...

Page 84: ...chains Do not use any other lubricants on the drive chain since they may contain solvents that could damage the O rings EAS30645 CHECKING AND ADJUSTING THE STEERING HEAD 1 Stand the vehicle on a level...

Page 85: ...CHASSIS FASTENERS Make sure that all nuts bolts and screws are properly tightened EAS30804 LUBRICATING THE BRAKE LEVER Lubricate the pivoting point and metal to metal moving parts of the lever EAS308...

Page 86: ...adjustment positions 1 Adjust Rebound damping a Turn the adjusting screw 1 in direction a or b TIP Although the total number of clicks of a damping force adjusting mechanism may not exactly match the...

Page 87: ...BER ASSEMBLY on page 4 73 EAS30655 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over Spring preload NOTICE ECA13590...

Page 88: ...al total number of turns of the damping force adjusting mechanism This ad justment range may not exactly match the spec ifications listed due to small differences in production Direction a Rebound dam...

Page 89: ...oils with a grade of CD or higher and do not use oils labeled ENERGY CONSERVING II Do not allow foreign materials to enter the crankcase 4 Start the engine warm it up for several min utes and then tur...

Page 90: ...vehicle on a suitable stand Make sure that the vehicle is upright 2 Check Engine oil level Below the minimum level mark a Add the recommended engine oil to the proper level 3 Start the engine warm it...

Page 91: ...and maximum level mark b Below the minimum level mark Add the recommended coolant to the proper level NOTICE ECA13470 Adding water instead of coolant lowers the antifreeze content of the coolant If w...

Page 92: ...ge 6 5 and WATER PUMP on page 6 10 EAS30813 CHANGING THE COOLANT 1 Remove Air scoop right Refer to GENERAL CHASSIS 3 on page 4 5 2 Remove Radiator cap bolt 1 Radiator cap 2 WARNING EWA13030 A hot radi...

Page 93: ...available soft water may be used If coolant comes into contact with painted surfaces immediately wash them with wa ter Do not mix different types of antifreeze 9 Install Radiator cap Radiator cap bolt...

Page 94: ...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 Check Throttle cables Dama...

Page 95: ...Turn the adjusting nut 3 until the speci fied throttle grip free play is obtained d Tighten the locknut e Slide the rubber cover to its original posi tion TIP Make sure that the adjusting nut is cover...

Page 96: ...cense plate light unit nuts 1 License plate light cover 2 3 Remove License plate light bulb 1 4 Install License plate light bulb 5 Install License plate light cover License plate light unit Lower fend...

Page 97: ...Y 4 10 INSTALLING THE WINDSHIELDS 4 10 INSTALLING THE METER ASSEMBLY 4 10 FRONT WHEEL 4 11 REMOVING THE FRONT WHEEL 4 13 DISASSEMBLING THE FRONT WHEEL 4 13 CHECKING THE FRONT WHEEL 4 13 MAINTENANCE OF...

Page 98: ...AR BRAKE MASTER CYLINDER 4 42 CHECKING THE REAR BRAKE MASTER CYLINDER 4 42 ASSEMBLING THE REAR BRAKE MASTER CYLINDER 4 42 INSTALLING THE REAR BRAKE MASTER CYLINDER 4 43 ASSEMBLING THE BRAKE PEDAL 4 43...

Page 99: ...Y ARM 4 73 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 4 73 INSTALLING THE RELAY ARM 4 74 SWINGARM 4 75 REMOVING THE SWINGARM 4 77 CHECKING THE SWINGARM 4 77 INSTALLING THE SWINGARM 4 78 CHAIN DRIVE 4...

Page 100: ...ts and battery Order Job Parts to remove Q ty Remarks 1 Passenger seat 1 2 Rider seat 1 3 Battery band 1 4 Negative battery lead 1 Disconnect 5 Positive battery lead 1 Disconnect 6 Battery 1 1 3 5 6 4...

Page 101: ...rake light assembly 1 6 License plate light coupler 1 7 Rear turn signal light coupler right 1 Disconnect 8 Rear turn signal light coupler left 1 Disconnect 9 Rear fender assembly 1 10 ECU cover 1 11...

Page 102: ...nect ECU coupler TIP While pushing the projection a and move the lock lever b of the ECU coupler in the direction of the arrow shown in the illustration to discon nect the coupler EAS31642 INSTALLING...

Page 103: ...GENERAL CHASSIS 2 4 4 TIP Fit the projections a on the side cover to the holes b in the tail cover and then fit the projec tions c to the grommets d 1 c a b d...

Page 104: ...p right 1 6 Front turn signal light coupler right 1 Disconnect 7 Front turn signal light right 1 8 Air duct right 1 9 Fuel tank side cover left 1 10 Fuel tank side cover right 1 3 0 N m 0 30 kgf m 2 2...

Page 105: ...s to both of the fuel tank side covers 1 Remove Fuel tank side cover 1 TIP Remove the projection a on the fuel tank side cover from the hole b EAS32778 INSTALLING THE FUEL TANK SIDE COVERS The followi...

Page 106: ...GENERAL CHASSIS 3 4 7 EAS31773 INSTALLING THE AIR SCOOPS The following procedure applies to both of the air scoops 1 Install Air scoop 1 TIP Fit the projections a on the air scoop to the holes b 1 b a...

Page 107: ...Meter assembly coupler 1 Disconnect 5 Meter assembly 1 6 Intake air temperature sensor coupler 1 Disconnect 7 Intake air temperature sensor 1 8 Auxiliary DC jack coupler left 1 Disconnect 9 Windshiel...

Page 108: ...panel right 1 13 Headlight inner cover 1 14 Headlight assembly 1 4 0 N m 0 40 kgf m 3 0 lb ft T R 7 N m 0 7 kgf m 5 2 lb ft T R 7 N m 0 7 kgf m 5 2 lb ft T R 7 N m 0 7 kgf m 5 2 lb ft T R 7 N m 0 7 k...

Page 109: ...lowing procedure applies to both of wind shields 1 Install Windshield left right 1 TIP Install the windshield to the inward of the por tion a on the windshield inner panel Fit the projection b on the...

Page 110: ...osen 10 Front wheel axle 1 11 Front wheel 1 12 Collar 2 13 Front brake disc 2 14 Front wheel sensor rotor 1 LT LT New New New LT 7 N m 0 7 kgf m 5 2 lb ft T R 8 N m 0 8 kgf m 5 9 lb ft T R 8 N m 0 8 k...

Page 111: ...FRONT WHEEL 4 12 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 LS LS 2 1 1 2 3...

Page 112: ...uter tube 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 seal Wheel bearings a Clean the surfac...

Page 113: ...alled on the inner side of the wheel hub When cleaning the wheel sensor rotor be careful not to damage the surface of the sensor rotor 3 Measure Wheel sensor rotor deflection Out of specification Clea...

Page 114: ...re wheel or both the front wheel static balance should be adjusted Adjust the front wheel static balance with the brake disc installed 1 Remove Balancing weight s 2 Find Front wheel s heavy spot 3 Adj...

Page 115: ...front wheel sensor TIP a Fit the projection a on the front fork into the hole b on the front wheel sensor lead holder When installing the front wheel sensor check the wheel sensor lead for twists To r...

Page 116: ...ion of the front wheel Do not turn the front wheel while the thickness gauge is installed This may damage the front wheel sen sor rotor and the front wheel sensor Distance a between the front wheel se...

Page 117: ...Loosen 3 Adjusting bolt 2 Loosen 4 Rear wheel axle nut 1 5 Washer 1 6 Adjusting block 2 7 Rear wheel axle 1 8 Rear wheel 1 9 Rear brake caliper 1 10 Collar left 1 11 Collar right 1 LT 7 N m 0 7 kgf m...

Page 118: ...et 1 3 Rear wheel drive hub 1 4 Rear wheel drive hub damper 6 5 Collar 1 6 Oil seal 1 7 Bearing 1 8 Rear brake disc 1 9 Rear brake disc plate 1 10 Rear wheel sensor rotor 1 11 Rear wheel 1 LT LT New N...

Page 119: ...REAR WHEEL 4 20 Disassembling the rear wheel Order Job Parts to remove Q ty Remarks 1 Oil seal 1 2 Wheel bearing 2 3 Spacer 1 New New New LS 2 2 3 1...

Page 120: ...e Rear wheel axle nut Washer Rear wheel axle Adjusting blocks Rear wheel TIP Push the rear wheel forward and remove the drive chain from the rear wheel sprocket EAS30158 DISASSEMBLING THE REAR WHEEL 1...

Page 121: ...Rear wheel sensor Refer to MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR on page 4 14 2 Check Rear wheel sensor rotor Refer to MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR on page 4...

Page 122: ...ake disc Refer to CHECKING THE REAR BRAKE DISC on page 4 40 4 Lubricate Oil seal lips 5 Install Collar right Collar left Rear brake caliper 1 Rear wheel Adjusting blocks Rear wheel axle Washer Rear wh...

Page 123: ...sensor and sensor rotor installation conditions warpage caused by overtorque wrong in stallation direction rotor decentering LOC TITE on the mounting surface of the rotor deformation caused by an impa...

Page 124: ...e Q ty Remarks The following procedure applies to both of the front brake calipers 1 Brake caliper bleed screw 1 Loosen 2 Front brake caliper 1 3 Brake pad clip 2 4 Brake pad pin 1 5 Brake pad 2 6 Bra...

Page 125: ...inder reservoir diaphragm 1 4 Brake lever 1 5 Front brake light switch connector 2 Disconnect 6 Front brake light switch 1 7 Front brake hose union bolt 1 8 Brake hose gasket 2 9 Brake hose front brak...

Page 126: ...FRONT BRAKE 4 27 Disassembling the front brake master cylinder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder kit 1 2 Brake master cylinder body 1 2 1 New BF BF S...

Page 127: ...DING THE HYDRAULIC BRAKE SYSTEM ABS on page 3 14 1 Front brake hose union bolt 1 2 Brake hose gasket 2 3 Brake hose gasket 1 Right side only 4 Brake hose right front brake caliper to left front brake...

Page 128: ...ove Q ty Remarks The following procedure applies to both of the front brake calipers 1 Brake pad clip 2 2 Brake pad pin 1 3 Brake pad 2 4 Brake pad spring 1 5 Brake pad support 1 6 Boot 1 7 Boot 1 8 B...

Page 129: ...brake disc a Place the vehicle on a suitable stand so that the front wheel is elevated b Remove the brake caliper c Hold the dial gauge at a right angle against the brake disc surface d Measure the de...

Page 130: ...caliper 4 Check Brake fluid level Below the minimum level mark Add the specified brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 16 5 Check Brake lever operation Sof...

Page 131: ...the pins b of the brake hose hydraulic unit to right front brake and brake hose right front brake caliper to left brake caliper 2 Remove Front brake caliper 3 Install Brake pad spring Brake pads Brake...

Page 132: ...e master cylinder to hydraulic unit TIP To collect any remaining brake fluid place a container under the master cylinder and the end of the brake hose EAS30725 CHECKING THE FRONT BRAKE MASTER CYLINDER...

Page 133: ...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 br...

Page 134: ...rear brake pads Order Job Parts to remove Q ty Remarks Rear wheel Refer to REAR WHEEL on page 4 18 1 Brake pad clip 1 2 Brake pad pin 1 3 Brake pad 2 4 Brake pad spring 1 5 Brake caliper bleed screw 1...

Page 135: ...Brake fluid reservoir cap 1 3 Brake fluid reservoir diaphragm holder 1 4 Brake fluid reservoir diaphragm 1 5 Brake fluid reservoir hose 1 6 Rear brake hose union bolt 1 7 Brake hose gasket 2 8 Brake...

Page 136: ...rake master cylinder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder yoke 1 2 Brake master cylinder kit 1 3 Hose joint 1 4 Bushing 1 5 Brake master cylinder body 1 1 2 2 3 4 5 S BF BF N...

Page 137: ...ke fluid Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS on page 3 14 Rear wheel Refer to REAR WHEEL on page 4 18 1 Rear brake hose union bolt 1 2 Brake hose gasket 2 3 Brake hose hydraulic uni...

Page 138: ...rake caliper Order Job Parts to remove Q ty Remarks 1 Brake pad clip 1 2 Brake pad pin 1 3 Brake pad 2 4 Brake pad spring 1 5 Brake pad support 1 6 Boot 1 7 Boot 1 8 Brake caliper bleed screw 1 10 N m...

Page 139: ...he brake disc deflection or replace the brake disc Refer to CHECKING THE FRONT BRAKE DISCS on page 4 30 3 Measure Brake disc thickness Measure the brake disc thickness at a few dif ferent locations Ou...

Page 140: ...carefully 2 Remove Rear wheel Rear brake caliper Refer to REMOVING THE REAR WHEEL on page 4 21 EAS30188 CHECKING THE REAR BRAKE CALIPER Brake caliper body Cracks damage Replace the brake caliper asse...

Page 141: ...ing Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS on page 3 14 EAS30193 REMOVING THE REAR BRAKE MASTER CYLINDER 1 Remove Brake hose union bolt Brake hose gaskets Brake hose...

Page 142: ...a harmful chemical reaction leading to poor brake performance When refilling be careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling point of the brak...

Page 143: ...UEL TANK on page 7 1 Brake fluid Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS on page 3 14 1 Stator coil coupler 1 Disconnect 2 Rectifier regulator coupler 1 Disconnect 3 Rectifier regulator...

Page 144: ...ke caliper 1 Disconnect 10 Brake hose rear brake master cylinder to hy draulic unit 1 Disconnect 11 Brake hose front brake master cylinder to hy draulic unit 1 Disconnect 12 Hydraulic unit bracket 1 1...

Page 145: ...connect 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 ope...

Page 146: ...e front brake master cylinder to hydraulic unit c Temporarily tighten the union bolt for the brake hose rear brake master cylinder to hydraulic unit 4 TIP Make sure that the pipe section b of the brak...

Page 147: ...o B 3 DE LETING THE FAULT CODES on page 8 125 9 Perform a trial run Refer to CHECKING THE ABS WARNING LIGHT on page 4 51 EAS31040 HYDRAULIC UNIT OPERATION TESTS The reaction force pulsating action gen...

Page 148: ...screen indicate when the brakes are being applied and released respectively NOTICE ECA18280 Check that the pulse is felt in the brake le ver brake pedal and again in the brake le ver in this order If...

Page 149: ...er and brake pedal are not being operated 9 A reaction force pulsating action is generated in the brake lever 1 and continues for a few seconds TIP The reaction force pulsating action consists of quic...

Page 150: ...brake pipes are connected cor rectly to the hydraulic unit assembly 12 Turn the main switch to OFF 13 Remove the Yamaha diagnostic tool from the Yamaha diagnostic tool coupler and then in stall the pr...

Page 151: ...LS LS LT LT LT LT 18 N m 1 8 kgf m 13 lb ft T R 26 N m 2 6 kgf m 19 lb ft T R 2 0 N m 0 20 kgf m 1 5 lb ft T R 2 0 N m 0 20 kgf m 1 5 lb ft T R 10 N m 1 0 kgf m 7 4 lb ft T R 28 N m 2 8 kgf m 21 lb f...

Page 152: ...handlebar holder 1 LT LS LS LS LS LS LT LT LT LT 18 N m 1 8 kgf m 13 lb ft T R 26 N m 2 6 kgf m 19 lb ft T R 2 0 N m 0 20 kgf m 1 5 lb ft T R 2 0 N m 0 20 kgf m 1 5 lb ft T R 10 N m 1 0 kgf m 7 4 lb f...

Page 153: ...t there is no danger of it falling over 2 Install Lower handlebar holder 1 Handlebar 2 Upper handlebar holder 3 NOTICE ECA19130 First tighten the bolts on the front side of the upper handlebar holder...

Page 154: ...ithium soap based grease Fit the projection b on the bottom of the bolt head into the slot c in the bolt hole in the clutch lever holder While squeezing the clutch lever fit the projec tion d on the c...

Page 155: ...4 in of clear ance a between the throttle grip and the grip end 10 Install Throttle cable holder 1 TIP Align the throttle cable holder 1 with the edge of the front brake master cylinder 11 Adjust Thro...

Page 156: ...view mirror left 17 N m 1 7 kgf m 13 lb ft Rearview mirror right 17 N m 1 7 kgf m 13 lb ft Left hand threads Handguard bolt grip end 18 N m 1 8 kgf m 13 lb ft Handguard bolt rearview mirror 7 N m 0 7...

Page 157: ...to both of the front fork legs Front brake calipers Front fender Front wheel Refer to FRONT WHEEL on page 4 11 1 Upper bracket pinch bolt 2 Loosen 2 Front fork cap bolt 1 Loosen 3 Lower bracket pinch...

Page 158: ...ng 1 3 Fork spring seat 1 4 Fork spring 1 5 Damper rod locknut 1 6 Fork spring guide 1 7 Damper adjusting rod 1 8 Outer tube 1 9 Inner tube bushing 1 10 Outer tube bushing 1 11 Washer 1 12 Oil seal 1...

Page 159: ...arts to remove Q ty Remarks 15 Cap 1 16 Damper rod assembly 1 17 Damper rod assembly bolt 1 18 O ring 2 19 Copper washer 1 20 Inner tube 1 17 15 19 18 New New New LT LT LT LS 20 16 New New New New New...

Page 160: ...move Cap bolt 1 from the damper rod assembly Locknut 2 Fork spring seat 3 Fork spring a Press down on the fork spring with the fork spring compression tool 4 b Install the rod holder 5 between the loc...

Page 161: ...E FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Check Inner tube Outer tube Bends damage scratches Replace WARNING EWA13650 Do not attempt to straighten a bent inner...

Page 162: ...ube Be careful not to damage the inner tube 2 Tighten Damper rod assembly bolt along with the O rings and the copper washer TIP While holding the damper rod assembly with the damper rod holder 1 tight...

Page 163: ...m mended fork oil NOTICE ECA14230 Be sure to use the recommended fork oil Other oils may have an adverse effect on front fork performance Fork seal driver 90890 01442 Adjustable fork seal driver 36 46...

Page 164: ...specification Correct 14 Install Damper adjusting rod Fork spring guide Locknut a Install the fork spring guide TIP Install the fork spring guide with its shorter end a pointing up A b Install the loc...

Page 165: ...nch bolts EAS30210 INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Install Front fork leg Temporarily tighten the lower bracket pinch bolts TIP Put the...

Page 166: ...FRONT FORK 4 67 T R Front fork cap bolt 30 N m 3 0 kgf m 22 lb ft Upper bracket pinch bolt 23 N m 2 3 kgf m 17 lb ft...

Page 167: ...nt brake calipers Front fender Front wheel Refer to FRONT WHEEL on page 4 11 Front fork legs Refer to FRONT FORK on page 4 58 Handlebar Refer to HANDLEBAR on page 4 52 1 Main switch coupler 2 Disconne...

Page 168: ...g nut 1 9 Rubber washer 1 10 Lower ring nut 1 11 Lower bracket 1 12 Lower bearing 1 13 Lower bracket cap 1 14 Upper bearing cover 1 15 Upper bearing 1 7 N m 0 7 kgf m 5 2 lb ft T R 1st 75 N m 7 5 kgf...

Page 169: ...age pitting Replace the bearings and bearing races as a set 3 Replace Bearings Bearing races a Remove the bearing races from the steer ing head pipe 1 with a long rod 2 and hammer b Remove the bearing...

Page 170: ...fork legs Refer to INSTALLING THE FRONT FORK LEGS on page 4 66 TIP Temporarily tighten the upper and lower bracket pinch bolts 5 Tighten Steering stem nut 6 Tighten Upper and lower bracket pinch bolt...

Page 171: ...ENERAL CHASSIS 2 on page 4 2 Exhaust pipe Refer to ENGINE REMOVAL on page 5 3 1 Connecting arm 2 2 Relay arm 1 3 Collar 1 4 Collar 1 5 Collar 1 6 Oil seal 6 7 Bearing 2 8 Bearing 2 9 Bearing 1 10 Rear...

Page 172: ...ll a 2 3 mm 0 08 0 12 in hole through the rear shock absorber at the point a as shown WARNING EWA13760 Wear eye protection to prevent eye damage from released gas or metal chips EAS30219 REMOVING THE...

Page 173: ...4 TIP When installing the oil seals to the relay arm face the character stamps of the oil seals out ward 2 Install Relay arm 1 TIP Install the relay arm bolt 2 so that the bolt head fits between the p...

Page 174: ...Refer to REAR SHOCK ABSORBER AS SEMBLY on page 4 72 1 Drive chain case 1 2 Stay 1 3 Rear brake hose lead holder 1 4 Rear brake hose lead guide 1 5 Pivot shaft nut 1 6 Washer 1 7 Adjusting bolt 1 Loos...

Page 175: ...uide 1 12 Dust cover 2 13 Oil seal 2 14 Collar 1 15 Bearing 3 16 Collar 1 17 Oil seal 2 18 Bearing 2 12 13 14 15 15 13 New 12 17 16 18 11 17 18 LS LS LS New New New LS LS 7 N m 0 7 kgf m 5 2 lb ft T R...

Page 176: ...nt B by moving the swingarm up and down If the swingarm vertical movement is not smooth or if there is binding check the piv ot shaft collars bearings dust covers and adjusting bolt 3 Loosen Adjusting...

Page 177: ...pecification with the engine alignment tool 1 Make sure that the flange on the adjusting bolt contacts the dust cover on the swingarm Recommended lubricant Lithium soap based grease Installed depth a...

Page 178: ...shaft nut 7 Install Rear wheel Refer to REAR WHEEL on page 4 18 8 Adjust Drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3 18 T R Pivot shaft nut 110 N m 11 kgf m 81 lb ft Drive cha...

Page 179: ...Rear shock absorber assembly Refer to REAR SHOCK ABSORBER AS SEMBLY on page 4 72 Swingarm Refer to SWINGARM on page 4 75 1 Shift rod locknut shift arm side 1 Loosen 2 Shift rod locknut shift pedal sid...

Page 180: ...ket cover 1 7 Drive chain guide 1 8 Drive chain 1 9 Drive sprocket nut 1 10 Washer 1 11 Drive sprocket 1 6 7 9 11 8 10 LT LT LT LT E New LT LS 10 N m 1 0 kgf m 7 4 lb ft T R 9 N m 0 9 kgf m 6 6 lb ft...

Page 181: ...uter sides 2 TIP When measuring a 15 link section of the drive chain make sure that the drive chain is taut Perform this procedure 2 3 times at a different location each time 2 Check Drive chain Stiff...

Page 182: ...drive chain and rear wheel sprocket as a set EAS30232 CHECKING THE REAR WHEEL SPROCKET Refer to CHECKING AND REPLACING THE REAR WHEEL SPROCKET on page 4 21 EAS30233 CHECKING THE REAR WHEEL DRIVE HUB R...

Page 183: ...left hand threads b Turn the shift rod 2 to obtain the correct shift pedal position c Tighten both locknuts d Make sure that the angle between the shift arm and the shift rod is about 90 6 Adjust Dri...

Page 184: ...is too tight will overload the engine and other vital parts and one that is too loose can skip and damage the swing arm or cause an accident Therefore keep the drive chain slack within the specified...

Page 185: ...ING THE CYLINDER HEAD 5 24 CHECKING THE TIMING CHAIN GUIDES 5 24 CHECKING THE CYLINDER HEAD 5 24 INSTALLING THE CYLINDER HEAD 5 25 VALVES AND VALVE SPRINGS 5 27 REMOVING THE VALVES 5 28 CHECKING THE V...

Page 186: ...T SHAFT 5 53 OIL PUMP 5 54 CHECKING THE SPROCKET AND CHAIN 5 56 CHECKING THE OIL PUMP 5 56 CHECKING THE RELIEF VALVE 5 56 ASSEMBLING THE OIL PUMP 5 56 INSTALLING THE OIL PUMP 5 57 OIL PAN 5 58 REMOVIN...

Page 187: ...R SHAFT ASSEMBLY 5 77 CHECKING THE CRANKSHAFT 5 79 INSTALLING THE CRANKSHAFT 5 81 INSTALLING THE BALANCER SHAFT ASSEMBLY 5 81 TRANSMISSION 5 82 REMOVING THE TRANSMISSION 5 86 CHECKING THE SHIFT FORKS...

Page 188: ...the reading on the compression gauge stabilizes WARNING EWA12940 To prevent sparking ground all spark plug leads before cranking the engine TIP The difference in compression pressure be tween cylinde...

Page 189: ...ENGINE INSPECTION 5 2 7 Install Spark plugs Ignition coils T R Spark plug 13 N m 1 3 kgf m 9 6 lb ft...

Page 190: ...cap 1 7 Engine guard 1 8 O2 sensor coupler 1 Disconnect 9 Exhaust pipe 1 10 Gasket 2 11 Exhaust pipe bracket 1 12 O2 sensor 1 Remove the O2 sensor only when neces sary New 6 4 1 5 9 7 11 8 12 2 New 10...

Page 191: ...2 Air scoop left Air duct left Fuel tank side cov ers Refer to GENERAL CHASSIS 3 on page 4 5 Fuel tank Canister Refer to FUEL TANK on page 7 1 Drive sprocket Refer to CHAIN DRIVE on page 4 80 Starter...

Page 192: ...Clutch cable 1 Disconnect 2 Gear position sensor coupler 1 Disconnect 3 Crankshaft position sensor coupler 1 Disconnect 4 Stator coil coupler 1 Disconnect 5 Ignition coil coupler 2 Disconnect 6 Sidest...

Page 193: ...ng nut rear lower side 1 9 Washer 1 10 Engine mounting nut rear upper side 1 11 Washer 1 12 Engine mounting bolt front right side 1 13 Collar 1 LT LT LT LT LT LT LT LT LT LT 3 4 2 1 6 5 5 7 12 13 8 9...

Page 194: ...ht 1 18 Engine mounting bolt front left side 1 19 Washer 1 20 Engine mounting bolt rear lower side 1 21 Engine mounting bolt rear upper side 1 22 Engine 1 LT LT LT LT LT LT LT LT LT LT 14 22 19 18 20...

Page 195: ...2 inch hexagon bit sock et Make sure that the flange of the engine mount ing adjust bolt contacts the engine 3 Install Collar 14 Engine mounting bolt front right side 15 TIP Temporarily tighten the bo...

Page 196: ...in the il lustration 2 Install Damper 1 to the frame TIP Install the damper with the mark a facing rear wheel side 3 Install Exhaust pipe bracket 1 to the frame TIP Install the exhaust pipe bracket wi...

Page 197: ...e covers Refer to GENERAL CHASSIS 3 on page 4 5 Fuel tank Refer to FUEL TANK on page 7 1 Coolant Drain Refer to CHANGING THE COOLANT on page 3 27 Radiator Refer to RADIATOR on page 6 2 Throttle cables...

Page 198: ...upler 2 Disconnect 3 Ignition coil 2 4 Spark plug 2 5 Cylinder head cover 1 6 Cylinder head cover gasket 1 7 Breather plate 1 8 Breather plate gasket 1 9 Timing chain guide upper side 1 13 N m 1 3 kgf...

Page 199: ...1 10 Intake camshaft sprocket 1 11 Exhaust camshaft sprocket 1 12 Decompressor lever 2 1 13 Decompressor lever 1 1 14 Decompressor lever pin 2 10 N m 1 0 kgf m 7 4 lb ft T R 10 N m 1 0 kgf m 7 4 lb f...

Page 200: ...28 00 into the timing chain ten sioner b Remove the timing chain tensioner 4 Remove Intake camshaft cap Exhaust camshaft cap NOTICE ECA13720 To prevent damage to the cylinder head camshafts or camshaf...

Page 201: ...el pins and camshaft caps TIP Tighten the camshaft cap bolts in stages and in a crisscross pattern working from the inner caps out Do not turn the camshaft when measuring the camshaft journal to camsh...

Page 202: ...oner housing by hand TIP While pressing the timing chain tensioner rod wind it counterclockwise with a hexagon wrench 1 Parts No 1WS 12228 00 until it stops b Make sure that the timing chain tensioner...

Page 203: ...b as shown in the illustration While holding the intake camshaft sprocket with the rotor holding tool 2 tighten the intake camshaft sprocket bolts in the proper tighten ing sequence as shown 3 Install...

Page 204: ...ing chain start with the exhaust camshaft and be sure to keep the tim ing chain as tight as possible on the exhaust side Make sure that the match marks a on the ex haust camshaft sprocket and cam lobe...

Page 205: ...chain tensioner bolts 5 on the cyl inder block TIP Be sure to install the timing chain tensioner gas ket so that the portion a of the gasket is pro truding from the upper inner side of the timing chai...

Page 206: ...74 INSTALLING THE CYLINDER HEAD COVER 1 Install Timing chain guide top side Cylinder head cover gasket 1 to the cylinder head cover Cylinder head cover 2 TIP Apply Yamaha bond No 1215 3 onto the mat i...

Page 207: ...AMSHAFTS 5 20 2 Install Spark plugs Ignition coils 1 TIP Install the ignition coils 1 in the direction shown in the illustration A Exhaust side T R Spark plug 13 N m 1 3 kgf m 9 6 lb ft 2 1 c b A New...

Page 208: ...Air ducts Fuel tank side covers Refer to GENERAL CHASSIS 3 on page 4 5 Fuel tank Refer to FUEL TANK on page 7 1 Throttle bodies Refer to THROTTLE BODIES on page 7 5 Radiator Refer to RADIATOR on page...

Page 209: ...1 Oil cooler inlet hose 1 Disconnect 2 Engine bracket bolt left 2 3 Engine mounting bolt left upper side 1 4 Engine bracket left 1 5 Engine mounting bolt front right side 1 6 Collar 1 6 5 3 4 2 2 6 1...

Page 210: ...inder head 1 12 Timing chain guide exhaust side 1 13 Cylinder head 1 14 Cylinder head gasket 1 15 Dowel pin 2 16 Timing chain 1 17 Timing chain guide intake side 1 11 7 12 17 16 6 13 9 10 8 8 14 15 15...

Page 211: ...f a turn at a time After all of the bolts are fully loosened remove them M6 45 mm 1 2 M10 100 mm 3 8 EAS30278 CHECKING THE TIMING CHAIN GUIDES 1 Check Timing chain guide exhaust side Timing chain guid...

Page 212: ...ating surface with engine oil 2 Tighten Cylinder head bolts 1 6 Cylinder head bolts 7 8 Following the tightening order loosen the bolt one by one and then retighten it to the specific torque and angle...

Page 213: ...CYLINDER HEAD 5 26...

Page 214: ...remove Q ty Remarks Cylinder head Refer to CYLINDER HEAD on page 5 21 1 Valve lifter 8 2 Valve pad 8 3 Valve cotter 16 4 Valve spring retainer 8 5 Valve spring 8 6 Exhaust valve 4 7 Intake valve 4 8 V...

Page 215: ...should be no leakage at the valve seat 1 3 Remove Valve cotters TIP Remove the valve cotters by compressing the valve spring with the valve spring compressor 1 and the valve spring compressor attachm...

Page 216: ...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 0...

Page 217: ...cification Replace the cylinder head a Apply blue layout fluid b onto the valve face b Install the valve into the cylinder head c Press the valve through the valve guide and onto the valve seat to mak...

Page 218: ...head i Press the valve through the valve guide and onto the valve seat to make a clear impression j Measure the valve seat width c again If the valve seat width is out of specification reface and lap...

Page 219: ...or attachment 2 5 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 6...

Page 220: ...t 2 Crankshaft position sensor coupler 1 Disconnect 3 Crankshaft end cover 1 4 Timing mark accessing bolt 1 5 Oil filler cap 1 6 Generator cover 1 7 Generator cover gasket 1 8 Bearing 1 3 8 3 1 2 7 8...

Page 221: ...15 Starter clutch 1 16 Woodruff key 1 17 Starter clutch idle gear shaft 1 18 Starter clutch idle gear 1 19 Starter clutch gear 1 16 18 3 8 3 13 17 12 19 15 14 9 9 11 10 New New New New New FWD FWD LT...

Page 222: ...d over the generator rotor EAS30868 REMOVING THE STARTER CLUTCH 1 Remove Starter clutch bolts 1 Starter clutch TIP While holding the generator rotor 2 with the ro tor holding tool 3 loosen the starter...

Page 223: ...he arrow mark a is toward the generator rotor 2 While holding the generator rotor with the rotor holding tool 3 tighten the starter clutch bolts 4 EAS30872 INSTALLING THE GENERATOR 1 Install Woodruff...

Page 224: ...et Generator cover TIP Tighten the generator cover bolts in stages and in a crisscross pattern Apply LOCTITE to the threads of only the generator cover bolts 1 shown in the illustra tion 7 Connect Sta...

Page 225: ...R Removing the starter motor Order Job Parts to remove Q ty Remarks Canister Refer to FUEL TANK on page 7 1 1 Starter motor lead 1 Disconnect 2 Starter motor 1 3 Canister holder 1 3 1 2 10 N m 1 0 kgf...

Page 226: ...ove Q ty Remarks 1 O ring 1 2 Starter motor front cover 1 3 Starter motor yoke 1 4 Armature assembly 1 5 Gasket 2 6 Brush holder set 1 7 Starter motor rear cover 1 8 Lead guide 1 5 5 2 7 8 6 1 3 4 LS...

Page 227: ...tor 4 Measure Brush length a Out of specification Replace the brush holder set 5 Measure Brush spring force Out of specification Replace the brush holder set 6 Check Gear teeth Damage wear Replace the...

Page 228: ...Align the match marks a on the starter motor yoke with the match marks b on the front cover and rear covers EAS30327 INSTALLING THE STARTER MOTOR 1 Install Canister holder Starter motor TIP Pass the s...

Page 229: ...to CHANGING THE COOLANT on page 3 27 Water pump housing Refer to WATER PUMP on page 6 10 1 Clutch cable 1 Disconnect 2 Circlip 1 3 Pull lever 1 4 Pull lever spring 1 5 Clutch cable holder 1 6 Pull lev...

Page 230: ...Job Parts to remove Q ty Remarks 9 Dowel pin 2 10 Circlip 1 11 Pull lever shaft 1 12 Oil seal 1 13 Bearing 1 14 Bearing 1 8 9 9 11 12 14 10 13 LS New New E E LT LT FWD FWD 7 N m 0 7 kgf m 5 2 lb ft T...

Page 231: ...re plate 1 3 Pull rod 1 4 Bearing 1 5 Friction plate 1 2 6 Clutch plate 6 7 Friction plate 2 5 8 Clutch boss nut 1 9 Conical spring washer 1 LT LT E E E LS New E FWD FWD 8 9 5 5 6 6 6 6 6 6 1 6 6 2 3...

Page 232: ...ss 1 12 Thrust plate 1 13 Spacer 1 14 Bearing 1 15 Clutch housing 1 16 Thrust plate 1 17 Oil pump drive chain 1 18 Oil pump drive chain guide 1 LT LT E E E LS New E FWD FWD 6 6 11 10 17 16 14 13 12 18...

Page 233: ...utch boss nut 6 Remove Spacer Bearing Clutch housing a Remove the spacer and bearing b Remove the oil pump drive chain 1 from the oil pump driven sprocket a and then remove the clutch housing 2 EAS303...

Page 234: ...Cracks damage wear Replace 3 Check Bearing Damage wear Replace the bearing and clutch housing EAS30353 CHECKING THE CLUTCH BOSS 1 Check Clutch boss splines Damage pitting wear Replace the clutch boss...

Page 235: ...oil Install the washer on the main axle with the OUT mark facing away from the vehicle While holding the clutch boss 1 with the uni versal clutch holder 3 tighten the clutch boss nut Stake the clutch...

Page 236: ...the serrations on the clutch pull rod 1 rearward and align the rod with the hole c in the clutch cover Make sure that the pull rod teeth and pull lever shaft pinion gear are engaged Tighten the bolts...

Page 237: ...er installing the clutch cable bend the pro jection b on the pull lever 9 Adjust Clutch lever free play Refer to ADJUSTING THE CLUTCH LEVER FREE PLAY on page 3 12 Clutch lever free play 5 0 10 0 mm 0...

Page 238: ...NE OIL on page 3 24 Coolant Drain Refer to CHANGING THE COOLANT on page 3 27 Shift arm Refer to CHAIN DRIVE on page 4 80 Water pump housing Refer to WATER PUMP on page 6 10 Clutch housing Refer to CLU...

Page 239: ...r Order Job Parts to remove Q ty Remarks 7 Stopper lever 1 8 Stopper lever spring 1 9 Collar 1 10 Shift shaft spring 1 11 Shift shaft spring stopper 1 12 Oil seal 1 13 Bearing 1 22 N m 2 2 kgf m 16 lb...

Page 240: ...bearing does not protrude past the line b shown in the illustration Lubricate the oil seal lips with lithium soap based grease 2 Install Shift shaft spring stopper Washer Shift shaft assembly Stopper...

Page 241: ...t Drain Refer to CHANGING THE COOLANT on page 3 27 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 24 Clutch housing Refer to CLUTCH on page 5 42 1 Oil pump assembly 1 2 Holder 1 10 N m 1...

Page 242: ...2 Oil pump rotor assembly 1 3 Oil pump inner rotor 1 4 Oil pump outer rotor 1 5 Pin 1 6 Oil pump driven sprocket 1 7 Circlip 1 Hold down the washer when removing the circlip 8 Washer 1 9 Spring 1 10...

Page 243: ...s 1 and 2 or replace the oil pump assembly EAS30338 CHECKING THE RELIEF VALVE 1 Check Relief valve Spring Damage wear Replace the oil pump as sembly EAS30342 ASSEMBLING THE OIL PUMP 1 Lubricate Inner...

Page 244: ...OIL PUMP on page 5 56 EAS30343 INSTALLING THE OIL PUMP 1 Install Oil pump 1 Oil pump bolts 2 NOTICE ECA20940 After installing the oil pump drive chain and driven sprocket make sure the oil pump turns...

Page 245: ...ERAL CHASSIS 2 on page 4 2 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 24 Exhaust pipe Refer to ENGINE REMOVAL on page 5 3 1 Engine oil drain bolt 1 2 Oil pan 1 3 Oil pan gasket 1 4 Oi...

Page 246: ...oosened remove them Insert a flat head screwdriver into the slots a in the oil pan to remove the oil pan EAS31069 CHECKING THE OIL STRAINER 1 Check Oil strainer Damage Replace Contaminants Clean with...

Page 247: ...H on page 5 33 Clutch housing Refer to CLUTCH on page 5 42 Oil strainer Refer to OIL PAN on page 5 58 2 5 6 3 8 2 E E E E E New New New New LT LT LT LT LT LT LS LS LS 24 N m 2 4 kgf m 18 lb ft 17 N m...

Page 248: ...8 Blind plate 1 2 5 6 3 8 2 1 2 3 4 6 7 7 8 5 E E E E E New New New New LT LT LT LT LT LT LS LS LS 24 N m 2 4 kgf m 18 lb ft 17 N m 1 7 kgf m 13 lb ft 1st 2nd Final Specified angle 60 T R 10 N m 1 0...

Page 249: ...ith a soft face hammer Tap only on reinforced por tions of the crankcase not on the crankcase mating surfaces Work slowly and carefully and make sure the crankcase halves sepa rate evenly EAS30390 CHE...

Page 250: ...mat ing surfaces with engine oil M9 80 mm bolt 5 bolts with washers 1 3 6 M9 90 mm bolt 1 bolt with washer 2 M8 70 mm bolt 6 bolts with new O rings 7 12 M8 65 mm bolt 2 13 14 M6 65 mm bolt 2 15 16 M6...

Page 251: ...2 Apply Sealant onto the oil pressure switch threads TIP Apply Three bond No 1215 to the threads a of the oil pressure switch However do not ap ply Three bond No 1215 to the portion b of the oil pres...

Page 252: ...CRANKCASE 5 65 a 1 2 2 b 45 10 1...

Page 253: ...o all of the connecting rods and pistons Crankcase Separate Refer to CRANKCASE on page 5 60 1 Connecting rod cap 1 2 Big end lower bearing 1 3 Big end upper bearing 1 4 Piston pin clip 2 5 Piston pin...

Page 254: ...ton pin clip groove and the piston pin bore ar ea If both areas are debarred and the piston pin is still difficult to remove remove it with the piston pin puller set 3 3 Remove Top ring 2nd ring Oil r...

Page 255: ...nd piston rings 2 Install Piston ring into the cylinder TIP Use the piston crown to level the piston ring near the bottom of the cylinder where the cylinder wear is lowest 3 Measure Piston ring end ga...

Page 256: ...ds NOTICE ECA13930 Do not interchange the big end bearings and connecting rods To obtain the correct crankshaft pin to big end bearing clear ance and prevent engine damage the big end bearings must be...

Page 257: ...m onto the crankshaft TIP Install by carrying out the following procedures in order to assemble in the most suitable condition e Tighten the connecting rod bolt while checking that the sections shown...

Page 258: ...CA20890 Do not use a torque wrench to tighten the bolt to the specified angle j After the installation check that the sec tion shown a is flush with each other by touching the surface k Remove the con...

Page 259: ...gn the projections a on the big end bear ings with the notches b in the connecting rods and connecting rod caps Make sure that the projection c on the con necting rod cap faces the same direction as t...

Page 260: ...the big end bearing kept in the current condition 3 Install Oil ring expander 1 Lower oil ring rail 2 Upper oil ring rail 3 2nd ring 4 Top ring 5 TIP Be sure to install the piston rings so that the m...

Page 261: ...tion as the Y mark a on the connecting rod Apply Molybdenum disulfide oil to the threads and seats of the connecting rod bolt 9 Tighten Connecting rod bolts TIP Tighten the connecting rod bolts using...

Page 262: ...again NOTICE ECA20890 Do not use a torque wrench to tighten the bolt to the specified angle d After the installation check that the sec tion shown a is flush with each other by touching the surface W...

Page 263: ...se Separate Refer to CRANKCASE on page 5 60 Connecting rod Refer to CONNECTING RODS AND PIS TONS on page 5 66 1 Balancer shaft assembly 1 2 Balancer shaft journal lower bearing 3 3 Balancer shaft jour...

Page 264: ...ssembly Cracks damage wear Replace the balanc er shaft assembly and journal bearings Dirt Clean Bearings Damage wear Replace 4 Measure Balancer shaft journal to balancer shaft jour nal bearing clearan...

Page 265: ...E on page 5 60 f Remove the crankcase and the balancer shaft journal lower bearings g Measure the compressed Plastigauge width e on each balancer shaft journal If the balancer shaft journal to balance...

Page 266: ...ICE ECA13920 Do not interchange the crankshaft journal bearings To obtain the correct crankshaft journal to crankshaft journal bearing clear ance and prevent engine damage the crank shaft journal bear...

Page 267: ...idth g on each crankshaft journal If the crankshaft journal to crankshaft journal bearing clearance is out of specifi cation select replacement crankshaft journal bearings 5 Select Crankshaft journal...

Page 268: ...FT ASSEMBLY 1 Install Balancer shaft journal upper bearings into the upper crankcase Balancer shaft journal lower bearings into the lower crankcase TIP Align the projections a on the balancer shaft jo...

Page 269: ...ankcase Separate Refer to CRANKCASE on page 5 60 1 Drive axle assembly 1 2 Shift drum retainer 1 3 Shift fork guide bar 2 4 Shift fork L 1 5 Shift fork R 1 6 Shift drum assembly 1 7 Shift fork C 1 8 B...

Page 270: ...y Remarks 1 2nd pinion gear 1 2 Toothed lock washer 1 3 Toothed lock washer retainer 1 4 6th pinion gear 1 5 Collar 1 6 Washer 1 7 Circlip 1 8 3rd pinion gear 1 9 Circlip 1 10 Washer 1 11 5th pinion g...

Page 271: ...ty Remarks 1 1st wheel gear 1 2 Collar 1 3 5th wheel gear 1 4 Circlip 1 5 Washer 1 6 3rd wheel gear 1 7 Collar 1 8 Toothed lock washer 1 9 Toothed lock washer retainer 1 10 4th wheel gear 1 11 Collar...

Page 272: ...ob Parts to remove Q ty Remarks 13 Circlip 1 14 6th wheel gear 1 15 Circlip 1 16 Washer 1 17 Collar 1 18 2nd wheel gear 1 19 Oil seal 1 20 Circlip 1 21 Bearing 1 22 Collar 1 23 Drive axle 1 13 14 15 1...

Page 273: ...SHIFT FORKS The following procedure applies to all of the shift forks 1 Check Shift fork cam follower 1 Shift fork pawl 2 Bends damage scoring wear Replace the shift fork 2 Check Shift fork guide bar...

Page 274: ...heck Transmission gear engagement each pinion gear to its respective wheel gear Incorrect Reassemble the transmission axle assemblies 5 Check Transmission gear movement Rough movement Replace the defe...

Page 275: ...the cylinder 2 Install Shift fork C Shift drum assembly Shift fork guide bar TIP The embossed marks on the shift forks should face towards the right side of the engine Install shift fork C into the g...

Page 276: ...TRANSMISSION 5 89 4 Check Transmission Rough movement Repair TIP Oil each gear shaft and bearing thoroughly 3 2 1 c b a...

Page 277: ...OLER 6 5 CHECKING THE OIL COOLER 6 7 CHECKING THE WATER JACKET JOINT 6 7 CHECKING THE THERMOSTAT 6 7 INSTALLING THE OIL COOLER 6 7 INSTALLING THE THERMOSTAT 6 8 THERMOSTAT 6 9 WATER PUMP 6 10 DISASSEM...

Page 278: ...AGRAMS 1 2 3 4 5 6 7 7 8 9 10 6 3 4 5 8 1 Thermostat 2 Oil cooler inlet hose 3 Oil cooler 4 Oil cooler outlet hose 5 Water jacket joint inlet hose 6 Water pump outlet pipe 7 Water pump inlet pipe 8 Ra...

Page 279: ...voir hose 1 3 Coolant reservoir cap 1 4 Coolant reservoir cover 1 5 Coolant reservoir 1 6 Holder 1 7 Holder 1 Open 8 Radiator cover 1 9 Horn connector 2 Disconnect 10 Radiator fan motor coupler 1 Disc...

Page 280: ...t hose 1 13 Radiator cap 1 14 Radiator 1 15 Radiator fan motor 1 16 Horn 1 LT LT 1 0 N m 0 10 kgf m 0 73 lb ft T R 2 0 N m 0 20 kgf m 1 5 lb ft T R 7 N m 0 7 kgf m 5 2 lb ft T R 7 N m 0 7 kgf m 5 2 lb...

Page 281: ...onds and make sure there is no drop in pressure 4 Check Radiator fan Damage Replace Malfunction Check and repair Refer to COOLING SYSTEM on page 8 27 EAS30440 INSTALLING THE RADIATOR 1 Fill Cooling sy...

Page 282: ...Oil filter cartridge 1 2 Water jacket joint 1 3 Water jacket joint inlet hose 1 4 Oil cooler inlet hose 1 5 Oil cooler outlet hose 1 6 Oil filter cartridge union bolt 1 7 Oil cooler 1 8 Gasket 1 E LS...

Page 283: ...iator inlet hose 1 Disconnect 10 Thermostat cover 1 11 Thermostat 1 E LS LS New New New 10 N m 1 0 kgf m 7 4 lb ft T R 2 0 N m 0 20 kgf m 1 5 lb ft T R 40 N m 4 0 kgf m 30 lb ft T R 12 N m 1 2 kgf m 8...

Page 284: ...heating or overcooling 2 Check Thermostat cover Cracks damage Replace EAS30442 INSTALLING THE OIL COOLER 1 Clean Mating surfaces of the oil cooler and the crankcase with a cloth dampened with lacquer...

Page 285: ...THERMOSTAT 1 Install Thermostat TIP Install the thermostat with its breather valve a facing inward 2 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE CO...

Page 286: ...thermostat Order Job Parts to remove Q ty Remarks Coolant Drain Refer to CHANGING THE COOLANT on page 3 27 1 Radiator inlet hose 1 Disconnect 2 Thermostat cover 1 3 Thermostat 1 2 0 N m 0 20 kgf m 1 5...

Page 287: ...1 Clutch cable 1 Disconnect 2 Water pump outlet hose 1 Disconnect 3 Oil cooler outlet hose 1 Disconnect 4 Radiator outlet hose 1 Disconnect 5 Water pump inlet pipe 1 6 Water pump outlet pipe 1 7 Water...

Page 288: ...lder 1 10 Clutch cover 1 11 Impeller shaft 1 12 Water pump seal assembly 1 13 Oil seal 1 14 Bearing 1 LT LT LT LT E LS New New New New 10 N m 1 0 kgf m 7 4 lb ft T R 10 N m 1 0 kgf m 7 4 lb ft T R 7 N...

Page 289: ...r shaft Cracks damage wear Replace 2 Check Bearing Rough movement Replace 3 Check Water pump outlet pipe Water pump inlet pipe Cracks damage wear Replace EAS30448 ASSEMBLING THE WATER PUMP 1 Install O...

Page 290: ...cts the mechanical seal housing side is dirty clean it 5 Install Impeller shaft 1 Circlip 2 TIP Be sure the circlip sharp edged corner a is positioned opposite side to the bearing After installation c...

Page 291: ...clutch cover make sure that the alignment mark d on the clutch cover is aligned with the punch mark e on the pull le ver 6 2 Fill Cooling system with the specified amount of the recom mended coolant...

Page 292: ...WATER PUMP 6 15...

Page 293: ...IES 7 5 REMOVING THE THROTTLE BODIES 7 8 CHECKING THE INJECTORS BEFORE REMOVING 7 8 REMOVING THE INJECTORS 7 8 CHECKING THE INJECTORS 7 8 CHECKING AND CLEANING THE THROTTLE BODIES 7 8 CHECKING THE THR...

Page 294: ...1 Fuel tank cap 1 2 Fuel tank cover 1 3 Fuel tank mounting bracket rear side 1 4 Fuel tank breather overflow hose 1 Disconnect 5 Fuel pump coupler 1 Disconnect 6 Fuel hose 1 7 Fuel tank 1 8 Fuel pump...

Page 295: ...uel tank Refer to Removing the fuel tank on page 7 1 1 Fuel tank breather overflow hose fuel tank to rollover valve 1 2 Rollover valve 1 3 Fuel tank breather overflow hose rollover valve to canister 1...

Page 296: ...ere it will be removed 3 Remove Fuel tank TIP Do not set the fuel tank down on the installation surface of the fuel pump Be sure to lean the fuel tank against a wall or the like EAS30451 REMOVING THE...

Page 297: ...el pump bolts in the proper tight ening sequence as shown EAS30457 INSTALLING THE FUEL TANK 1 Install Fuel hose NOTICE ECA18420 When installing the fuel hose make sure that it is securely connected an...

Page 298: ...ad breather hose 1 2 Sub wire harness 1 3 Coolant temperature sensor 1 4 Canister purge hose hose joint to throttle bod ies 2 5 Hose joint 1 6 Intake air pressure sensor coupler 1 Disconnect 7 Intake...

Page 299: ...dy joint clamp screw 4 Loosen 12 Air filter case joint clamp screw 2 Loosen 13 Throttle bodies 1 Refer to REMOVING THE THROTTLE BODIES on page 7 8 14 Throttle body joint 2 3 0 N m 0 30 kgf m 2 2 lb ft...

Page 300: ...s 1 ISC Idle Speed Control valve plate 1 2 ISC Idle Speed Control valve 1 3 Spring 1 4 Throttle position sensor 1 5 Fuel rail 1 6 Fuel injector 2 7 Cap 1 New New New New New 3 5 N m 0 35 kgf m 2 6 lb...

Page 301: ...ustible materials Make sure that there is no smoking or use of electric tools in the vicinity of the injectors Be careful when disconnecting the fuel hose Any remaining pressure in the fuel hose may c...

Page 302: ...th the air filter case side facing up b Install the caps 895 14169 00 onto the hose fittings a c Push the lever in the direction shown in the illustration to hold the throttle valves in the open posit...

Page 303: ...ve or throttle bodies and do not immerse them in the cleaning agent To prevent scratching the components do not use a brush metal file or other abra sive tool Do not clean with compressed air Do not a...

Page 304: ...rottle position sensor to the wire harness d Remove the protective cap and then con nect the Yamaha diagnostic tool to cou pler TIP For information about using the Yamaha diag nostic tool refer to the...

Page 305: ...tor pres sure adapter until the specified pressure is reached NOTICE ECA18440 Never exceed the specified air pressure or damage could occur f Close the valve on the fuel injector pres sure adapter g C...

Page 306: ...HROTTLE BODY JOINTS 1 Install Throttle body joints 1 TIP Be sure to install the throttle body joints 1 as shown in the illustration EAS33279 INSTALLING THE AIR FILTER CASE JOINTS 1 Install Air filter...

Page 307: ...ers 2 into the holes in the frame and battery box d Tighten the air filter case bolts left right e Install the battery box bracket 1 and then tighten the battery box bracket bolts 2 and battery box bo...

Page 308: ...THROTTLE BODIES 7 15...

Page 309: ...8 19 CIRCUIT DIAGRAM 8 19 TROUBLESHOOTING 8 21 COOLING SYSTEM 8 27 CIRCUIT DIAGRAM 8 27 TROUBLESHOOTING 8 29 FUEL INJECTION SYSTEM 8 31 CIRCUIT DIAGRAM 8 31 ECU SELF DIAGNOSTIC FUNCTION 8 33 TROUBLESH...

Page 310: ...8 125 TROUBLESHOOTING FOR THE ABS CANCEL FUNCTION 8 126 ELECTRICAL COMPONENTS 8 127 CHECKING THE SWITCHES 8 129 CHECKING THE FUSES 8 130 REPLACING THE ECU engine control unit 8 130 CHECKING AND CHARGI...

Page 311: ......

Page 312: ...r W W G P L R G G W W Y R L R B P B B W R Y B Gy G Br L G Y O Gy R Gy W L L R L B Y L B L P W B R W L Y B R R B B Y G B L W Y G Br W W G P L R G G W W Y R L R B P B B W R Y B Gy G Br L G Y Gy R O Gy W...

Page 313: ...e 23 Relay unit diode 26 Joint coupler 27 Sidestand switch 29 Crankshaft position sensor 32 ECU Engine Control Unit 33 Ignition coil 1 34 Ignition coil 2 35 Spark plug 43 Lean angle sensor 66 Gear pos...

Page 314: ...en gine continues to run under the following conditions The transmission is in gear the neutral circuit of the gear position switch is open and the sidestand is up the sidestand switch circuit is clo...

Page 315: ...ERY on page 8 130 Clean the battery terminals Recharge or replace the battery 3 Check the spark plugs Refer to CHECKING THE SPARK PLUGS on page 3 5 Re gap or replace the spark plug s 4 Check the ignit...

Page 316: ...heck the sidestand switch Refer to CHECKING THE SWITCHES on page 8 129 Replace the sidestand switch 11 Check the relay unit diode Refer to CHECKING THE RELAY UNIT DIODE on page 8 133 Replace the relay...

Page 317: ...IGNITION SYSTEM 8 6...

Page 318: ...W L G B R B Y Sb W Sb R L W R W B R B B B L W L R R W R W L W B B L R R B B B R B Y Y Br W L R Dg B Y Ch P W Y R Y B R Dg R Y Ch Y Br W L R B Y B R W Y P B L W L W L W L W R W R W R W R W R W R W R W...

Page 319: ...ound 19 Main fuse 20 Starter relay 21 Starter motor 23 Relay unit diode 24 Starting circuit cut off relay 26 Joint coupler 27 Sidestand switch 28 Diode 66 Gear position switch 67 Handlebar switch righ...

Page 320: ...e starter motor from operating when neither of these condi tions has been met In this instance the starting circuit cut off relay is open so current cannot reach the starter motor When at least one of...

Page 321: ...ion Refer to CHECKING THE START ER MOTOR OPERATION on page 8 136 Starter motor is OK Perform the electric starting system troubleshooting starting with step 5 4 Check the starter motor Refer to CHECKI...

Page 322: ...n page 8 129 Replace the clutch switch 12 Check the engine stop switch Refer to CHECKING THE SWITCHES on page 8 129 The engine stop switch is faulty Replace the right handlebar switch 13 Check the sta...

Page 323: ...GING SYSTEM 8 12 EAS20074 CHARGING SYSTEM EAS30496 CIRCUIT DIAGRAM B R B W W W R L W R W B R R B R R B R B B R 15 16 17 18 19 15 Stator coil 16 Rectifier regulator 17 Battery 18 Engine ground 19 Main...

Page 324: ...r to CHECKING AND CHARGING THE BATTERY on page 8 130 Clean the battery terminals Recharge or replace the battery 3 Check the stator coil Refer to CHECKING THE STATOR COIL on page 8 136 Replace the sta...

Page 325: ...CHARGING SYSTEM 8 14...

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

Page 327: ...tery 18 Engine ground 19 Main fuse 26 Joint coupler 51 Meter assembly 54 Meter light 61 High beam indicator light 73 Handlebar switch left 75 Dimmer switch 76 Pass switch 84 Headlight assembly 85 Head...

Page 328: ...nd main Refer to CHECKING THE FUS ES on page 8 130 Replace the fuse s 3 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 130 Clean the battery terminals Recharge or replace the b...

Page 329: ...LIGHTING SYSTEM 8 18...

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

Page 331: ...r 57 Multi function meter 58 Oil pressure warning light 60 Coolant temperature warning light 62 Turn signal indicator light left 63 Turn signal indicator light right 65 Horn 66 Gear position switch 67...

Page 332: ...ignition signaling system and main Refer to CHECKING THE FUS ES on page 8 130 Replace the fuse s 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 130 Clean the battery termina...

Page 333: ...ht switch 3 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 8 19 Properly connect or replace the wiring har ness Replace the tail brake light 1 Check the turn signal light bu...

Page 334: ...position switch 2 Check the relay unit diode Refer to CHECKING THE RELAY UNIT DIODE on page 8 133 Replace the relay unit 3 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 8...

Page 335: ...al oil filter or oil pump Replace the oil pressure switch 1 Check the fuel sender Refer to CHECKING THE FUEL SENDER on page 8 137 Replace the fuel pump assembly 2 Check the entire signaling system wir...

Page 336: ...AND SENSOR ROTOR on page 4 14 Replace the front wheel sensor 2 Check the entire front wheel sensor wiring See TIP Properly connect or replace the wiring har ness Replace the ECU ABS ECU or meter assem...

Page 337: ...SIGNALING SYSTEM 8 26...

Page 338: ...R W R W R W Y Y Y Y L R L R L R B L B L B L L R L B Y L B L P W B R W L Y B R R B B Y G B L W Y G Br W W G P L R G G W W Y R L R B P B B W R Y B Gy G Br L G Y O Gy R Gy W L L R L B Y L B L P W B R W...

Page 339: ...fuse 17 Battery 18 Engine ground 19 Main fuse 26 Joint coupler 32 ECU Engine Control Unit 40 Coolant temperature sensor 90 Radiator fan motor relay 91 Radiator fan motor A Wire harness B Sub wire har...

Page 340: ...G THE BATTERY on page 8 130 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 129 Replace the main switch immobilizer unit 4...

Page 341: ...8 30 NG OK 7 Check the entire cooling system wiring Refer to CIRCUIT DIAGRAM on page 8 27 Properly connect or replace the wiring har ness Replace the ECU Refer to REPLAC ING THE ECU engine control uni...

Page 342: ...W L Y B R R B B Y G B L W Y G Br W W G P L R G G W W Y R L R B P B B W R Y B Gy G Br L G Y O Gy R Gy W L L R L B Y L B L P W B R W L Y B R R B B Y G B L W Y G Br W W G P L R G G W W Y R L R B P B B W...

Page 343: ...36 Fuel injector 1 37 Fuel injector 2 38 ISC Idle Speed Control unit 39 Intake air temperature sensor 40 Coolant temperature sensor 41 Intake air pressure sensor 43 Lean angle sensor 44 Front wheel s...

Page 344: ...the specified values that are programmed for each sensor in order to provide the engine with alternate operating instructions that enable the engine to continue operating or stop operating depending o...

Page 345: ...the protective cap 1 and then connect the Yamaha diagnostic tool to the coupler EAS31791 TROUBLESHOOTING DETAILS FAULT CODE This section describes the measures per fault code number displayed on the Y...

Page 346: ...number P0122 first If fault code numbers P0030 and P0123 are both indicated take the actions specified for fault code number P0123 first Crankshaft position sensor O2 sensor Fuel injector 1 Lean angl...

Page 347: ...n switch to ON and then check the condition of the fault code using the mal function mode of the Yamaha di agnostic tool Condition is Recover Go to item 6 and finish the service Condition is Malfuncti...

Page 348: ...delete the fault code Fault code No P0107 P0108 Item P0107 Intake air pressure sensor ground short circuit detected P0108 Intake air pressure sensor open or power short circuit de tected Fail safe sy...

Page 349: ...s continuity Open or short circuit Replace the wire harness Turn the main switch to ON and then check the condition of the fault code using the mal function mode of the Yamaha di agnostic tool Conditi...

Page 350: ...ts connected to the ECU on page 8 35 3 8 For P0107 P0108 Short circuit Between intake air pressure sensor output terminal pink white a of ECU coupler and any other ECU coupler terminal b If there is c...

Page 351: ...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 Check the intake air pressure...

Page 352: ...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...

Page 353: ...ct the couplers from the parts that are connected to the ECU Refer to Parts connected to the ECU on page 8 35 3 7 For P0112 P0113 Short circuit Between intake air temperature sensor output terminal br...

Page 354: ...Service is finished 7 Delete the fault code and check that the engine trouble warning light goes off Confirm that the fault code has a condition of Recover using the Yamaha diagnostic tool and then d...

Page 355: ...switch to ON and then check the condition of the fault code using the mal function mode of the Yamaha di agnostic tool Condition is Recover Go to item 8 and finish the service Condition is Malfunctio...

Page 356: ...terminal b If there is continuity replace the wire harness and or sub wire harness 5 Installed condition of coolant temperature sensor Check for looseness or pinch ing Improperly installed sensor Rein...

Page 357: ...rive vehicle Diagnostic code No 01 Tool display Throttle position sensor signal 11 21 fully closed position 96 106 fully open position Procedure Check with throttle valves fully closed Check with thro...

Page 358: ...rness and or sub wire harness Turn the main switch to ON and then check the condition of the fault code using the mal function mode of the Yamaha di agnostic tool Condition is Recover Go to item 9 and...

Page 359: ...s 4 7 Disconnect the couplers from the parts that are connected to the ECU Refer to Parts connected to the ECU on page 8 35 4 8 For P0122 P0123 Short circuit Between throttle position sensor output te...

Page 360: ...efective throttle position sen sor Check throttle position sensor signal Execute the diagnostic mode Code No 01 When the throttle valves are ful ly closed A value of 11 21 is indicated When throttle v...

Page 361: ...then check the condition of the fault code using the mal function mode of the Yamaha di agnostic tool Condition is Recover Go to item 7 and finish the service Condition is Malfunction Go to item 4 4...

Page 362: ...e Replace if out of specification Refer to CHECKING THE FUEL INJECTORS on page 8 140 Execute the diagnostic mode Code No 36 Operating sound Go to item 7 No operating sound Go to item 3 3 Connection of...

Page 363: ...njector 2 coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the coup...

Page 364: ...ion sensor Fail safe system Unable to start engine Unable to drive vehicle Diagnostic code No Tool display Procedure Item Probable cause of malfunc tion and check Maintenance job Confirmation of servi...

Page 365: ...NG THE CRANKSHAFT POSITION SENSOR on page 8 135 Replace if defective Crank the engine and then check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition...

Page 366: ...en cylinder 1 ignition coil coupler and ECU coupler orange orange Start the engine and let it idle for approximately 5 seconds Check the condition of the fault code using the malfunction mode of the Y...

Page 367: ...ls and locking condition of the pins Improperly connected Con nect the coupler securely or re place the wire harness Start the engine and let it idle for approximately 5 seconds Check the condition of...

Page 368: ...Go to item 7 and finish the service Condition is Malfunction Go to item 6 6 Malfunction in ECU Execute the diagnostic mode Code No 31 No spark Replace the ECU Refer to REPLACING THE ECU engine control...

Page 369: ...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 Execut...

Page 370: ...el sensor no normal signals are received from the front wheel sensor B Gear position switch open or short circuit is detected C Clutch switch open or short circuit is detected Fail safe system Able to...

Page 371: ...harness continuity Open or short circuit Replace the wire harness Between ECU coupler and joint coupler black red black red Between joint coupler and relay unit coupler black red black red Between rel...

Page 372: ...20 to 30 km h 12 to 19 mph Confirm that the fault code has a condition of Recover using the malfunction mode of the Yamaha diagnostic tool and then delete the fault code Delete this fault code even if...

Page 373: ...m C 3 C 3 Connection of clutch switch cou pler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperl...

Page 374: ...ecute the diagnostic mode Code No 21 When the clutch lever is re leased with the transmission in gear and when the sidestand is retracted OFF When the clutch lever is squeezed with the transmission in...

Page 375: ...a condition of Malfunction Fault code No P0507 Item A Component other than ISC idle speed control unit is defec tive ISC operating sound is heard B Defective ISC idle speed control unit ISC operating...

Page 376: ...e ISC idle speed control valve on page 7 10 Start the engine and let it idle for approximately 10 seconds Check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool...

Page 377: ...pler 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 Execute the di...

Page 378: ...itch to ON and then check the condition of the fault code using the mal function mode of the Yamaha di agnostic tool Condition is Recover Go to item 7 and finish the service Condition is Malfunction G...

Page 379: ...e Yamaha di agnostic tool Condition is Recover Go to item 7 and finish the service Condition is Malfunction Go to item 6 6 Malfunction in ECU Replace the ECU Refer to REPLACING THE ECU engine control...

Page 380: ...ON Check that the engine trouble warning light does not come on Fault code No P062F Item EEPROM fault code number an error is detected while reading or writing on EEPROM Fail safe system Able Unable...

Page 381: ...ic tool Set the main switch to ON and then check the condition of the fault code using the mal function mode of the Yamaha di agnostic tool Condition is Recover Go to item 6 and finish the service Con...

Page 382: ...inish the service Condition is Malfunction Go to item 2 2 Connection of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and lo...

Page 383: ...the engine trouble warning light goes off Confirm that the fault code has a condition of Recover using the Yamaha diagnostic tool and then delete the fault code Fault code No P1601 Item Sidestand swi...

Page 384: ...ess continuity Open or short circuit Replace the wire harness Between sidestand switch cou pler and relay unit coupler blue green blue green Between relay unit coupler and joint coupler black red blac...

Page 385: ...on of the pins Improperly connected Con nect the coupler securely or re place the wire harness Turn the main switch to ON and then check the condition of the fault code using the mal function mode of...

Page 386: ...iagnostic code No 08 Tool display Lean angle sensor output voltage 0 4 1 4 upright 3 7 4 4 overturned Procedure Remove the lean angle sensor and incline it more than 65 degrees Item Probable cause of...

Page 387: ...put lead 5 Sensor ground lead 3 2 Disconnect the ECU coupler from the ECU Disconnect the lean angle sensor coupler from the lean angle sensor 3 3 For P1604 Ground short circuit Between lean angle sens...

Page 388: ...al b If there is continuity replace the wire harness 4 Defective lean angle sensor Refer to CHECKING THE LEAN ANGLE SENSOR on page 8 136 Turn the main switch to ON then to OFF and then back to ON Chec...

Page 389: ...k for looseness or pinch ing Improperly installed sensor Reinstall or replace the sensor Start the engine and let it idle for approximately 10 seconds Check the condition of the fault code using the m...

Page 390: ...proximately 10 seconds Check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recover Go to item 8 and finish the service Condition is Malfunction...

Page 391: ...unction mode of the Yamaha di agnostic tool Condition is Recover Go to item 6 and finish the service Condition is Malfunction Go to item 2 2 Connection of ECU coupler Check the locking condition of th...

Page 392: ...The vehicle has overturned Raise the vehicle upright Turn the main switch to ON then to OFF and then back to ON Engine trouble warning light does not come on Service is finished Engine trouble warning...

Page 393: ...FUEL INJECTION SYSTEM 8 82...

Page 394: ...Y Y Y Y L R L R L R B L B L B L L R L B Y L B L P W B R W L Y B R R B B Y G B L W Y G Br W W G P L R G G W W Y R L R B P B B W R Y B Gy G Br L G Y O Gy R Gy W L L R L B Y L B L P W B R W L Y B R R B B...

Page 395: ...Ignition fuse 17 Battery 18 Engine ground 19 Main fuse 23 Relay unit diode 25 Fuel pump relay 26 Joint coupler 28 Diode 32 ECU Engine Control Unit 49 Fuel pump 67 Handlebar switch right 69 Engine sto...

Page 396: ...the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 129 Replace the main switch immobilizer unit 4 Check the engine stop switch Refe...

Page 397: ...8 86 NG OK 8 Check the entire fuel pump system wiring Refer to CIRCUIT DIAGRAM on page 8 83 Properly connect or replace the wiring har ness Replace the ECU Refer to REPLAC ING THE ECU engine control u...

Page 398: ...R W R W R W Y Y Y Y L R L R L R B L B L B L L R L B Y L B L P W B R W L Y B R R B B Y G B L W Y G Br W W G P L R G G W W Y R L R B P B B W R Y B Gy G Br L G Y O Gy R Gy W L L R L B Y L B L P W B R W L...

Page 399: ...n switch 8 Ignition fuse 12 Backup fuse 14 Immobilizer unit 17 Battery 18 Engine ground 19 Main fuse 26 Joint coupler 32 ECU Engine Control Unit 51 Meter assembly 52 Immobilizer system indicator light...

Page 400: ...ring key is lost regis tering new codes in the standard keys is impossible The standard keys can still be used to start the vehicle However if code re registering is required e g if a new standard key...

Page 401: ...he ignition key to OFF 30 seconds later the indicator light will start flashing continuously in the standby flashing mode pattern for up to 24 hours After that time the indicator light will stop flash...

Page 402: ...ory when the key registration mode is activated When the key registration mode is activated the immobilizer system indicator light flashes rapidly 4 While the indicator light is flashing turn the main...

Page 403: ...the memory thus disabling the lost standard key To re register refer to Standard key registration Standard key code voiding method a Main switch ON b Main switch OFF c LED on d LED off e Less than 5...

Page 404: ...the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 130 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 129 Re...

Page 405: ...dard key 53 IMMOBILIZER UNIT Codes cannot be transmitted between the ECU and the im mobilizer unit Noise interference or dis connected lead cable 1 Interference due to ra dio wave noise 2 Disconnected...

Page 406: ...or 0 5 second and off for 0 5 second Example fault code 52 56 ECU Unidentified code is received Noise interference or dis connected lead cable 1 Check the wire harness and con nector 2 Replace the mai...

Page 407: ...IMMOBILIZER SYSTEM 8 96...

Page 408: ...Y L B L P W B R W L Y B R R B B Y G B L W Y G Br W W G P L R G G W W Y R L R B P B B W R Y B Gy G Br L G Y O Gy R Gy W L L R L B Y L B L P W B R W L Y B R R B B Y G B L W Y G Br W W G P L R G G W W Y...

Page 409: ...Battery 18 Engine ground 19 Main fuse 22 Rear brake light switch 26 Joint coupler 32 ECU Engine Control Unit 42 Resistor unit 44 Front wheel sensor 45 Rear wheel sensor 46 ABS ECU 47 Yamaha diagnostic...

Page 410: ...B W B W B R L R W B G B B W B W G R G W Y Y Br W L R G R B L B B G L R L B R W B B W G B L B Dg Sb W Y Ch R G G R G W R W W P W G Y G L R Y W W R O Gy Gy 1 Front wheel sensor coupler 2 Rear wheel sens...

Page 411: ...form a final check before delivering the vehicle to the customer TIP To final check refer to C 1 FINAL CHECK on page 8 125 ABS operation when the ABS warning light comes on 1 The ABS warning light rem...

Page 412: ...s will be displayed again if another malfunction occurs EAS30993 BASIC INSTRUCTIONS FOR TROUBLESHOOTING WARNING EWA17420 Perform the troubleshooting A B C in order Be sure to follow the order since a...

Page 413: ...hecks completed normally Finished Yes No A Turn the main switch to ON and check the ABS warning light Fails to come on Comes on The ABS control unit fuse is blown The ABS ECU coupler is disconnected T...

Page 414: ...S warning light comes on the ABS ECU is defective Replace the hydraulic unit assembly EAS30997 A 2 ALL INDICATOR LIGHTS FAIL TO COME ON 1 Main switch Check the main switch for continuity Refer to CHEC...

Page 415: ...ECU coupler and blue black terminal of the Yamaha diagnostic tool coupler CANL 4 ABS ECU malfunction Replace the hydraulic unit assembly EAS31136 A 5 ABS ECU AND FI ECU FAIL TO COMMUNICATE 1 Battery...

Page 416: ...d 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 i...

Page 417: ...or short circuit in the wire harness between the rear wheel sensor and the hydraulic unit assembly Defective rear wheel sen sor or hydraulic unit as sembly 17 45 Front wheel sensor missing pulses Fron...

Page 418: ...supply circuit Short circuit is detected in the solenoid power supply circuit in the hydraulic unit assembly Defective hydraulic unit as sembly 33 Hydraulic unit assembly ab normal ABS motor power su...

Page 419: ...r signal is not received properly Miss ing pulses are detected in the signal while the vehicle is traveling Foreign material adhered around the rear wheel sen sor Incorrect installation of the rear wh...

Page 420: ...pply voltage of power supply is low Power voltage supplied from the ABS ECU to the front wheel sensor is too low Short circuit in the wire har ness between the front wheel sensor and the ABS ECU Defec...

Page 421: ...nsor 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 FRO...

Page 422: ...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 14 4 Defective front wheel sensor or incorrect installation of th...

Page 423: ...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 See...

Page 424: ...ydraulic 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 See TIP 2...

Page 425: ...om Open or short circuit is detected in the rear wheel sensor Order Item components and probable cause Check or maintenance job Fault code No 17 45 Item Front wheel sensor missing pulses Symptom Front...

Page 426: ...d the installed condition of the sensor Repair or replace the wheel sensor if necessary Refer to MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR on page 4 22 Fault code No 21 Item Hydraulic unit...

Page 427: ...icle is travel ing Brake light circuit or front or rear brake light switch circuit Order Item components and probable cause Check or maintenance job Fault code No 31 Item Hydraulic unit assembly abnor...

Page 428: ...o CHECKING THE FUSES on page 8 130 2 Defective coupler between the battery and the hydraulic unit assembly Check the coupler for any pins that may be pulled out Check the locking condition of the coup...

Page 429: ...ke caliper when the brake lever is operated and that the pressure decreases when the lever is re leased Refer to CHECKING THE FRONT BRAKE DISCS on page 4 30 4 Defective hydraulic unit assembly If the...

Page 430: ...ydraulic pressure Order Item components and probable cause Check or maintenance job Fault code No 43 Item Front wheel sensor missing pulses Symptom Front wheel sensor signal is not received properly M...

Page 431: ...isible damage Refer to MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR on page 4 22 4 Defective rear wheel sensor or incorrect installation of the sensor Check the wheel sensor for damage and th...

Page 432: ...RGING SYSTEM on page 8 12 Fault code No 54 Item Hydraulic unit assembly defective ABS solenoid and ABS motor power supply circuits Symptom Abnormality is detected in the solenoid or motor power supply...

Page 433: ...e cause Check or maintenance job 1 Short circuit in the wire harness between the front wheel sensor and the hydraulic unit assembly Check that there is no short circuit between the white terminal 1 an...

Page 434: ...enance job 1 Short circuit in the wire harness between the rear wheel sensor and the hydraulic unit assembly Check that there is no short circuit between the white terminal 1 and the black terminal 2...

Page 435: ...en the meter as sembly and the ABS ECU 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 sec...

Page 436: ...ON TESTS on page 4 48 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 8 125 5 Chec...

Page 437: ...n ABS turns on The ABS on off indicator light goes off A Turn the main switch to ON and check the ABS on off indicator light The meter assembly is defective The meter assembly is defective Check if th...

Page 438: ...Intake air temperature sensor 3 Front brake light switch 4 Clutch switch 5 Rectifier regulator 6 Ignition coil 7 Gear position switch 8 Battery 9 Lean angle sensor 10 Fuse box 1 11 Fuse box 2 12 Side...

Page 439: ...2 Intake air pressure sensor 3 Fuel pump 4 Main fuse 5 Starter relay 6 Relay unit diode 7 ECU Engine Control Unit 8 Rear wheel sensor 9 Turn signal hazard relay 10 Radiator fan motor relay 11 Cranksh...

Page 440: ...LO R L N ON OFF 1 2 3 4 5 11 10 9 8 7 6 13 12 R W Br L Br R Br Y G G W B W G B W Y R W L W B B L R R B B B R B Y Y Br W L R Dg B Y Ch P W Y R Y B R R W Br L Br R Y Br G G W B L W R B R W Y L R W GB W...

Page 441: ...EAS31006 REPLACING THE ECU engine control unit 1 Turn the main switch to OFF 2 Replace the ECU engine control unit Refer to REMOVING THE ECU engine con trol unit on page 4 3 3 Clean the throttle bodie...

Page 442: ...ose connection Connect properly 8 Lubricate Battery terminals 9 Install Rider seat Refer to GENERAL CHASSIS 1 on page 4 1 EAS30553 CHECKING THE RELAYS Check each switch for continuity with the digital...

Page 443: ...tage Out of specification Replace 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 1 Positive battery terminal...

Page 444: ...no continuity EAS30795 CHECKING THE RELAY UNIT DIODE 1 Check Relay unit diode Out of specification Replace Turn signal hazard relay output voltage DC 12V Digital circuit tester CD732 90890 03243 Mode...

Page 445: ...e black yellow 1 Negative tester probe sky blue 2 No continuity Positive tester probe sky blue 2 Negative tester probe black yellow 1 Continuity Positive tester probe black red 3 Negative tester probe...

Page 446: ...0560 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...

Page 447: ...step 4 Refer to TROUBLESHOOTING on page 8 10 a Connect the positive battery terminal 1 and starter motor lead 2 with a jumper lead 3 WARNING EWA13810 A wire that is used as a jumper lead must have at...

Page 448: ...ication Replace the fuel pump assembly a Connect the digital circuit tester to the fuel sender terminals as shown Stator coil resistance 0 128 0 192 Digital circuit tester CD732 90890 03243 Model 88 M...

Page 449: ...cation Replace a Connect the digital circuit tester to the coolant temperature sensor as shown b Immerse the coolant temperature sensor 1 in a container filled with coolant 2 TIP Make sure the coolant...

Page 450: ...Out of specification Replace the gear posi tion switch Resistance 2 64 6 16 k Digital circuit tester CD732 90890 03243 Model 88 Multimeter with ta chometer YU A1927 Positive tester probe Sensor termi...

Page 451: ...uel injec tor a Disconnect the fuel injector coupler from the fuel injector b Connect the digital circuit tester to the fuel injector coupler as shown c Measure the fuel injector resistance Resistance...

Page 452: ...ELECTRICAL COMPONENTS 8 141...

Page 453: ...IC CODE TABLE 9 1 SELF DIAGNOSTIC FUNCTION TABLE FOR FUEL INJECTION SYSTEM 9 1 SELF DIAGNOSTIC FUNCTION TABLE FOR IMMOBILIZER SYSTEM 9 7 DIAGNOSTIC CODE SENSOR OPERATION TABLE 9 8 DIAGNOSTIC CODE ACTU...

Page 454: ...es not oper ate O2 feedback is not carried out P0107 P0108 P0107 Intake air pressure sensor ground short circuit detected P0108 Intake air pressure sensor open or power short circuit detected P0107 Lo...

Page 455: ...is not carried out ISC learning is not carried out P0117 P0118 P0117 Coolant tem perature sensor ground short circuit detected P0118 Coolant tem perature sensor open or power short circuit detected P...

Page 456: ...ttle open ing Output is restricted ISC feedback is not carried out ISC learning is not carried out P0132 O2 sensor short cir cuit detected power short circuit P0132 High voltage of the O2 sensor cir c...

Page 457: ...feedback is not carried out ISC learning is not carried out P0500 Front wheel sensor no normal signals are received from the front wheel sen sor Gear position switch open or short circuit is detected...

Page 458: ...efective coupler between ISC unit and ECU Open or short cir cuit in wire harness between ISC unit and ECU Defective ISC step ping motor Malfunction in ECU Engine is difficult to start Engine idling sp...

Page 459: ...to start Engine idling speed is unstable OBD memory value is not correct CO adjustment value for the faulty cylinder 0 default value ISC learning values Default values OBD memory value is initialized...

Page 460: ...angle sen sor circuit 4 8 V or more Open or short cir cuit in wire harness between lean angle sensor and ECU Defective lean an gle sensor Malfunction in ECU Engine cannot be started Engine cannot be...

Page 461: ...to air temperature When engine is hot Displays current coolant temperature Compare the actually mea sured coolant temperature with the tool display value 07 Front wheel vehicle speed pulses Front whe...

Page 462: ...s defective the display al ternates every two seconds to show all the detected cylinder numbers When all cylinder numbers are shown the display re peats the same process 11 Data error for ISC idle spe...

Page 463: ...is actuated five times by listen ing for the operating sound 37 Fuel injector 2 Actuates fuel injector 2 five times at one second inter vals The indicator on the Yamaha diagnostic tool screen come on...

Page 464: ...pens the valve This operation is performed 3 times and takes approxi mately 6 seconds each time The indicator on the Yamaha diagnostic tool screen come on during the operation Check that the ISC unit...

Page 465: ...er P0122 and P0123 Perform the checks and maintenance jobs for fault code number P0122 and P0123 195 Sidestand switch Brief abnormality de tected in black red in put lead of ECU Same as for fault code...

Page 466: ...st Event code number 241 may be indicated even if the system is normal 242 ISC idle speed con trol Correction value re mains at upper limit Correction value re mains at upper limit while the engine is...

Page 467: ...ult 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 Improperly adjusted clutch...

Page 468: ...ht 61 High beam indicator light 62 Turn signal indicator light left 63 Turn signal indicator light right 64 ABS warning light 65 Horn 66 Gear position switch 67 Handlebar switch right 68 Front brake l...

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Page 470: ......

Page 471: ...B Y Y Br W L R Dg B Y Ch P W Y R Y B R Dg R Y Ch Y Br W L R B Y B R W Y P Br Y B Br Y B B W Y L R W G B B Lg R G R R R R R R W Br L Br L Br R R R R Br L Br W Br Y L R R W L R R W Br R W R G R G R B L...

Page 472: ...SH ON OFF ON OFF HI PUSH FREE RUN OFF R L N ON OFF LO D C B B Gy Gy B B B B B B B B B B Gy B B B B B B B B Gy Gy Gy Gy Gy Gy B B B B B B L B B B 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 2...

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