Yamaha TMAX XP500F 2015 Service Manual Download Page 268

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CYLINDER AND PISTONS

5-31

EAS20046

CYLINDER AND PISTONS

Removing the cylinder and pistons

Order

Job/Parts to remove

Q’ty

Remarks

Cylinder head

Refer to “CYLINDER HEAD” on page 5-20.

Coolant hose

Refer to “WATER PUMP” on page 6-11.

Timing chain guide (exhaust side)

Cylinder

Cylinder gasket

Dowel pin

Piston pin clip

Piston pin

Piston

Top ring

2nd ring

Oil ring

Summary of Contents for TMAX XP500F 2015

Page 1: ...2015 SERVICE MANUAL XP500F LIT 11616 28 54 2PW 28197 10 ...

Page 2: ...Yamaha Motor Corporation U S A First edition November 2014 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in U S A P N LIT 11616 28 54 ...

Page 3: ...th the most satisfaction from his vehicle and to conform to federal environmental quality objectives Yamaha Motor Company Ltd is continually striving to improve all of its models Modifications and sig nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable TIP This Service Manual contains...

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

Page 5: ...ITION 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 clearance Molybdenum disulfide grease Engine speed Silicone grease Electrical data Apply locking agent LOCTITE Engine oil Replace the part with a new one G M BF B T R LS M S LT E New ...

Page 6: ......

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

Page 8: ......

Page 9: ... MULTI FUNCTION DISPLAY 1 4 IMPORTANT INFORMATION 1 9 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 9 REPLACEMENT PARTS 1 9 GASKETS OIL SEALS AND O RINGS 1 9 LOCK WASHERS PLATES AND COTTER PINS 1 9 BEARINGS AND OIL SEALS 1 10 CIRCLIPS 1 10 RUBBER PARTS 1 10 BASIC SERVICE INFORMATION 1 11 QUICK FASTENERS 1 11 ELECTRICAL SYSTEM 1 12 SPECIAL TOOLS 1 16 ...

Page 10: ... EAS30002 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the frame EAS30003 MODEL LABEL The model label 1 is affixed to the storage box This information will be needed to order spare parts 1 ...

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

Page 12: ...d The injection duration and the injection timing are controlled by the ECU engine control unit Signals that are input from the throttle position sensor crankshaft position sensor intake air pressure sensor intake air temperature sensor coolant temperature sensor and O2 sensor enable the ECU engine control unit to determine the injection duration The injection timing is determined through the sign...

Page 13: ...nge a V belt replacement tripmeter which shows the distance traveled since the last V belt re placement TIP Be sure to turn the vehicle power on before us ing the SELECT and RESET buttons When the vehicle power is turned on all of the display segments of the multi function display will appear one after the other and then disap pear in order to test the electrical circuits Clock To set the clock 1 ...

Page 14: ...If you do not reset the fuel reserve tripmeter manually it will reset itself automatical ly and the display will return to the prior mode af ter refueling and traveling 5 km 3 mi TIP The display cannot be changed back to Trip F after resetting the fuel reserve tripmeter Fuel meter The fuel meter indicates the amount of fuel in the fuel tank The display segments of the fuel meter disappear towards ...

Page 15: ... If the oil change indicator does not come on check the electrical circuit Refer to SIGNALING SYSTEM on page 8 19 V belt replacement indicator V Belt This indicator flashes every 20000 km 12500 mi when the V belt needs to be replaced After changing the V belt reset the V belt re placement indicator To reset the V belt replace ment indicator select it by pushing the SELECT button until V Belt Trip ...

Page 16: ... AVE_ _ _ MPG This display shows the average fuel consump tion since it was last reset When the display is set to AVE_ _ _ MPG the average distance that can be traveled on 1 0 Imp gal of fuel is shown To reset the average fuel consumption display select it by pushing the RESET button and then push the RESET button for at least one second TIP After resetting an average fuel consumption dis play _ _...

Page 17: ...gine trouble warning light comes on and the display indicates a fault code If the display indicates any fault codes note the code number and check the fuel injection sys tem Refer to FUEL INJECTION SYSTEM on page 8 31 NOTICE ECA20220 If the display indicates a fault code the vehi cle should be checked as soon as possible in order to avoid engine damage 1 Fault code display 1 ...

Page 18: ... correct installation of all parts 5 Keep all parts away from any source of fire EAS30007 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace ments Use oil and grease recommended by Yamaha for all lubrication jobs Other brands may be similar in function and appearance but inferior in quality EAS30008 GASKETS OIL SEALS AND O RINGS 1 When overhauling the engine replace all gaskets seals ...

Page 19: ...d air because this will damage the bearing surfac es EAS30011 CIRCLIPS Before reassembly check all circlips carefully and replace damaged or distorted circlips Al ways replace piston pin clips after one use When installing a circlip 1 make sure the sharp edged corner 2 is positioned opposite the thrust 3 that the circlip receives EAS30012 RUBBER PARTS Check rubber parts for deterioration during in...

Page 20: ...stener push its pin so that it protrudes from the fastener head then insert the fastener into the part to be secured and push the pin in with a screwdriver Make sure that the pin is flush with the fastener s head Screw type 1 Remove Quick fastener TIP To remove the quick fastener loosen the screw with a screwdriver then pull the fastener out 2 Install Quick fastener TIP To install the quick fasten...

Page 21: ...a battery lead is difficult to disconnect due to rust on the battery terminal remove the rust us ing hot water NOTICE ECA16760 Be sure to connect the battery leads to the correct battery terminals Reversing the bat tery lead connections could damage the electrical components NOTICE ECA16771 When connecting the battery leads to the battery be sure to connect the positive bat tery lead first then th...

Page 22: ...imately 5 seconds before pushing the ON start switch Checking the electrical system TIP Before checking the electrical system make sure that the battery voltage is at least 12 V NOTICE ECA14371 Never insert the tester probes into the cou pler terminal slots Always insert the probes from the opposite end a of the coupler tak ing care not to loosen or damage the leads NOTICE ECA16640 For waterproof ...

Page 23: ...erefore be sure to check the type of cou pler lock before disconnecting the coupler NOTICE ECA16790 When disconnecting a connector do not pull the leads Hold both sections of the connec tor securely and then disconnect the con nector 2 Check Lead Coupler Connector Moisture Dry with an air blower Rust stains Connect and disconnect sev eral times 3 Connect Lead Coupler Connector TIP When connecting ...

Page 24: ...stance TIP The resistance values shown were obtained at the standard measuring temperature of 20 C 68 F If the measuring temperature is not 20 C 68 F the specified measuring conditions will be shown Pocket tester 90890 03112 Analog pocket tester YU 03112 C Pocket tester 90890 03112 Analog pocket tester YU 03112 C Intake air temperature sensor re sistance 5400 6600 Ω 0 C 5400 6600 Ω 32 F Intake air...

Page 25: ...ng an order refer to the list provided below to avoid any mistakes TIP For U S A and Canada use part numbers starting with YM YU or ACC For others use part numbers starting with 90890 Tool name Tool No Illustration Reference pages Rotor holding tool 90890 01235 Universal magneto and rotor holder YU 01235 5 63 5 67 Piston pin puller set 90890 01304 Piston pin puller YU 01304 5 32 Radiator cap teste...

Page 26: ...ing nut wrench 90890 01403 Exhaust flange nut wrench YU A9472 3 24 4 91 Damper rod holder 90890 01423 Damping rod holder YM 01423 4 83 4 86 Rod holder 90890 01434 Damper rod holder double ended YM 01434 4 82 4 88 Rod puller attachment M10 90890 01436 Universal damping rod bleeding tool set YM A8703 4 86 Tool name Tool No Illustration Reference pages YU 33984 YM A8703 ...

Page 27: ... driver 90890 01442 Adjustable fork seal driver 36 46 mm YM 01442 4 85 4 85 4 85 Oil filter wrench 90890 01469 Oil filter wrench YM 01469 3 26 6 7 Sheave holder 90890 01481 5 46 5 46 5 49 5 50 5 50 Clutch spring compressor 90890 01482 5 63 5 66 Sheave holder 90890 01701 Primary clutch holder YS 01880 A 5 56 5 56 5 57 5 58 Tool name Tool No Illustration Reference pages YM A8703 66 8 ...

Page 28: ...pocket tester YU 03112 C 1 15 1 15 8 89 8 90 8 90 8 91 8 94 8 97 8 97 8 98 8 99 8 99 8 99 8 100 8 100 8 102 8 102 8 103 8 104 8 104 8 105 8 106 8 106 8 107 Oil pressure gauge set 90890 03120 3 28 Oil pressure adapter B 90890 03124 3 28 Pressure gauge 90890 03153 Pressure gauge YU 03153 3 28 7 5 Tool name Tool No Illustration Reference pages 90890 03081 YU 33223 YU 44456 ...

Page 29: ...03189 Model 88 Multimeter with tachometer YU A1927 5 38 8 101 8 105 Test harness S pressure sensor 3P 90890 03207 Test harness S pressure sensor 3P YU 03207 8 105 Test harness speed sensor 3P 90890 03208 Test harness speed sensor 3P YU 03208 8 103 Test harness lean angle sensor 6P 90890 03209 Test harness lean angle sensor 6P YU 03209 8 100 Tension gauge 90890 03226 3 21 Tool name Tool No Illustra...

Page 30: ... bearing installer 40 50 mm YM 04058 6 15 Universal clutch holder 90890 04086 Universal clutch holder YM 91042 5 63 5 66 Valve lapper 90890 04101 Valve lapping tool YM A8998 3 6 Valve guide remover ø4 90890 04111 Valve guide remover 4 0 mm YM 04111 5 26 Valve guide installer ø4 90890 04112 Valve guide installer 4 0 mm YM 04112 5 26 Tool name Tool No Illustration Reference pages 90890 04101 YM A899...

Page 31: ...4 Valve spring compressor adapter 19 5 mm YM 04114 5 24 5 29 Mechanical seal installer 90890 04132 Water pump seal installer YM 33221 A 6 15 Sheave spring compressor 90890 04134 Sheave spring compressor YM 04134 5 46 5 49 Sheave fixed block 90890 04135 Sheave fixed bracket YM 04135 5 46 5 49 Tool name Tool No Illustration Reference pages ...

Page 32: ...82 Ignition checker 90890 06754 Oppama pet 4000 spark checker YM 34487 8 100 Digital tachometer 90890 06760 Digital tachometer YU 39951 B 3 8 3 9 Yamaha bond No 1215 90890 85505 Three bond No 1215 5 18 5 49 5 58 5 74 Tool name Tool No Illustration Reference pages ...

Page 33: ...TORQUES 2 12 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 12 ENGINE TIGHTENING TORQUES 2 13 CHASSIS TIGHTENING TORQUES 2 16 LUBRICATION POINTS AND LUBRICANT TYPES 2 20 ENGINE 2 20 CHASSIS 2 22 LUBRICATION SYSTEM CHART AND DIAGRAMS 2 23 ENGINE OIL LUBRICATION CHART 2 23 LUBRICATION DIAGRAMS 2 25 COOLING SYSTEM DIAGRAMS 2 33 CABLE ROUTING 2 37 ...

Page 34: ...verall length 2200 mm 86 6 in Overall width 775 mm 30 5 in Overall height Lo Hi 1420 1475 mm 55 9 58 1 in Seat height 800 mm 31 5 in Wheelbase 1580 mm 62 2 in Ground clearance 125 mm 4 92 in Minimum turning radius 2800 mm 110 2 in Weight Curb weight 220 kg 485 lb Maximum load 195 kg 430 lb ...

Page 35: ...Recommended engine oil grade API service SG type or higher JASO standard MA Engine oil quantity Quantity disassembled 3 50 L 3 70 US qt 3 08 Imp qt Without oil filter cartridge replacement 2 70 L 2 85 US qt 2 38 Imp qt With oil filter cartridge replacement 2 90 L 3 07 US qt 2 55 Imp qt Oil filter Oil filter type Cartridge Oil pump Oil pump type Trochoid Oil pressure 120 0 kPa 1200 r min 70 C 17 4 ...

Page 36: ...1 2791 1 2831 in Limit 32 390 mm 1 2752 in Base circle diameter Intake 24 950 25 050 mm 0 9823 0 9862 in Limit 24 850 mm 0 9783 in Lobe height Exhaust 32 690 32 790 mm 1 2870 1 2909 in Limit 32 590 mm 1 2831 in Base circle diameter Exhaust 24 950 25 050 mm 0 9823 0 9862 in Limit 24 850 mm 0 9783 in Camshaft runout limit 0 030 mm 0 0012 in Valve valve seat valve guide Valve clearance cold Intake 0 ...

Page 37: ...96 60 111 20 N 9 85 11 34 kgf 21 72 25 00 lbf Installed compression spring force exhaust 96 60 111 20 N 9 85 11 34 kgf 21 72 25 00 lbf Spring tilt intake 1 6 mm 0 06 in Spring tilt exhaust 1 6 mm 0 06 in Winding direction intake Clockwise Winding direction exhaust Clockwise Cylinder Bore 68 000 68 010 mm 2 6772 2 6776 in Taper limit 0 050 mm 0 0020 in Out of round limit 0 050 mm 0 0020 in Piston P...

Page 38: ...ng color code 0 White 1 Blue 2 Black 3 Brown 4 Green 5 Yellow Balancer Balancer drive method Piston Clutch Clutch type Wet multiple disc automatic Clutch release method Automatic Friction plate thickness 2 92 3 08 mm 0 115 0 121 in Wear limit 2 82 mm 0 111 in Plate quantity 6 pcs Clutch plate 1 thickness 1 30 1 50 mm 0 051 0 059 in Plate quantity 5 pcs Warpage limit 0 10 mm 0 004 in Clutch plate 2...

Page 39: ...16 kΩ Output voltage at idle 0 63 0 73 V Fuel injection sensor Crankshaft position sensor resistance 284 372 Ω Intake air pressure sensor output voltage 3 57 3 71 V 103 0 kPa 3 57 3 71 V 1 03 kgf cm 3 57 3 71 V 14 9 psi Intake air temperature sensor resistance 5400 6600 Ω 0 C 5400 6600 Ω 32 F Intake air temperature sensor resistance 290 390 Ω 80 C 290 390 Ω 176 F Coolant temperature sensor resista...

Page 40: ... 0 25 mm 0 01 in Front tire Type Tubeless Size 120 70R15 M C 56H Manufacturer model DUNLOP GPR 100F Wear limit front 1 0 mm 0 04 in Rear tire Type Tubeless Size 160 60R15 M C 67H Manufacturer model DUNLOP GPR 100 Wear limit rear 1 0 mm 0 04 in Tire air pressure measured on cold tires Loading condition 0 90 kg 0 198 lb Front 225 kPa 2 25 kgf cm 33 psi 2 25 bar Rear 250 kPa 2 50 kgf cm 36 psi 2 50 b...

Page 41: ...diameter 14 0 mm 0 55 in Caliper cylinder inside diameter 38 10 mm 1 50 in Specified brake fluid DOT 4 Rear brake lock Rear brake lock pad Brake pad lining thickness 3 0 mm 0 12 in Limit 0 8 mm 0 03 in Steering Center to lock angle left 38 5 Center to lock angle right 38 5 Front suspension Type Telescopic fork Spring shock absorber type Coil spring oil damper Front fork travel 120 0 mm 4 72 in For...

Page 42: ...8 18 lbf in Spring rate K2 294 00 N mm 29 98 kgf mm 1678 74 lbf in Spring stroke K1 0 0 28 8 mm 0 00 1 13 in Spring stroke K2 28 8 43 0 mm 1 13 1 69 in Enclosed gas air pressure STD 4900 kPa 49 0 kgf cm 696 9 psi Swingarm Swingarm end free play limit radial 1 0 mm 0 04 in Swingarm end free play limit axial 1 0 mm 0 04 in Drive belt Drive belt slack 0 2 mm 0 01 in ...

Page 43: ...dard output 14 0 V 350 W 5000 r min Stator coil resistance 0 224 0 336 Ω W W Rectifier regulator Regulator type Semi conductor short circuit Regulated voltage DC 14 1 14 9 V Rectifier capacity DC 22 0 A Battery Model YTZ12S Voltage capacity 12 V 11 0 Ah Specific gravity 1 310 Manufacturer GS YUASA Ten hour rate charging current 1 10 A Bulb voltage wattage quantity Headlight LED Auxiliary light LED...

Page 44: ... Horn Horn type Plane Quantity 1 Maximum amperage 3 0 A Coil resistance 1 06 1 11 Ω Turn signal hazard relay Built in self canceling device No Fuel sender unit Sender unit resistance full 4 0 10 0 Ω Sender unit resistance empty 93 0 100 0 Ω Fuses Main fuse 40 0 A Headlight fuse 10 0 A Signaling system fuse 15 0 A Ignition fuse 7 5 A Radiator fan motor fuse 15 0 A Parking lighting fuse 10 0 A Fuel ...

Page 45: ... To avoid warpage tight en multi fastener assemblies in a crisscross pat tern and progressive stages until the specified tightening torque is reached Unless otherwise specified tightening torque specifications re quire clean dry threads Components should be at room temperature A Distance between flats B Outside thread diameter A nut B bolt General tightening torques Nm m kgf ft lbf 10 mm 6 mm 6 0 ...

Page 46: ...g cover bolt M6 2 10 Nm 1 0 m kgf 7 2 ft lbf Water pump assembly bolt M6 2 10 Nm 1 0 m kgf 7 2 ft lbf Water pump inlet pipe bolt M6 1 10 Nm 1 0 m kgf 7 2 ft lbf Water pump outlet pipe M6 1 10 Nm 1 0 m kgf 7 2 ft lbf Thermostat cover bolt M6 2 10 Nm 1 0 m kgf 7 2 ft lbf Coolant pipe bolt M6 1 10 Nm 1 0 m kgf 7 2 ft lbf Coolant drain bolt M12 1 1 6 Nm 0 16 m kgf 1 2 ft lbf Coolant reservoir bolt M6 ...

Page 47: ... 1 8 m kgf 13 ft lbf L 25 mm 0 98 in Inner V belt case bolt M8 1 24 Nm 2 4 m kgf 17 ft lbf Outer V belt case nut M6 1 10 Nm 1 0 m kgf 7 2 ft lbf Crankshaft end access cover screw M6 3 7 Nm 0 7 m kgf 5 1 ft lbf V belt case air filter case screw M6 3 7 Nm 0 7 m kgf 5 1 ft lbf Generator cover protector screw M6 1 7 Nm 0 7 m kgf 5 1 ft lbf V belt case air filter case cover screw M6 2 7 Nm 0 7 m kgf 5 ...

Page 48: ...e generator rotor nuts to 65 Nm 6 5 m kgf 47 ft lbf and then tighten them further to reach the specified angle 120 Cylinder head tightening sequence Secondary sheave nut M18 1 90 Nm 9 0 m kgf 65 ft lbf YAMAHA GREASE H Poly urea Grease Secondary sheave spring seat nut M36 1 90 Nm 9 0 m kgf 65 ft lbf V belt case bearing retainer screw M6 1 11 Nm 1 1 m kgf 8 0 ft lbf Secondary shaft bearing retainer ...

Page 49: ...ide M6 4 1 5 Nm 0 15 m kgf 1 1 ft lbf Side cover bolt rear side M6 2 4 0 Nm 0 40 m kgf 2 9 ft lbf Center cover bolt M5 2 1 5 Nm 0 15 m kgf 1 1 ft lbf Bottom side cowling bolt top M5 6 1 5 Nm 0 15 m kgf 1 1 ft lbf Bottom side cowling bolt front side M5 2 1 5 Nm 0 15 m kgf 1 1 ft lbf Bottom side cowling bolt rear side M5 2 1 5 Nm 0 15 m kgf 1 1 ft lbf Side cover moulding screw M5 2 1 5 Nm 0 15 m kgf...

Page 50: ...n socket bolt M6 4 10 Nm 1 0 m kgf 7 2 ft lbf Speed sensor rotor bolt M5 3 8 Nm 0 8 m kgf 5 8 ft lbf Front wheel air valve nut M8 1 2 0 Nm 0 20 m kgf 1 4 ft lbf Front wheel air valve locknut M8 1 3 0 Nm 0 30 m kgf 2 2 ft lbf Rear brake caliper bolt M10 2 27 Nm 2 7 m kgf 20 ft lbf Rear brake lock caliper bolt M8 2 23 Nm 2 3 m kgf 17 ft lbf Drive belt guard bolt M6 4 10 Nm 1 0 m kgf 7 2 ft lbf Drive...

Page 51: ...lbf Rear brake lock caliper bracket bolt M8 1 22 Nm 2 2 m kgf 16 ft lbf Rear brake lock holder bolt M5 2 6 Nm 0 6 m kgf 4 3 ft lbf Throttle cable adjusting locknut M8 1 3 8 Nm 0 38 m kgf 2 8 ft lbf Rear brake lock caliper slide pin bolt M8 1 17 Nm 1 7 m kgf 12 ft lbf Upper bracket pinch bolt M8 2 30 Nm 3 0 m kgf 22 ft lbf Horn nut M8 1 16 Nm 1 6 m kgf 12 ft lbf Horn lead coupler nut M6 1 7 Nm 0 7 ...

Page 52: ...10 Nm 1 0 m kgf 7 2 ft lbf Radiator bracket bolt M8 4 30 Nm 3 0 m kgf 22 ft lbf Fuel tank bracket bolt M6 4 10 Nm 1 0 m kgf 7 2 ft lbf Fuel tank bolt M6 2 9 Nm 0 9 m kgf 6 5 ft lbf Fuel tank nut M6 2 9 Nm 0 9 m kgf 6 5 ft lbf Fuel pump bolt M5 6 3 8 Nm 0 38 m kgf 2 8 ft lbf Fuel rail screw M5 2 3 5 Nm 0 35 m kgf 2 5 ft lbf Canister bolt M6 2 7 Nm 0 7 m kgf 5 1 ft lbf Canister bracket nut M6 2 7 Nm...

Page 53: ... exhaust Water pump impeller shaft O ring coolant pipe or silicone flu id Oil pump shaft and rotors inner and outer Oil pump gaskets V belt case air filter case screw bushing Water V belt case air filter case cover screw bushing Water Crankshaft end access cover screw bushing Water or silicone fluid Generator cover protector cover screw bushing Water or silicone fluid Generator cover protector scr...

Page 54: ...olyurea Grease Secondary shaft right end bearing Pivot shaft taper roller bearing Crankcase mating surface Yamaha bond No 1215 Three bond No 1215 Inner V belt case seal mating surface Yamaha bond No 1215 Three bond No 1215 Crankshaft position sensor stator lead grommet Yamaha bond No 1215 Three bond No 1215 Lubrication point Lubricant LS LS ...

Page 55: ...E J Shell Alvania EP Grease R0 Rear shock absorber assembly bearing inner surface Rear shock absorber assembly spacer and collar Pivot shaft oil seal and collar Rear shock absorber assembly bolt front side seats Seat lock metal to metal moving parts Seat hinge metal to metal moving parts Seat lock cable Passenger footrest pivoting point Centerstand pivoting point and metal to metal moving parts Ce...

Page 56: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 23 EAS20019 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS30020 ENGINE OIL LUBRICATION CHART ...

Page 57: ...To piston 6 Starter clutch gear 7 Crankshaft 8 Balancer connecting rod 9 To balancer piston 10 Oil pipe 11 Check valve 12 Relief valve 13 Oil filter 14 Oil cooler 15 Oil tank 16 Oil strainer 17 Feed pump 18 Delivery pipe 19 Scavenge pump 20 Oil strainer 21 To starter idle gear 22 Clutch 23 Secondary shaft 24 To transmission ...

Page 58: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 25 EAS30021 LUBRICATION DIAGRAMS ...

Page 59: ...CATION SYSTEM CHART AND DIAGRAMS 2 26 1 Exhaust camshaft 2 Intake camshaft 3 Delivery pipe 4 Oil pump assembly 5 Scavenge pump 6 Feed pump 7 Oil pipe 8 Oil cooler 9 Oil filter 10 Relief valve 11 Check valve ...

Page 60: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 27 ...

Page 61: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 28 1 Crankshaft 2 Secondary shaft 3 Drive axle 4 Clutch 5 Generator cover ...

Page 62: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 29 ...

Page 63: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 30 1 Oil strainer 2 Intake camshaft 3 Exhaust camshaft ...

Page 64: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 31 ...

Page 65: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 32 1 Generator cover 2 Oil strainer 3 Main gallery 4 Crankcase right A Forward ...

Page 66: ...COOLING SYSTEM DIAGRAMS 2 33 EAS20020 COOLING SYSTEM DIAGRAMS ...

Page 67: ... Thermostat outlet hose 7 Oil cooler outlet hose 8 Thermostat 9 Oil cooler 10 Coolant hose 11 Water pump inlet pipe 12 Water pump outlet pipe 13 Oil cooler inlet hose 14 Radiator outlet hose 15 Coolant reservoir hose 16 Fast idle plunger outlet coolant hose 17 Coolant reservoir 18 Coolant reservoir breather hose 19 Radiator 20 Water pump ...

Page 68: ...COOLING SYSTEM DIAGRAMS 2 35 ...

Page 69: ...ostat 2 Thermostat outlet hose 3 Cooling system air bleed hose 4 Radiator cap 5 Radiator filler pipe 6 Radiator filler hose 7 Coolant reservoir hose 8 Radiator 9 Radiator inlet hose 10 Coolant pipe 11 Oil cooler 12 Oil cooler outlet hose ...

Page 70: ...CABLE ROUTING 2 37 EAS20021 CABLE ROUTING Handlebar top side front side and left side view 1 2 3 4 5 6 7 A B C D E L 4 5 7 6 5 1 4 8 2 K F G H I J 9 M 7 6 1 8 2 ...

Page 71: ...ebar switch leads and to the front of the rear brake lock cable G Route the right handlebar switch lead to the front of the throttle cables and then route it through the opening in the lower handlebar holder toward the front of the vehicle H Route the rear brake hose to the front of the handlebar and then route it through the opening in the lower handlebar holder toward the rear of the vehicle I R...

Page 72: ...CABLE ROUTING 2 39 Front brake left side and front view A B C D E F G H I J K L M N O 1 3 1 2 3 1 2 1 2 3 1 2 ...

Page 73: ...ective sleeve of the speed sensor lead Make sure that the speed sensor lead is routed within the range to the left and to the rear of the front brake hose F Pass the speed sensor lead through the hole in the lower bracket cover G Fasten the grommet on the speed sensor lead with the holder H Forward I Position the holder 0 5 mm 0 0 20 in from the bend in the brake hose J 0 5 mm 0 0 20 in K Face the...

Page 74: ...CABLE ROUTING 2 41 Frame front side view 1 2 3 4 5 7 8 9 10 12 13 13 A B D E F G A H I J K L M N O A A 11 9 9 C 6 ...

Page 75: ...tay Route the handlebar switch leads to the inside of the starter relay lead F Insert the projection on the right handlebar switch coupler into the hole in the plastic stay G Insert the projection on the left handlebar switch coupler into the hole in the plastic stay H Insert the projection on the wire harness holder white tape into the hole in the front cowling stay I Secure the holder by inserti...

Page 76: ...CABLE ROUTING 2 43 Frame left side view A B D E P Q T U V X Y 1 2 3 5 8 9 17 18 19 9 17 17 5 6 7 W 10 11 1 3 C 4 8 5 6 7 9 8 G 10 11 H 12 13 I J K L M N O 14 15 16 R F S ...

Page 77: ... any order J Install the stator coil coupler to the battery box K Install the crankshaft position sensor coupler to the battery box L Route the starter motor lead to the outside of the wire harness M Route the battery negative lead to the inside of the wire harness N Route the battery negative lead through the hole in the battery box O The starting circuit cut off relay and sidestand relay may be ...

Page 78: ...CABLE ROUTING 2 45 Frame right side view A M N P Q 1 2 8 18 19 20 21 R 25 23 24 22 N O O 5 N 17 M 1 3 4 5 B C 6 D 7 9 10 11 12 13 F E G D H 15 16 I J 1 K 17 L 14 S ...

Page 79: ...he headlight relay smart key system relay lead F Route the wire harness along the frame as shown in the illustration G Route the buzzer lead over the control switch assembly lead H Insert the projection on the wire harness holder into the hole in the frame I Fasten the seat lock cable with the holders on the bracket J Route the rear brake lock cable to the inside of the bracket K Route the steerin...

Page 80: ...CABLE ROUTING 2 47 Rear frame right side view A B C D E F G H I J K L M 1 2 3 4 6 7 A 3 4 5 N 8 9 ...

Page 81: ...motor lead with the plastic band Point the end of the plastic band outward Do not cut off the excess end of the plastic band F Fasten the wire sub lead coupler to the wire harness G Insert the projection on the wire harness holder into the hole in the frame H Route the coolant temperature sensor lead under the rear brake lock cable I Position the paint mark on the fuel tank breather hose between t...

Page 82: ...CABLE ROUTING 2 49 Frame top side view 6 7 B C G 2 3 4 5 D E F 8 9 10 H 1 A 17 L 11 12 13 14 15 16 I J K K ...

Page 83: ...he projection on the holder into the hole in the fuel tank mounting bracket and then fasten the seat lock cable and rear brake lock cable with the holder F Insert the projection on the wire harness holder into the hole in the frame G Insert the projection on the wire harness holder into the hole in the fuel tank mounting bracket from the bottom of the bracket H Route the AC magneto lead so that it...

Page 84: ...CABLE ROUTING 2 51 Rear brake top side and left side view ...

Page 85: ...o prevent kinks install the rear brake hose holder left first and then the brake hose holder B Face the opening of the brake hose holder upward C Route the brake hose along the concave face of the left rear cowling D Install the cap pushing it against the nut and washer E Route the rear brake lock cable under the brake hose F Face the opening of the cable holder to the inside of the vehicle G Inst...

Page 86: ...CABLE ROUTING 2 53 Throttle body left side view ...

Page 87: ...ark plug leads and radiator should be turned downwards slightly to the front I Insert the air filter case until it touches the throttle body Engine oil may be applied J 8 K 3 L 30 M 65 N Insert the intake air pressure sensor hose until it does not move any further O Position the clip 1 4 mm 0 04 0 16 in away from the end of the cylinder head breather hose Face the clip to the left of the vehicle P...

Page 88: ...CABLE ROUTING 2 55 Fuel tank top side and right side view A J E D C B 1 5 4 2 2 3 2 2 8 K L M N O P 8 F G H I 6 7 8 9 16 11 11 12 10 13 14 15 15 ...

Page 89: ...ay joint to canister over the fuel pump lead E Route the canister purge hose 3 way joint to canister under the seat lock cable and rear brake lock cable F White paint mark G Install the fuel tank overflow hose and filler cover making sure that they contact the connector boss H Route the fuel tank overflow hose so that the end of the hose protrudes past the bottom center cowling I Route the fuel ta...

Page 90: ...CABLE ROUTING 2 57 Fuel tank left side view A B C D E F G H I I J K L L P L M I N O Q R R N N S S T U V X 1 1 3 1 1 1 2 3 3 4 5 6 8 3 1 1 4 4 8 9 11 10 12 7 W ...

Page 91: ...ther hose holding the positioning protector behind the holder I Make sure that the fuel tank breather hose contacts the rollover valve J Route the fuel tank breather hose through the slot in the storage box K Install the rollover valve stay so that it contacts the projection on the storage box L Point the ends of the hose clamp rearward M Install the fuel tank breather hose with its paint mark fac...

Page 92: ...CABLE ROUTING 2 59 ...

Page 93: ... BRAKE PADS 3 15 BLEEDING THE HYDRAULIC BRAKE SYSTEM 3 15 CHECKING THE FRONT BRAKE HOSES 3 16 CHECKING THE REAR BRAKE HOSE 3 16 ADJUSTING THE REAR BRAKE LOCK CABLE 3 17 CHECKING THE REAR BRAKE LOCK 3 17 CHECKING THE REAR BRAKE LOCK PADS 3 18 CHECKING THE WHEELS 3 18 CHECKING THE TIRES 3 18 CHECKING THE WHEEL BEARINGS 3 19 CHECKING THE SWINGARM 3 20 CHECKING THE DRIVE BELT 3 20 ADJUSTING THE DRIVE ...

Page 94: ... 31 CHECKING THE BRAKE LIGHT SWITCHES 3 31 CHECKING AND LUBRICATING THE CABLES 3 31 LUBRICATING THE REAR SUSPENSION 3 32 CHECKING THE THROTTLE GRIP 3 32 CHECKING AND CHARGING THE BATTERY 3 33 CHECKING THE FUSES 3 33 ADJUSTING THE HEADLIGHT BEAMS 3 33 ...

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Page 96: ...sterisk require special tools data and technical skills have a Yamaha dealer perform the service NO ITEM ROUTINE INITIAL ODOMETER READINGS 600 mi 1000 km or 1 month 4000 mi 7000 km or 6 months 8000 mi 13000 km or 12 months 12000 mi 19000 km or 18 months 16000 mi 25000 km or 24 months 20000 mi 31000 km or 30 months 1 Fuel line Check fuel hoses for cracks or damage Replace if necessary 2 Spark plugs...

Page 97: ... bearing assemblies for looseness Moderately repack with lithi um soap based grease Every 12000 mi 19000 km 15 Chassis fasteners Check all chassis fitting and fasteners Correct if necessary 16 Front brake lever pivot shaft Apply silicone grease lightly 17 Rear brake lever pivot shaft Apply silicone grease lightly 18 Centerstand and sidestand pivots Check operation Apply lithium soap based grease l...

Page 98: ...omponents of the brake master cylinders and calipers and change the brake fluid Replace the brake hoses every four years and if cracked or damaged 24 Cooling system Check coolant level and vehi cle for coolant leakage Change coolant Every 3 years 25 V belt Replace When the V belt replacement indicator flashes every 12500 mi 20000 km 26 Front and rear brake switches Check operation 27 Control cable...

Page 99: ...8 Center cover Refer to GENERAL CHASSIS 2 on page 4 8 EAS30620 CHECKING THE SPARK PLUGS The following procedure applies to all of the spark plugs 1 Remove Radiator cover Refer to GENERAL CHASSIS 2 on page 4 8 2 Disconnect Spark plug cap 3 Remove Spark plug NOTICE ECA13320 Before removing the spark plugs blow away any dirt accumulated in the spark plug wells with compressed air to prevent it from f...

Page 100: ...4 Remove Fuel tank Refer to FUEL TANK on page 7 1 5 Remove Air filter case Throttle body Intake manifold Refer to THROTTLE BODY on page 7 6 6 Remove Spark plugs Cylinder head cover Cylinder head cover gasket Refer to CAMSHAFTS on page 5 10 7 Remove Timing mark accessing plug 1 Crankshaft end access cover 2 8 Measure Valve clearance Out of specification Adjust a Turn the crankshaft clockwise b When...

Page 101: ...at TDC turn the crankshaft clockwise as specified in the following table 9 Remove Camshafts TIP Refer to CAMSHAFTS on page 5 10 When removing the timing chain and cam shafts fasten the timing chain with a wire to re trieve it if it falls into the crankcase 10 Adjust Valve clearance a Remove the valve lifter 1 and the valve pad 2 with a valve lapper 3 Valve clearance measuring sequence Cylinder 1 2...

Page 102: ...n d Calculate the sum of the values obtained in steps b and c to determine the required valve pad thickness and the valve pad num ber Example 1 55 mm 0 061 in 0 03 mm 0 001 in 1 58 mm 0 062 in The valve pad number is 158 e Round off the valve pad number according to the following table and then select the suit able valve pad TIP Refer to the following table for the available valve pads Example Val...

Page 103: ... adjusting the engine idling speed the throttle body synchronization should be adjusted properly the air filter element should be clean and the engine should have adequate compres sion 1 Start the engine and let it warm up for several minutes 2 Remove Radiator cover Refer to GENERAL CHASSIS 2 on page 4 8 Side cover right Refer to GENERAL CHASSIS 2 on page 4 8 3 Install Digital tachometer onto the ...

Page 104: ...for cylinder 1 1 Synchronizing pipe cap for cylinder 2 2 4 Install Hose 1 Parts No 5JW 24311 00 3 Way joint 2 Parts No 68V 24376 00 Cylinder 1 intake air pressure sensor hose 3 Vacuum gauge hose for cylinder 1 4 Vacuum gauge hose for cylinder 2 5 Vacuum gauge Digital tachometer onto the spark plug lead of cylinder 1 5 Start the engine and let it warm up for several minutes 6 Check Engine idling sp...

Page 105: ... GRIP on page 3 32 11 Install All removed parts EAS31318 CHECKING THE THROTTLE BODY JOINTS 1 Remove Center cover Refer to GENERAL CHASSIS 2 on page 4 8 2 Check Throttle body joints 1 Cracks damage Replace 3 Install Center cover Refer to GENERAL CHASSIS 2 on page 4 8 EAS30623 CHECKING THE CYLINDER HEAD BREATHER HOSE 1 Remove Center cover Refer to GENERAL CHASSIS 2 on page 4 8 Side cover right Refer...

Page 106: ...er right Refer to GENERAL CHASSIS 2 on page 4 8 EAS30626 CHECKING THE CANISTER 1 Remove Storage box Refer to GENERAL CHASSIS 5 on page 4 20 Fuel tank Refer to FUEL TANK on page 7 1 2 Check Canister 1 Canister purge hoses 2 Cracks damage Replace 3 Install Fuel tank Refer to FUEL TANK on page 7 1 Storage box Refer to GENERAL CHASSIS 5 on page 4 20 EAS30628 REPLACING THE AIR FILTER ELEMENT 1 Remove C...

Page 107: ...ion leading to poor engine per formance and possible overheating TIP When installing the air filter element into the air filter case cover make sure that the sealing sur faces are aligned to prevent any air leaks 5 Install Center cover Refer to GENERAL CHASSIS 2 on page 4 8 EAS31181 CLEANING THE V BELT CASE AIR FILTER ELEMENT 1 Remove Center cover Refer to GENERAL CHASSIS 2 on page 4 8 Footboards ...

Page 108: ...g properly Check the brake system Refer to FRONT BRAKE on page 4 39 and REAR BRAKE on page 4 53 TIP Drive on the road operate the front and rear brakes separately and check to see if the brakes are operating properly EAS30632 CHECKING THE BRAKE FLUID LEVEL 1 Stand the vehicle on a level surface TIP Place the vehicle on the centerstand Make sure the vehicle is upright 2 Check Brake fluid level Belo...

Page 109: ...ke 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 2 on the brake lever WARNING EWA13060 After adjusting the brake lever position make sure the pin on the brake lever holder is firmly inserted in the hole in the adjusting dial A soft or spongy feeling in...

Page 110: ...e brake 2 Check Rear brake pad Wear indicators 1 almost touch the brake disc Replace the brake pads as a set Refer to REAR BRAKE on page 4 53 EAS30637 BLEEDING THE HYDRAULIC BRAKE SYSTEM WARNING EWA13100 Bleed the hydraulic brake system whenever the system is disassembled a brake hose is loosened disconnected or replaced the brake fluid level is very low brake operation is faulty TIP Be careful no...

Page 111: ...Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 13 WARNING EWA13110 After bleeding the hydraulic brake system check the brake operation EAS30635 CHECKING THE FRONT BRAKE HOSES The following procedure applies to all of the brake hoses and brake hose holders 1 Check Brake hose 1 Cracks damage wear Replace 2 Check Brake hose holder Loose Tighten the holder bolt 3 Hold the vehicle upright and apply ...

Page 112: ...placed within the width of the wear indicator groove 4 when the rear brake lock is activated Recommended procedure Tighten the piston adjusting bolt to 3 0 Nm 0 30 m kgf 2 2 ft lbf and then loosen the bolt 1 1 2 turn d Tighten the rear brake lock adjusting nut while holding the piston adjusting bolt so as not to turn the bolt e Make sure that the tire can be turned by hand when the rear brake lock...

Page 113: ... Wear indicators 1 almost touch the brake disc Replace the brake pads as a set Refer to REPLACING THE REAR BRAKE LOCK PADS on page 4 67 EAS31428 CHECKING THE WHEELS The following procedure applies to both of the wheels 1 Check Wheel Damage out of round Replace WARNING EWA13260 Never attempt to make any repairs to the wheel TIP After a tire or wheel has been changed or re placed always balance the ...

Page 114: ...rmal speed before any high speed riding is done TIP For tires with a direction of rotation mark 1 Install the tire with the mark pointing in the di rection of wheel rotation Align the mark 2 with the valve installation point EAS30641 CHECKING THE WHEEL BEARINGS The following procedure applies to all of the wheel bearings Tire air pressure measured on cold tires Loading condition 0 90 kg 0 198 lb F...

Page 115: ...ace Missing teeth B Replace Hook wear C Replace Stone damage D Replace if damage is on the edge Internal tooth cracks hairline E OK to run but monitor condition Chipping not serious F OK to run but monitor condition Fuzzy edge cord G OK to run but moni tor condition Bevel wear outboard edge only H OK to run but monitor condition Refer to BELT DRIVE on page 4 93 3 Install Drive belt upper guard and...

Page 116: ... in dicator b and edge of handle c to lap over c Read the read side scale at over lap point and record it on paper etc In this explanation should be read 13 2 Its value is calibration value of the tension gauge d Loosen the tension gauge enough until you can remove the calibration plate without any force TIP Both small and large characters are printed on the handle of the actual gauge However the ...

Page 117: ...e will be around 14 mm 0 55 in d Turn both left and right adjusting bolts 2 in direction a equivalently till aligning both indi cator and edge of handle with calibrated val ue e Check the difference in the distance c be tween the left and right sides should be 0 8 mm 0 03 in or less f Tighten the wheel axle nut to specification g Tighten the locknuts to specification h Check the difference in the ...

Page 118: ...he vehicle on a level surface WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over TIP Place the vehicle on a suitable stand so that the front wheel is elevated 2 Check Steering head Grasp the bottom of the front fork legs and gently rock the front fork Binding looseness Adjust the steering head 3 Remove Upper bracket Refer to STEERING HEAD on page 4 89 4 Adj...

Page 119: ...g nut and tighten the upper ring nut until their slots are aligned h Install the lock washer 1 TIP Make sure the lock washer tabs a sit correctly in the ring nut slots b 5 Install Upper bracket Refer to STEERING HEAD on page 4 89 EAS31186 CHECKING THE CHASSIS FASTENERS Make sure that all nuts bolts and screws are properly tightened Refer to CHASSIS TIGHTENING TORQUES on page 2 16 EAS30648 LUBRICAT...

Page 120: ...es and check if the front fork rebounds smoothly Rough movement Repair Refer to FRONT FORK on page 4 78 EAS30808 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 1 Check Rear shock absorber assembly operation Push down hard on the seat several times and check if the rear shock absorber rebound smoothly Rough movement Replace Refer to REAR SHOCK ABSORBER AS SEMBLY on page 4 96 2 Check Rear shock absorber ...

Page 121: ...NG THE ENGINE OIL 1 Start the engine warm it up for several min utes and then turn it off 2 Place a container under the engine oil drain bolt 3 Remove Engine oil filler cap 1 along with the O ring Engine oil drain bolt 2 along with the gasket 4 Drain Engine oil completely from the crankcase 5 If the oil filter cartridge is also to be replaced perform the following procedure a Remove the oil filter...

Page 122: ... to seep from the oil check bolt If no engine oil comes out after one minute turn the engine off so that it will not seize d Check the engine oil passages the oil filter cartridge and the oil pump for damage or leakage Refer to OIL PUMP on page 5 68 e Start the engine after solving the problem s and check the engine oil pressure again f Tighten the oil check bolt to specification g Install the bot...

Page 123: ...ap based grease EAS30811 CHECKING THE COOLANT LEVEL 1 Stand the vehicle on a level surface TIP Place the vehicle on the centerstand Make sure the vehicle is upright 2 Check Coolant level The coolant level should be between the maximum level mark a and minimum level mark b Below the minimum level mark Remove the left footboard mat coolant reservoir cap access panel 1 and coolant reservoir cap and t...

Page 124: ...e 4 8 Footboards Refer to GENERAL CHASSIS 2 on page 4 8 2 Check Radiator 1 Radiator inlet hose 2 Radiator outlet hose 3 Oil cooler inlet hose 4 Oil cooler outlet hose 5 Oil cooler 6 Thermostat outlet hose 7 Water pump 8 Water pump inlet pipe 9 Water pump outlet pipe 10 Radiator filler pipe 11 Radiator filler hose 12 Coolant pipe 13 Cracks damage Replace Refer to RADIATOR on page 6 1 THER MOSTAT on...

Page 125: ...O ring 6 Drain Coolant from the engine and radiator 7 Install Coolant drain bolt along with the O ring 8 Connect Coolant reservoir hose 9 Fill Cooling system with the specified amount of the recom mended coolant Handling notes for coolant Coolant is potentially harmful and should be handled with special care WARNING EWA13040 If coolant splashes in your eyes thorough ly wash them with water and con...

Page 126: ...ge 4 8 Center cover Refer to GENERAL CHASSIS 2 on page 4 8 EAS31188 REPLACING THE V BELT 1 Remove Center cover Refer to GENERAL CHASSIS 2 on page 4 8 Side cover right Refer to GENERAL CHASSIS 2 on page 4 8 Footboard right Refer to GENERAL CHASSIS 2 on page 4 8 Outer V belt case Refer to V BELT AUTOMATIC TRANSMIS SION on page 5 40 2 Check V belt Cranks damage wear Replace Grease oil Clean the prima...

Page 127: ...e stopped turn the throttle grip slowly and release it Make sure that the throttle grip turns smoothly and returns properly when released Repeat this check with the handlebar turned all the way to the left and right 3 Check Throttle grip free play a Out of specification Adjust 4 Adjust Throttle grip free play TIP Prior to adjusting the throttle grip free play throt tle body synchronization should ...

Page 128: ...socket wrench the adjusting screws can be turned with a screwdriver Phillips No 2 2 as shown in the illustration 2 Adjust Headlight beam horizontally a Turn the adjusting screw 1 in direction a or b TIP Other than the socket wrench the adjusting screws can be turned with a screwdriver Phillips No 2 2 as shown in the illustration Left headlight Right headlight Direction a Headlight beam is raised D...

Page 129: ...SIDE COVER 4 10 INSTALLING THE SIDE COVER 4 10 REMOVING THE SIDE COVER MOULDING 4 10 INSTALLING THE SIDE COVER MOULDING 4 11 REMOVING THE FOOTBOARD 4 11 INSTALLING THE FOOTBOARD 4 12 GENERAL CHASSIS 3 4 13 REMOVING THE INNER PANEL CENTER COVER 4 15 INSTALLING THE INNER PANEL CENTER COVER 4 15 GENERAL CHASSIS 4 4 16 REMOVING THE REAR COVER 4 19 INSTALLING THE REAR COVER 4 19 GENERAL CHASSIS 5 4 20 ...

Page 130: ...ASSEMBLING THE FRONT BRAKE MASTER CYLINDER 4 50 INSTALLING THE FRONT BRAKE MASTER CYLINDER 4 50 REAR BRAKE 4 53 INTRODUCTION 4 62 CHECKING THE REAR BRAKE DISC 4 62 REPLACING THE REAR BRAKE PADS 4 62 REMOVING THE REAR BRAKE CALIPER 4 63 DISASSEMBLING THE REAR BRAKE CALIPER 4 64 CHECKING THE REAR BRAKE CALIPER 4 64 ASSEMBLING THE REAR BRAKE CALIPER 4 64 INSTALLING THE REAR BRAKE CALIPER 4 65 REMOVIN...

Page 131: ...AD 4 91 INSTALLING THE STEERING HEAD 4 92 BELT DRIVE 4 93 CHECKING THE DRIVE BELT 4 95 INSTALLING THE DRIVE BELT 4 95 REAR SHOCK ABSORBER ASSEMBLY 4 96 HANDLING THE REAR SHOCK ABSORBER 4 97 DISPOSING OF A REAR SHOCK ABSORBER 4 97 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 4 97 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 4 97 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 4 97 SWINGARM 4 99 REMOVING THE ...

Page 132: ... GENERAL CHASSIS 2 on page 4 8 Side panel Refer to GENERAL CHASSIS 2 on page 4 8 1 Windshield cover 2 2 Windshield bracket 2 3 Windshield 1 4 Front under cover 1 5 Front cover 1 6 Rearview mirror 2 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 1 5 Nm 0 15 m kgf 1 1 ft Ibf T R 1 6 Nm 0 16 m kgf 1 2 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 6 6 4 5 2 2 4 ...

Page 133: ...shield inner panel 1 8 Headlight sub wire harness coupler 2 Disconnect 9 Front cowling assembly 1 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 1 5 Nm 0 15 m kgf 1 1 ft Ibf T R 1 6 Nm 0 16 m kgf 1 2 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 9 8 2 2 4 2 2 2 2 2 2 2 2 2 2 2 ...

Page 134: ...light coupler 2 Disconnect 2 Headlight coupler 2 Disconnect 3 Headlight sub wire harness 1 4 Auxiliary light coupler left 1 Disconnect 5 Auxiliary light coupler right 1 Disconnect 6 Front turn signal position light left 1 7 Front turn signal position light right 1 8 Side cowling 2 9 Headlight under panel 1 8 1 3 1 8 7 9 3 6 2 2 4 5 ...

Page 135: ...ews 2 d Removing the windshield brackets 3 EAS30141 INSTALLING THE WINDSHIELD 1 Install Windshield a Assembling the windshield 1 and wind shield brackets 2 with the windshield screws 3 b Installing the windshield assembly with the windshield bracket bolts 4 2 Install Windshield cover a Insert the projection into the hole and slide it downwards b Installing the quick fastener 1 T R Windshield screw...

Page 136: ...assembly to the desired position by installing the bolts 1 e Tighten the bolts to the specified torque f Installing the windshield cover Refer to INSTALLING THE WINDSHIELD on page 4 4 EAS31517 REMOVING THE FRONT UNDER COVER 1 Remove Front under cover a Remove the quick fasteners 1 b Pull the claws 2 of the front under cover to the front side and remove them EAS31518 INSTALLING THE FRONT UNDER COVE...

Page 137: ... metal clips 2 from the wind shield inner panel and claws 3 from the front cowling assembly c Pull the projections 4 of the front cover to the front side and remove them EAS31399 INSTALLING THE FRONT COVER 1 Install Front cover a Insert the projections 1 of the front cover b Fit the metal clips 2 and claws 3 of the front cover c Installing the quick fastener 4 2 1 1 1 1 2 2 3 2 3 3 1 4 1 2 3 2 3 3...

Page 138: ...fasteners 1 b Removing the bolts 2 c Pull the projections 3 of the windshield inner panel to the front side and remove them EAS31401 INSTALLING THE WINDSHIELD INNER PANEL 1 Install Windshield inner panel a Insert the projections 1 of the windshield in ner panel b Installing the bolts 2 c Installing the quick fasteners 3 ...

Page 139: ... bottom cowling Order Job Parts to remove Q ty Remarks 1 Footboard mat 4 2 Radiator cover 1 3 Side panel 2 4 Center cover 1 5 Side cover 2 6 Bottom side cowling 2 7 Bottom center cowling 1 8 Side cover moulding 2 9 Footboard 2 9 3 8 1 6 5 9 4 1 5 8 3 6 2 7 6 4 3 ...

Page 140: ... Side panel a Insert the metal clip 1 b Installing the screws 2 c Installing the quick fasteners 3 EAS31094 REMOVING THE CENTER COVER 1 Remove Center cover a Removing the screws 1 b Use an appropriate hook from the service hole 2 to raise the center cover c When the center cover is raised pull the cen ter cover upwards and remove the claws 3 EAS31095 INSTALLING THE CENTER COVER 1 Install Center co...

Page 141: ...the claws 2 outside of the vehicle and raise them c When the side cover is raised pull the side cover outsides of the vehicle and remove the projections 3 EAS31520 INSTALLING THE SIDE COVER 1 Install Side cover a Insert the projections 1 b Insert the claws 2 c Installing the bolts 3 EAS31521 REMOVING THE SIDE COVER MOULDING 1 Remove Side cover moulding ...

Page 142: ...cle and remove the claws 3 EAS31522 INSTALLING THE SIDE COVER MOULDING 1 Install Side cover moulding a Insert the claws 1 b Installing the screws 2 c Installing the quick fastener 3 EAS31523 REMOVING THE FOOTBOARD 1 Remove Footboard a Removing the screws 1 b Removing the bolts 2 c Remove the claws 3 A Left side B Right side ...

Page 143: ...ootboard upwards pull it toward you and then remove it EAS31524 INSTALLING THE FOOTBOARD 1 Install Footboard a Insert the hooks of the footboard b Fit the claws 1 c Installing the bolts 2 d Installing the screws 3 A Left side B Right side ...

Page 144: ...y Refer to GENERAL CHASSIS 1 on page 4 1 Footboard Refer to GENERAL CHASSIS 2 on page 4 8 1 Inner panel center cover 1 2 Auxiliary DC jack assembly cover 1 3 Inner panel cover left side 1 4 Auxiliary DC jack assembly 1 5 Battery 1 6 Meter assembly coupler 1 Disconnect 7 Meter panel assembly 1 8 Meter assembly 1 4 2 2 2 2 4 3 5 7 6 8 1 ...

Page 145: ...trol unit coupler 1 Disconnect 11 Storage box front right side 1 12 Remote control unit 1 13 Seat lock cable cover 1 Applicable unit range SJ13Y 0000635 and after 14 Seat lock cable 1 Disconnect 15 Leg shield 1 16 Control switch assembly 1 17 Control switch assembly bracket 1 4 2 2 2 14 10 11 12 13 15 16 17 9 14 11 ...

Page 146: ...VER 1 Remove Inner panel center cover a Removing the screws 1 b There are claws 2 Remove them starting from the top EAS31526 INSTALLING THE INNER PANEL CENTER COVER 1 Install Inner panel center cover a Fit the claws 1 starting from the bottom b Installing the screws 2 ...

Page 147: ...ootboard Refer to GENERAL CHASSIS 2 on page 4 8 O2 sensor lead Refer to ENGINE REMOVAL on page 5 2 1 Seat 1 2 Fuel tank cover 1 3 Grab bar 2 4 Rear cover 1 5 Tail brake light lead cover 1 6 Tail brake light lead guide 1 7 Storage box light switch coupler 1 Disconnect 8 Storage box light switch 1 9 Seat hinge assembly 1 3 2 3 ...

Page 148: ...Order Job Parts to remove Q ty Remarks 10 Tail brake light assembly coupler 1 Disconnect 11 License plate light lead coupler 1 Disconnect 12 Rear turn signal light lead coupler 2 Disconnect 13 Mudguard 1 14 Rear fender 1 15 Rear cowling assembly 1 12 10 11 13 ...

Page 149: ... rear cowling assembly Order Job Parts to remove Q ty Remarks 1 Tail brake light bracket 1 2 Rear cowling left 1 3 Rear cowling right 1 4 Turn signal light left 1 5 Turn signal light right 1 6 Tail brake light 1 7 Tail brake light cover 1 2 2 ...

Page 150: ...the rear side of the rear cover and slightly applying a force upward slide the cover rearward to remove it EAS31413 INSTALLING THE REAR COVER 1 Install Rear cowling a Insert the claws 1 of the rear cover though the holes of the rear cowling assembly Slide the cover forward to install it b Installing the quick fasteners 2 ...

Page 151: ...r to GENERAL CHASSIS 4 on page 4 16 1 Fuel pump coupler access cover 1 2 Fuel pump coupler 1 Disconnect 3 Fuel hose connector cover 1 4 Fuel hose 1 Disconnect 5 Fuel tank overflow hose 1 6 Storage box inner mat 1 7 Seat lock assembly 1 8 Storage box light connector 2 Disconnect 9 Rollover valve stay 1 10 Storage box 1 11 Storage box light 1 ...

Page 152: ...re may be fuel remain ing in it Do not disconnect the fuel hose from the fuel hose connector Disconnect the con nector from the fuel pump TIP Before removing the hose place a few rags in the area under where it will be removed EAS31415 INSTALLING THE FUEL HOSE 1 Connect Fuel hose 2 Install Fuel hose connector cover NOTICE ECA22030 When installing the fuel hose make sure that it is securely connect...

Page 153: ...xle pinch bolt 4 Loosen 8 Front wheel axle bolt 1 9 Front wheel axle 1 10 Front wheel 1 11 Collar 1 Length 12 mm 0 47 in LT LT New New LS 10 Nm 1 0 m kgf 7 2 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 21 Nm 2 1 m kgf 15 ft Ibf T R 23 Nm 2 3 m kgf 17 ft Ibf T R 23 Nm 2 3 m kgf 17 ft Ibf T R 23 Nm 2 3 m kgf 17 ft Ibf T R 35 Nm 3 5 m kgf 25 ft Ibf T R 35 Nm 3 5 m kgf 25 ft Ibf T R 91 Nm 9 1 m kgf 66 ft...

Page 154: ... LT LT New New LS 10 Nm 1 0 m kgf 7 2 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 21 Nm 2 1 m kgf 15 ft Ibf T R 23 Nm 2 3 m kgf 17 ft Ibf T R 23 Nm 2 3 m kgf 17 ft Ibf T R 23 Nm 2 3 m kgf 17 ft Ibf T R 35 Nm 3 5 m kgf 25 ft Ibf T R 35 Nm 3 5 m kgf 25 ft Ibf T R 91 Nm 9 1 m kgf 66 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 5 5 2 2 4 12 13 13 14 ...

Page 155: ... the front wheel Order Job Parts to remove Q ty Remarks 1 Speed sensor rotor 1 2 Oil seal 2 3 Wheel bearing right 1 4 Collar 1 5 Wheel bearing left 1 6 Air valve 1 2 3 4 6 2 5 New New LT New New New 8 Nm 0 8 m kgf 5 8 ft Ibf T R 1 3 ...

Page 156: ...e Front wheel TIP Place the vehicle on a suitable stand so that the front wheel is elevated EAS30146 DISASSEMBLING THE FRONT WHEEL NOTICE ECA22350 Keep magnets including magnetic pick up tools magnetic screwdrivers etc away from the speed sensor rotor Do not drop the speed sensor rotor or sub ject it to shocks If any solvent gets on the speed sensor ro tor wipe it off immediately 1 Remove Speed se...

Page 157: ... it off immediately 1 Install Wheel bearings Oil seals a Install the new wheel bearing left side NOTICE ECA20540 Do not apply pressure to the wheel bearing inner race 1 or balls 2 Pressure should only be applied to the outer race 3 TIP Use a socket 4 that matches the diameter of the wheel bearing outer race b Install the collar c Install the new wheel bearing right side TIP Place a suitable washer...

Page 158: ...ve nut so as not to turn the nut EAS30152 ADJUSTING THE FRONT WHEEL STATIC BALANCE TIP After replacing the tire 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 TIP Place the front wheel on a suitable balancing stand a Spin the front wheel b When the front ...

Page 159: ...heavier weight d Repeat steps b and c until the front wheel is balanced 4 Check Front wheel static balance a Turn the front wheel and make sure it stays at each position shown b If the front wheel does not remain stationary at all of the positions rebalance it EAS30932 INSTALLING THE FRONT WHEEL FRONT BRAKE DISC 1 Install Front brake discs TIP Tighten the brake disc bolts in stages and in a crissc...

Page 160: ...011 Make sure there are no foreign materials in the speed sensor rotor and speed sensor Foreign materials cause damage to the speed sensor rotor and speed sensor TIP When installing the speed sensor check the speed sensor lead for twists To route the speed sensor lead refer to CA BLE ROUTING on page 2 37 7 Measure Distance a between the speed sensor rotor 1 and speed sensor 2 Out of specification ...

Page 161: ...e speed sensor 8 Install Front brake calipers Front brake hose lead holders WARNING EWA13500 Make sure the brake hose is routed properly Thickness gauge 90890 03180 Feeler gauge set YU 26900 9 T R Front brake caliper bolt 35 Nm 3 5 m kgf 25 ft lbf Front brake hose lead holder bolt 7 Nm 0 7 m kgf 5 1 ft lbf a 1 1 2 2 ...

Page 162: ...Parts to remove Q ty Remarks 1 Rear brake caliper 1 2 Rear brake pad 2 3 Rear brake lock cable adjusting nut 1 4 Pin 1 5 Rear brake lock spring 1 6 Rear brake lock caliper 1 7 Drive belt upper guard 1 Non disassemble 8 Drive belt lower guard 1 Non disassemble 9 Drive belt adjusting locknut 2 Loosen 10 Drive belt adjusting bolt 2 Loosen 11 Rear wheel axle nut 1 ...

Page 163: ...rake caliper bracket replace them as a set Order Job Parts to remove Q ty Remarks 12 Washer 1 13 Adjusting block right 1 14 Rear wheel axle 1 15 Adjusting block left 1 16 Rear wheel 1 17 Rear brake caliper bracket 1 18 Caliper bolt boot 2 19 Collar right 1 20 Collar left 1 21 Dust cover 1 ...

Page 164: ...REAR WHEEL 4 33 Removing the rear brake disc and rear wheel pulley Order Job Parts to remove Q ty Remarks 1 Rear brake disc 1 2 Drive belt guide 1 3 Rear wheel pulley 1 4 Rear wheel 1 ...

Page 165: ...REAR WHEEL 4 34 Disassembling the rear wheel assembly Order Job Parts to remove Q ty Remarks 1 Oil seal 2 2 Wheel bearing left 1 3 Collar 1 4 Wheel bearing right 1 ...

Page 166: ...brake caliper bracket Rear wheel Collars TIP Push the rear wheel forward and remove the drive belt from the rear wheel pulley EAS30158 DISASSEMBLING THE REAR WHEEL 1 Remove Oil seals Wheel bearings Refer to DISASSEMBLING THE FRONT WHEEL on page 4 25 EAS30159 CHECKING THE REAR WHEEL 1 Check Wheel axle Wheel bearings Oil seals Refer to CHECKING THE FRONT WHEEL on page 4 25 2 Check Tire Rear wheel Da...

Page 167: ...ening the drive belt guide bolts tighten the bolt at the punch mark a first and then other bolts in stages and in a crisscross pattern EAS30163 ASSEMBLING THE REAR WHEEL 1 Install Wheel bearings Oil seals a Install the new wheel bearing right side NOTICE ECA18110 Do not contact the wheel bearing inner race 1 or balls 2 Contact should be made only with the outer race 3 TIP Use a socket 4 that match...

Page 168: ... brake disc bolts with new ones TIP Tighten the brake disc bolts in stages and in a crisscross pattern 2 Check Rear brake disc Refer to CHECKING THE REAR BRAKE DISC on page 4 62 3 Install Drive belt guide Rear wheel pulley TIP Tighten the rear wheel pulley bolts in stages and in a crisscross pattern When tightening the drive belt guide bolts tighten the bolt at the punch mark a first and then othe...

Page 169: ...m of the ve hicle 5 Install Rear brake caliper Rear brake lock caliper temporarily 6 Adjust Drive belt slack Refer to ADJUSTING THE DRIVE BELT SLACK on page 3 20 7 Tighten Wheel axle nut Rear brake caliper bolts Rear brake lock caliper bolts WARNING EWA13500 Make sure the brake hose is routed properly TIP When tightening the wheel axle nut there should be no clearance a between the adjust ing bloc...

Page 170: ...nt brake hose lead holder bolt 1 2 Front reflector 1 3 Front brake hose lead holder left 1 4 Front brake caliper bolt 2 5 Front brake caliper 1 6 Brake pad clip 2 7 Brake pad pin 1 8 Brake pad spring 1 9 Front brake pad 2 10 Bleed screw 1 7 Nm 0 7 m kgf 5 1 ft Ibf T R 5 Nm 0 5 m kgf 3 6 ft Ibf T R 35 Nm 3 5 m kgf 25 ft Ibf T R 35 Nm 3 5 m kgf 25 ft Ibf T R 10 7 6 4 4 9 8 5 3 1 2 ...

Page 171: ...DLEBAR on page 4 72 Brake fluid Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 15 1 Brake master cylinder reservoir cap 1 2 Brake master cylinder reservoir diaphragm hold er 1 3 Brake master cylinder reservoir diaphragm 1 4 Front brake lever 1 5 Front brake light switch connector 2 Disconnect 6 Brake hose union bolt 1 ...

Page 172: ...oving the front brake master cylinder Order Job Parts to remove Q ty Remarks 7 Front brake hose 1 8 Brake hose gasket 2 9 Front brake master cylinder holder 1 10 Front brake master cylinder 1 11 Front brake light switch 1 ...

Page 173: ...FRONT BRAKE 4 42 Disassembling the front brake master cylinder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder kit 1 2 Brake master cylinder body 1 ...

Page 174: ... to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 15 1 Front brake hose lead holder bolt 1 2 Front reflector 1 3 Front brake hose lead holder left 1 4 Brake hose union bolt 1 5 Brake hose gasket 2 6 Front brake hose 1 7 Front brake caliper bolt 2 8 Front brake caliper 1 New 5 7 Nm 0 7 m kgf 5 1 ft Ibf T R 30 Nm 3 0 m kgf 22 ft Ibf T R 35 Nm 3 5 m kgf 25 ft Ibf T R 1 7 7 8 2 4 6 3 ...

Page 175: ...cedure applies to both of the front brake calipers 1 Brake pad clip 2 2 Brake pad pin 1 3 Brake pad spring 1 4 Front brake pad 2 5 Brake caliper piston 4 6 Brake caliper piston dust seal 4 7 Brake caliper piston seal 4 8 Bleed screw 1 New New New New New New 5 Nm 0 5 m kgf 3 6 ft Ibf T R 2 1 5 8 3 4 6 6 6 5 7 6 7 ...

Page 176: ...er to FRONT WHEEL on page 4 22 2 Check Brake disc Damage galling Replace 3 Measure Brake disc deflection Out of specification Correct the brake disc deflection or replace the brake disc a Place the vehicle on a suitable stand so that the front wheel is elevated b Before measuring the front brake disc deflec tion turn the handlebar to the left or right to ensure that the front wheel is stationary c...

Page 177: ... disassem ble the brake caliper 1 Remove Brake pad clips 1 Brake pad pin 2 Brake pad spring 2 Remove Brake pads 1 3 Measure Brake pad wear limit a Out of specification Replace the brake pads as a set 4 Remove Front brake caliper 5 Install Brake pads Brake pad spring TIP Always install new brake pads and new brake pad spring as a set a Connect a clear plastic hose 1 tightly to the bleed screw 2 Put...

Page 178: ...3 15 EAS30171 REMOVING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers TIP Before removing the brake caliper drain the brake fluid from the entire brake system 1 Remove Front brake hose lead holder bolt 1 Brake hose union bolt 2 Brake hose gaskets 3 Front brake hose 4 TIP Put the end of the brake hose into a container and pump out the brake fluid carefully EA...

Page 179: ...delivery passages brake caliper body Obstruction Blow out with compressed air WARNING EWA13611 Whenever a brake caliper is disassembled replace the brake caliper piston dust seals and brake caliper piston seals EAS30174 ASSEMBLING THE FRONT BRAKE CALIPERS WARNING EWA13621 Before installation all internal brake com ponents should be cleaned and lubricated with clean or new brake fluid Never use sol...

Page 180: ...the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake performance When refilling be careful that water does not enter the brake master cylinder reser voir Water will significantly lower the boil ing point of the brake fluid ...

Page 181: ...lace Brake fluid delivery passages brake master cylinder body Obstruction Blow out with compressed air 2 Check Brake master cylinder kit Damage scratches wear Replace 3 Check Brake master cylinder reservoir cap 1 Brake master cylinder reservoir 2 Brake master cylinder reservoir diaphragm holder 3 Cracks damage Replace Brake master cylinder reservoir diaphragm 4 Damage wear Replace 4 Check Brake ho...

Page 182: ...ated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake performance When refilling be careful that water does not enter the brake master cylinder reser voir Water will significantl...

Page 183: ...FRONT BRAKE 4 52 Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 15 ...

Page 184: ...BRAKE 4 53 EAS20031 REAR BRAKE Removing the rear brake pads Order Job Parts to remove Q ty Remarks 1 Rear brake caliper bolt 2 2 Rear brake caliper 1 3 Rear brake pad 2 4 Brake pad support 2 5 Bleed screw 1 ...

Page 185: ...DLEBAR on page 4 72 Brake fluid Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 15 1 Brake master cylinder reservoir cap 1 2 Brake master cylinder reservoir diaphragm hold er 1 3 Brake master cylinder reservoir diaphragm 1 4 Rear brake lever 1 5 Rear brake light switch connector 2 Disconnect 6 Brake hose union bolt 1 ...

Page 186: ...emoving the rear brake master cylinder Order Job Parts to remove Q ty Remarks 7 Rear brake hose 1 8 Brake hose gasket 2 9 Rear brake master cylinder holder 1 10 Rear brake master cylinder 1 11 Rear brake light switch 1 ...

Page 187: ...REAR BRAKE 4 56 Disassembling the rear brake master cylinder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder kit 1 2 Brake master cylinder body 1 ...

Page 188: ...ve Q ty Remarks Brake fluid Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 15 1 Brake hose union bolt 1 2 Brake hose gasket 2 3 Rear brake hose 1 4 Rear brake caliper bolt 2 5 Rear brake caliper 1 6 Rear brake pad 2 7 Brake pad support 2 8 Caliper bolt boot 2 ...

Page 189: ...E 4 58 Disassembling the rear brake caliper Order Job Parts to remove Q ty Remarks 1 Brake caliper piston 1 2 Brake caliper piston dust seal 1 3 Brake caliper piston seal 1 4 Bleed screw 1 5 Brake caliper body 1 ...

Page 190: ...AKE 4 59 Removing the rear brake lock pads Order Job Parts to remove Q ty Remarks 1 Rear brake lock cable adjusting nut 1 2 Pin 1 3 Rear brake lock spring 1 4 Rear brake lock caliper 1 5 Rear brake lock pad 2 ...

Page 191: ...REAR BRAKE 4 60 Removing the rear brake lock caliper Order Job Parts to remove Q ty Remarks 1 Rear brake lock cable adjusting nut 1 2 Pin 1 3 Rear brake lock spring 1 4 Rear brake lock caliper 1 ...

Page 192: ...rks 1 Cap 1 2 Rear brake lock adjusting nut 1 3 Rear brake lock caliper arm 1 4 Boot 1 5 Rear brake lock pad 2 6 Caliper piston assembly 1 7 Boot 1 8 Sleeve 1 9 Boot 2 10 Rear brake lock caliper bracket bolt 1 11 Rear brake lock caliper bracket 1 12 Slide pin bolt 1 13 Rear brake lock caliper 1 ...

Page 193: ...eel Refer to REAR WHEEL on page 4 31 2 Check Brake disc Damage galling Replace 3 Measure Brake disc deflection Out of specification Correct the brake disc deflection or replace the brake disc Refer to CHECKING THE FRONT BRAKE DISCS on page 4 45 4 Measure Brake disc thickness Measure the brake disc thickness at a few dif ferent locations Out of specification Replace Refer to CHECKING THE FRONT BRAK...

Page 194: ...o the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 13 7 Check Brake lever operation Soft or spongy feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 15 EAS30186 REMOVING THE REAR BRAKE CALIPER TIP Before removing the brake caliper drain the brake fluid from the entire brake system 1 Remove Brake hose union bolt 1 Brake hose gaskets Rear brake ...

Page 195: ...r assembly Brake caliper body 3 Cracks damage Replace the brake caliper assembly Brake fluid delivery passages brake caliper body Obstruction Blow out with compressed air WARNING EWA13601 Whenever a brake caliper is disassembled replace the brake caliper piston dust seal and brake caliper piston seal 2 Check Brake caliper bracket 1 Cracks damage Replace EAS30189 ASSEMBLING THE REAR BRAKE CALIPER W...

Page 196: ...ake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake performance When refilling be careful that water does not enter the brake master cylinder reser voir Water will significantly lower...

Page 197: ...ke master cylinder reservoir cap Brake master cylinder reservoir Brake master cylinder reservoir diaphragm holder Cracks damage Replace 4 Check Brake hose Cracks damage wear Replace EAS30195 ASSEMBLING THE REAR BRAKE MASTER CYLINDER WARNING EWA13520 Before installation all internal brake com ponents should be cleaned and lubricated with clean or new brake fluid Never use solvents on internal brake...

Page 198: ...ul chemical reaction leading to poor brake performance When refilling be careful that water does not enter the brake master cylinder reser voir Water will significantly lower the boil ing point of the brake fluid and could cause vapor lock NOTICE ECA13540 Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 4 Bleed Brake system Refer...

Page 199: ... seal on the side of the piston adjusting bolt carefully 5 Measure Rear brake lock pads wear limit a Out of specification Replace the rear brake lock pads 6 Remove Cap Rear brake lock adjusting nut Rear brake lock caliper arm 7 Adjust Piston adjusting bolt Refer to ASSEMBLING THE REAR BRAKE LOCK CALIPER on page 4 70 8 Install Rear brake lock caliper arm Rear brake lock adjusting nut Cap Rear brake...

Page 200: ... Refer to ADJUSTING THE REAR BRAKE LOCK CABLE on page 3 17 b Activate the rear brake lock cable 10 times c Carry out adjustment using rear brake lock cable adjusting nut 1 so that dimension a is 43 45 mm 1 69 1 77 in d Repeat steps a to c until dimension a is 43 45 mm 1 69 1 77 in EAS31419 REMOVING THE REAR BRAKE LOCK CALIPER 1 Remove Rear brake lock cable adjusting nut 1 Pin 2 Rear brake lock spr...

Page 201: ...es the locknut b With shaft L fastened turn and adjust the pis ton adjusting bolt so that the length a be tween the end of shaft L and the end of the piston adjusting bolt is changed to 19 mm 0 75 in T R Rear brake lock caliper slide pin bolt 17 Nm 1 7 m kgf 12 ft lbf Recommended lubricant Silicone grease T R Rear brake lock caliper bracket bolt 22 Nm 2 2 m kgf 16 ft lbf LOCTITE Recommended lubric...

Page 202: ...installing the rear brake lock pad to the caliper check that the pad rotates smoothly EAS31422 INSTALLING THE REAR BRAKE LOCK CALIPER 1 Install Rear brake lock caliper 1 Rear brake lock caliper bolts 2 Rear brake lock spring 3 Pin 4 Rear brake lock cable adjusting nut 5 2 Adjust Rear brake lock cable length Refer to ADJUSTING THE REAR BRAKE LOCK CABLE on page 3 17 T R Rear brake lock adjusting nut...

Page 203: ...r brake lock cable adjusting nut Loosen Refer to REAR BRAKE on page 4 53 Front cowling assembly Refer to GENERAL CHASSIS 1 on page 4 1 Meter assembly Refer to GENERAL CHASSIS 3 on page 4 13 1 Upper handlebar cover 1 2 Holder 4 3 Grip end 2 4 Front brake light switch connector 2 Disconnect 5 Handlebar switch right 1 ...

Page 204: ...e master cylinder holder 1 9 Front brake master cylinder assembly 1 10 Rear brake light switch connector 2 Disconnect 11 Rear brake lock holder 1 12 Rear brake lock lever 1 13 Rear brake lock cable 1 Disconnect 14 Handlebar switch left 1 15 Rear brake master cylinder holder 1 16 Rear brake master cylinder assembly 1 17 Handlebar grip 1 15 17 14 16 14 13 ...

Page 205: ...4 Removing the handlebar YAMAHA GREASE F Order Job Parts to remove Q ty Remarks 18 Lower handlebar cover 1 19 Upper handlebar holder 2 20 Handlebar 1 21 Lower handlebar holder 1 22 Holder bracket 1 21 22 18 19 19 20 ...

Page 206: ...e WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over 2 Install Holder bracket Lower handlebar holder TIP Pass the projection of the lower handlebar hold er through the hole of the holder bracket 3 Install Handlebar Upper handlebar holder TIP Align the punch mark on the handlebar to the end of the lower handlebar holder First tighten the bolts on the front s...

Page 207: ...rojection a on the left handlebar switch with the hole b in the handlebar Install the rear brake lock cable after rotating the lever to the position shown in the illustra tion 9 Connect Rear brake light switch connector 10 Install Front brake master cylinder assembly 1 Front brake master cylinder holder 2 TIP Install the front brake master cylinder holder with the mark a facing up Align the end of...

Page 208: ...h with the hole b in the handlebar 13 Connect Front brake light switch connector 14 Adjust Throttle grip free play Refer to CHECKING THE THROTTLE GRIP on page 3 32 15 Adjust Rear brake lock cable length Refer to ADJUSTING THE REAR BRAKE LOCK CABLE on page 3 17 16 Install Grip end Holder Upper handlebar cover Throttle grip free play 3 0 5 0 mm 0 12 0 20 in 1 2 LS 1 a b 1 ...

Page 209: ...e applies to both of the front fork legs Meter assembly Leg shield Refer to GENERAL CHASSIS 3 on page 4 13 Front wheel Front fender Refer to FRONT WHEEL on page 4 22 1 Upper bracket pinch bolt 1 Loosen 2 Cap bolt 1 Loosen 3 Horn coupler 1 Disconnect 4 Brake pipe joint 1 5 Horn 1 6 Lower bracket pinch bolt 2 Loosen 2 1 6 4 5 3 ...

Page 210: ...FRONT FORK 4 79 Removing the front fork legs Order Job Parts to remove Q ty Remarks 7 Front fork leg 1 8 Lower bracket cover 1 9 Horn bracket 1 7 8 9 ...

Page 211: ...the front fork legs 1 Cap bolt 1 2 O ring 1 3 Damper rod locknut 1 4 Spacer 1 5 Fork spring 1 6 Damper rod assembly bolt 1 7 Copper washer 1 8 Damper rod assembly 1 9 Dust seal 1 10 Oil seal clip 1 11 Outer tube 1 New New New New New New New LT LS LS 1 2 3 4 5 7 6 9 10 8 11 23 Nm 2 3 m kgf 17 ft Ibf T R 15 Nm 1 5 m kgf 11 ft Ibf T R ...

Page 212: ... legs Order Job Parts to remove Q ty Remarks 12 Oil seal 1 13 Washer 1 14 Outer tube bushing 1 15 Inner tube bushing 1 16 Inner tube 1 New New New New New New New LT LS LS 16 13 12 15 14 23 Nm 2 3 m kgf 17 ft Ibf T R 15 Nm 1 5 m kgf 11 ft Ibf T R ...

Page 213: ...oth of the front fork legs NOTICE ECA22020 Because the left and right damper rod as semblies are different be sure to install them in the correct positions 1 Remove Cap bolt 1 Spacer 2 Damper rod locknut 3 a Press down on the spacer with the fork spring compressor 4 b Install the rod holder 5 between the damper rod locknut 3 and the spacer 2 TIP Use the side of the rod holder that is marked B c Ho...

Page 214: ...ICE ECA14180 Do not scratch the inner tube 5 Remove Outer tube a Hold the front fork leg horizontally b Securely clamp the brake caliper bracket in a vise with soft jaws c Separate the outer tube from the inner tube by pulling the outer tube forcefully but careful ly NOTICE ECA19880 Excessive force will damage the bushings Damaged bushings must be replaced EAS30208 CHECKING THE FRONT FORK LEGS The...

Page 215: ... stability TIP When assembling the front fork leg be sure to replace the following parts Inner tube bushing Outer tube bushing Oil seal Dust seal Oil seal clip O ring Copper washer Before assembling the front fork leg make sure all of the components are clean 1 Lubricate Inner tube outer surface 2 Install Dust seal 1 Oil seal clip 2 Oil seal 3 Washer 4 Outer tube bushing 5 Inner tube bushing 6 NOT...

Page 216: ...its into the outer tube groove 7 Install Dust seal 1 with the fork seal driver 2 8 Install Damper rod assembly 1 to inner tube 2 Copper washer Damper rod assembly bolt Fork seal driver 90890 01442 Adjustable fork seal driver 36 46 mm YM 01442 Fork seal driver 90890 01442 Adjustable fork seal driver 36 46 mm YM 01442 4 6 New 5 New 1 New 2 New 3 New 1 3 2 Fork seal driver 90890 01442 Adjustable fork...

Page 217: ...e holding the damper rod assembly with the damper rod holder 2 tighten the damper rod assembly bolt 10 Install Rod puller 1 Rod puller attachment M10 2 onto the damper rod 3 11 Fill Front fork leg with the specified amount of the recom mended fork oil A Compression side B Rebound side T R Damper rod assembly bolt 23 Nm 2 3 m kgf 17 ft lbf LOCTITE a A B Damper rod holder 90890 01423 Damping rod hol...

Page 218: ...o bleed the front fork leg of any residual air 14 Measure Front fork leg oil level a from the top of the outer tube with the outer tube fully compressed and without the fork spring Out of specification Correct 15 Install Damper rod locknut 1 Fork spring 2 Spacer 3 Cap bolt 4 along with the O ring WARNING EWA12850 Always use a new O ring a Remove the rod puller and rod puller attach ment b Install ...

Page 219: ...rocedure applies to both of the front fork legs 1 Install Front fork leg Temporarily tighten the upper and lower bracket pinch bolts TIP Make sure the outer tube is flush with the top of the upper bracket 2 Tighten Lower bracket pinch bolts 1 Cap bolt 2 Upper bracket pinch bolt 3 Fork spring compressor 90890 01441 Fork spring compressor YM 01441 Rod holder 90890 01434 Damper rod holder double ende...

Page 220: ...bly Refer to GENERAL CHASSIS 1 on page 4 1 Meter assembly Refer to GENERAL CHASSIS 3 on page 4 13 Front wheel Refer to FRONT WHEEL on page 4 22 Handlebar Refer to HANDLEBAR on page 4 72 Front fork legs Refer to FRONT FORK on page 4 78 1 Steering stem nut 1 2 Upper bracket 1 3 Lock washer 1 4 Upper ring nut 1 5 Rubber washer 1 2 ...

Page 221: ...D 4 90 Removing the lower bracket Order Job Parts to remove Q ty Remarks 6 Lower ring nut 1 7 Lower bracket 1 8 Upper bearing cover 1 9 Upper bearing 1 10 Lower bearing 1 11 Dust seal 1 12 Steering lock unit 1 12 2 ...

Page 222: ...ash Bearings Bearing races 2 Check Bearings 1 Bearing races 2 Damage pitting Replace 3 Replace Bearings Bearing races a Remove the bearing races from the steering head pipe 1 with a long rod 2 and hammer b Remove the bearing race from the lower bracket 3 with a floor chisel 4 and ham mer c Install a new rubber seal and new bearing races NOTICE ECA14270 If the bearing race is not installed properly...

Page 223: ... ring nut 3 Lock washer 4 Refer to CHECKING AND ADJUSTING THE STEERING HEAD on page 3 23 3 Install Upper bracket Washer Steering stem nut TIP Temporarily tighten the steering stem nut 4 Install Front fork legs Refer to FRONT FORK on page 4 78 TIP Temporarily tighten the upper and lower bracket pinch bolts 5 Tighten Steering stem nut Recommended lubricant Lithium soap based grease T R Steering stem...

Page 224: ...0 Order Job Parts to remove Q ty Remarks Rear wheel Refer to REAR WHEEL on page 4 31 1 Rear brake lock cable holder swingarm 1 2 Rear brake hose bracket 1 3 Rear brake hose holder right 1 4 Rear brake hose holder left 1 5 Drive pulley cover 1 6 Dust cover 1 7 Holder 1 8 Circlip 1 9 Bearing 1 10 Oil seal 1 3 4 10 7 ...

Page 225: ...BELT DRIVE 4 94 Removing the drive belt Filling the YAMAHA GREASE J Shell Alvania EP Grease R0 Order Job Parts to remove Q ty Remarks 11 Drive pulley 1 12 Collar 2 13 Drive belt 1 13 12 12 11 ...

Page 226: ... belt from the mixture and rinse it off with clean water Then let the drive belt thoroughly dry 2 Check Drive belt Refer to CHECKING THE DRIVE BELT on page 3 20 3 Check Drive pulley 1 Rear wheel pulley 2 Bent teeth Replace the drive belt and pul leys as a set 4 Check Holder 1 Cracks damage Replace EAS31423 INSTALLING THE DRIVE BELT 1 Install Drive belt 2 Adjust Drive belt slack Refer to ADJUSTING ...

Page 227: ...ssembly Order Job Parts to remove Q ty Remarks Exhaust assembly Refer to ENGINE REMOVAL on page 5 2 1 Rear shock absorber assembly bolt front side 1 2 Lock washer 1 3 Collar 1 4 Rear shock absorber assembly bolt nut rear side 1 1 5 Rear shock absorber assembly 1 6 Collar 1 7 Washer 1 8 Spacer 1 9 Bearing 2 ...

Page 228: ...shock absorber at a point from its end as shown WARNING EWA13760 Wear eye protection to prevent eye damage from released gas or metal chips EAS30219 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 1 Stand the vehicle on a level surface WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over TIP Place the vehicle on the centerstand so that the rear wheel is elevated 2 ...

Page 229: ...r assembly bolt front side TIP With the swingarm and rear wheel lowered by own weight tighten the rear shock absorber assembly bolt front side and rear shock ab sorber assembly nut rear side After tightening the rear shock absorber as sembly bolt front side align the wide claw with the bolt head and bent it Recommended lubricant Lithium soap based grease T R Rear shock absorber assembly nut rear s...

Page 230: ...assembly Refer to REAR SHOCK ABSORBER AS SEMBLY on page 4 96 Drive belt Refer to BELT DRIVE on page 4 93 Exhaust assembly Refer to ENGINE REMOVAL on page 5 2 1 Drive belt inner guard 1 Non disassemble 2 Swingarm left 1 3 Swingarm right 1 4 Dowel pin 2 5 Swingarm stopper 1 6 Pivot shaft 1 7 Oil seal 1 8 Oil seal 1 ...

Page 231: ...SWINGARM 4 100 Removing the swingarm Order Job Parts to remove Q ty Remarks 9 Outer race 1 10 Bearing 1 11 Bearing housing 1 12 O ring 1 13 Collar 1 14 Oil seal 1 15 Bearing 1 15 14 13 ...

Page 232: ...ement is not smooth or if there is binding check the bearings 3 Remove Drive belt Refer to BELT DRIVE on page 4 93 4 Remove Drive pulley assembly bolt Swingarm bolt Pivot shaft nut EAS30227 CHECKING THE SWINGARM 1 Check Swingarm left 1 Swingarm right 2 Bends cracks damage Replace 2 Check Drive pulley assembly bolts Swingarm bolts Damage wear Replace EAS30228 INSTALLING THE SWINGARM 1 Lubricate Tap...

Page 233: ... Drive pulley assembly bolt 4 Tighten Pivot shaft Pivot shaft nut a With your fingers screw in the pivot shaft until it touches the collar and then tighten the piv ot shaft to the specified torque b Tighten the pivot shaft nut to the specified torque T R Swingarm bolt 40 Nm 4 0 m kgf 29 ft lbf Drive pulley assembly bolt 48 Nm 4 8 m kgf 35 ft lbf T R Pivot shaft 7 Nm 0 7 m kgf 5 1 ft lbf Pivot shaf...

Page 234: ...SWINGARM 4 103 ...

Page 235: ...G THE CYLINDER HEAD 5 21 INSTALLING THE CYLINDER HEAD 5 21 VALVES AND VALVE SPRINGS 5 23 REMOVING THE VALVES 5 24 CHECKING THE VALVES AND VALVE GUIDES 5 24 CHECKING THE VALVE SEATS 5 26 CHECKING THE VALVE SPRINGS 5 28 CHECKING THE VALVE LIFTERS 5 28 INSTALLING THE VALVES 5 29 CYLINDER AND PISTONS 5 31 REMOVING THE PISTON 5 32 CHECKING THE CYLINDERS AND PISTONS 5 32 CHECKING THE PISTON RINGS 5 33 C...

Page 236: ...IL STRAINER 5 57 ASSEMBLING THE OIL TANK 5 57 INSTALLING THE STARTER CLUTCH 5 57 INSTALLING THE GENERATOR 5 58 CLUTCH 5 60 REMOVING THE CLUTCH 5 63 DISASSEMBLING THE CLUTCH 5 63 CHECKING THE FRICTION PLATES 5 64 CHECKING THE CLUTCH PLATES 5 64 CHECKING THE CLUTCH DAMPER SPRINGS 5 64 CHECKING THE CLUTCH SPRING PLATE 5 64 CHECKING THE CLUTCH SPRINGS 5 65 CHECKING THE CLUTCH HOUSING 5 65 CHECKING THE...

Page 237: ... THE CRANKSHAFT JOURNAL BEARINGS 5 78 CHECKING THE CRANKSHAFT AND CONNECTING RODS 5 78 INSTALLING THE CRANKSHAFT JOURNAL BEARINGS 5 82 INSTALLING THE CONNECTING RODS 5 82 INSTALLING THE CRANKSHAFT ASSEMBLY 5 84 TRANSMISSION 5 85 CHECKING THE TRANSMISSION 5 86 ...

Page 238: ...on gauge stabilizes TIP The difference in compression pressure be tween cylinders should not exceed 100 kPa 1 kgf cm 14 psi c If the compression pressure is above the maximum specification check the cylinder head valve surfaces and piston crown for carbon deposits Carbon deposits Eliminate d If the compression pressure is below the min imum specification pour a teaspoonful of en gine oil into the ...

Page 239: ...ts to remove Q ty Remarks Side cover right Refer to GENERAL CHASSIS 2 on page 4 8 1 O2 sensor coupler 1 Disconnect 2 O2 sensor 1 Remove the O2 sensor only when neccessa ry 3 Exhaust assembly 1 4 Gasket 2 5 Front muffler protector 1 6 Center muffler protector 1 7 Upper muffler protector 1 ...

Page 240: ...he exhaust assembly Order Job Parts to remove Q ty Remarks 8 Muffler end 1 TIP When installing the muffler end face the dummy bolt to the upper side of the muffler It is not required to remove the dummy bolt 9 Muffler end bracket 1 ...

Page 241: ...er to GENERAL CHASSIS 1 on page 4 1 Storage box Refer to GENERAL CHASSIS 5 on page 4 20 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 26 Coolant Drain Refer to CHANGING THE COOLANT on page 3 29 Fuel tank Refer to FUEL TANK on page 7 1 Front wheel Front fender Refer to FRONT WHEEL on page 4 22 Intake manifold Refer to THROTTLE BODY on page 7 6 ...

Page 242: ...page 6 5 Exhaust assembly Refer to ENGINE REMOVAL on page 5 2 Rear wheel Refer to REAR WHEEL on page 4 31 Rear shock absorber assembly Refer to REAR SHOCK ABSORBER AS SEMBLY on page 4 96 Swingarm Refer to SWINGARM on page 4 99 1 Spark plug cap 2 Disconnect 2 Crankshaft position sensor coupler 1 Disconnect 3 Stator coil coupler 1 Disconnect 4 Sidestand switch coupler 1 Disconnect 5 Coolant temperat...

Page 243: ... REMOVAL 5 6 Disconnecting the leads Order Job Parts to remove Q ty Remarks 6 Ground lead 1 Disconnect 7 Starter motor lead 1 Disconnect 8 Rear brake lock cable holder crankcase 1 9 Wire harness 1 Disconnect ...

Page 244: ...TRANSMIS SION on page 5 40 1 Damper 2 2 Rear frame bolt 2 3 Engine mounting nut rear side 1 4 Engine mounting bolt rear side 1 5 Spacer 1 6 Rear frame 1 7 Engine mounting bolt front left lower side 2 8 Footboard bracket left 1 9 Sidestand 1 10 Engine mounting bolt front right lower side 2 11 Engine mounting nut front upper side 1 ...

Page 245: ...ENGINE REMOVAL 5 8 Removing the engine Order Job Parts to remove Q ty Remarks 12 Engine mounting bolt front upper side 1 13 Engine 1 ...

Page 246: ... side 4 Rear frame bolts 5 TIP When tightening the engine mounting nuts and engine mounting bolts do not apply an upward load to the frame such as supporting the area around steering head of the frame upwards Al so do not apply an upward or downward load on the rear frame such as supporting the rear end of the rear frame upwards or pushing it down wards T R Engine mounting nut front upper side 88 ...

Page 247: ...ne oil Drain Refer to CHANGING THE ENGINE OIL on page 3 26 Air filter case Refer to THROTTLE BODY on page 7 6 1 Spark plug cap 2 Disconnect 2 Spark plug 2 3 Cylinder head breather hose 1 Disconnect 4 Cylinder head cover 1 5 Cylinder head cover gasket 1 6 Dowel pin 2 7 Gasket 2 8 Timing chain guide upper side 1 ...

Page 248: ...cover Refer to V BELT AUTOMATIC TRANSMIS SION on page 5 40 Storage box Refer to GENERAL CHASSIS 5 on page 4 20 Fuel tank Refer to FUEL TANK on page 7 1 Intake manifold Refer to THROTTLE BODY on page 7 6 Cylinder head cover Refer to CAMSHAFTS on page 5 10 1 Timing mark accessing plug 1 2 Timing chain tensioner rod accessing plug 1 3 Timing chain tensioner 1 ...

Page 249: ...ob Parts to remove Q ty Remarks 4 Timing chain tensioner gasket 1 5 Intake camshaft cap 1 6 Exhaust camshaft cap 1 7 Dowel pin 4 TIP During removal the dowel pins may still be connected to the camshaft caps 8 Intake camshaft 1 9 Exhaust camshaft 1 ...

Page 250: ... that the piston is at TDC the alignment marks c on the intake camshaft sprocket and the alignment marks d on the exhaust camshaft sprocket must align with the cylinder head mating surface as shown in the illustration 2 Remove Timing chain tensioner 1 Timing chain tensioner gasket 3 Remove Intake camshaft cap 1 Exhaust camshaft cap 2 Dowel pins NOTICE ECA13720 To prevent damage to the cylinder hea...

Page 251: ...r head without the dowel pins and camshaft caps b Position a strip of Plastigauge 1 onto the camshaft journal as shown Camshaft lobe dimensions Lobe height Intake 32 490 32 590 mm 1 2791 1 2831 in Limit 32 390 mm 1 2752 in Base circle diameter Intake 24 950 25 050 mm 0 9823 0 9862 in Limit 24 850 mm 0 9783 in Lobe height Exhaust 32 690 32 790 mm 1 2870 1 2909 in Limit 32 590 mm 1 2831 in Base circ...

Page 252: ... to camshaft cap clearance with the Plastigauge d Remove the camshaft caps and then mea sure the width of the Plastigauge 1 5 Measure Camshaft journal diameter a Out of specification Replace the camshaft Within specification Replace the cylinder head and the camshaft caps as a set EAS30936 CHECKING THE CAMSHAFT SPROCKETS The following procedure applies to both of the camshaft sprockets 1 Check Cam...

Page 253: ...er rod comes out d of the timing chain tensioner housing smoothly If there is rough move ment replace the timing chain tensioner EAS30269 INSTALLING THE CAMSHAFTS 1 Install Exhaust camshaft 1 Intake camshaft 2 a Turn the crankshaft clockwise b When piston 1 is at TDC on the compres sion stroke align the I mark a on the gen erator rotor with the stationary pointer b on the generator cover c Install...

Page 254: ... engine oil When tightening the camshaft cap tighten the four bolts on the both ends of the cap tempo rarily to lower the entire cap while paying at tention not to twist the dowel pins and camshaft journal After the camshaft cap touches the cyl inder head tighten the two bolts in the middle to the specified torque and then the remaining four bolts to the specified torque To prevent the camshaft ca...

Page 255: ...rocket alignment marks c and d Make sure that the camshaft sprocket align ment marks are aligned with the cylinder head mating surface Out of alignment Correct Refer to the installation steps above 7 Measure Valve clearance Out of specification Adjust Refer to ADJUSTING THE VALVE CLEAR ANCE on page 3 5 8 Install Timing chain guide upper side Gaskets to the cylinder head cover TIP Apply Yamaha bond...

Page 256: ...CAMSHAFTS 5 19 TIP Tighten the cylinder head cover bolts in stages and in a crisscross pattern T R Cylinder head cover bolt 10 Nm 1 0 m kgf 7 2 ft lbf ...

Page 257: ... remove Q ty Remarks Camshafts Refer to CAMSHAFTS on page 5 10 Exhaust assembly Refer to ENGINE REMOVAL on page 5 2 Thermostat Coolant temperature sensor Refer to THERMOSTAT on page 6 8 Radiator bracket Refer to RADIATOR on page 6 1 1 Cylinder head 1 2 Cylinder head gasket 1 3 Dowel pin 2 ...

Page 258: ...ust Eliminate 3 Measure Cylinder head warpage Out of specification Resurface the cylinder head a Place a straightedge 1 and a thickness gauge 2 across the cylinder head b Measure the warpage c If the limit is exceeded resurface the cylinder head as follows d Place a 400 600 grit wet sandpaper on the surface plate and resurface the cylinder head using a figure eight sanding pattern TIP To ensure an...

Page 259: ...nder head nuts cylinder head bolts and cylinder bolt when the cylinder head and cylinder are cold Use three steps to tighten the cylinder head nuts 4 Install Exhaust camshaft Intake camshaft Refer to INSTALLING THE CAMSHAFTS on page 5 16 T R Cylinder head nut 1st 10 Nm 1 0 m kgf 7 2 ft lbf 2nd 20 Nm 2 0 m kgf 14 ft lbf 3rd 120 Cylinder head bolt 10 Nm 1 0 m kgf 7 2 ft lbf Cylinder bolt 10 Nm 1 0 m...

Page 260: ...prings Silicone fluid Order Job Parts to remove Q ty Remarks Cylinder head Refer to CYLINDER HEAD on page 5 20 1 Valve lifter 8 2 Valve pad 8 3 Valve cotter 16 4 Valve spring retainer 8 5 Valve spring 8 6 Intake valve 4 7 Exhaust valve 4 8 Valve stem seal 8 9 Valve spring seat 8 10 Valve guide 8 ...

Page 261: ...clean solvent a into the intake and exhaust ports b Check that the valves properly seal TIP There should be no leakage at the valve seat 1 3 Remove Valve cotters TIP Remove the valve cotters by compressing the valve spring with the valve spring compressor 1 and the valve spring compressor attachment 2 4 Remove Valve spring retainer 1 Valve spring 2 Valve 3 Valve stem seal 4 Valve spring seat 5 TIP...

Page 262: ...uide with the valve guide installer 2 and valve guide remover 1 c After installing the valve guide bore the valve guide with the valve guide reamer 3 to ob tain the proper valve stem to valve guide clearance TIP After replacing the valve guide reface the valve seat Valve stem to valve guide clearance Valve guide inside diameter a Valve stem diameter b Valve stem to valve guide clear ance intake 0 ...

Page 263: ...ves and valve seats 1 Eliminate Carbon deposits from the valve face and valve seat 2 Check Valve seat Pitting wear Replace the cylinder head 3 Measure Valve seat width a Out of specification Replace the cylinder head a Apply blue layout fluid b onto the valve face Valve guide remover ø4 90890 04111 Valve guide remover 4 0 mm YM 04111 Valve guide installer ø4 90890 04112 Valve guide installer 4 0 m...

Page 264: ...olybdenum disulfide oil onto the valve stem c Install the valve into the cylinder head d Turn the valve until the valve face and valve seat are evenly polished then clean off all of the lapping compound TIP For the best lapping results lightly tap the valve seat while rotating the valve back and forth be tween your hands e Apply a fine lapping compound to the valve face and repeat the above steps ...

Page 265: ... The following procedure applies to all of the valve lifters 1 Check Valve lifter Damage scratches Replace the valve lift ers and cylinder head Free length intake 36 73 mm 1 45 in Limit 34 89 mm 1 37 in Free length exhaust 36 73 mm 1 45 in Limit 34 89 mm 1 37 in Installed compression spring force intake 96 60 111 20 N 9 85 11 34 kgf 21 72 25 00 lbf Installed compression spring force exhaust 96 60 ...

Page 266: ... 5 into the cylinder head TIP Make sure each valve is installed in its original place Install the valve springs with the larger pitch a facing up 4 Install Valve cotters 1 TIP Install the valve cotters by compressing the valve spring with the valve spring compressor 2 and the valve spring compressor attachment 3 Recommended lubricant Molybdenum disulfide oil New b Smaller pitch Valve spring compre...

Page 267: ...icant 7 Lubricate Valve lifter with the recommended lubricant 8 Install Valve pad Valve lifter NOTICE ECA22150 After making sure that the valve pads are ful ly inserted install the valve lifter taking care so that the pads do not fall TIP The valve lifter must move smoothly when ro tated with a finger Each valve lifter and valve pad must be rein stalled in its original position Recommended lubrica...

Page 268: ...Job Parts to remove Q ty Remarks Cylinder head Refer to CYLINDER HEAD on page 5 20 Coolant hose Refer to WATER PUMP on page 6 11 1 Timing chain guide exhaust side 1 2 Cylinder 1 3 Cylinder gasket 1 4 Dowel pin 2 5 Piston pin clip 4 6 Piston pin 2 7 Piston 2 8 Top ring 2 9 2nd ring 2 10 Oil ring 2 ...

Page 269: ...ring Oil ring TIP When removing a piston ring open the end gap with your fingers and lift the other side of the ring over the piston crown EAS30291 CHECKING THE CYLINDERS AND PISTONS The following procedure applies to all of the cyl inders and pistons 1 Check Piston wall Cylinder wall Vertical scratches Replace the cylinder piston and piston rings as a set 2 Measure Piston to cylinder clearance a ...

Page 270: ...iston ring grooves and 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 gap Out of specification Replace the piston ring set TIP The oil ring expander spacer s end gap cannot be measured If the oil ring rail s gap is exces sive replace all three piston r...

Page 271: ...plies to all of the pis tons and cylinders 1 Install Oil ring expander 1 Lower oil ring rail 2 Upper oil ring rail 3 2nd ring 4 Top ring 5 into the piston Piston ring Top ring End gap installed 0 25 0 35 mm 0 0098 0 0138 in Limit 0 60 mm 0 0236 in 2nd ring End gap installed 0 35 0 50 mm 0 0138 0 0197 in Limit 0 75 mm 0 0295 in Oil ring End gap installed 0 10 0 35 mm 0 0039 0 0138 in a Bottom of cy...

Page 272: ...in clips so that the clip ends are 3 mm 0 12 in b or more from the cutout in the piston Reinstall each piston into its original cylinder 3 Install Dowel pins Cylinder gasket 4 Lubricate Piston Piston rings Cylinder with the recommended lubricant 5 Offset Piston ring end gaps 6 Install Cylinder Cylinder bolt TIP While compressing the piston rings install the cylinder Pass the timing chain and timin...

Page 273: ...R Removing the starter motor Order Job Parts to remove Q ty Remarks Storage box Refer to GENERAL CHASSIS 5 on page 4 20 Fuel tank Refer to FUEL TANK on page 7 1 1 Ground lead 1 Disconnect 2 Starter motor lead 1 Disconnect 3 Starter motor assembly 1 ...

Page 274: ...ver armature assembly starter motor yoke insulator and starter motor rear cover replace the starter motor assembly Order Job Parts to remove Q ty Remarks 1 Starter motor front cover 1 2 Armature assembly 1 3 Starter motor yoke 1 4 O ring 2 5 Brush holder set 1 6 Insulator 1 7 Starter motor rear cover 1 ...

Page 275: ...ure the armature assembly resistances with the digital circuit tester b If any resistance is out of specification re place the starter motor assembly 4 Measure Brush length a Out of specification Replace the brush holder set 5 Measure Brush spring force Out of specification Replace the brush holder set Mica undercut depth 0 70 mm 0 03 in Digital circuit tester CD 731a 90890 03189 Model 88 Multimet...

Page 276: ... as shown in the illustration 2 Install Starter motor yoke 1 Starter motor rear cover 2 Starter motor front cover 3 TIP Align tab a of the starter motor rear cover with notch b of the starter motor yoke Align the match mark c on the starter motor yoke with the match mark d on the starter mo tor front cover EAS30327 INSTALLING THE STARTER MOTOR 1 Connect Battery negative lead 1 TIP Make sure that t...

Page 277: ... GENERAL CHASSIS 2 on page 4 8 Storage box Refer to GENERAL CHASSIS 5 on page 4 20 V belt case air filter element left Refer to WATER PUMP on page 6 11 Fuel tank Refer to FUEL TANK on page 7 1 Exhaust assembly Refer to ENGINE REMOVAL on page 5 2 1 Passenger footrest right 1 2 Crankshaft end access cover 1 3 V belt case air filter case cover 1 4 V belt case air filter case 1 ...

Page 278: ...b Parts to remove Q ty Remarks 5 V belt case air filter element right 1 6 Rear brake lock cable holder crankcase 1 7 Rear brake lock cable holder bracket 1 8 Outer V belt case 1 9 Outer V belt case gasket 1 10 Bearing retainer 1 11 Bearing 1 12 Circlip 1 13 Oil seal 1 14 Bearing 1 ...

Page 279: ...ply YAMAHA GREASE H Polyurea Grease Order Job Parts to remove Q ty Remarks 1 Primary sheave nut 1 2 Spacer 1 3 O ring 2 4 Primary sheave assembly 1 5 Secondary sheave nut 1 6 Secondary sheave assembly 1 7 V belt 1 8 Primary fixed sheave 1 9 V belt case air duct joint clamp 1 Loosen 10 V belt case air duct 1 11 Inner V belt case plate 1 ...

Page 280: ... the V belt and primary secondary sheave 1 Apply YAMAHA GREASE G Shell Sunlight Grease 3 2 Apply YAMAHA GREASE H Polyurea Grease Order Job Parts to remove Q ty Remarks 12 Inner V belt case 1 13 Dowel pin 2 14 Plate 1 15 Inner V belt case seal 1 ...

Page 281: ...ry sheave 1 Apply YAMAHA GREASE H Polyurea Grease 2 When replacing the primary sliding sheave or collar replace them as a set Order Job Parts to remove Q ty Remarks 1 Cam 1 2 Slider 8 3 Primary sheave weight 8 4 Primary sliding sheave 1 5 Collar 1 6 Oil seal 2 ...

Page 282: ...AMAHA GREASE H Polyurea Grease Order Job Parts to remove Q ty Remarks 1 Secondary sheave spring seat nut 1 2 Upper spring seat 1 3 Secondary sheave compression spring 1 4 Spring seat 1 5 Guide pin 6 6 Secondary sliding sheave 1 7 O ring 2 8 Oil seal 2 9 Secondary fixed sheave 1 ...

Page 283: ... sheave 2 with the sheave holder 3 loosen the second ary sheave spring seat nut with the locknut wrench 4 Do not loosen the secondary sheave spring seat nut 1 more than 1 4 turn 2 Remove Secondary sheave spring seat nut 1 TIP Install the sheave spring compressor 2 and sheave fixed block 3 onto the secondary sheave assembly as shown Then compress the spring and remove the secondary sheave spring se...

Page 284: ...o all of the pri mary sheave weights 1 Check Primary sheave weight Cracks damage wear Replace 2 Measure Primary sheave weight outside diameter Out of specification Replace EAS30318 CHECKING THE SLIDERS The following procedure applies to all of the slid ers 1 Check Slider Cracks damage wear Replace EAS30319 CHECKING THE SECONDARY SHEAVE 1 Check Secondary fixed sheave Secondary sliding sheave Cracks...

Page 285: ...eave inner surface 2 Oil seals with the recommended lubricant 2 Install Guide pins TIP Before installing the guide pin align the position where fixed sheave rivet head a and guide pin hole b are in alignment with each other with alignment mark c of the sliding sheave Install the guide pin Then make sure that the sliding sheave slides to the LOW side without an inter ference of rivet head d 3 Lubri...

Page 286: ...ave 2 with the sheave holder 3 tighten the second ary sheave spring seat nut 1 with the locknut wrench 4 EAS31437 INSTALLING THE PRIMARY SHEAVE ASSEMBLY SECONDARY SHEAVE ASSEMBLY AND V BELT 1 Apply Sealant onto the inner V belt case seal 2 Install V belt case air duct joint clamp 1 V belt case air duct 2 Sheave spring compressor 90890 04134 Sheave spring compressor YM 04134 Sheave fixed block 9089...

Page 287: ...embly then pass the V belt the primary sheave side Align the a and b during reassembly 4 Tighten Secondary sheave nut 1 TIP While holding the secondary sheave with the sheave holder 2 tighten the secondary sheave nut 5 Tighten Primary sheave nut 1 NOTICE ECA22200 Before tightening the nut to remount the primary sheave make sure that the serra tions of the cam are fitted firmly into the serrations ...

Page 288: ... with 10 g 0 35 oz or more of lithium soap based grease 3 Install Bearing retainer 1 TIP Install the bearing retainer 1 with its mark a facing outward Apply locking agent LOCTITE to the threads of the bearing retainer screw Installed depth of oil seal a 4 0 4 3 mm 0 16 0 17 in T R V belt case bearing retainer screw 11 Nm 1 1 m kgf 8 0 ft lbf LOCTITE b a 1 1 a ...

Page 289: ...E ENGINE OIL on page 3 26 Coolant Drain Refer to CHANGING THE COOLANT on page 3 29 Front cowling assembly Refer to GENERAL CHASSIS 1 on page 4 1 Storage box Refer to GENERAL CHASSIS 5 on page 4 20 Water pump assembly Refer to WATER PUMP on page 6 11 Fuel tank Refer to FUEL TANK on page 7 1 V belt case air duct Refer to V BELT AUTOMATIC TRANSMIS SION on page 5 40 8 9 10 11 7 7 6 12 15 16 14 13 5 ...

Page 290: ...er 1 2 Passenger footrest left 1 3 Crankshaft position sensor coupler 1 Disconnect 4 Stator coil coupler 1 Disconnect 5 Generator cover 1 6 Generator cover gasket 1 7 Dowel pin 2 8 Starter clutch idle gear shaft 1 9 Starter clutch idle gear 1 10 Generator rotor nut 1 11 Spacer 1 12 Generator rotor 1 13 Starter clutch 1 8 9 10 11 7 7 6 12 13 5 ...

Page 291: ...GENERATOR AND STARTER CLUTCH 5 54 Removing the generator rotor and starter clutch Order Job Parts to remove Q ty Remarks 14 Woodruff key 1 15 Starter clutch gear 1 16 Washer 1 15 16 14 ...

Page 292: ...placing the crankshaft position sensor or stator coil replace them as a set Order Job Parts to remove Q ty Remarks 1 Oil tank 1 2 Oil tank gasket 1 3 Dowel pin 2 4 Oil strainer 1 5 Crankshaft position sensor 1 6 Stator coil 1 7 Bearing cover 1 8 Oil seal 1 9 Bearing 1 10 Bearing 1 ...

Page 293: ... Generator rotor 1 with the flywheel puller 2 Woodruff key TIP Make sure the flywheel puller is centered 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 sheave holder 3 remove the starter clutch bolts Do not allow the sheave holder to touch the projection on the generator rotor EAS30869 CH...

Page 294: ... When turning the starter clutch gear clock wise B it should turn freely otherwise the starter clutch is faulty and must be replaced EAS31439 CHECKING THE OIL STRAINER 1 Check Oil strainer Damage Replace Contaminants Clean with solvent EAS31440 ASSEMBLING THE OIL TANK 1 Install Bearing TIP Seal a is adhered only on one side of the bear ing Note the press in orientation EAS30871 INSTALLING THE STAR...

Page 295: ...generator rotor 2 with the sheave holder 3 tighten the generator rotor nut Do not allow the sheave holder to touch the projection on the generator rotor TIP When tightening the generator rotor nut be sure to use a beam type torque wrench Tighten the nut until it is at the specified angle 3 Apply Sealant onto the crankshaft position sensor stator lead grommet 4 Install Generator cover T R Generator...

Page 296: ...GENERATOR AND STARTER CLUTCH 5 59 TIP Tighten the generator cover bolts in stages and in a crisscross pattern ...

Page 297: ...TCH 5 60 EAS20055 CLUTCH Removing the clutch Order Job Parts to remove Q ty Remarks Generator cover Refer to GENERATOR AND STARTER CLUTCH on page 5 52 1 Clutch assembly nut 1 2 Clutch assembly 1 3 Washer 1 ...

Page 298: ...Clip 1 2 Spring stopper plate 1 3 Clutch spring plate 1 4 Pressure plate 1 5 Clutch plate 2 2 6 Clutch damper spring 7 7 Friction plate 6 8 Clutch plate 1 5 9 Clutch spring 6 10 Thrust plate 1 11 Clutch boss nut 1 12 Primary drive gear 1 13 Bearing 2 14 Clutch boss 1 15 Collar 1 ...

Page 299: ...CLUTCH 5 62 Disassembling the clutch Order Job Parts to remove Q ty Remarks 16 Thrust plate 1 17 Clutch weight 12 18 Clutch housing 1 ...

Page 300: ... stopper plate 1 TIP To ensure proper balance of the clutch assem bly one to three holes a or no hole at all may have been drilled in the spring stopper plate Be fore removing the spring stopper plate make alignment marks on both the plate and the clutch housing so that the plate can be reinstalled in its original position 3 Loosen Clutch boss nut 1 TIP While holding the clutch boss 2 with the uni...

Page 301: ...cation Replace the clutch plates as a set EAS31442 CHECKING THE CLUTCH DAMPER SPRINGS The following procedure applies to all of the clutch damper springs 1 Check Clutch damper spring Damage Replace 2 Measure Clutch damper spring free height a Out of specification Replace the clutch damper springs as a set EAS30350 CHECKING THE CLUTCH SPRING PLATE 1 Check Clutch spring plate Damage Replace Friction...

Page 302: ...utch housing dogs Damage pitting wear Deburr the clutch housing dogs or replace the clutch housing TIP Pitting on the clutch housing dogs will cause er ratic clutch operation EAS30353 CHECKING THE CLUTCH BOSS 1 Check Clutch boss splines Damage pitting wear Replace the clutch boss TIP Pitting on the clutch boss splines will cause er ratic clutch operation EAS31443 CHECKING THE PRESSURE PLATE AND TH...

Page 303: ...s 2 3 Friction plates 4 Clutch plates 1 5 Pressure plate 6 Clutch spring plate 7 TIP Clutch damper spring a installed at the end must be installed backwards The pressure plate 6 and thrust plate 1 can be identified by punch mark b on the pressure plate 4 Install Clip 1 TIP While compressing the clutch springs with the clutch spring compressor 2 install the clip T R Clutch boss nut 130 Nm 13 m kgf ...

Page 304: ...h assembly nut 2 TIP Align the a and b during reassembly While holding the clutch assembly with the ro tor holding tool 3 tighten the clutch assembly nut T R Clutch assembly nut 65 Nm 6 5 m kgf 47 ft lbf Rotor holding tool 90890 01235 Universal magneto and rotor holder YU 01235 ...

Page 305: ...oil pump assembly Order Job Parts to remove Q ty Remarks Starter clutch gear Refer to GENERATOR AND STARTER CLUTCH on page 5 52 1 Oil pump assembly 1 2 Oil pump drive chain 1 3 Gasket 2 4 Oil delivery pipe 1 5 Oil pipe 1 6 Relief valve assembly 1 ...

Page 306: ...mp assembly Order Job Parts to remove Q ty Remarks 1 Oil pump housing 1 1 2 Dowel pin 2 3 Oil pump outer rotor 1 1 4 Oil pump inner rotor 1 1 5 Pin 1 6 Washer 1 7 Oil pump housing center 1 8 Oil pump outer rotor 2 1 9 Oil pump inner rotor 2 1 10 Pin 1 11 Oil pump driven gear 1 12 Oil pump housing 2 1 ...

Page 307: ...CHECKING THE OIL PUMP DRIVE CHAIN 1 Check Oil pump drive chain Cracks stiffness Replace the oil pump chain and oil pump assembly as a set EAS30342 ASSEMBLING THE OIL PUMP 1 Lubricate Inner rotor Outer rotor Oil pump shaft with the recommended lubricant 2 Install Inner rotors TIP When installing the inner rotor align the pins 1 in the oil pump shaft with the grooves a in the inner rotor 3 Check Oil...

Page 308: ... Cylinder Pistons Refer to CYLINDER AND PISTONS on page 5 31 Oil cooler Refer to OIL COOLER on page 6 5 Starter motor Refer to ELECTRIC STARTER on page 5 36 Starter clutch gear Refer to GENERATOR AND STARTER CLUTCH on page 5 52 Clutch assembly Refer to CLUTCH on page 5 60 Oil pump assembly Refer to OIL PUMP on page 5 68 Inner V belt case Refer to V BELT AUTOMATIC TRANSMIS SION on page 5 40 ...

Page 309: ...case Order Job Parts to remove Q ty Remarks Bearing housing Refer to SWINGARM on page 4 99 1 Centerstand assembly 1 2 Timing chain 1 3 Timing chain guide intake side 1 4 Crankcase left 1 5 Dowel pin 2 6 Oil strainer 1 7 Crankcase right 1 ...

Page 310: ...moving the oil seals and bearings Order Job Parts to remove Q ty Remarks Crankshaft assembly Refer to CRANKSHAFT on page 5 76 Transmission Refer to TRANSMISSION on page 5 85 1 Bearing retainer 2 2 Oil seal 2 3 Bearing 5 ...

Page 311: ...lean all the gasket surfaces and crankcase mating surfaces 3 Check Crankcase Cracks damage Replace Oil delivery passages Obstruction Blow out with compressed air EAS31445 CHECKING THE TIMING CHAIN 1 Check Timing chain Damage stiffness Replace the timing chain camshafts and crankshaft assembly as a set EAS30397 ASSEMBLING THE CRANKCASE 1 Install Cylinder stud bolts 1 TIP For the cylinder stud bolt ...

Page 312: ... a turn at a time in stag es and in a crisscross pattern M8 110 mm 4 33 in bolts 1 M6 50 mm 1 97 in bolts 2 M6 35 mm 1 38 in bolts 3 6 Check Crankshaft and transmission operation Rough movement Repair T R Crankcase bolt M8 24 Nm 2 4 m kgf 17 ft lbf Crankcase bolt M6 10 Nm 1 0 m kgf 7 2 ft lbf ...

Page 313: ...SHAFT Removing the crankshaft assembly Order Job Parts to remove Q ty Remarks Crankcase Separate Refer to CRANKCASE on page 5 71 1 Dowel pin 2 2 Balancer cylinder 1 3 Crankshaft assembly 1 4 Oil seal 1 5 Crankshaft journal bearing 2 ...

Page 314: ...rod cap 2 2 Big end lower bearing 2 3 Connecting rod 2 4 Big end upper bearing 2 5 Circlip 2 6 Balancer piston pin 1 7 Balancer piston 1 8 Balancer connecting rod cap 1 9 Balancer big end lower bearing 1 10 Balancer connecting rod 1 11 Balancer big end upper bearing 1 60 Nm 6 0 m kgf 43 ft Ibf T R ...

Page 315: ...ankshaft journal bearings 1 Remove Crankshaft assembly Crankshaft journal bearing 1 TIP Remove the crankshaft journal bearing using the plane bearing installer 2 TIP Identify the position of each crankshaft journal bearing so that it can be reinstalled in its original place EAS30423 CHECKING THE CRANKSHAFT AND CONNECTING RODS 1 Measure Crankshaft runout Out of specification Replace the crank shaft...

Page 316: ...cting rod cap c Put a piece of Plastigauge 1 on the crank shaft pin d Assemble the connecting rod halves TIP Do not move the connecting rod or crankshaft until the clearance measurement has been completed Lubricate the bolts threads and nut seats with molybdenum disulfide grease Make sure the Y mark c on the connecting rod faces towards the left side of the crank shaft Make sure the characters d o...

Page 317: ... of the crankshaft journal bearings NOTICE ECA13920 Do not interchange the crankshaft journal bearings To obtain the correct crankshaft journal to crankshaft journal bearing clear ance and prevent engine damage the crank shaft journal bearings must be installed in their original positions a Clean the crankshaft journal bearings crank shaft journals and bearing portions of the crankcase b Check the...

Page 318: ...J1 J2 TIP The numbers A stamped into the crankshaft web and the numbers B on the crankcase are used to determine the replacement crankshaft journal bearing size J1 J2 refer to the bearings shown in the crank shaft illustration For example if the crankcase J1 and the crankshaft web J1 numbers are 4 and 2 re spectively then the bearing size for J1 is Crankshaft journal diameter 54 984 55 000 mm 2 16...

Page 319: ...nkshaft pins Big end bearings inner surface Balancer big end bearings inner surface with the recommended lubricant 3 Install Big end bearings Connecting rods Connecting rod caps onto the crankshaft pins TIP Align the projections a on the big end bear ings with the notches b in the connecting rods and connecting rod caps Be sure to reinstall each big end bearing in its original place Bearing color ...

Page 320: ... cap 3 c Tighten the connecting rod nuts further to reach the specified angle 90 WARNING EWA13400 If the connecting rod nut is tightened more than the specified angle do not loosen the nut and then retighten it Instead replace the connecting rod bolt and nut with a new one and perform the procedure again NOTICE ECA19930 Do not use a torque wrench to tighten the connecting rod nut to the specified ...

Page 321: ...e specified torque Apply continuous torque between 30 Nm 3 0 m kgf 22 ft lbf and 60 Nm 6 0 m kgf 43 ft lbf without pausing After reaching 30 Nm 3 0 m kgf 22 ft lbf do not stop tightening until the specified torque is achieved If the tightening is interrupted between 30 Nm 3 0 m kgf 22 ft lbf and 60 Nm 6 0 m kgf 43 ft lbf loosen the nut to less than 30 Nm 3 0 m kgf 22 ft lbf and start again EAS3042...

Page 322: ...ty Remarks Crankcase Separate Refer to CRANKCASE on page 5 71 1 Secondary shaft 1 2 Collar 1 3 Primary driven gear 1 4 Main axle 1 TIP When installing main axle install the main axle with groove a facing to the primary driven gear 5 1st pinion gear 1 6 Drive axle 1 7 1st wheel gear 1 8 Circlip 1 ...

Page 323: ...ve part s 3 Check Main axle Cracks damage wear Replace the main axle 4 Measure Drive axle runout with a centering device and dial gauge Out of specification Replace the drive axle 5 Measure Secondary shaft runout with a centering device and dial gauge Out of specification Replace the second ary shaft Drive axle runout limit 0 10 mm 0 0039 in Secondary shaft runout limit 0 120 mm 0 0047 in ...

Page 324: ...TRANSMISSION 5 87 ...

Page 325: ...OLER 6 5 CHECKING THE OIL COOLER 6 7 INSTALLING THE OIL COOLER 6 7 THERMOSTAT 6 8 CHECKING THE THERMOSTAT 6 10 INSTALLING THE THERMOSTAT ASSEMBLY 6 10 WATER PUMP 6 11 DISASSEMBLING THE WATER PUMP 6 14 CHECKING THE WATER PUMP 6 14 ASSEMBLING THE WATER PUMP 6 14 INSTALLING THE WATER PUMP 6 15 ...

Page 326: ... Footboards Refer to GENERAL CHASSIS 2 on page 4 8 Coolant Drain Refer to CHANGING THE COOLANT on page 3 29 1 Coolant reservoir hose 1 2 Coolant reservoir 1 3 Coolant reservoir cap 1 4 Coolant reservoir breather hose 1 5 Radiator cap 1 TIP Remove Install it with the radiator filler pipe held ...

Page 327: ...bleed hose 1 Disconnect 7 Radiator filler pipe 1 8 Radiator filler hose 1 9 Fast idle plunger outlet coolant hose 1 Disconnect 10 Radiator outlet hose 1 Disconnect 11 Radiator fan motor coupler 1 Disconnect 12 Radiator 1 13 Radiator fan 1 14 Radiator inlet hose 1 15 Radiator bracket 1 15 12 14 13 ...

Page 328: ... Radiator fan Damage Replace Malfunction Check and repair Refer to COOLING SYSTEM on page 8 27 EAS30440 INSTALLING THE RADIATOR 1 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 29 2 Check Cooling system Leaks Repair or replace any faulty part a Attach the radiator cap tester 1 and radiator cap tester adapter 2 to the radiator Radia...

Page 329: ...RADIATOR 6 4 b Apply 137 3 kPa 1 37 kgf cm2 19 9 psi of pressure c Measure the indicated pressure with the gauge ...

Page 330: ...arks Storage box Refer to GENERAL CHASSIS 5 on page 4 20 Fuel tank Refer to FUEL TANK on page 7 1 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 26 Coolant Drain Refer to CHANGING THE COOLANT on page 3 29 1 Oil filter cartridge 1 2 Oil cooler inlet hose 1 3 Oil cooler outlet hose 1 ...

Page 331: ... COOLER 6 6 Removing the oil cooler Order Job Parts to remove Q ty Remarks 4 Radiator inlet hose 1 Disconnect 5 Coolant pipe 1 6 Thermostat outlet hose 1 7 Oil filter cartridge union bolt 1 8 Oil cooler 1 ...

Page 332: ... filter cartridge Refer to CHANGING THE ENGINE OIL on page 3 26 4 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 29 Crankcase with the specified amount of the recom mended engine oil Refer to CHANGING THE ENGINE OIL on page 3 26 5 Check Cooling system Leaks Repair or replace any faulty part Refer to INSTALLING THE RADIATOR on page ...

Page 333: ...AL CHASSIS 5 on page 4 20 Fuel tank Refer to FUEL TANK on page 7 1 Coolant Drain Refer to CHANGING THE COOLANT on page 3 29 1 Coolant temperature sensor coupler 1 Disconnect 2 Coolant temperature sensor 1 3 Copper washer 1 4 Cooling system air bleed hose 1 Disconnect 5 Thermostat outlet hose 1 Disconnect 6 Thermostat cover 1 ...

Page 334: ...THERMOSTAT 6 9 Removing the thermostat Order Job Parts to remove Q ty Remarks 7 Thermostat 1 8 Fast idle plunger inlet coolant hose 1 Disconnect 9 Coolant hose 1 Disconnect ...

Page 335: ...uld cause serious overheating or overcooling 2 Check Thermostat cover Cracks damage Replace EAS30445 INSTALLING THE THERMOSTAT ASSEMBLY 1 Install Thermostat TIP Install the thermostat with its breather hole a facing forward 2 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 29 3 Check Cooling system Leaks Repair or replace any faulty...

Page 336: ...oard left Refer to GENERAL CHASSIS 2 on page 4 8 Coolant Drain Refer to CHANGING THE COOLANT on page 3 29 1 V belt case air filter element joint clamp 1 Loosen 2 V belt case air filter element left 1 3 Generator cover protector cover 1 4 Generator cover protector 1 5 Oil cooler inlet hose 1 Disconnect 6 Coolant hose 1 Disconnect ...

Page 337: ...UMP 6 12 Removing the water pump Water or silicone fluid Order Job Parts to remove Q ty Remarks 7 Radiator outlet hose 1 Disconnect 8 Water pump inlet pipe 1 9 Water pump outlet pipe 1 10 Water pump assembly 1 ...

Page 338: ... PUMP 6 13 Disassembling the water pump Order Job Parts to remove Q ty Remarks 1 Water pump housing cover 1 2 Circlip 1 3 Impeller shaft 1 4 Mechanical seal 1 5 Bearing 1 6 Oil seal 1 7 Water pump housing 1 ...

Page 339: ...HE WATER PUMP 1 Check Water pump housing cover 1 Water pump housing 2 Impeller shaft 3 Cracks damage wear Replace 2 Check Water pump inlet pipe Water pump outlet pipe Cracks damage wear Replace EAS30448 ASSEMBLING THE WATER PUMP 1 Install Oil seal 1 Bearing 2 into the water pump housing TIP Before installing the oil seal apply tap water or coolant onto its outer surface Install the oil seal with a...

Page 340: ... If the surface a of the mechanical seal impeller side that contacts the mechanical seal housing side is dirty clean it EAS30449 INSTALLING THE WATER PUMP 1 Install O ring Water pump assembly TIP Align the slit a on the impeller shaft with the projection b on the oil pump shaft Lubricate the O ring with a thin coat of lithium soap based grease Mechanical seal installer 90890 04132 Water pump seal ...

Page 341: ...nt Refer to CHANGING THE COOLANT on page 3 29 3 Check Cooling system Leaks Repair or replace any faulty part Refer to INSTALLING THE RADIATOR on page 6 3 4 Measure Radiator cap opening pressure Below the specified pressure Replace the radiator cap Refer to CHECKING THE RADIATOR on page 6 3 ...

Page 342: ...WATER PUMP 6 17 ...

Page 343: ...ECKING THE ROLLOVER VALVE 7 3 INSTALLING THE FUEL PUMP 7 4 INSTALLING THE FUEL TANK 7 4 INSTALLING THE FUEL HOSE 7 4 CHECKING THE FUEL PRESSURE 7 4 THROTTLE BODY 7 6 REMOVING THE FUEL HOSE INJECTOR SIDE 7 9 CHECKING THE INJECTORS 7 9 CHECKING THE THROTTLE BODY 7 9 INSTALLING THE INJECTORS 7 9 INSTALLING THE FUEL HOSE INJECTOR SIDE 7 10 ADJUSTING THE THROTTLE POSITION SENSOR 7 10 ...

Page 344: ...efer to GENERAL CHASSIS 5 on page 4 20 1 Fuel pump coupler 1 Disconnect 2 Fuel hose connector cover 1 3 Fuel hose 1 Disconnect 4 Fuel tank overflow hose 1 5 Fuel tank breather hose 2 6 Rollover valve 1 7 Fuel tank 1 8 Fuel tank cap 1 9 Filler cover 1 10 Fuel pump bracket 1 11 Fuel pump 1 12 Fuel pump gasket 1 ...

Page 345: ...ty Remarks Storage box Refer to GENERAL CHASSIS 5 on page 4 20 Fuel tank Refer to FUEL TANK on page 7 1 1 Fuel tank breather hose 1 2 Canister purge hose 3 way joint to canister 1 3 Canister purge hose throttle body to 3 way joint 2 4 Canister 1 5 Canister bracket 1 ...

Page 346: ...REMOVING THE FUEL TANK 1 Extract the fuel in the fuel tank through the fuel tank cap with a pump 2 Remove Fuel tank overflow hose Fuel tank breather hoses Rollover valve 3 Disconnect Fuel pump coupler 4 Remove Fuel tank EAS30451 REMOVING THE FUEL PUMP 1 Remove Fuel pump bracket Fuel pump Fuel pump gasket NOTICE ECA14721 Do not drop the fuel pump or give it a strong shock Do not touch the base sect...

Page 347: ... make sure that it is securely connected and that the fuel hose connector cover is in the correct posi tion otherwise the fuel hose will not be prop erly installed TIP Wipe up any fuel remaining in the recess a in the fuel pump with a dry rag 1 After installing the fuel hose connector cover make sure that it is installed securely EAS30703 CHECKING THE FUEL PRESSURE 1 Check Fuel pressure a Remove t...

Page 348: ...nnect the pressure gauge 1 and fuel pressure adapter 2 to the fuel pump and the fuel hose 3 c Start the engine d Measure the fuel pressure Faulty Replace the fuel pump e Push the OFF steering lock switch f Remove the pressure gauge and fuel pres sure adapter TIP Before removing the special tools place a few rags in the area under where they will be re moved Pressure gauge 90890 03153 Pressure gaug...

Page 349: ...nk Refer to FUEL TANK on page 7 1 Coolant Drain Refer to CHANGING THE COOLANT on page 3 29 1 Cylinder head breather hose 1 2 Fast idle plunger intake hose 1 3 Air filter case joint clamp 2 Loosen 4 Air filter case cover 1 5 Air filter element 1 6 Air filter case 1 7 Throttle cable 2 Disconnect 8 Fast idle plunger outlet coolant hose 1 Disconnect 1 2 4 6 8 7 7 3 3 5 ...

Page 350: ...arness cou pler 1 Disconnect 11 Throttle body joint clamp 4 Loosen 12 Throttle body assembly 1 13 Throttle position sensor sub wire harness 1 14 Throttle body joint 2 15 Fuel hose 1 16 Fuel injector coupler 2 Disconnect 17 Fuel rail 1 18 Fuel injector 2 19 Intake air pressure sensor hose 1 Disconnect 20 Intake manifold 1 9 11 14 11 11 14 11 20 18 16 16 15 17 19 13 10 12 18 ...

Page 351: ...ty Remarks TIP Before disassembling the throttle body as sembly make sure to note the number of times the air screw is turned out from the seated position to its set position 1 Throttle position sensor 1 2 Idling speed adjusting screw set 1 3 Plunger 1 4 Plunger spring 1 5 Air screw set 2 ...

Page 352: ...or resistance Refer to CHECKING THE FUEL INJEC TOR on page 8 106 EAS30479 CHECKING THE THROTTLE BODY 1 Check Throttle body Cracks damage Replace 2 Check Fuel passages Obstructions Clean NOTICE ECA21770 Do not adjust the stop screw 1 a Wash the throttle body in a petroleum based solvent Do not use any caustic carburetor cleaning solution b Blow out all of the passages with compressed air EAS30480 I...

Page 353: ...e connector cover 1 on the end of the hose in the direction of the arrow shown It is prohibited to wear the cotton work gloves or equivalent coverings EAS30485 ADJUSTING THE THROTTLE POSITION SENSOR WARNING EWA15950 Handle the throttle position sensor with special care Never subject the throttle position sensor to strong shocks If the throttle position sensor is dropped replace it TIP Before adjus...

Page 354: ...g Adjust the position of the throttle position sen sor angle so that 14 20 can appear in the meter h After adjusting the throttle position sensor an gle tighten the throttle position sensor screws 2 T R Throttle position sensor screw 3 5 Nm 0 35 m kgf 2 5 ft lbf ...

Page 355: ...ROUBLESHOOTING 8 13 LIGHTING SYSTEM 8 15 CIRCUIT DIAGRAM 8 15 TROUBLESHOOTING 8 17 SIGNALING SYSTEM 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 TROUBLESHOOTING METHOD 8 33 YAMAHA DIAGNOSTIC TOOL 8 34 TROUBLESHOOTING DETAILS 8 37 FUEL PUMP SYSTEM 8 63 CI...

Page 356: ...CHECKING THE DIODES 8 98 CHECKING THE SPARK PLUG CAPS 8 98 CHECKING THE IGNITION COIL 8 99 CHECKING THE IGNITION SPARK GAP 8 99 CHECKING THE CRANKSHAFT POSITION SENSOR 8 100 CHECKING THE LEAN ANGLE SENSOR 8 100 CHECKING THE STARTER MOTOR OPERATION 8 101 CHECKING THE STATOR COIL 8 101 CHECKING THE RECTIFIER REGULATOR 8 101 CHECKING THE FUEL SENDER 8 102 CHECKING THE FUEL METER FUEL LEVEL WARNING IN...

Page 357: ......

Page 358: ...B R G R G R G R G L RBr Dg Y Ch G L Y L B W R W R G G Y L Y L Y L W Y R G Br B R G R G R G R G R G R G B L G R L G L G L G B B L G R G R Y R Y R Y R Y Y B R Y Y B R Y Y B Y Y Y B Y B Y Y L L B B Ch Ch Dg Dg Y R Y B B R Y Y BY L L L L L B B B B B B B B B B B Ch Dg Ch Dg Br G Br G B B B B R G Y P B R G R G R G B B B B B B B B B R G R G R G R G R G R G R G Br L L Y R R R B R W W W B Y B L B Gy R R R ...

Page 359: ...ay 14 Ignition fuse 18 Backup fuse 19 Joint coupler 20 Battery 21 Engine ground 22 Main fuse 30 Sidestand switch 31 Handlebar switch right 32 Engine stop switch 36 ECU engine control unit 37 Ignition coil 38 Spark plug 44 Lean angle sensor A Wire harness B Negative battery sub wire harness ...

Page 360: ...lace the battery 3 Check the spark plugs Refer to CHECKING THE SPARK PLUGS on page 3 4 Re gap or replace the spark plugs 4 Check the ignition spark gap Refer to CHECKING THE IGNI TION SPARK GAP on page 8 99 Ignition system is OK 5 Check the spark plug caps Refer to CHECKING THE SPARK PLUG CAPS on page 8 98 Replace the spark plug caps 6 Check the ignition coil Refer to CHECKING THE IGNI TION COIL o...

Page 361: ...r to CHECKING THE SWITCHES on page 8 87 The engine stop switch is faulty Replace the right handlebar switch 11 Check the lean angle sensor Refer to CHECKING THE LEAN ANGLE SENSOR on page 8 100 Replace the lean angle sensor 12 Check the entire ignition system s wiring Refer to CIRCUIT DIAGRAM on page 8 1 Properly connect or replace the wire har ness Replace the ECU or smart key unit ...

Page 362: ... G Y R B B R G R G R G R G L RBr Dg Y Ch G L Y L B W R W R G G Y L Y L Y L W Y R G Br B R G R G R G R G R G R G B L G R L G L G L G B B L G R G R Y R Y R Y R Y Y B R Y Y B R Y Y B Y Y Y B Y B Y Y L L B B Ch Ch Dg Dg Y R Y B B R Y Y BY L L L L L B B B B B B B B B B B Ch Dg Ch Dg Br G Br G B B B B R G Y P B R G R G R G B B B B B B B B B R G R G R G R G R G R G R G Br L L Y R R R B R W W W B Y B L B ...

Page 363: ...ine ground 22 Main fuse 23 Starter relay 24 Starter motor 25 Diode 1 26 Starting circuit cut off relay 27 Sidestand relay 28 Diode 2 30 Sidestand switch 31 Handlebar switch right 32 Engine stop switch 33 ON start switch 35 Front brake light switch 56 Handlebar switch left 61 Rear brake light switch A Wire harness B Negative battery sub wire harness ...

Page 364: ...ch is closed The rear brake lever is pulled to the handlebar the rear brake light switch is closed and the sidestand is up the sidestand switch is closed The starting circuit cut off relay prevents the starter motor from operating when neither of these condi tions has been met In this instance the starting circuit cut off relay is open so current cannot reach the starter motor When at least one of...

Page 365: ...4 Smart key unit 5 Signaling system fuse 6 Ignition fuse 7 Front brake light switch 8 Rear brake light switch 9 Engine stop switch 10 Diode 2 11 Sidestand relay 12 Sidestand switch 13 Starter relay 14 Starter motor 15 Starting circuit cut off relay 16 ON start switch 17 Diode 1 ...

Page 366: ... replace the battery 3 Check the starter motor operation Refer to CHECKING THE START ER MOTOR OPERATION on page 8 101 Starter motor is OK Perform the electric starting system troubleshooting starting with step 5 4 Check the starter motor Refer to CHECKING THE START ER MOTOR on page 5 38 Repair or replace the starter motor 5 Check the smart key system relay Refer to CHECKING THE RE LAYS on page 8 9...

Page 367: ...light switch Refer to CHECKING THE SWITCHES on page 8 87 Replace the front brake light switch 12 Check the rear brake light switch Refer to CHECKING THE SWITCHES on page 8 87 Replace the rear brake light switch 13 Check the ON start switch Refer to CHECKING THE SWITCHES on page 8 87 The ON start switch is faulty Re place the right handlebar switch 14 Check the start diodes diode 1 and 2 Refer to C...

Page 368: ... R G R G R G R G L RBr Dg Y Ch G L Y L B W R W R G G Y L Y L Y L W Y R G Br B R G R G R G R G R G R G B L G R L G L G L G B B L G R G R Y R Y R Y R Y Y B R Y Y B R Y Y B Y Y Y B Y B Y Y L L B B Ch Ch Dg Dg Y R Y B B R Y Y BY L L L L L B B B B B B B B B B B Ch Dg Ch Dg Br G Br G B B B B R G Y P B R G R G R G B B B B B B B B B R G R G R G R G R G R G R G Br L L Y R R R B R W W W B Y B L B Gy R R R R...

Page 369: ...CHARGING SYSTEM 8 12 10 AC magneto 11 Rectifier regulator 20 Battery 21 Engine ground 22 Main fuse A Wire harness B Negative battery sub wire harness ...

Page 370: ...the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 91 Clean the battery terminals Recharge or replace the battery 3 Check the stator coil Refer to CHECKING THE STATOR COIL on page 8 101 Replace the stator coil 4 Check the rectifier regulator Refer to CHECKING THE RECTI FIER REGULATOR on page 8 101 Replace the rectifier regulator 5 Check the entire charging system s wiring Refer to CI...

Page 371: ...CHARGING SYSTEM 8 14 ...

Page 372: ... B R G R G R G R G L RBr Dg Y Ch G L Y L B W R W R G G Y L Y L Y L W Y R G Br B R G R G R G R G R G R G B L G R L G L G L G B B L G R G R Y R Y R Y R Y Y B R Y Y B R Y Y B Y Y Y B Y B Y Y L L B B Ch Ch Dg Dg Y R Y B B R Y Y BY L L L L L B B B B B B B B B B B Ch Dg Ch Dg Br G Br G B B B B R G Y P B R G R G R G B B B B B B B B B R G R G R G R G R G R G R G Br L L Y R R R B R W W W B Y B L B Gy R R R...

Page 373: ...tic tool coupler 53 License plate light 54 Tail brake light assembly 56 Handlebar switch left 57 Pass switch 58 Dimmer switch 63 Headlight relay 66 Auxiliary light 71 Headlight control unit 72 Headlight low 73 Headlight hight 75 Headlight fuse 78 Storage box light 79 Storage box light switch 80 Meter assembly 84 High beam indicator light 88 Multi function meter 89 Meter light A Wire harness B Nega...

Page 374: ...light ignition parking lighting signaling system and back up Refer to CHECKING THE FUS ES on page 8 91 Replace the fuse s 3 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 91 Clean the battery terminals Recharge or replace the battery 4 Check the smart key system relay Refer to CHECKING THE RE LAYS on page 8 94 Replace the smart key system relay 5 Check the dimmer switch Ref...

Page 375: ...fer to CHECKING THE SWITCHES on page 8 87 Replace the storage box light switch 9 Check the entire lighting system s wiring Refer to CIRCUIT DIAGRAM on page 8 15 Properly connect or replace the wire har ness Replace the ECU headlight assembly smart key unit or meter assembly ...

Page 376: ...B B R G R G R G R G L RBr Dg Y Ch G L Y L B W R W R G G Y L Y L Y L W Y R G Br B R G R G R G R G R G R G B L G R L G L G L G B B L G R G R Y R Y R Y R Y Y B R Y Y B R Y Y B Y Y Y B Y B Y Y L L B B Ch Ch Dg Dg Y R Y B B R Y Y BY L L L L L B B B B B B B B B B B Ch Dg Ch Dg Br G Br G B B B B R G Y P B R G R G R G B B B B B B B B B R G R G R G R G R G R G R G Br L L Y R R R B R W W W B Y B L B Gy R R ...

Page 377: ...ke air temperature sensor 41 Yamaha diagnostic tool coupler 45 Speed sensor 50 Fuel sender 54 Tail brake light assembly 55 Tail brake light 56 Handlebar switch left 59 Horn switch 60 Turn signal switch 61 Rear brake light switch 62 Horn 64 Turn signal hazard relay 2 67 Front turn signal position light left 68 Front turn signal position light right 69 Rear turn signal light left 70 Rear turn signal...

Page 378: ...NG OK NG OK NG OK Checking the signaling system The horn fails to sound NG OK 1 Check the fuses Main ignition signaling system parking lightning and backup Refer to CHECKING THE FUS ES on page 8 91 Replace the fuse s 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 91 Clean the battery terminals Recharge or replace the battery 3 Check the smart key system relay Refer to CHE...

Page 379: ...87 Replace the rear brake light switch 3 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 8 19 Properly connect or replace the wire har ness Replace the tail brake light assembly or smart key unit 1 Check the turn signal switch Refer to CHECKING THE SWITCHES on page 8 87 The turn signal switch is faulty Replace the left handlebar switch 2 Check the hazard switch Refer to...

Page 380: ...on page 8 102 Replace the fuel pump assembly 2 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 8 19 Properly connect or replace the wire har ness Replace the meter assembly 1 Check the coolant temperature sen sor Refer to CHECKING THE COOL ANT TEMPERATURE SENSOR on page 8 103 Replace the coolant temperature sensor 2 Check the entire signaling system wiring Refer to CIRC...

Page 381: ...8 100 Replace the stator coil 2 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 8 19 Properly connect or replace the wire har ness Replace the ECU or meter assembly 1 Check the air temperature sensor Refer to CHECKING THE INTAKE AIR TEMPERATURE SENSOR on page 8 105 Replace the intake air temperature sensor 2 Check the entire signaling system wiring Refer to CIRCUIT DIAGRA...

Page 382: ...e buzzer sounds when the ON start switch or OFF steering lock switch is pushed Perform the signaling system troubleshoot ing starting with step 3 2 Check the sidestand switch Refer to CHECKING THE SWITCHES on page 8 87 Replace the sidestand switch 3 Check the buzzer Refer to CHECKING THE BUZZ ER on page 8 107 Replace the buzzer 4 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM on...

Page 383: ...SIGNALING SYSTEM 8 26 ...

Page 384: ...B R G R G R G R G L RBr Dg Y Ch G L Y L B W R W R G G Y L Y L Y L W Y R G Br B R G R G R G R G R G R G B L G R L G L G L G B B L G R G R Y R Y R Y R Y Y B R Y Y B R Y Y B Y Y Y B Y B Y Y L L B B Ch Ch Dg Dg Y R Y B B R Y Y BY L L L L L B B B B B B B B B B B Ch Dg Ch Dg Br G Br G B B B B R G Y P B R G R G R G B B B B B B B B B R G R G R G R G R G R G R G Br L L Y R R R B R W W W B Y B L B Gy R R R ...

Page 385: ... 18 Backup fuse 19 Joint coupler 20 Battery 21 Engine ground 22 Main fuse 36 ECU engine control unit 39 Coolant temperature sensor 41 Yamaha diagnostic tool coupler 51 Radiator fan motor relay 52 Radiator fan motor 80 Meter assembly 88 Multi function meter A Wire harness B Negative battery sub wire harness ...

Page 386: ...replace the battery 3 Check the smart key system relay Refer to CHECKING THE RE LAYS on page 8 94 Replace the smart key system relay 4 Check the radiator fan motor Refer to CHECKING THE RADIA TOR FAN MOTOR on page 8 103 Replace the radiator fan motor 5 Check the radiator fan motor relay Refer to CHECKING THE RE LAYS on page 8 94 Replace the radiator fan motor relay 6 Check the coolant temperature ...

Page 387: ...COOLING SYSTEM 8 30 ...

Page 388: ... Y R B B R G R G R G R G L RBr Dg Y Ch G L Y L B W R W R G G Y L Y L Y L W Y R G Br B R G R G R G R G R G R G B L G R L G L G L G B B L G R G R Y R Y R Y R Y Y B R Y Y B R Y Y B Y Y Y B Y B Y Y L L B B Ch Ch Dg Dg Y R Y B B R Y Y BY L L L L L B B B B B B B B B B B Ch Dg Ch Dg Br G Br G B B B B R G Y P B R G R G R G B B B B B B B B B R G R G R G R G R G R G R G Br L L Y R R R B R W W W B Y B L B Gy...

Page 389: ...it 37 Ignition coil 38 Spark plug 39 Coolant temperature sensor 40 Intake air temperature sensor 41 Yamaha diagnostic tool coupler 42 Intake air pressure sensor 43 Throttle position sensor 44 Lean angle sensor 45 Speed sensor 46 Fuel injector 1 47 Fuel injector 2 48 O2 sensor 51 Radiator fan motor relay 63 Headlight relay 71 Headlight control unit 72 Headlight low 73 Headlight high 80 Meter assemb...

Page 390: ...r around 2 seconds after the ON start switch is pushed If the warning light does not come on under these conditions the warning light LED may be defective ECU detects an abnormal signal from a sensor If the ECU detects an abnormal signal from a sensor while the vehicle is being driven the ECU illumi nates the engine trouble warning light and provides the engine with alternate operating instruction...

Page 391: ... Refer to TROU BLESHOOTING DETAILS on page 8 37 If a malfunction is detected in the sensors or actuators repair or replace all faulty parts If no malfunction is detected in the sensors and actuators check and repair the inner parts of the engine EAS30951 YAMAHA DIAGNOSTIC TOOL This model uses the Yamaha diagnostic tool to identify malfunctions For information about using the Yamaha diagnostic tool...

Page 392: ...e the operation of the multi function meter and indicators will be different from the normal operation Operation of the Yamaha diagnostic tool Malfunction mode Malfunction results are displayed in the top part of the window area Fault diagnosis mode Fault codes recorded on the ECU are read and the contents are dis played Function diagnostic mode Check the operation of the output value of each sens...

Page 393: ...list of the malfunction currently occurred are displayed 3 Code The following icons and the fault code numbers for the detected malfunctions are displayed 4 ECU The types of the control units are displayed 5 Item The item names of the detected malfunction are displayed 2 3 1 4 5 6 7 8 9 10 11 12 A B A Detected malfunction B Recovered malfunction ...

Page 394: ...mponents that are the probable cause of the malfunction following the order given After the check and service of the malfunctioning part have been completed reset the meter display according to the reinstatement method Fault code No Fault code number displayed on the meter when the engine failed to work normally Diagnostic code No Diagnostic code number to be used when the diagnostic mode is opera...

Page 395: ...pinch ing Check the gap between the crankshaft position sensor and the pickup rotor Incorrect installation Reinstall the sensor Refer to GENERATOR AND STARTER CLUTCH on page 5 52 Crank the engine and check the fault code indication No fault code indicated Ser vice is finished Fault code indicated Go to item 5 5 Crankshaft position sensor mal function Sensor inspection procedure Refer to CHECKING T...

Page 396: ...t code indicated Ser vice is finished Fault code indicated Go to item 3 3 Continuity of wire harness Open or short circuit Replace the wire harness Between intake air pressure sensor coupler and ECU cou pler Pink White Pink White Between intake air pressure sensor coupler and joint cou pler Black Blue Black Blue Blue Blue Between joint coupler and ECU coupler Black Blue Black Blue Blue Blue Push t...

Page 397: ...n Sensor malfunction Replace the in take air pressure sensor Confirmation of service comple tion Refer to CHECKING THE IN TAKE AIR PRESSURE SEN SOR on page 8 105 Push the ON start switch and check the fault code indication No fault code indicated Ser vice is finished Fault code indicated Go to item 6 6 ECU malfunction Replace the ECU Fault code No 13 Item Intake air pressure sensor open or short c...

Page 398: ...ea lev el Approx 90 kPa 675 1 mmHg 26 6 inHg 2000 m 6700 ft above sea lev el Approx 80 kPa 600 0 mmHg 23 6 inHg 3000 m 9800 ft above sea lev el Approx 70 kPa 525 0 mmHg 20 7 inHg When engine is cranking Make sure that the indication value changes The value does not change when engine is cranking Re place the intake air pressure sensor Confirmation of service comple tion Refer to CHECKING THE IN TA...

Page 399: ...r bending wear or locking Poor connection Connect it securely or replace the wire harness Push the ON start switch and check the fault code indication No fault code indicated Ser vice is finished Fault code indicated Go to item 4 4 Continuity of wire harness Open or short circuit Replace the wire harness Between throttle position sensor coupler and sub wire harness coupler Black Blue Black Blue Ye...

Page 400: ...diagnostic mode Code No 01 When throttle is fully closed A value of 14 20 is indicated When throttle is fully open A value of 97 107 is indicated If the indication is outside of range Replace the throttle position sensor Push the ON start switch and check the fault code indication No fault code indicated Ser vice is finished Fault code indicated Go to item 8 8 ECU malfunction Replace the ECU Fault...

Page 401: ... Sidestand switch a break or disconnection of the light green lead of the ECU is detected Fail safe system Unable to start engine Unable to drive vehicle Diagnostic code No 20 Indicated Sidestand switch ON sidestand retracted OFF sidestand extended Procedure Extend and retract the sidestand Item Probable cause of malfunc tion and check Maintenance job Confirmation of service com pletion 1 Connecti...

Page 402: ...ndicated Ser vice is finished Fault code indicated Go to item 5 5 Sidestand switch malfunction Check in the diagnostic mode Code No 20 Sidestand retracted ON indica tion Sidestand extended OFF indi cation Indication is incorrect Re place the sidestand switch Push the ON start switch and check the fault code indication when the side stand is retracted and extended No fault code indicated Ser vice i...

Page 403: ... Red Between coolant temperature coupler and joint coupler Black Blue Black Blue Between joint coupler and ECU coupler Black Blue Black Blue Push the ON start switch and check the fault code indication No fault code indicated Ser vice is finished Fault code indicated Go to item 4 4 Installation status of coolant temperature sensor Check the mounting section for a loose or pinched mounting Make sur...

Page 404: ...item 2 2 Connection of wire harness ECU coupler Check the locking condition of the coupler Disconnect the coupler and check each pin for bending wear or locking Poor connection Connect it securely or replace the wire harness Push the ON start switch and check the fault code indication No fault code indicated Ser vice is finished Fault code indicated Go to item 3 3 Continuity of wire harness Open o...

Page 405: ...ce job Confirmation of service com pletion 1 O2 sensor installation status Check the sensor for a loose mounting or a pinch Either start and warm up the en gine and then racing it or reset it with diagnostic code No 63 No fault code indicated Ser vice is finished Fault code indicated Go to item 2 2 Connection of O2 sensor cou pler Check the locking condition of the coupler Disconnect the coupler a...

Page 406: ...nostic code No 63 No fault code indicated Ser vice is finished Fault code indicated Go to item 6 6 O2 sensor malfunction Check the O2 sensor for an ab normality Refer to ENGINE REMOVAL on page 5 2 O2 sensor malfunction Re place the O2 sensor Either start and warm up the en gine and then racing it or reset it with diagnostic code No 63 No fault code indicated Ser vice is finished Fault code indicat...

Page 407: ...of service comple tion Refer to CHECKING THE LEAN ANGLE SENSOR on page 8 100 In vertical position 0 4 1 4 V When turned over 3 7 4 4 V Indication is incorrect Re place the lean angle sensor Push the ON start switch then push the OFF steering lock switch and then push the ON start switch again Then check the fault code indication No fault code indicated Ser vice is finished Fault code indicated Go ...

Page 408: ...p proximately 5 seconds Then check the fault code indi cation No fault code indicated Ser vice is finished Fault code indicated Go to item 3 3 Continuity of wire harness Open or short circuit Replace the wire harness Between ignition coil coupler and ECU coupler Orange Orange Start and idle the engine for ap proximately 5 seconds Then check the fault code indi cation No fault code indicated Ser vi...

Page 409: ...le valve does not fully close Check the throttle body Refer to THROTTLE BODY on page 7 6 Check the throttle cables Refer to CHECKING THE THROTTLE GRIP on page 3 32 Start and idle the engine for ap proximately 10 seconds Then check the fault code indication No fault code indicated Ser vice is finished Fault code indicated Go to item 3 3 Stuck fast idle plunger detected Check the throttle body Refer...

Page 410: ...er vice is finished Fault code indicated Go to item 3 3 Continuity of wire harness Open or short circuit Replace the wire harness Between lean angle sensor cou pler and ECU coupler Yellow Green Yellow Green Between lean angle sensor cou pler and joint coupler Black Blue Black Blue Blue Blue Between joint coupler and ECU coupler Black Blue Black Blue Blue Blue Push the ON start switch then push the...

Page 411: ...ection of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the coupler securely or re place the wire harness Execute the diagnostic mode Code No 07 Rotate the front wheel by hand and check that the indicated val ue increases Value increases Service is finished Va...

Page 412: ...rness ECU coupler Check the locking condition of the coupler Disconnect the coupler and check each pin for bending wear or locking Poor connection Connect it securely or replace the wire harness Start and idle the engine for ap proximately 5 seconds Then check the fault code indi cation No fault code indicated Ser vice is finished Fault code indicated Go to item 3 3 Continuity of wire harness Open...

Page 413: ...ault code No 44 Item EEPROM fault code number an error is detected while reading or writing on EEPROM Fail safe system Under certain conditions Under certain conditions Diagnostic code No 60 Indicated EEPROM fault code display 00 no history 01 or 02 Cylinder fault code number history exists If both cylinders are defective the display alternates every two sec onds Procedure Item Probable cause of m...

Page 414: ...on and check Maintenance job Confirmation of service com pletion 1 ECU malfunction Replace the ECU Push the ON start switch Then check that no fault code indicated Fault code No Er 1 fault code display Item ECU engine control unit internal malfunction output signal error signals cannot be transmitted between the ECU and the multi func tion meter Fail safe system Able to start engine Unable if ECU ...

Page 415: ...it operation Replace the meter assembly Push the ON start switch and check the fault code indication No fault code indicated Ser vice is finished Fault code indicated Go to item 5 5 ECU malfunction Replace the ECU Fault code No Er 1 fault code display Item ECU engine control unit internal malfunction output signal error signals cannot be transmitted between the ECU and the multi func tion meter Fa...

Page 416: ...em 4 4 Abnormal meter unit operation Replace the meter assembly Push the ON start switch and check the fault code indication No fault code indicated Ser vice is finished Fault code indicated Go to item 5 5 ECU malfunction Replace the ECU Fault code No Er 2 Item ECU engine control unit internal malfunction output signal error no signals are received from the ECU within the specified duration Fault ...

Page 417: ...Go to item 4 4 Abnormal meter unit operation Replace the meter assembly Push the ON start switch and check the fault code indication No fault code indicated Ser vice is finished Fault code indicated Go to item 5 5 ECU malfunction Replace the ECU Fault code No Er 4 fault code display Item ECU engine control unit internal malfunction input signal error non registered data has been received from the ...

Page 418: ... joint coupler Yellow Blue Yellow Blue Between joint coupler and Yamaha diagnostic coupler Yellow Blue Yellow Blue Between Yamaha diagnostic coupler and ECU coupler Yellow Blue Yellow Blue Push the ON start switch and check the fault code indication No fault code indicated Ser vice is finished Fault code indicated Go to item 4 4 Abnormal meter unit operation Replace the meter assembly Push the ON ...

Page 419: ...FUEL INJECTION SYSTEM 8 62 ...

Page 420: ...B B R G R G R G R G L RBr Dg Y Ch G L Y L B W R W R G G Y L Y L Y L W Y R G Br B R G R G R G R G R G R G B L G R L G L G L G B B L G R G R Y R Y R Y R Y Y B R Y Y B R Y Y B Y Y Y B Y B Y Y L L B B Ch Ch Dg Dg Y R Y B B R Y Y BY L L L L L B B B B B B B B B B B Ch Dg Ch Dg Br G Br G B B B B R G Y P B R G R G R G B B B B B B B B B R G R G R G R G R G R G R G Br L L Y R R R B R W W W B Y B L B Gy R R ...

Page 421: ... fuse 17 Fuel injection system fuse 18 Backup fuse 19 Joint coupler 20 Battery 21 Engine ground 22 Main fuse 29 Fuel injection system relay 31 Handlebar switch right 32 Engine stop switch 36 ECU engine control unit 49 Fuel pump A Wire harness B Negative battery sub wire harness ...

Page 422: ...eplace the battery 3 Check the engine stop switch Refer to CHECKING THE SWITCHES on page 8 87 The engine stop switch is faulty Replace the right handlebar switch 4 Check the smart key system relay Refer to CHECKING THE RE LAYS on page 8 94 Replace the smart key system relay 5 Check the fuel injection system re lay Refer to CHECKING THE RE LAYS on page 8 94 Replace the fuel injection system relay 6...

Page 423: ...FUEL PUMP SYSTEM 8 66 ...

Page 424: ...B B R G R G R G R G L RBr Dg Y Ch G L Y L B W R W R G G Y L Y L Y L W Y R G Br B R G R G R G R G R G R G B L G R L G L G L G B B L G R G R Y R Y R Y R Y Y B R Y Y B R Y Y B Y Y Y B Y B Y Y L L B B Ch Ch Dg Dg Y R Y B B R Y Y BY L L L L L B B B B B B B B B B B Ch Dg Ch Dg Br G Br G B B B B R G Y P B R G R G R G B B B B B B B B B R G R G R G R G R G R G R G Br L L Y R R R B R W W W B Y B L B Gy R R ...

Page 425: ...4 Hazard switch 36 ECU engine control unit 41 Yamaha diagnostic tool coupler 56 Handlebar switch left 60 Turn signal switch 64 Turn signal hazard relay 2 67 Front turn signal position light left 68 Front turn signal position light right 69 Rear turn signal light left 70 Rear turn signal light right 78 Storage box light 79 Storage box light switch 80 Meter assembly 81 Smart key indicator light 82 T...

Page 426: ...NG THE BATTERY on page 8 91 Clean the battery terminals Recharge or replace the battery 3 Check the smart key switch assem bly Refer to CHECKING THE SWITCHES on page 8 87 Replace the smart key switch assembly 4 Check the smart key system relay Refer to CHECKING THE RE LAYS on page 8 94 Replace the smart key system relay 5 Check the smart key The smart key indicator light comes on when the ON OFF s...

Page 427: ...operated in the emer gency mode Replace the smart key or smart key unit The vehicle cannot be turned on in the emergency mode but the storage box light comes on when the seat is opened Replace the smart key unit The storage box light does not come on when the seat is opened Replace the seat or storage box light 3 The smart key system indicator light flashes The indicator light flashes once ev ery ...

Page 428: ...electro magnetic waves in the vicinity Move the vehicle Smart key malfunction Register and use a different smart key Smart key unit malfunction Re place the smart key unit 1 When the vehicle power is turned on the smart key system indicator light flashes Refer to SMART KEY SYSTEM SELF DIAGNOSIS on page 8 72 Check and repair the electric starting sys tem Refer to ELECTRIC STARTING SYSTEM on page 8 ...

Page 429: ...OSIS on page 8 72 The seat can be opened There is a sensor malfunction in the seat lock solenoid Replace the smart key unit The seat cannot be opened Check the mechanical components of the lock for malfunctions Repair or replace any defective parts Adjust or replace the seat lock cable Check the seat lock solenoid Re fer to CHECKING THE SEAT LOCK SOLENOID on page 8 107 Re place the smart key unit ...

Page 430: ... and the battery is not dis charged Running detection er ror a LED on b LED off Flashes continuously until the error is re solved The smart key cannot be recognized Check that there are no sources of strong elec tromagnetic waves in the vicinity the smart key is not lost and the battery is not dis charged Steering lock is stuck Steering lock cannot be released a LED on b LED off 20 seconds 10 time...

Page 431: ...IP These fault code numbers are not stored in the memory of the ECU Note all of the displayed fault code numbers and then check the vehicle ECU communication error Data error ECU malfunction a LED on b LED off Flashes continuously until the error is re solved flashes 4 times in a repeating cycle Check the wire harness Check the ECU Check the smart key unit Fault code No 53 54 or 56 is displayed on...

Page 432: ...unit Codes transmitted be tween the ECU and the smart key unit do not match Radio wave noise inter ference or disconnect ed lead Obstruction due to ra dio wave noise Disconnection in the wire harness Defective ECU when the ECU or smart key unit is replaced with a unit from a different vehicle Defective smart key unit Register the smart key Check the wire har ness Replace the ECU Replace the smart ...

Page 433: ...on for 3 seconds 6 After the smart key system indicator light goes off use the seat open parking switch to enter the smart key identification number 1 located inside the smart key case open the smart key case as shown or the identification number 2 located on the key tag Refer to the following procedure on how to input the identification number 7 The input identification number is indicated by the...

Page 434: ...tor light will come on for 10 seconds if the correct 6 digit identifica tion number was entered 9 Press the ON start switch while the smart key system indicator light is on to turn on the vehicle power TIP If the identification number is not correctly entered the smart key system indicator light will flash quickly for 3 seconds and the emergency mode will become deactivated If the emergency mode i...

Page 435: ...he number of currently registered smart keys For example if 5 smart keys are regis tered the indicator light flashes 5 times 5 While the smart key indicator light is on for 10 seconds push the ON OFF switch on the smart key to transmit a signal from the smart key to the smart key unit 6 If the smart key is registered successfully the smart key system indicator light will come on for 3 seconds and ...

Page 436: ... want to enable and place them within 80 cm 31 5 in of the smart key unit 6 Push the OFF steering lock switch 1 time to start the communication between the smart key unit and the smart keys that are located within 80 cm 31 5 in of the unit TIP The number of smart keys that currently can be used will be indicated Number of flashes Number of verified smart keys 1 cycle of on for 0 3 second and off f...

Page 437: ...n push the ON start switch to check that the op eration is correct TIP An identification number is not written to the steering lock unit when it is shipped from the factory When the vehicle system is turned on for the first time the smart key unit identification number and smart key identification number are automatically registered from the smart key unit to the steering lock unit EAS31541 REPLAC...

Page 438: ...number is automatically registered to the steering lock unit and ECU Smart key unit ECU When the vehicle system is turned on the smart key identifi cation number is automatically registered to the smart key unit and ECU Smart key unit Steering lock unit The original smart keys can be used if they are registered as ad ditional smart keys Replace the smart key smart key unit steer ing lock unit and ...

Page 439: ...smart key identifi cation number is automatically registered to the steering lock unit and ECU Faulty part Required item when re placing parts Replacement parts when an item is required in order to replace parts Remarks Required Replace Smart key identifi cation number or smart key is re quired Do not replace Not required This part must be replaced even if it is not faulty Smart key identifica tio...

Page 440: ...ELECTRICAL COMPONENTS 8 83 EAS20089 ELECTRICAL COMPONENTS 16 17 18 19 20 22 23 24 25 15 13 12 11 10 14 26 27 28 9 8 7 6 5 4 3 2 1 21 ...

Page 441: ...9 Starter relay 10 Battery 11 Starting circuit cut off relay 12 Sidestand relay 13 Fuel injection system relay 14 Diode 1 15 Diode 2 16 Horn 17 Rectifier regulator 18 Headlight control unit 19 Seat open relay 20 Radiator fan motor relay 21 Turn signal hazard relay 2 22 Smart key system relay 23 Headlight relay 24 Buzzer 25 Lean angle sensor 26 Diode 4 27 Smart key unit 28 ECU engine control unit ...

Page 442: ...ELECTRICAL COMPONENTS 8 85 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 ...

Page 443: ...take air pressure sensor 4 Fuel injector 5 Coolant temperature sensor 6 Fuel pump 7 Seat lock solenoid 8 O2 sensor 9 Crankshaft position sensor 10 AC magneto 11 Sidestand switch 12 Spark plug 13 Radiator fan motor 14 Speed sensor 15 Ignition coil 16 Throttle position sensor ...

Page 444: ...AS30549 CHECKING THE SWITCHES OFF ON N L W B Dg G Y Ch R W Br W B Br R B L G R B B L G L B Y Br W Br B Y R Dg L B Ch L Y B L W B R B R W Br WDg Ch Y Y Br W Br P R Dg L B Ch B Y L Y L G B B B G Y Br R L G 11 7 8 9 10 12 1 2 3 4 5 6 ...

Page 445: ...tch 2 Dimmer switch 3 Horn switch 4 Turn signal switch 5 Rear brake light switch 6 Smart key switch assembly 7 Engine stop switch 8 ON start switch 9 Hazard switch 10 Front brake light switch 11 Sidestand switch 12 Storage box light switch ...

Page 446: ...the pocket tester to 0 and to the Ω 1 range When checking for continuity switch back and forth between the switch positions a few times The switches and their terminal connections are illustrated as in the following example of the ON start switch The switch positions a are shown in the far left column and the switch lead colors b are shown in the top row The continuity i e a closed circuit between...

Page 447: ...r hands away from them until they have cooled down NOTICE ECA14381 Be sure to hold the socket firmly when re moving the bulb Never pull the lead other wise it may be pulled out of the terminal in the coupler Avoid touching the glass part of a headlight bulb to keep it free from oil otherwise the transparency of the glass the life of the bulb and the luminous flux will be adverse ly affected If the...

Page 448: ...ly blows again check the electrical circuit WARNING EWA13310 Never use a fuse with an amperage rating other than that specified Improvising or us ing a fuse with the wrong amperage rating may cause extensive damage to the electri cal system cause the lighting and ignition systems to malfunction and could possibly cause a fire 4 Install Front cover Refer to GENERAL CHASSIS 1 on page 4 1 EAS30552 CH...

Page 449: ...d Acid bat teries are sealed it is not possible to check the charge state of the battery by measuring the specific gravity of the electrolyte Therefore the charge of the battery has to be checked by mea suring the voltage at the battery terminals 1 Remove Inner panel cover left side Refer to GENERAL CHASSIS 3 on page 4 13 2 Disconnect Battery leads from the battery terminals NOTICE ECA13640 First ...

Page 450: ...cess dis connect the battery charger and let the bat tery cool before reconnecting it Hot batteries can explode As shown in the following illustration the open circuit voltage of a VRLA Valve Reg ulated Lead Acid battery stabilizes about 30 minutes after charging has been com pleted Therefore wait 30 minutes after charging is completed before measuring the open circuit voltage Charging method usin...

Page 451: ...le voltage charger is recommended d Charge the battery until the battery s charg ing voltage is 15 V TIP Set the charging time at 20 hours maximum e Measure the battery open circuit voltage after leaving the battery unused for more than 30 minutes 6 Install Battery Refer to GENERAL CHASSIS 3 on page 4 13 7 Connect Battery leads to the battery terminals NOTICE ECA13630 First connect the positive ba...

Page 452: ...tester probe Result Continuity between 3 and 4 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 G B L W R G G W 1 2 B 1 Positive tester probe 2 Negative tester probe 3 Negative tester probe Result Continuity between 1 and 2 No continuity between 1 and 3 1 Positive battery terminal 2 Negative battery terminal 3...

Page 453: ... 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 1 Positive battery terminal Lg G Y G W L Y 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 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 termina...

Page 454: ...tion Replace a Connect the pocket tester DC 20 V to the turn signal hazard relay 2 terminal as shown 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 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 Turn signal hazard rela...

Page 455: ...e reversed EAS30557 CHECKING THE SPARK PLUG CAPS The following procedure applies to all of the spark plug caps 1 Check Spark plug cap resistance Out of specification Replace a Remove the spark plug cap from the spark plug lead b Connect the pocket tester Ω 1k to the spark plug cap as shown Pocket tester 90890 03112 Analog pocket tester YU 03112 C Diode 2 Continuity Positive tester probe Blue Yello...

Page 456: ...SPARK GAP 1 Check Ignition spark gap Out of specification Perform the ignition system troubleshooting starting with step 5 Refer to TROUBLESHOOTING on page 8 3 TIP If the ignition spark gap is within specification the ignition system circuit is operating normally a Disconnect the spark plug cap from the spark plug b Connect the ignition checker 1 as shown Pocket tester 90890 03112 Analog pocket te...

Page 457: ...Remove Lean angle sensor from the bracket 2 Check Lean angle sensor output voltage Out of specification Replace a Connect the test harness lean angle sensor 6P 1 to the lean angle sensor and wire harness as shown b Connect the pocket tester DC 20 V to the test harness lean angle sensor 6P Ignition checker 90890 06754 Oppama pet 4000 spark checker YM 34487 2 Spark plug cap Crankshaft position senso...

Page 458: ...luid is in the vicinity b Check the starter motor operation EAS30566 CHECKING THE STATOR COIL 1 Disconnect Stator coil coupler from the wire harness 2 Check Stator coil resistance Out of specification Replace the stator coil a Connect the digital circuit tester CD 731a Ω 1 to the stator coil coupler as shown b Measure the stator coil resistance EAS30680 CHECKING THE RECTIFIER REGULATOR 1 Check Bat...

Page 459: ...UEL TANK on page 7 1 EAS31557 CHECKING THE FUEL METER FUEL LEVEL WARNING INDICATOR This model is equipped with a self diagnosis de vice for the fuel level detection circuit 1 Check Fuel meter fuel level warning indicator 1 Push the ON start switch Fuel meter fuel level warning indicator comes on for a few seconds then goes off Fuel meter fuel level warning indicator is OK Fuel meter fuel level war...

Page 460: ...OR 1 Check Radiator fan motor Faulty rough movement Replace a Disconnect the radiator fan motor coupler from the wire harness b Connect the battery DC 12 V as shown c Measure the radiator fan motor movement EAS30578 CHECKING THE COOLANT TEMPERATURE SENSOR 1 Remove Coolant temperature sensor Refer to THERMOSTAT on page 6 8 WARNING EWA14130 Handle the coolant temperature sensor with special care Nev...

Page 461: ...ition sensor as shown b Measure the throttle position sensor maxi mum resistance Out of specification Replace the throttle position sensor c Connect the pocket tester Ω 1 k to the throttle position sensor as shown d While slowly turning the throttle position sen sor shaft check that the throttle position sen sor resistance is within the specified range Coolant temperature sensor re sistance 2320 2...

Page 462: ...SENSOR 1 Remove Intake air temperature sensor from the air filter case WARNING EWA14110 Handle the intake air temperature sensor with special care Never subject the intake air temperature sensor to strong shocks If the intake air temperature sensor is dropped replace it 2 Check Intake air temperature sensor resistance Out of specification Replace a Connect the pocket tester Ω 1k 100 to the intake ...

Page 463: ...ter Ω 1 to the fuel injector coupler c Measure the fuel injector resistance EAS31553 CHECKING THE SMART KEY BATTERY 1 Check Smart key battery voltage Out of specification Replace the smart key battery a Remove the smart key battery from the smart key b Connect the pocket tester DC 20 V to the smart key battery as shown c Measure the smart key battery voltage T R Intake air temperature sensor bolt ...

Page 464: ...Measure the seat lock solenoid resistance EAS31555 CHECKING THE BUZZER 1 Check Buzzer operation Buzzer does not sound Replace a Disconnect the buzzer coupler from the wire harness b Connect the battery 12 V to the buzzer cou pler as shown c Check that the buzzer sounds Seat lock solenoid resistance 2 85 3 15 Ω Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe Yellow 1...

Page 465: ... OVERHEATING 9 2 OVERCOOLING 9 3 POOR BRAKING PERFORMANCE 9 3 FAULTY FRONT FORK LEGS 9 3 UNSTABLE HANDLING 9 3 FAULTY LIGHTING OR SIGNALING SYSTEM 9 4 SELF DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE 9 5 SELF DIAGNOSTIC FUNCTION TABLE 9 5 COMMUNICATION ERROR WITH THE METER OR YAMAHA DIAGNOSTIC TOOL 9 5 DIAGNOSTIC CODE SENSOR OPERATION TABLE 9 6 DIAGNOSTIC CODE ACTUATOR OPERATION TABLE 9 8 ...

Page 466: ...d fuel hose 2 Fuel pump Faulty fuel pump Faulty fuel injection system relay Damaged vacuum hose Improperly routed hose 3 Throttle body Deteriorated or contaminated fuel Sucked in air Electrical system 1 Battery Discharged battery Faulty battery 2 Fuse s Blown damaged or incorrect fuse Improperly installed fuse 3 Spark plug s Incorrect spark plug gap Incorrect spark plug heat range Fouled spark plu...

Page 467: ... belt Slipping V belt 2 Primary pulley cam and primary pulley slider Damaged or worn primary pulley cam Damaged or worn primary pulley slider 3 Clutch spring s Damaged clutch spring 4 Transmission gear s Damaged transmission gear Clutch slips 1 Clutch Improperly assembled clutch Fatigued clutch spring Worn clutch weight Worn friction plate Worn clutch plate 2 Engine oil Incorrect oil level Incorre...

Page 468: ...TY FRONT FORK LEGS Leaking oil Bent damaged or rusty inner tube Cracked or damaged outer tube Improperly installed oil seal Damaged oil seal lip Incorrect oil level high Loose damper rod bolt Damaged damper rod bolt copper washer Cracked or damaged cap bolt O ring Malfunction Bent or damaged inner tube Bent or damaged outer tube Damaged fork spring Worn or damaged outer tube bushing Bent or damage...

Page 469: ...smart key system relay Faulty smart key unit Turn signal does not come on Faulty turn signal switch Faulty turn signal hazard relay Burnt out turn signal bulb Incorrect connection Damaged or faulty wire harness Improperly grounded circuit Faulty battery Blown damaged or incorrect fuse Turn signal blinks slowly Faulty turn signal hazard relay Faulty smart key unit Faulty turn signal switch Incorrec...

Page 470: ...ensor no normal signals are received from the O2 sensor 30 Latch up detected 33 Ignition coil open or short circuit detected 37 Fast idle plunger engine speed is high when the engine is idling 41 Lean angle sensor open or short circuit detected 42 Speed sensor no normal signals are received from the speed sensor 43 Fuel system voltage incorrect voltage supplied to the fuel injection system relay f...

Page 471: ...er display value 06 Coolant temperature When engine is cold Dis plays temperature closer to air temperature When engine is hot Displays current coolant temperature Compare the actually mea sured coolant temperature with the meter display value 07 Speed sensor pulses Speed sensor pulse 0 999 Check that the number in creases when the front wheel is rotated The num ber is cumulative and does not rese...

Page 472: ...o seconds to show all the detected code numbers When all code numbers are shown the display repeats the same process 62 Malfunction history code era sure No history 00 History exists Displays the total number of malfunctions including the current malfunction that have occurred since the history was last erased For example if there have been three malfunctions 03 is displayed Save the malfunction h...

Page 473: ...e on each time the fuel injector is actuated Disconnect the fuel pump coupler Check that fuel injector 2 is actuated five times by listen ing for the operating sound 50 Fuel injection system relay Actuates the fuel injection system relay five times at one second intervals The CHECK indicator and on the Yamaha diag nostic tool screen come on each time the fuel pump is actuated Check that the fuel i...

Page 474: ... Turn signal switch 61 Rear brake light switch 62 Horn 63 Headlight relay 64 Turn signal hazard relay 2 65 Diode 3 66 Auxiliary light 67 Front turn signal position light left 68 Front turn signal position light right 69 Rear turn signal light left 70 Rear turn signal light right 71 Headlight control unit 72 Headlight low 73 Headlight high 74 Diode 4 75 Headlight fuse 76 Auxiliary DC jack fuse 77 A...

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Page 477: ... G L RBr Dg Y Ch G L Y L B W R W R G G Y L Y L Y L W Y R G Br B R G R G R G R G R G R G B L G R L G L G L G B B L G R G R Y R Y R Y R Y Y B R Y Y B R Y Y BY Y Y B Y BY Y L L B B Ch Ch Dg Dg Y R Y B B R Y Y BY L L L L L L L L L B B B B B B B B B B B Ch Dg Ch Dg Br G G Br Br G B B B B R G Y P B R G R G R G B B B B B B B B B R G R G R G R G R G R G R G Br L L Y R R R B R W W W B Y B L B Gy R R R R R ...

Page 478: ... 68 D A A A C D D B A C A B B 1 2 3 4 5 6 7 8 9 10 11 12 19 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 13 14 15 16 17 18 19 19 19 19 19 19 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 66 69 70 71 71 72 73 72 73 74 75 76 77 78 79 80 81 82 83 85 86 87 88 89 84 90 19 19 19 ...

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Summary of Contents for TMAX XP500F 2015

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Yamaha TMAX XP500F 2015, Service Manual, Page: 268 / 478

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Summary of Contents for TMAX XP500F 2015

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