Yamaha TRACER MT09 TRA Service Manual Download Page 207

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FRONT BRAKE

4-42

c. Tighten the bleed screw.

d. Install the brake pads and brake pad spring.

TIP

The arrow mark “a” on the brake pad spring
must point in the direction of disc rotation.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

6. Install:

•

Brake pad pin

•

Brake pad clips

•

Front brake caliper

7. Check:

•

Brake fluid level
Below the minimum level mark “a”



Add the

specified brake fluid to the proper level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” on page 3-13.

8. Check:

•

Brake lever operation
Soft or spongy feeling



Bleed the brake sys-

tem.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM (ABS)” on page 3-15.

EAS30724

REMOVING THE FRONT BRAKE CALIPERS

The following procedure applies to both of the
brake calipers.

TIP

Before removing the brake caliper, drain the
brake fluid from the entire brake system.

1. Remove:

•

Brake hose union bolts “1”

•

Brake hose gaskets “2”

•

Brake hoses “3”

TIP

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

Brake caliper bleed screw

5 Nm (0.5 m·kgf, 3.6 ft·lbf)

Front brake caliper bolt

35 Nm (3.5 m·kgf, 25 ft·lbf)

Summary of Contents for TRACER MT09 TRA

Page 1: ...2015 SERVICE MANUAL MT09TRA MT09TRAF 2PP 28197 E0 ...

Page 2: ......

Page 3: ...TRA MT09TRAF SERVICE MANUAL 2014 by Yamaha Motor Co Ltd First edition June 2014 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited ...

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

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

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

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

Page 8: ......

Page 9: ...N 1 15 ABS WARNING LIGHT AND OPERATION 1 18 OUTLINE OF THE TCS Traction Control System 1 19 MULTI FUNCTION METER UNIT 1 23 D mode drive mode 1 31 IMPORTANT INFORMATION 1 33 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 33 REPLACEMENT PARTS 1 33 GASKETS OIL SEALS AND O RINGS 1 33 LOCK WASHERS PLATES AND COTTER PINS 1 33 BEARINGS AND OIL SEALS 1 33 CIRCLIPS 1 34 RUBBER PARTS 1 34 BASIC SERVICE INFORMATI...

Page 10: ...ENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the steering head pipe EAS30003 MODEL LABEL The model label 1 is affixed to the battery box under the passenger seat This information will be needed to order spare parts 1 1 ...

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

Page 12: ...rom the throttle position sensor accelerator position sensor coolant temperature sensor lean angle sensor crankshaft position sensor intake air pressure sensor intake air temperature sensor rear wheel sensor and O2 sensor enable the ECU to determine the injection duration The injection timing is determined through the signals from the crankshaft position sensor As a result the volume of fuel that ...

Page 13: ...espond extremely quickly to the slightest adjustments made by the rider In par ticular optimized control of the throttle valve opening provides the optimum volume of intake air for easy to use torque even in a high revving engine Aims and advantages of using YCC T Increased engine power By shortening the air intake path higher engine speed is possible Increased engine power Improved driveability A...

Page 14: ...design to help maintain the basic maneuverability of the vehicle 3 The hydraulic unit assembly which is the main component of the ABS is centrally located on the vehicle to increase mass centralization 5 6 7 8 9 3 2 1 4 1 Throttle position sensor 2 Throttle servo motor 3 Accelerator position sensor 4 ECU engine control unit 5 Sensor input 6 Gear position switch 7 Crankshaft position sensor 8 Rear ...

Page 15: ...d of the front and rear wheels Chassis speed The speed of the chassis When the brakes are applied wheel speed and chassis speed are reduced However the chassis travels forward by its inertia even though the wheel speed is reduced Brake force The force applied by braking to reduce the wheel speed Wheel lock A condition that occurs when the rotation of one or both of the wheels has stopped but the v...

Page 16: ...lipping occurs between the tire and the road surface and brake force is generated The limit of this brake force is determined by the friction force between the tire and the road surface and is closely related to wheel slippage Wheel slippage is represented by the slip ratio Side force is also closely related to wheel slippage See figure A If the brakes are applied while keep ing the proper slip ra...

Page 17: ...ished after the brake fluid pressure is reduced it increases the hydraulic pressure point B in the following figure The hydraulic pressure is initially increased quickly and then it is increased gradually ABS operation and vehicle control If the ABS starts operating there is a tendency of the wheel to lock and the vehicle is approaching the limit of control To make the rider aware of this conditio...

Page 18: ...ncy of the wheel to lock caused by applying the brakes The ABS cannot prevent wheel lock on slippery surfaces such as ice when it is caused by engine braking even if the ABS is operating Electronic ABS features The Yamaha ABS anti lock brake system has been developed with the most advanced electronic technology The ABS control is processed with good response under various vehicle travel conditions...

Page 19: ...ent in the hall IC installed in the wheel sensor generates pulses The pulse frequency which is proportional to the magnetic flux density is converted into a wave in the hall IC so that it can be output The ABS ECU calculates the wheel rotation speed by detecting the pulse frequency 1 2 3 4 4 7 7 5 6 6 8 9 9 10 11 12 13 14 1 Rear brake master cylinder 2 Hydraulic unit assembly 3 Front brake master ...

Page 20: ...ng are completed the ABS warning light will go off when the vehicle is ridden or pushed at a speed of 7 km h 4 mi h or faster NOTICE ECA20350 If the rear wheel is raced with the vehicle on the centerstand the ABS warning light may flash or come on If this occurs turn the main switch to OFF then back to ON The ABS operation is normal if the ABS warning light goes off after the vehicle starts off If...

Page 21: ... solenoid valve The electromagnetic force generated in the inlet solenoid valve varies proportionally with the duty cycle control voltage that is supplied to it Since this voltage is continuously variable the solenoid valve moves smoothly and the hydraulic pressure is adjusted linearly 1 When the brakes are operated normally the inlet solenoid valve 1 is open and the outlet solenoid valve 2 is clo...

Page 22: ... fluid in the lower brake lines brake caliper side Buffer chamber The buffer chamber accumulates the brake fluid that is depressurized while the ABS is operating ABS ECU The ABS ECU is integrated with the hydraulic unit to achieve a compact and lightweight design As shown in the following block diagram the ABS ECU receives wheel sensor signals from the front and rear wheels and also receives signa...

Page 23: ... turned on During this test a clicking noise can be heard from under the seat and if the brake lever or brake pedal are even slightly applied a vibration can be felt at the lever and pedal but these do not indicate a malfunction 14 7 4 5 6 2 3 1 9 10 11 12 13 17 15 24 20 22 23 21 26 27 18 19 16 25 8 1 Battery 2 AC magneto 3 Rectifier regulator 4 Main fuse 5 ABS motor fuse 6 ABS solenoid fuse 7 Mai...

Page 24: ...ezed the hydraulic pressure in the brake master cylinder increases and the brake fluid is sent to the brake caliper At this time the inlet and outlet check valves of the hydraulic pump are closed As a result of eliminating the orifice the brake master cylinder directly pressurizes the brake caliper during normal braking When the brake lever is released the brake fluid in the brake caliper returns ...

Page 25: ...outlet solenoid valve is open the brake fluid is sent to the buffer chamber As a result the hydraulic pressure in the brake caliper is reduced The brake fluid stored in the buffer chamber is pumped back to the brake master cylinder by the hy draulic pump linked to the ABS motor 12 13 7 6 11 3 4 5 9 8 10 1 Brake master cylinder 2 Brake light switch 3 ABS motor 4 Hydraulic pump 5 Buffer chamber 6 Ou...

Page 26: ...solenoid valve As the inlet solenoid valve opens the brake line from the brake master cylinder opens allowing the brake fluid to be sent to the brake caliper 1 Brake master cylinder 2 Brake light switch 3 ABS motor 4 Hydraulic pump 5 Buffer chamber 6 Outlet solenoid valve 7 Inlet solenoid valve 8 Brake caliper 9 Wheel sensor 10 ABS ECU 11 ABS warning light 12 Brake fluid pressure 13 Time ...

Page 27: ...is occurs turn the main switch to OFF then back to ON The ABS operation is normal if the ABS warning light comes on then goes off The ABS operation is normal if the ABS warning light flashes Even if the ABS warning light remains on and does not go off or if it comes on after riding conven tional braking performance of the vehicle is maintained 1 Brake master cylinder 2 Brake light switch 3 ABS mot...

Page 28: ... even in the worst case is principally executed when the vehicle is advancing straight ahead During a turn sudden braking is liable to cause a loss of traction of the tires Even vehicles equipped with ABS cannot be prevented from falling over if braked suddenly The ABS does not work when the main switch is turned to OFF The conventional braking function can be used Wheel lock A condition that occu...

Page 29: ... the preset value the ECU controls the ignition timing fuel cut off and throttle valve opening of the YCC T system so that the amount of slip is less than the preset value The traction control system indicator warning light in the meter assembly flashes when the traction control system has activated 1 2 3 6 7 8 9 10 4 5 1 TCS button 2 Traction control system indicator warning light 3 ECU engine co...

Page 30: ...e braking and cannot prevent front wheel slip ping As with any motorcycle approach surfaces that may be slippery with caution and avoid especially slippery surfaces When the main switch is turned to ON the traction control system automatically turns on The traction control system can be turned on or off manually only when the main switch is in the ON position and the motorcycle is stopped To turn ...

Page 31: ...t will go off Resetting The traction control system will be disabled in the following conditions The rear wheel is rotated with the centerstand down and the main switch in the ON position Either the front wheel or rear wheel comes off the ground while riding Excessive rear wheel spinning If the traction control system has been disabled both the traction control system indicator warning light and t...

Page 32: ...arious information such as the odometer reading a setting mode display which allows you to set select or reset the items shown in the in formation display TIP Turn the key to ON before pushing the select switch menu switch MENU RE SET button and TCS button For the UK only To switch the meter displays between kilometers and miles refer to Setting mode Speedometer The speedometer shows the vehicle s...

Page 33: ...roblem is detected in the electrical circuit the following cycle is repeated until the malfunction is corrected fuel level segments and fuel level warning indicator flash eight times then go off for approximately 3 seconds If this occurs check the electrical circuit Refer to CHECKING THE FUEL METER FUEL LEVEL WARNING LIGHT on page 8 143 Eco indicator This indicator comes on when the vehicle is be ...

Page 34: ...de display The items shown in each information display can be selected To set or select the items shown refer to Set ting mode Odometer display 1 Tripmeter displays 1 TRIP 1 and TRIP 2 show the distance traveled since they were last set to zero When approximately 2 6 L 0 69 US gal 0 57 Imp gal of fuel remains in the fuel tank the last segment of the fuel meter and fuel level warning indicator star...

Page 35: ...3 elapsed time displays but they cannot be set to the infor mation display Refer to Setting mode Ambient temperature display 1 This display shows the ambient temperature from 9 C to 93 C in 1 C increments The temperature displayed may vary from the am bient temperature TIP 9 C will be displayed even if the ambient tem perature falls below 9 C The accuracy of the temperature reading may be affected...

Page 36: ...on 1 0 Imp gal of fuel TIP If traveling at speeds under 10 km h 6 0 mi h _ _ _ will be displayed Setting mode TIP The transmission must be in neutral and the vehicle must be stopped to change settings in this mode Shifting the transmission into gear and starting off or turning the key to OFF saves all set tings made then exits the setting mode Push and hold the menu switch MENU for at least 2 seco...

Page 37: ...setting mode menu Selecting the units 1 Use the select switch to highlight Unit 2 Push the menu switch MENU The unit set ting display will be shown and km or mile for the UK only or km L or L 100km ex cept for the UK will flash in the display Display This function allows you to change the items shown in 3 information displays Brightness This function allows you to adjust the brightness of the mult...

Page 38: ... to return to the setting mode menu Selecting the display items 1 Use the select switch to highlight Display 2 Push the menu switch MENU use the se lect switch to highlight the display to change and then push the menu switch MENU again 3 Use the select switch to highlight the item to change and then push the menu switch MENU 4 Use the select switch to select the item to show and then push the menu...

Page 39: ...ashing use the select switch to set the hours 4 Push the menu switch MENU and the min ute digits start flashing 5 Use the select switch to set the minutes 6 Push the menu switch MENU to return to the setting mode menu Resetting all of the display items 1 Use the select switch to highlight All Reset 2 Push the menu switch MENU 3 Use the select switch to highlight YES and then push the menu switch M...

Page 40: ...eys may cause signal inter ference which may prevent the engine from starting 2 If the engine starts turn it off and try starting the engine with the standard keys 3 If one or both of the standard keys do not start the engine re register the standard keys If the display indicates any fault codes note the code number and then check the vehicle Refer to FUEL INJECTION SYSTEM on page 8 31 and IMMOBIL...

Page 41: ...FEATURES 1 32 Mode B Mode B offers response that is somewhat less sharp compared to mode STD for riding situa tions that require especially sensitive throttle op eration ...

Page 42: ...m any source of fire EAS30007 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace ments Use oil and grease recommended by Yamaha for all lubrication jobs Other brands may be similar in function and appearance but inferior in quality EAS30008 GASKETS OIL SEALS AND O RINGS 1 When overhauling the engine replace all gaskets seals and O rings All gasket surfac es oil seal lips and O rings m...

Page 43: ... CIRCLIPS Before reassembly check all circlips carefully and replace damaged or distorted circlips Al ways replace piston pin clips after one use When installing a circlip 1 make sure the sharp edged corner 2 is positioned opposite the thrust 3 that the circlip receives EAS30012 RUBBER PARTS Check rubber parts for deterioration during in spection Some of the rubber parts are sensitive to gasoline ...

Page 44: ...ener push its pin so that it protrudes from the fastener head then insert the fastener into the part to be secured and push the pin a in with a screwdriver Make sure that the pin is flush with the fastener s head Screw type 1 Remove Quick fastener TIP To remove the quick fastener loosen the screw with a screwdriver then pull the fastener out 2 Install Quick fastener TIP To install the quick fasten...

Page 45: ...uld be gener ated which is extremely dangerous TIP If a battery lead is difficult to disconnect due to rust on the battery terminal remove the rust us ing hot water NOTICE ECA16760 Be sure to connect the battery leads to the correct battery terminals Reversing the bat tery lead connections could damage the electrical components NOTICE ECA16771 When connecting the battery leads to the battery be su...

Page 46: ...city Therefore never touch the terminals and be sure to keep the contacts clean TIP When resetting the ECU by turning the main switch to OFF be sure to wait approximately 5 seconds before turning the main switch back to ON Checking the electrical system TIP Before checking the electrical system make sure that the battery voltage is at least 12 V NOTICE ECA14371 Never insert the tester probes into ...

Page 47: ...the coupler lock hold both sections of the cou pler securely and then disconnect the cou pler There are many types of coupler locks therefore be sure to check the type of cou pler lock before disconnecting the coupler NOTICE ECA16790 When disconnecting a connector do not pull the leads Hold both sections of the connec tor securely and then disconnect the con nector 2 Check Lead Coupler Connector M...

Page 48: ...lizer available at most part stores 5 Check Resistance TIP The resistance values shown were obtained at the standard measuring temperature of 20 C 68 F If the measuring temperature is not 20 C 68 F the specified measuring condi tions 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 sis...

Page 49: ...n placing an order refer to the list provided below to avoid any mistakes TIP For U S A and Canada use part number starting with YM YU or ACC For others use part number starting with 90890 Tool name Tool No Illustration Reference pages Ring nut wrench 90890 01268 Spanner wrench YU 01268 4 89 Piston pin puller set 90890 01304 Piston pin puller YU 01304 5 61 Radiator cap tester 90890 01325 Mityvac c...

Page 50: ...holder 90890 01582 Damper rod holder YM 01582 4 80 4 82 Oil filter wrench 90890 01426 Oil filter wrench YU 38411 3 25 Rod holder 90890 01434 Damper rod holder double ended YM 01434 4 79 4 84 4 85 Rod puller attachment M10 long 90890 01578 Universal damping rod bleeding tool set YM A8703 4 83 4 84 4 85 Tool name Tool No Illustration Reference pages 90890 01578 YM A8703 ...

Page 51: ...river 90890 01442 Adjustable fork seal driver 36 46 mm YM 01442 4 82 4 83 Pivot shaft wrench adapter 90890 01476 5 7 5 8 Pivot shaft wrench 90890 01485 Frame mount insert wrench YM 01485 5 7 Pivot shaft wrench 90890 01518 Frame spanner socket YM 01518 5 7 5 8 Drive chain cut rivet tool 90890 01550 Drive chain cut rivet tool YM 01550 4 99 4 101 Tool name Tool No Illustration Reference pages YM A870...

Page 52: ...ge 90890 03094 Vacuummate YU 44456 3 8 Pocket tester 90890 03112 Analog pocket tester YU 03112 C 1 39 8 129 8 130 8 131 8 135 8 136 8 137 8 138 8 139 8 141 8 142 8 144 8 145 8 146 8 147 8 148 Oil pressure adapter H 90890 03139 3 26 Pressure gauge 90890 03153 Pressure gauge YU 03153 3 26 7 10 Tool name Tool No Illustration Reference pages 90890 03081 YU 33223 YU 44456 ...

Page 53: ... 3 6 4 26 4 34 5 20 5 43 Test harness S pressure sensor 3P 90890 03207 Test harness S pressure sensor 3P YU 03207 8 146 Test harness lean angle sensor 6P 90890 03209 Test harness lean angle sensor 6P YU 03209 8 139 Fuel injector pressure adapter 90890 03210 Fuel injector pressure adapter YU 03210 7 10 Yamaha diagnostic tool 90890 03231 4 65 4 66 8 37 8 101 8 122 Valve spring compressor 90890 04019...

Page 54: ...r 90890 04086 Universal clutch holder YM 91042 5 42 5 45 Valve lapper 90890 04101 Valve lapping tool YM A8998 3 6 Valve spring compressor attachment 90890 04108 Valve spring compressor adapter 22 mm YM 04108 5 23 5 28 Valve guide remover ø4 5 90890 04116 Valve guide remover 4 5 mm YM 04116 5 25 Valve guide installer ø4 5 90890 04117 Valve guide installer 4 5 mm YM 04117 5 25 Tool name Tool No Illu...

Page 55: ... 1 Piston installing tool 90890 04161 Piston installing tool YM 04161 5 68 Camshaft wrench 90890 04162 Camshaft wrench YM 04162 5 12 5 15 Ignition checker 90890 06754 Oppama pet 4000 spark checker YM 34487 8 138 Yamaha bond No 1215 90890 85505 Three bond No 1215 5 34 5 57 Tool name Tool No Illustration Reference pages ...

Page 56: ...SPECIAL TOOLS 1 47 ...

Page 57: ...HTENING TORQUES 2 13 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 13 ENGINE TIGHTENING TORQUES 2 14 CHASSIS TIGHTENING TORQUES 2 18 LUBRICATION POINTS AND LUBRICANT TYPES 2 22 ENGINE 2 22 CHASSIS 2 23 LUBRICATION SYSTEM CHART AND DIAGRAMS 2 25 ENGINE OIL LUBRICATION CHART 2 25 LUBRICATION DIAGRAMS 2 27 COOLING SYSTEM DIAGRAMS 2 37 CABLE ROUTING 2 41 ...

Page 58: ...CYP CZE DEU DNK ESP FIN GBR GRC HUN IRL ITA NLD NOR POL PRT SVK SVN SWE TUR ZAF MT09TRA 2SCA BEL FRA MT09TRA 2SCB RUS MT09TRAF 2SC4 Dimensions Overall length 2160 mm 85 0 in Overall width 950 mm 37 4 in Overall height 1345 1375 mm 53 0 54 1 in Seat height 845 860 mm 33 3 33 9 in Wheelbase 1440 mm 56 7 in Ground clearance 135 mm 5 31 in Minimum turning radius 3000 mm 118 1 in Weight Curb weight 210...

Page 59: ...6 US gal 3 96 Imp gal Fuel reserve amount 2 6 L 0 69 US gal 0 57 Imp gal Engine oil Recommended brand YAMALUBE Type SAE 10W 30 10W 40 10W 50 15W 40 20W 40 or 20W 50 Recommended engine oil grade API service SG type or higher JASO standard MA Lubrication system Wet sump Engine oil quantity Quantity disassembled 3 40 L 3 59 US qt 2 99 Imp qt Without oil filter cartridge replacement 2 40 L 2 54 US qt ...

Page 60: ...meter 24 500 24 521 mm 0 9646 0 9654 in Camshaft journal diameter 24 459 24 472 mm 0 9630 0 9635 in Camshaft journal to camshaft cap clearance 0 028 0 062 mm 0 0011 0 0024 in Camshaft lobe dimensions Lobe height Intake 36 290 36 390 mm 1 4287 1 4327 in Limit 36 190 mm 1 4248 in Base circle diameter Intake 27 950 28 050 mm 1 1004 1 1043 in Limit 27 850 mm 1 0965 in Lobe height Exhaust 35 720 35 820...

Page 61: ...ing rate K2 intake 43 93 N mm 4 48 kgf mm 250 84 lbf in Spring rate K1 exhaust 30 11 N mm 3 07 kgf mm 171 93 lbf in Spring rate K2 exhaust 41 48 N mm 4 23 kgf mm 236 85 lbf in Installed compression spring force intake 192 00 220 00 N 19 58 22 43 kgf 43 16 49 46 lbf Installed compression spring force exhaust 162 00 186 00 N 16 52 18 97 kgf 36 42 41 81 lbf Spring tilt intake 1 7 mm 0 07 in Spring ti...

Page 62: ...012 in Balancer shaft journal to balancer shaft bear ing clearance 0 024 0 048 mm 0 0009 0 0019 in Bearing color code 1 Blue 2 Black 3 Brown 4 Green 5 Yellow Clutch Clutch type Wet multiple disc Clutch release method Outer pull rack and pinion pull Clutch lever free play 10 0 15 0 mm 0 39 0 59 in Friction plate 1 thickness 2 92 3 08 mm 0 115 0 121 in Wear limit 2 82 mm 0 111 in Plate quantity 7 pc...

Page 63: ...A Fuel injector Model quantity 297500 1110 3 Throttle body Type quantity EACW41 B1 1 ID mark 1RC1 00 Throttle position sensor Resistance 1 20 2 80 k Output voltage at idle 0 63 0 73 V Accelerator position sensor Resistance 1 08 2 52 k Output voltage 0 63 0 73 V Idling condition Engine idling speed 1100 1300 r min CO AI system OFF exhaust pipe 1 50 3 50 Intake vacuum 30 5 34 5 kPa 229 259 mmHg 9 0 ...

Page 64: ...22F Wear limit front MT09TRA 1 6 mm 0 06 in MT09TRAF 1 5 mm 0 06 in Rear tire Type Tubeless Size 180 55 ZR17M C 73W Manufacturer model DUNLOP D222 Wear limit rear MT09TRA 1 6 mm 0 06 in MT09TRAF 1 5 mm 0 06 in Tire air pressure measured on cold tires Loading condition 0 90 kg 0 198 lb Front 250 kPa 2 50 kgf cm 36 psi Rear 290 kPa 2 90 kgf cm 42 psi Loading condition 90 180 kg 198 397 lb Front 250 ...

Page 65: ...ter 38 18 mm 1 50 in Specified brake fluid DOT 4 Steering Steering bearing type Angular bearing Center to lock angle left 32 0 Center to lock angle right 32 0 Front suspension Type Telescopic fork Spring shock absorber type Coil spring oil damper Front fork travel 137 0 mm 5 39 in Fork spring free length 305 3 mm 12 02 in Limit 299 3 mm 11 78 in Collar length 120 0 mm 4 72 in Spring rate K1 6 86 N...

Page 66: ...N mm 10 19 kgf mm 570 77 lbf in Spring stroke K1 0 0 60 0 mm 0 00 2 36 in Enclosed gas air pressure STD 980 kPa 9 8 kgf cm 139 4 psi Spring preload adjusting positions Minimum 1 Standard 4 Maximum 7 Rebound damping adjusting positions Minimum 3 turn s out Standard 1 1 2 turn s out Maximum Adjusting screw fully turned in With the adjusting screw fully turned in Drive chain Size manufacturer 525V10 ...

Page 67: ...4 1 4 V More than 65 3 7 4 4 V AC magneto Standard output 14 0 V 415 W 5000 r min Stator coil resistance 0 152 0 228 W W Rectifier regulator Regulator type Semi conductor short circuit Regulated voltage DC 14 3 14 7 V Rectifier capacity 50 0 A Battery Model YTZ10S Voltage capacity 12 V 8 6 Ah Specific gravity 1 310 Manufacturer GS YUASA Ten hour rate charging current 0 86 A Bulb voltage wattage qu...

Page 68: ...vel switch resistance maximum level po sition 484 0 536 0 Oil level switch resistance minimum level po sition 114 0 126 0 Fuel sender unit Sender unit resistance full 9 0 11 0 Sender unit resistance empty 213 0 219 0 Fuel injection sensor Crankshaft position sensor resistance 228 342 Gy B Intake air pressure sensor output voltage 3 57 3 71 V 101 3 kPa 3 57 3 71 V 1 01 kgf cm 3 57 3 71 V 14 7 psi I...

Page 69: ... fuse 15 0 A Auxiliary fuse 1 2 0 A Auxiliary fuse 2 2 0 A Terminal fuse 1 2 0 A Terminal fuse 2 2 0 A Backup fuse 7 5 A Electronic throttle valve fuse 7 5 A Spare fuse 30 0 A Spare fuse 20 0 A Spare fuse 15 0 A Spare fuse 7 5 A Spare fuse 2 0 A ...

Page 70: ...l To avoid warpage tight en multi fastener assemblies in a crisscross pat tern and progressive stages until the specified tightening torque is reached Unless otherwise specified tightening torque specifications re quire clean dry threads Components should be at room temperature A Distance between flats B Outside thread diameter A nut B bolt General tightening torques Nm m kgf ft lbf 10 mm 6 mm 6 0...

Page 71: ...Timing chain tensioner bolt M6 2 10 Nm 1 0 m kgf 7 2 ft lbf Timing chain tensioner cap bolt M6 1 7 Nm 0 7 m kgf 5 1 ft lbf Oil pump bolt M6 4 10 Nm 1 0 m kgf 7 2 ft lbf Oil pump driven sprocket bolt M6 1 15 Nm 1 5 m kgf 11 ft lbf Oil pump cover screw M5 1 3 8 Nm 0 38 m kgf 2 8 ft lbf Water pump housing cover bolt M6 1 10 Nm 1 0 m kgf 7 2 ft lbf Water pump drain bolt M6 1 10 Nm 1 0 m kgf 7 2 ft lbf...

Page 72: ...M16 2 8 Nm 0 8 m kgf 5 8 ft lbf Sub gallery plug M14 1 6 Nm 0 6 m kgf 4 3 ft lbf Clutch cable holder bolt M6 2 12 Nm 1 2 m kgf 8 7 ft lbf Timing chain cover bolt M6 8 12 Nm 1 2 m kgf 8 7 ft lbf Starter clutch bolt M8 3 32 Nm 3 2 m kgf 23 ft lbf Clutch boss nut M20 1 125 Nm 12 5 m kgf 90 ft lbf Clutch spring bolt M6 6 10 Nm 1 0 m kgf 7 2 ft lbf Clutch cable locknut M8 1 7 Nm 0 7 m kgf 5 1 ft lbf Dr...

Page 73: ...r M6 1 8 Nm 0 8 m kgf 5 8 ft lbf Left thread Shift rod joint bolt M6 1 10 Nm 1 0 m kgf 7 2 ft lbf Centerstand bracket bolt M6 2 12 Nm 1 2 m kgf 8 7 ft lbf Oil filler cap M20 1 1 5 Nm 0 15 m kgf 1 1 ft lbf Starter motor assembly bolt M5 2 5 Nm 0 5 m kgf 3 6 ft lbf Starter motor insulator nut M6 1 11 Nm 1 1 m kgf 8 0 ft lbf Throttle position sensor screw M5 2 3 5 Nm 0 35 m kgf 2 5 ft lbf Accelerator...

Page 74: ...2 Tighten the bolts to 25 Nm 2 5 m kgf 18 ft lbf in the order shown in the illustration 3 Fully loosen the bolt 1 and then tighten the bolt again to the specified torque shown below Repeat this one by one until bolt 8 in the order shown in the illustration Tightening torque Bolts 1 to 6 15 Nm 1 5 m kgf 11 ft lbf Bolts 7 and 8 18 Nm 1 8 m kgf 13 ft lbf 4 Tighten the bolts in the order shown in the ...

Page 75: ... upper nut M10 1 55 Nm 5 5 m kgf 40 ft lbf Connecting arm lower nut M10 1 55 Nm 5 5 m kgf 40 ft lbf Rear shock absorber assembly nut upper M10 1 44 Nm 4 4 m kgf 32 ft lbf Rear shock absorber assembly nut lower M10 1 44 Nm 4 4 m kgf 32 ft lbf Drive chain guard bolt M6 2 7 Nm 0 7 m kgf 5 1 ft lbf Rear fender bolt M6 3 7 Nm 0 7 m kgf 5 1 ft lbf Swingarm bracket left and Swing arm M6 4 7 Nm 0 7 m kgf ...

Page 76: ...4 6 Nm 0 6 m kgf 4 3 ft lbf Fuel tank bracket assembly and Rear frame M6 4 7 Nm 0 7 m kgf 5 1 ft lbf Front wheel axle M16 1 65 Nm 6 5 m kgf 47 ft lbf Front wheel axle pinch bolt M8 1 23 Nm 2 3 m kgf 17 ft lbf Front brake caliper bolt M10 4 35 Nm 3 5 m kgf 25 ft lbf Front brake disc bolt M6 10 18 Nm 1 8 m kgf 13 ft lbf Rear wheel axle nut M18 1 150 Nm 15 m kgf 108 ft lbf Rear brake disc bolt M8 5 3...

Page 77: ...8 m kgf 13 ft lbf Rear brake caliper bolt front M12 1 27 Nm 2 7 m kgf 20 ft lbf Rear brake caliper bolt rear M8 1 22 Nm 2 2 m kgf 16 ft lbf Rear brake pad retaining bolt M10 1 17 Nm 1 7 m kgf 12 ft lbf Rear brake caliper screw plug M10 1 2 5 Nm 0 25 m kgf 1 8 ft lbf Rearview mirror locknut M10 2 17 Nm 1 7 m kgf 12 ft lbf Throttle cable housing bolt M5 2 3 8 Nm 0 38 m kgf 2 8 ft lbf Handlebar switc...

Page 78: ...13 Nm 1 3 m kgf 9 4 ft lbf Seat lock assembly nut M6 2 7 Nm 0 7 m kgf 5 1 ft lbf Tail brake light bolt M6 2 7 Nm 0 7 m kgf 5 1 ft lbf Auxiliary DC jack nut M27 1 2 8 Nm 0 28 m kgf 2 0 ft lbf Windshield screw M5 4 0 5 Nm 0 05 m kgf 0 36 ft lbf Front cover bolt M6 4 7 Nm 0 7 m kgf 5 1 ft lbf Headlight assembly bolt M6 4 7 Nm 0 7 m kgf 5 1 ft lbf Headlight stay bolt M8 2 33 Nm 3 3 m kgf 24 ft lbf Ele...

Page 79: ... ends intake and exhaust Crankshaft big ends Piston surfaces Piston pins Connecting rod bolts Crankshaft journals Balancer shaft journals Generator rotor assembly Water pump impeller shaft Oil pump rotors inner and outer Oil pump assembly Oil cooler bolts Oil filter cartridge union bolt Oil nozzle O rings or Main gallery bolt O ring or Oil cooler sub gallery O ring or Drive axle sub gallery O ring...

Page 80: ...41C Lubrication point Lubricant LS E E M M M E E E E E E Lubrication point Lubricant Steering bearings seal lip and ball race lip Tube guide throttle grip inner surface and throttle cables Brake lever pivot bolt and metal to metal moving parts Clutch lever pivot bolt metal to metal moving parts and clutch cable end Swingarm collar outer surface oil seal lip Pivot shaft Swingarm pivot bush outer su...

Page 81: ...ing parts Shift shaft joint rod moving parts Front wheel oil seal left and right Rear wheel oil seal Rear wheel drive hub oil seal Rear wheel drive hub mating surface Brake caliper piston seal Master cylinder inside Brake caliper piston dust seal Brake caliper bolts Lubrication point Lubricant LS LS LS LS LS LS LS S S ...

Page 82: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 25 EAS20019 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS30020 ENGINE OIL LUBRICATION CHART 1 3 4 5 11 12 13 13 14 15 16 17 13 7 8 9 10 10 10 10 6 2 ...

Page 83: ...Oil pump 3 Relief valve 4 Oil cooler 5 Oil filter cartridge 6 Main gallery 7 Drive axle 8 Main axle 9 Shift fork upper 10 Mission shower 11 Crankshaft 12 AC magneto 13 Oil nozzle 14 Balancer shaft 15 Timing chain tensioner 16 Intake camshaft 17 Exhaust camshaft ...

Page 84: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 27 EAS30021 LUBRICATION DIAGRAMS 1 2 3 4 ...

Page 85: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 28 1 Oil level switch 2 Oil filter cartridge union bolt 3 Oil filter cartridge 4 Crankshaft ...

Page 86: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 29 4 7 7 8 9 5 6 2 3 1 7 8 ...

Page 87: ...ming chain tensioner 2 Intake camshaft 3 Exhaust camshaft 4 Balancer shaft 5 Crankshaft 6 Oil cooler 7 Oil strainer 8 Oil drain bolt 9 Oil pump driven sprocket A MT09TRA for Europe RN29F0011886 and after MT09TRAG for Oceania RN29K 0000556 and after ...

Page 88: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 31 4 5 6 2 3 1 ...

Page 89: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 32 1 Oil cooler 2 Oil filter cartridge 3 Oil level switch 4 Oil strainer 5 Oil pump 6 Main gallery bolt ...

Page 90: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 33 6 5 3 2 7 4 1 ...

Page 91: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 34 1 Balancer shaft 2 Crankshaft 3 Main axle 4 Shift fork guide bar shift fork C side 5 Drive axle 6 Sub gallery bolt 7 Shift fork ...

Page 92: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 35 9 8 7 6 3 3 2 5 4 1 ...

Page 93: ...36 1 Cylinder head 2 Exhaust camshaft 3 Intake camshaft 4 Oil passage to the timing chain tensioner 5 Oil passage to the cylinder head 6 Oil passage to the clutch chamber 7 Oil return passage from the cylinder head 8 Crankshaft 9 Main gallery ...

Page 94: ...COOLING SYSTEM DIAGRAMS 2 37 EAS20020 COOLING SYSTEM DIAGRAMS 1 1 2 3 ...

Page 95: ...COOLING SYSTEM DIAGRAMS 2 38 1 Water pump 2 Thermostat 3 Radiator ...

Page 96: ...COOLING SYSTEM DIAGRAMS 2 39 1 2 3 4 5 6 ...

Page 97: ...COOLING SYSTEM DIAGRAMS 2 40 1 Water jacket 2 Thermostat 3 Radiator 4 Water pump 5 Oil cooler 6 Coolant reservoir ...

Page 98: ...CABLE ROUTING 2 41 EAS20021 CABLE ROUTING Handlebar top view ...

Page 99: ...nstalling the rubber cover silicone water or soapy water may be applied to the inside of the rubber cover B Connect the front brake light switch connec tor onto the front brake light switch C Detailed drawing of around the front brake master cylinder D Straight line parallel to the front brake master cylinder reservoir cap E 3 13 F Center of the metal fitting for the front brake hose ...

Page 100: ...CABLE ROUTING 2 43 Handlebar front view ...

Page 101: ...nd immobilizer lead to the right of the throttle cables F Insert the clamp of the left handlebar switch lead into the hole in the headlight stay G Route the left handlebar switch lead over the wire harness H Let the horn lead sag between them I Fasten the horn lead to the bracket with the clamp so that the mating section faces down ward Route the horn lead on the front side from the hole in the cl...

Page 102: ...CABLE ROUTING 2 45 Radiator front side view and right side view ...

Page 103: ...or inlet hose so that the tip of the hose contacts the rib of the water jacket joint H Install the radiator inlet hose with its yellow paint mark facing downward I Point the hose clamp installation bolt upward J Install the radiator inlet hose up to the base of the bend in the radiator pipe K Install the radiator inlet hose with its white paint mark facing inward L Install the radiator hose up to ...

Page 104: ...CABLE ROUTING 2 47 Fuel tank left and bottom view ...

Page 105: ... from the rear of the vehicle Within 45 B Install the clip so that the end is on the paint mark Do not put it on the clip spool guard Point the end to the rear and store it inside to the hose C Align the fuel pump positioning to the inner panel marking visual guide during installa tion D Insert the fuel tank breather hose up to the section where the fuel tank pipe increases in diameter Install it ...

Page 106: ...CABLE ROUTING 2 49 Air filter case and throttle body top view and left side view ...

Page 107: ...the pipe of the cylinder head Install the breather hose on the white paint mark side to the engine Install the breather hose so that the white paint mark is in the rear of the vehicle and parallel to the cylinder head mating surfaces Install the clip so that the end is in the rear of the vehicle and parallel to the cylinder head mating surfaces C Install the ECU harness by storing it in the recess...

Page 108: ...CABLE ROUTING 2 51 Air cut off valve left side view ...

Page 109: ...ve so that the tip of the hose contacts the air filter case B Insert the protrusion on the radiator fan cover into the hole in the air cut off valve holder C Point the end of the clip for the air induction system hose air cut off valve to reed valve cover 2 3 forward D Point the end of the clip for the air induction system hose air filter case to air cut off valve to the left E 45 F Point the end ...

Page 110: ...CABLE ROUTING 2 53 Frame and engine right side view ...

Page 111: ...the bracket F Route the O2 sensor lead and the rear brake light switch lead through the bracket guide G Route the rear brake light switch lead outside brake fluid reservoir hose H It does not matter whether the O2 sensor lead or the rear brake light switch lead is on top bottom in the area shown in the illustration I Connect the radiator fan motor coupler and then position it in front of the conne...

Page 112: ...CABLE ROUTING 2 55 Frame and engine right side view ...

Page 113: ...mp into the hole in the headlight stay Align the clamp with the tapes red to the left and blue to the right on the handlebar switch lead and face the end of the clamp forward E Make sure that there is no slack in the main switch lead and immobilizer lead between the clamps shown F Make sure that the main switch lead immobi lizer lead and handlebar switch leads are not twisted between the clamps sh...

Page 114: ...CABLE ROUTING 2 57 Frame and engine left side view ...

Page 115: ...and point it forward Pull the oil level switch lead when fastening D Route the gear position switch lead inside to the shift arm E Hose bending edge F Align the sidestand switch lead oil level switch lead fuel tank drain hose and fuel tank breather hose with the bending edge of the hose and then install them Face the clamp opening to the rearward G 30 50 mm 1 18 1 97 in H Point the tips of fuel ta...

Page 116: ...CABLE ROUTING 2 59 Frame top view ...

Page 117: ... into the fuel rail hole C Fold back the injector lead 1 by the coupler and then fasten it with tape D Connect the sub lead to the injector coupler 2 Fasten the injector coupler on the wire harness side with tape E For the air cut off valve lead ignition coil lead 3 and fuel injector lead 3 it does not mat ter which is routed above the others F Route the coolant temperature sensor sub lead between...

Page 118: ...CABLE ROUTING 2 61 Frame top view ...

Page 119: ...mat ter B Fasten the wire harness side of the oil level switch coupler to the battery box C Fasten the rear brake light switch coupler of the wire harness with tape D Fasten the sidestand switch coupler of the wire harness to the battery box E Route the negative battery lead inside to the branch of the O2 sensor lead and the rear brake light switch lead and through between the wire harness and the...

Page 120: ...CABLE ROUTING 2 63 Frame top view ...

Page 121: ...ber bracket of the turn sig nal hazard relay in the battery box G Install the clamp into the hole in the battery box H Connect each rear turn signal coupler to the coupler with the same color After connecting the license plate light coupler store the turn signal light coupler left right furthest to the bottom of the vehicle After connecting the other couplers store them below the tail brake light ...

Page 122: ...CABLE ROUTING 2 65 Front brake right side view and left side view ...

Page 123: ...tion Route the front wheel sensor lead outside of the front brake hose F Install the front brake hose with its blue paint mark facing outward G Install the brake hose from the hydraulic unit so that the brake pipe touches the projection on the brake caliper Install the brake hose to the right brake caliper so that it aligned with the direction of the brake pipe from the hydraulic unit H Fasten the...

Page 124: ...CABLE ROUTING 2 67 Rear brake ...

Page 125: ...heel sensor lead and the brake pipe with the clamp Make sure that the clamp touches the end of the brake pipe D Make sure to install the clamp all the way in the rear frame E Install the clamp facing the direction in the illustration F Face the engaging section catch of the clamp downward G Do not clamp the rear wheel sensor lead H Fasten the protector of the brake hose with the clamp Face the eng...

Page 126: ...CABLE ROUTING 2 69 Hydraulic unit top view and left side view ...

Page 127: ...Bracket A Make sure to insert the ABS ECU coupler all the way in B Install the brake hose front brake master cyl inder to hydraulic unit so that the protrusion contact to the brake hose hydraulic unit to front brake calipers C In the plug hole install the brake hose rear brake master cylinder to hydraulic unit the brake hose hydraulic unit to rear brake cali per and rear wheel sensor lead D 28 34 ...

Page 128: ...CABLE ROUTING 2 71 ...

Page 129: ...EAR BRAKE PADS 3 15 BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS 3 15 CHECKING THE FRONT BRAKE HOSES 3 16 CHECKING THE REAR BRAKE HOSE 3 16 CHECKING THE WHEELS 3 16 CHECKING THE TIRES 3 16 CHECKING THE WHEEL BEARINGS 3 18 CHECKING THE SWINGARM OPERATION 3 18 LUBRICATING THE SWINGARM PIVOT 3 18 ADJUSTING THE DRIVE CHAIN SLACK 3 18 LUBRICATING THE DRIVE CHAIN 3 19 CHECKING AND ADJUSTING THE STEERING HEAD...

Page 130: ...G THE COOLING SYSTEM 3 27 CHANGING THE COOLANT 3 27 CHECKING THE FRONT BRAKE LIGHT SWITCH 3 29 ADJUSTING THE REAR BRAKE LIGHT SWITCH 3 29 CHECKING AND LUBRICATING THE CABLES 3 29 CHECKING THE THROTTLE GRIP 3 30 CHECKING AND CHARGING THE BATTERY 3 30 CHECKING THE FUSES 3 30 ADJUSTING THE HEADLIGHT BEAMS 3 30 ...

Page 131: ...HART FOR THE EMISSION CONTROL SYSTEM EAS30615 GENERAL MAINTENANCE AND LUBRICATION CHART NO ITEM CHECK OR MAINTENANCE JOB ODOMETER READING ANNUAL CHECK 1000 km 600 mi 10000km 6000 mi 20000 km 12000 mi 30000 km 18000 mi 40000 km 24000 mi 1 Fuel line Check fuel hoses for cracks or damage 2 Spark plugs Check condition Clean and regap Replace 3 Valves Check valve clearance Adjust Every 40000 km 24000 m...

Page 132: ...erly tight ened 14 Brake lever pivot shaft Lubricate with silicone grease 15 Brake pedal pivot shaft Lubricate with lithium soap based grease 16 Clutch lever pivot shaft Lubricate with lithium soap based grease 17 Shift pedal pivot shaft Lubricate with lithium soap based grease 18 Sidestand center stand Check operation Lubricate with lithium soap based grease 19 Sidestand switch Check operation 20...

Page 133: ...uid level Every two years replace the internal components of the brake master cylinders and calipers and change the brake fluid Replace the brake hoses every four years and if cracked or damaged 27 Moving parts and cables Lubricate 28 Throttle grip Check operation Check throttle grip free play and adjust if necessary Lubricate cable and grip housing 29 Lights signals and switches Check operation A...

Page 134: ...l Fuel tank front cover Refer to GENERAL CHASSIS 2 on page 4 6 EAS30620 CHECKING THE SPARK PLUGS The following procedure applies to all of the spark plugs 1 Remove Fuel tank front cover Front side panel Front side cowling Refer to GENERAL CHASSIS 2 on page 4 6 Passenger seat Rider seat Refer to GENERAL CHASSIS 1 on page 4 1 Fuel tank cover Refer to GENERAL CHASSIS 3 on page 4 13 Fuel tank Refer to...

Page 135: ...side cowling Refer to GENERAL CHASSIS 2 on page 4 6 Passenger seat Rider seat Refer to GENERAL CHASSIS 1 on page 4 1 Fuel tank cover Refer to GENERAL CHASSIS 3 on page 4 13 Fuel tank Refer to FUEL TANK on page 7 1 Air filter case Refer to GENERAL CHASSIS 3 on page 4 13 Air cut off valve Refer to AIR INDUCTION SYSTEM on page 7 15 Radiator Refer to RADIATOR on page 6 1 2 Remove Ignition coils Spark ...

Page 136: ... the following table 5 Remove Camshaft TIP Refer to CAMSHAFTS on page 5 9 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 6 Adjust Valve clearance a Remove the valve lifter 1 and the valve pad 2 with a valve lapper 3 TIP Cover the timing chain opening with a rag to Thickness gauge 90890 03180 Feeler gauge set YU 26900...

Page 137: ...d num ber Example 1 58 mm 0 062 in 0 05 mm 0 002 in 1 63 mm 0 064 in The valve pad number is 163 e Round off the valve pad number according to the following table and then select the suit able valve pad TIP Refer to the following table for the available valve pads Example Valve pad number 163 Rounded value 165 New valve pad number 165 f Install the new valve pad 1 and the valve lift er 2 TIP Lubri...

Page 138: ...rol learning value 00 or 01 Check the intake system 02 Clean the throttle bodies Refer to CHECKING AND CLEANING THE THROTTLE BODIES on page 7 7 a Connect the Yamaha diagnostic tool Use the diagnostic code number 67 Refer to SELF DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE on page 9 5 b Check the ISC idle speed control leaning value EAS30797 SYNCHRONIZING THE THROTTLE BODIES TIP Before synchroniz...

Page 139: ... oper ate properly TIP Turn the bypass air screw using the carburetor angle driver After each step rev the engine two or three times each time for less than a second and check the synchronization again If a bypass air screw was removed turn the screw in fully and be sure to synchronize the throttle bodies If the throttle body synchronization can not be adjusted using the bypass air screw clean or ...

Page 140: ...ay 3 Simultaneously press the TCS button 1 and RESET button 2 for 2 seconds or more TIP DIAG appears on the multi function meter right display 4 Press the TCS button 1 to select the CO adjustment mode CO 2 or the diagnostic mode DIAG 5 After selecting CO simultaneously press the TCS button 1 and RESET button 2 for 2 seconds or more to execute the selec tion 6 Press the TCS button or RESET button t...

Page 141: ...der head breather hose 1 Cracks damage Replace Loose connection Connect properly NOTICE ECA14920 Make sure the cylinder head breather hose is routed correctly 3 Install Air filter case Refer to GENERAL CHASSIS 3 on page 4 13 EAS30628 REPLACING THE AIR FILTER ELEMENT 1 Remove Fuel tank front cover Front side panel Front side cowling Refer to GENERAL CHASSIS 2 on page 4 6 Passenger seat Rider seat R...

Page 142: ...t Refer to GENERAL CHASSIS 1 on page 4 1 Front side cowling Front side panel Fuel tank front cover Refer to GENERAL CHASSIS 2 on page 4 6 EAS30629 ADJUSTING THE CLUTCH LEVER FREE PLAY 1 Check Clutch lever free play a Out of specification Adjust 2 Adjust Clutch lever free play Handlebar side a Turn the adjusting bolt 1 in direction a or b until the specified clutch lever free play is obtained TIP I...

Page 143: ...d poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake performance When refilling be careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock NOTICE ECA13540 Brake fluid may dam...

Page 144: ...all of the brake pads 1 Operate the brake 2 Check Front brake pad Wear indicators 1 almost touch the brake disc Replace the brake pads as a set Refer to FRONT BRAKE on page 4 35 EAS30631 ADJUSTING THE REAR DISC BRAKE 1 Adjust Brake pedal position a Loosen the locknut 1 b Turn the adjusting bolt 2 in direction a or b until the specified brake pedal position is obtained WARNING EWA13070 After adjust...

Page 145: ...replaced the brake fluid level is very low brake operation is faulty TIP Be careful not to spill any brake fluid or allow the brake master cylinder reservoir or brake fluid reservoir to overflow When bleeding the ABS make sure that there is always enough brake fluid before applying the brake Ignoring this precaution could allow air to enter the ABS considerably lengthening the bleeding procedure I...

Page 146: ...G 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 Cracks damage wear Replace 2 Check Brake hose holder Loose Tighten the holder bolt 3 Hold the vehicle upright and apply the brake several ...

Page 147: ...stics can be giv en if a tire combination other than one approved by Yamaha is used on this vehicle WARNING EWA13210 New tires have a relatively low grip on the road surface until they have been slightly worn Therefore approximately 100 km should be traveled at normal speed before any high speed riding is done TIP For tires with a direction of rotation mark 1 Tire air pressure measured on cold tir...

Page 148: ...e engine and other vital parts and one that is too loose can skip and damage the swing arm or cause an accident Therefore keep the drive chain slack within the specified lim its 1 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 Shift the tra...

Page 149: ...ubricant that is suitable for O ring chains Do not use any other lubricants on the drive chain since they may contain solvents that could damage the O rings EAS30645 CHECKING AND ADJUSTING THE STEERING HEAD 1 Stand the vehicle on a level surface WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over TIP Place the vehicle on a suitable stand so that the front wh...

Page 150: ...page 4 69 EAS30646 LUBRICATING THE STEERING HEAD 1 Lubricate Upper bearing Lower bearing Bearing race EAS31186 CHECKING THE CHASSIS FASTENERS Make sure that all nuts bolts and screws are properly tightened Refer to CHASSIS TIGHTENING TORQUES on page 2 18 EAS30804 LUBRICATING THE BRAKE LEVER Lubricate the pivoting point and metal to metal moving parts of the lever EAS30805 LUBRICATING THE CLUTCH LE...

Page 151: ...ovement Repair or replace EAS30857 LUBRICATING THE CENTERSTAND Lubricate the pivoting point and metal to metal moving parts of the centerstand EAS30652 CHECKING THE SIDESTAND SWITCH Refer to ELECTRICAL COMPONENTS on page 8 123 EAS30653 CHECKING THE FRONT FORK 1 Stand the vehicle on a level surface WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over 2 Check I...

Page 152: ...g bolt 1 in direction a or b TIP The spring preload setting is determined by measuring the distance c shown in the illustra tion The shorter distance c is the higher the spring preload the longer distance c is the lower the spring preload Rebound damping right side only NOTICE ECA13590 Never go beyond the maximum or minimum adjustment positions 1 Adjust Rebound damping a Turn the adjusting screw 1...

Page 153: ...t positions 1 Adjust Spring preload a Adjust the spring preload with the special wrench 1 and extension bar 2 included in the owner s tool kit b Turn the adjusting ring 3 in direction a or b c Align the desired position on the adjusting ring with the stopper 4 Rebound damping NOTICE ECA13590 Never go beyond the maximum or minimum adjustment positions 1 Adjust Rebound damping a Turn the adjusting s...

Page 154: ...tes the clutch and the wrong oil types or additives could cause clutch slippage Therefore do not add any chemical additives or use engine oils with a grade of CD or higher and do not use oils labeled ENERGY CONSERVING II Do not allow foreign materials to enter the crankcase TIP Before checking the engine oil level wait a few minutes until the oil has settled 4 Start the engine warm it up for sever...

Page 155: ...ch 2 b Lubricate the O ring 3 of the new oil filter cartridge with a thin coat of engine oil NOTICE ECA13390 Make sure the O ring 3 is positioned cor rectly in the groove of the oil filter cartridge c Tighten the new oil filter cartridge to specifi cation with an oil filter wrench 6 Install Engine oil drain bolt along with the gasket 7 Fill Crankcase with the specified amount of the recom mended e...

Page 156: ... up the engine 3 Remove Main gallery bolt 1 WARNING EWA12980 The engine muffler and engine oil are ex tremely hot 4 Install Oil pressure gauge 1 Adapter 2 5 Measure Engine oil pressure at the following conditions Out of specification Check 6 Install Main gallery bolt Engine oil quantity Quantity disassembled 3 40 L 3 59 US qt 2 99 Imp qt Without oil filter cartridge re placement 2 40 L 2 54 US qt ...

Page 157: ...LING SYSTEM 1 Check Radiator 1 Radiator inlet hose 2 Radiator outlet hose 3 Oil cooler 4 Oil cooler inlet hose 5 Oil cooler outlet hose 6 Water jacket joint 7 Water pump inlet hose 8 Cracks damage Replace Refer to RADIATOR on page 6 1 OIL COOLER on page 6 4 THERMOSTAT on page 6 6 and WATER PUMP on page 6 8 EAS30813 CHANGING THE COOLANT 1 Remove Front side panel right Refer to GENERAL CHASSIS 2 on ...

Page 158: ...ugh ly wash them with water and consult a doc tor If coolant splashes on your clothes quickly wash it away with water and then with soap and water If coolant is swallowed induce vomiting and get immediate medical attention NOTICE ECA21291 Adding water instead of coolant dilutes the antifreeze concentration of the coolant If water is used instead of coolant check 2 1 3 1 1 2 4 3 4 1 1 2 Water pump ...

Page 159: ...AL COMPONENTS on page 8 123 EAS30659 ADJUSTING THE REAR BRAKE LIGHT SWITCH TIP The rear brake light switch is operated by move ment of the brake pedal The rear brake light switch is properly adjusted when the brake light comes on just before the braking effect starts 1 Check Rear brake light operation timing Incorrect Adjust 2 Adjust Rear brake light operation timing a Hold the main body 1 of the ...

Page 160: ...y throt tle body synchronization should be adjusted properly a Slide back the rubber cover 1 b Loosen the locknut 2 c Turn the adjusting nut 3 in direction a or b until the specified throttle grip free play is ob tained d Tighten the locknut e Slide the rubber cover to its original position TIP Make sure that the adjusting nut is covered com pletely by the rubber cover EAS30816 CHECKING AND CHARGI...

Page 161: ...adjusting screws 1 in direction a or b Left headlight Right headlight Direction a Headlight beam moves to the right Direction b Headlight beam moves to the left Direction a Headlight beam moves to the left Direction b Headlight beam moves to the right a a b b 1 1 a b 1 a b 1 ...

Page 162: ...PERIODIC MAINTENANCE 3 32 ...

Page 163: ...NCE 4 24 INSTALLING THE FRONT WHEEL DISC BRAKE 4 25 REAR WHEEL 4 27 REMOVING THE REAR WHEEL 4 30 DISASSEMBLING THE REAR WHEEL 4 30 CHECKING THE REAR WHEEL 4 31 CHECKING THE REAR WHEEL DRIVE HUB 4 31 CHECKING AND REPLACING THE REAR WHEEL SPROCKET 4 31 ASSEMBLING THE REAR WHEEL 4 31 MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR 4 32 ADJUSTING THE REAR WHEEL STATIC BALANCE 4 32 INSTALLING THE...

Page 164: ...AULIC UNIT ASSEMBLY 4 63 INSTALLING THE HYDRAULIC UNIT ASSEMBLY 4 63 HYDRAULIC UNIT OPERATION TESTS 4 65 CHECKING THE ABS WARNING LIGHT 4 68 HANDLEBAR 4 69 ADJUSTING THE HANDLEBAR POSITION 4 71 REMOVING THE HANDLEBAR 4 72 CHECKING THE HANDLEBAR 4 72 INSTALLING THE HANDLEBAR 4 72 INSTALLING THE REARVIEW MIRRORS AND HANDGUARDS 4 74 FRONT FORK 4 76 REMOVING THE FRONT FORK LEGS 4 79 DISASSEMBLING THE ...

Page 165: ...ING THE SWINGARM 4 96 CHECKING THE SWINGARM 4 96 INSTALLING THE SWINGARM 4 97 CHAIN DRIVE 4 98 REMOVING THE DRIVE CHAIN 4 99 CHECKING THE DRIVE CHAIN 4 99 CHECKING THE DRIVE SPROCKET 4 100 CHECKING THE REAR WHEEL SPROCKET 4 100 CHECKING THE REAR WHEEL DRIVE HUB 4 100 INSTALLING THE DRIVE CHAIN 4 101 ...

Page 166: ...er seat 1 2 Cap 1 3 Rider seat 1 4 Rider seat height position adjuster 1 5 Battery band 1 6 Negative battery lead 1 Disconnect 7 Positive battery lead 1 Disconnect 8 Battery 1 9 Spacer 1 10 Grab bar left 1 11 Grab bar right 1 1 3 4 5 6 7 8 9 10 11 25 Nm 2 5 m kgf 18 ft lbf 32 Nm 3 2 m kgf 23 ft lbf 2 2 Nm 0 22 m kgf 1 6 ft lbf 2 ...

Page 167: ...bar Refer to GENERAL CHASSIS 1 on page 4 1 1 Top cover 1 2 Stay right 1 3 Rear side cover right 1 4 Seat lock bracket 1 5 Seat lock assembly 1 6 Seat lock cable 1 Disconnect 7 Stay left 1 8 Rear side cover left 1 13 Nm 1 3 m kgf 9 4 ft lbf 7 Nm 0 7 m kgf 5 1 ft Ibf 26 Nm 2 6 m kgf 19 ft lbf 3 5 Nm 0 35 m kgf 2 5 ft lbf 1 2 3 4 5 6 7 8 26 Nm 2 6 m kgf 19 ft lbf ...

Page 168: ...S 1 on page 4 1 1 Tail brake light coupler 1 Disconnect 2 Tail brake light 1 3 Owner s tool kit band 1 4 Owner s tool kit 1 5 Rear turn signal light coupler 2 Disconnect 6 License plate light coupler 1 Disconnect 7 Mudguard assembly 1 8 Lower tail cover 1 9 Stator coil coupler 1 Disconnect 10 Rectifier regulator coupler 1 Disconnect 11 Rectifier regulator 1 12 Tail brake light cover 1 7 Nm 0 7 m k...

Page 169: ...er seat with the H position slot f and then push the rear of the seat down to lock it in place as shown To install the rider seat in the low position a Insert the projection a on the rider seat height position adjuster into the grommet b b Insert the projection c on the front of the rid er seat into the seat holder d c Align the projection e on the bottom of the rider seat with the L position slot...

Page 170: ...GENERAL CHASSIS 1 4 5 1 a b ...

Page 171: ...k front cover 1 2 Front side panel left 1 3 Turn signal light coupler left 1 Disconnect 4 Front side cowling left 1 5 Front side panel right 1 6 Turn signal light coupler right 1 Disconnect 7 Front side cowling right 1 4 0 Nm 0 40 m kgf 2 9 ft lbf 2 3 4 0 Nm 0 40 m kgf 2 9 ft lbf 1 5 Nm 0 15 m kgf 1 1 ft lbf 4 0 Nm 0 40 m kgf 2 9 ft lbf 1 5 Nm 0 15 m kgf 1 1 ft lbf 1 4 5 6 7 ...

Page 172: ... 3 Support stay 1 4 Inner panel 1 5 Auxiliary light coupler 1 Disconnect 6 Headlight coupler 1 Disconnect 7 Headlight assembly 1 8 Meter assembly coupler 1 Disconnect 9 Meter assembly 1 10 Auxiliary DC jack coupler 1 Disconnect 11 Auxiliary DC jack 1 7 Nm 0 7 m kgf 5 1 ft Ibf 1 3 Nm 0 13 m kgf 0 94 ft lbf 0 5 Nm 0 05 m kgf 0 36 ft lbf 1 2 3 4 5 6 7 8 9 10 11 2 8 Nm 0 28 m kgf 2 0 ft lbf 7 Nm 0 7 m...

Page 173: ...rder Job Parts to remove Q ty Remarks 1 Headlight top cover left 1 2 Headlight top cover right 1 3 Headlight side cover left 1 4 Headlight side cover right 1 5 Center cover 1 6 Headlight control unit coupler 1 Disconnect 7 Headlight control unit 1 1 2 3 4 5 6 7 ...

Page 174: ...nt side panel Front side cowling Refer to GENERAL CHASSIS 2 on page 4 6 Headlight assembly Refer to GENERAL CHASSIS 2 on page 4 6 Meter assembly Refer to GENERAL CHASSIS 2 on page 4 6 1 Handlebar switch lead left 1 2 Handlebar switch lead right 1 3 Wire harness 2 4 Headlight stay 1 1 2 3 4 33 Nm 3 3 m kgf 24 ft lbf ...

Page 175: ...ng it forward b Install the fuel tank front cover bolts 2 and quick fastener screws 3 and then tighten the bolts to specification EAS31381 REMOVING THE FRONT SIDE COWLINGS 1 Remove Fuel tank front cover Front side panel 2 Remove Front side cowling left 1 a Remove the front side cowling bolts 2 front side cowling screw 3 and quick fastener screw 4 b Disengage portion a and then remove the front sid...

Page 176: ...1382 INSTALLING THE FRONT SIDE COWLINGS 1 Install Front side cowling left 1 a Insert the slot a into the projection b and then install the front side cowling as shown in the illustration b Install the quick fastener screw 2 front side cowling screw 3 and front side cowling bolts 4 and then tighten the screw and bolts to specification a 1 2 1 2 3 4 a Front side cowling screw 1 5 Nm 0 15 m kgf 1 1 f...

Page 177: ...T 1 Adjust Windshield height position a Loosen the windshield height position adjust ing knob 1 on each side of the windshield until resistance is felt NOTICE ECA20430 Do not continue turning the knob after resis tance is felt Otherwise the knob could be damaged b Align the slide plate holder 2 with the match marks 3 at the desired position TIP Make sure that the projection on plate holder fits in...

Page 178: ... cover Front side panel Front side cowling Refer to GENERAL CHASSIS 2 on page 4 6 Passenger seat Rider seat Refer to GENERAL CHASSIS 1 on page 4 1 Rider seat height position adjuster Refer to GENERAL CHASSIS 1 on page 4 1 1 Fuel tank cover left 1 2 Fuel tank cover right 1 3 Fuel tank protector 1 4 0 Nm 0 40 m kgf 2 9 ft lbf 4 0 Nm 0 40 m kgf 2 9 ft lbf 1 2 3 ...

Page 179: ...owling Refer to GENERAL CHASSIS 2 on page 4 6 Passenger seat Rider seat Refer to GENERAL CHASSIS 1 on page 4 1 Fuel tank cover Refer to GENERAL CHASSIS 3 on page 4 13 Fuel tank Refer to FUEL TANK on page 7 1 1 Electrical components tray left 1 2 Handlebar switch lead left 1 3 Wire harness 1 4 Intake air temperature sensor 1 1 2 3 4 7 Nm 0 7 m kgf 5 1 ft Ibf ...

Page 180: ...de cowling Refer to GENERAL CHASSIS 2 on page 4 6 Passenger seat Rider seat Refer to GENERAL CHASSIS 1 on page 4 1 Fuel tank cover Refer to GENERAL CHASSIS 3 on page 4 13 Fuel tank Refer to FUEL TANK on page 7 1 1 Electrical components tray right 1 2 Handlebar switch lead right 1 3 Wire harness 1 1 2 3 7 Nm 0 7 m kgf 5 1 ft Ibf 3 7 Nm 0 7 m kgf 5 1 ft Ibf ...

Page 181: ...uel tank cover Refer to GENERAL CHASSIS 3 on page 4 13 Fuel tank Refer to FUEL TANK on page 7 1 1 ECU engine control unit 1 2 ECU coupler 2 Disconnect 3 Air filter case cover 1 4 Air filter element 1 5 Air filter case joint clamp screw 3 Loosen 6 Air induction system hose 1 Disconnect 7 Cylinder head breather hose 1 Disconnect 8 Air filter case 1 7 Nm 0 7 m kgf 5 1 ft Ibf 1 2 3 4 5 6 7 8 2 8 Nm 0 ...

Page 182: ... by sliding it in the direction shown in the illustration EAS31385 INSTALLING THE FUEL TANK COVERS 1 Install Fuel tank cover left 1 a Insert the slot a into the projection b and then install the fuel tank cover as shown in the illustration b Install the fuel tank cover bolt 2 and then tighten the bolt to specification 2 Install Fuel tank cover right 1 a Insert the slot a into the projection b and ...

Page 183: ...GENERAL CHASSIS 3 4 18 3 Install Rider seat Passenger seat 4 Install Front side cowling Front side panel Fuel tank front cover 2 ...

Page 184: ...ector 1 4 Front wheel sensor 1 5 Wheel axle pinch bolt 1 Loosen 6 Wheel axle 1 7 Front wheel 1 8 Collar 1 9 Front wheel sensor housing 1 10 Front brake disc 2 1 6 7 10 8 10 5 1 5 5 18 Nm 1 8 m kgf 13 ft Ibf LT 35 Nm 3 5 m kgf 25 ft Ibf LT 18 Nm 1 8 m kgf 13 ft Ibf 35 Nm 3 5 m kgf 25 ft Ibf 3 4 9 10 Nm 1 0 m kgf 7 2 ft Ibf 7 Nm 0 7 m kgf 5 1 ft Ibf 23 Nm 2 3 m kgf 17 ft Ibf 65 Nm 6 5 m kgf 47 ft Ib...

Page 185: ...FRONT WHEEL 4 20 Disassembling the front wheel Order Job Parts to remove Q ty Remarks 1 Front wheel sensor rotor 1 2 Oil seal 2 3 Wheel bearing 2 4 Spacer 1 A 1 2 3 4 2 3 3 LT 8 Nm 0 8 m kgf 5 8 ft Ibf ...

Page 186: ...el sensor from the sensor housing 3 Elevate Front wheel TIP Place the vehicle on a suitable stand so that the front wheel is elevated 4 Loosen Wheel axle pinch bolt 5 Remove Wheel axle Front wheel EAS30146 DISASSEMBLING THE FRONT WHEEL NOTICE ECA21340 Do not drop the wheel sensor rotor or sub ject it to shocks If any solvent gets on the wheel sensor ro tor wipe it off immediately 1 Remove Oil seal...

Page 187: ... wipe it off immediately 1 Install Wheel bearings Oil seals a Install the new wheel bearing right side NOTICE ECA18110 Do not contact the wheel bearing inner race 1 or balls 2 Contact should be made only with the outer race 3 TIP Use a socket 4 that matches the diameter of the wheel bearing outer race b Install the spacer c Install the new wheel bearing left side TIP Place a suitable washer 1 betw...

Page 188: ...ic screwdrivers etc away from the front wheel sensor or front wheel sensor rotor Do not drop or shock the wheel sensor or the wheel sensor rotor 1 Check Front wheel sensor 1 Cracks bends distortion Replace Iron powder dust Clean 2 Check Front wheel sensor rotor 1 Cracks damage scratches Replace the front wheel sensor rotor Iron powder dust solvent Clean TIP The wheel sensor rotor is installed on t...

Page 189: ...ot TIP Place the front wheel on a suitable balancing stand a Spin the front wheel b When the front wheel stops put an X1 mark at the bottom of the wheel c Turn the front wheel 90 so that the X1 mark is positioned as shown d Release the front wheel e When the wheel stops put an X2 mark at the bottom of the wheel f Repeat steps c through e several times until all the marks come to rest at the same s...

Page 190: ...s and in a crisscross pattern 2 Check Front brake discs Refer to CHECKING THE FRONT BRAKE DISCS on page 4 40 3 Lubricate Oil seal lips 4 Install Collar Front wheel sensor housing Front wheel Front wheel axle TIP Align the slot a in the sensor housing with the projection b of the front fork before assembly 5 Tighten Front wheel axle Front wheel axle pinch bolt NOTICE ECA19760 Before tightening the ...

Page 191: ... overtorque wrong in stallation direction rotor decentering LOC TITE on the mounting surface of the rotor deformation caused by an impact during ser vice and caught foreign materials If there is any defective part repair or replace the de fective part TIP Measure the distance between the front wheel sensor rotor and front wheel sensor in several places in one rotation of the front wheel Do not tur...

Page 192: ...age 4 48 1 Rear wheel sensor 1 2 Locknut 2 Loosen 3 Adjusting bolt 2 Loosen 4 Wheel axle nut 1 5 Washer 1 6 Wheel axle 1 7 Adjusting block left 1 8 Adjusting block right 1 9 Rear wheel 1 10 Brake caliper bracket 1 2 3 2 3 4 5 6 7 8 9 10 16 Nm 1 6 m kgf 12 ft Ibf 150 Nm 15 m kgf 108 ft Ibf 16 Nm 1 6 m kgf 12 ft Ibf 1 7 Nm 0 7 m kgf 5 1 ft Ibf ...

Page 193: ...ve Q ty Remarks 1 Rear brake disc 1 2 Bracket 1 3 Rear wheel sprocket 1 4 Collar 1 5 Collar 1 6 Oil seal 1 7 Bearing 1 8 Rear wheel drive hub 1 9 Collar 1 10 Rear wheel drive hub damper 6 11 Rear wheel 1 1 2 3 3 4 5 7 8 9 10 11 5 6 30 Nm 3 0 m kgf 22 ft Ibf LT 6 80 Nm 8 0 m kgf 58 ft Ibf ...

Page 194: ...HEEL 4 29 Disassembling the rear wheel Order Job Parts to remove Q ty Remarks 1 Rear wheel sensor rotor 1 2 Oil seal 1 3 Wheel bearing 1 4 Spacer 1 5 Wheel bearing 1 A 1 3 4 LT 2 3 8 Nm 0 8 m kgf 5 8 ft Ibf 5 ...

Page 195: ...the brake caliper Be sure not to contact the sensor electrode to any metal part when removing the rear wheel sensor from the rear brake caliper bracket 3 Loosen Locknuts 1 Adjusting bolts 2 4 Remove Wheel axle nut 1 Washer Wheel axle 2 Rear wheel Brake caliper bracket NOTICE ECA21400 Be sure to remove the rear wheel sensor be fore removing the brake caliper bracket oth erwise the sensor could be d...

Page 196: ...ear Replace the drive sprocket the rear wheel sprocket and the drive chain as a set Bent teeth Replace the drive sprocket the rear wheel sprocket and the drive chain as a set 2 Replace Rear wheel sprocket a Remove the rear wheel sprocket nuts and the rear wheel sprocket b Clean the rear wheel drive hub with a clean cloth especially the surfaces that contact the sprocket c Install the new rear whee...

Page 197: ... WHEEL SENSOR AND SENSOR ROTOR on page 4 23 EAS30164 ADJUSTING THE REAR WHEEL STATIC BALANCE TIP After replacing the tire wheel or both the rear wheel static balance should be adjusted Adjust the rear wheel static balance with the brake disc and rear wheel drive hub installed 1 Adjust Rear wheel static balance Refer to ADJUSTING THE FRONT WHEEL STATIC BALANCE on page 4 24 EAS30165 INSTALLING THE R...

Page 198: ...or looseness and the rear wheel sensor and sensor rotor installation conditions warpage caused by overtorque wrong in stallation direction rotor decentering LOC TITE on the mounting surface of the rotor deformation caused by an impact during ser vice and caught foreign materials If there is any defective part repair or replace the de fective part TIP Measure the distance between the rear wheel sen...

Page 199: ...REAR WHEEL 4 34 Thickness gauge 90890 03180 Feeler gauge set YU 26900 9 1 2 a ...

Page 200: ...ty Remarks The following procedure applies to both of the front brake calipers 1 Brake pad clip 2 2 Brake pad pin 1 3 Brake pad spring 1 4 Brake pad 2 5 Front brake caliper 1 6 Bleed screw 1 7 Bleed screw 1 Right brake caliper side 1 2 3 4 5 6 7 35 Nm 3 5 m kgf 25 ft Ibf 5 Nm 0 5 m kgf 3 6 ft Ibf ...

Page 201: ...reservoir diaphragm holder 1 6 Brake master cylinder reservoir diaphragm 1 7 Brake lever 1 8 Front brake light switch lead connector 2 Disconnect 9 Front brake light switch 1 10 Brake hose union bolt 1 11 Brake hose gasket 2 12 Brake hose 1 13 Front brake master cylinder holder 1 14 Front brake master cylinder 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 S 10 Nm 1 0 m kgf 7 2 ft lbf 6 Nm 0 6 m kgf 4 3 ft Ib...

Page 202: ...FRONT BRAKE 4 37 Disassembling the front brake master cylinder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder kit 1 2 Brake master cylinder body 1 2 1 S BF BF ...

Page 203: ... procedure applies to both of the front brake calipers Brake fluid Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS on page 3 15 1 Brake hose union bolt 1 2 Brake hose gasket 1 3 Brake hose 2 4 Brake hose gasket 2 5 Front brake caliper 1 1 2 3 4 5 35 Nm 3 5 m kgf 25 ft Ibf 30 Nm 3 0 m kgf 22 ft Ibf ...

Page 204: ...he front brake calipers 1 Brake pad clip 2 2 Brake pad pin 1 3 Brake pad spring 1 4 Brake pad 2 5 Brake caliper piston 4 6 Brake caliper piston dust seal 4 7 Brake caliper piston seal 4 8 Bleed screw 1 9 Bleed screw 1 Right brake caliper side 1 2 3 4 5 6 6 7 5 6 6 7 7 7 8 9 S S BF S BF S 5 Nm 0 5 m kgf 3 6 ft Ibf 5 Nm 0 5 m kgf 3 6 ft Ibf ...

Page 205: ...1 Remove Front wheel Refer to FRONT WHEEL on page 4 19 2 Check Front brake disc Damage galling Replace 3 Measure Brake disc runout Out of specification Correct the brake disc runout or replace the brake disc a Place the vehicle on a suitable stand so that the front wheel is elevated b Before measuring the brake disc runout turn the handlebar to the left or right to ensure that the front wheel is s...

Page 206: ...m ble the brake caliper 1 Remove Brake pad clips 1 Brake pad pin 2 Brake pad spring 3 2 Remove Brake pads 1 3 Measure Brake pad wear limit a Out of specification Replace the brake pads as a set 4 Remove Brake caliper bolts 5 Install Brake pads Brake pad spring TIP Always install new brake pads and new brake pad spring as a set a Connect a clear plastic hose 1 tightly to the bleed screw 2 Put the o...

Page 207: ...ake lever operation Soft or spongy feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS on page 3 15 EAS30724 REMOVING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers TIP Before removing the brake caliper drain the brake fluid from the entire brake system 1 Remove Brake hose union bolts 1 Brake hose gaskets 2 Brake hoses 3 TIP Put ...

Page 208: ...e the brake caliper pistons Brake caliper cylinders 2 Scratches wear Replace the brake caliper assembly Brake caliper body 3 Cracks damage Replace the brake caliper assembly Brake fluid delivery passages brake caliper body Obstruction Blow out with compressed air WARNING EWA13611 Whenever a brake caliper is disassembled replace the brake caliper piston dust seals and brake caliper piston seals EAS...

Page 209: ... WARNING EWA13090 Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake performance When refilling be careful that water does not enter the brake fluid reservo...

Page 210: ... brake master cylinder body Obstruction Blow out with compressed air 2 Check Brake master cylinder kit Damage scratches wear Replace 3 Check Brake master cylinder reservoir 1 Brake master cylinder reservoir diaphragm holder 2 Cracks damage Replace Brake master cylinder reservoir diaphragm 3 Damage wear Replace 4 Check Brake hoses Cracks damage wear Replace EAS30181 ASSEMBLING THE FRONT BRAKE MASTE...

Page 211: ...ed brake fluid WARNING EWA13540 Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake performance When refilling be careful that water does not enter the brake...

Page 212: ...FRONT BRAKE 4 47 BRAKE SYSTEM ABS on page 3 15 ...

Page 213: ...emoving the rear brake pads Order Job Parts to remove Q ty Remarks 1 Screw plug 1 2 Brake pad retaining bolt 1 3 Rear brake caliper 1 4 Brake pad 2 5 Brake pad shim 2 6 Brake pad insulator 2 7 Brake pad spring 1 8 Bleed screw 1 LT S S S S ...

Page 214: ...in Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS on page 3 15 1 Brake fluid reservoir cap 1 2 Brake fluid reservoir diaphragm holder 1 3 Brake fluid reservoir diaphragm 1 4 Brake fluid reservoir 1 5 Brake fluid reservoir hose 1 6 Brake hose union bolt 1 7 Brake hose gasket 2 8 Brake hose 1 9 Rear brake light switch coupler 1 Disconnect 10 Right footrest assembly 1 11 Wire guide 1 110 Nm 11 m kg...

Page 215: ...remove Q ty Remarks 12 Brake pedal 1 13 Rear brake master cylinder assembly 1 14 Rear brake light switch 1 110 Nm 11 m kgf 80 ft Ibf 55 Nm 5 5 m kgf 40 ft Ibf 3 8 Nm 0 38 m kgf 2 8 ft Ibf 30 Nm 3 0 m kgf 22 ft Ibf LT 30 Nm 3 0 m kgf 22 ft Ibf 23 Nm 2 3 m kgf 17 ft Ibf 12 13 14 ...

Page 216: ... 51 Disassembling the rear brake master cylinder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder yoke 1 2 Brake master cylinder kit 1 3 Hose joint 1 4 Bushing 1 5 Brake master cylinder body 1 S BF BF ...

Page 217: ...rear brake caliper Order Job Parts to remove Q ty Remarks Brake fluid Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS on page 3 15 1 Brake hose union bolt 1 2 Brake hose gasket 2 3 Brake hose 1 4 Rear brake caliper 1 LT S S ...

Page 218: ...arts to remove Q ty Remarks 1 Screw plug 1 2 Brake pad retaining bolt 1 3 Brake pad 2 4 Brake pad shim 2 5 Brake pad insulator 2 6 Brake pad spring 1 7 Brake caliper piston 1 8 Brake caliper piston dust seal 1 9 Brake caliper piston seal 1 10 Bleed screw 1 S S S BF ...

Page 219: ... Replace 3 Measure Brake disc runout Out of specification Correct the brake disc runout or replace the brake disc Refer to CHECKING THE FRONT BRAKE DISCS on page 4 40 4 Measure Brake disc thickness Measure the brake disc thickness at a few dif ferent locations Out of specification Replace Refer to CHECKING THE FRONT BRAKE DISCS on page 4 40 5 Adjust Brake disc runout Refer to CHECKING THE FRONT BR...

Page 220: ... caliper piston 3 Lubricate Rear brake caliper bolts NOTICE ECA14150 Do not allow grease to contact the brake pads Remove any excess grease 4 Install Rear brake caliper Brake pad retaining bolts Screw plug 5 Check Brake fluid level Below the minimum level mark a Add the specified brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 13 6 Check Brake pedal operation Soft...

Page 221: ...brake caliper pis ton b Remove the brake caliper piston dust seal and brake caliper piston seal EAS30188 CHECKING THE REAR BRAKE CALIPER 1 Check Brake caliper piston 1 Rust scratches wear Replace the brake caliper piston Brake caliper cylinder 2 Scratches wear Replace the brake caliper assembly Brake caliper body 3 Cracks damage Replace the brake caliper assembly Brake fluid delivery passages brak...

Page 222: ...ets Brake hose 2 Brake hose union bolt 3 WARNING EWA13531 Proper brake hose routing is essential to in sure safe vehicle operation NOTICE ECA19080 When installing the brake hose onto the brake caliper 1 make sure the brake pipe a passes between the projections b on the brake caliper 2 Remove Rear brake caliper 3 Install Brake pad insulators Brake pad shims onto the brake pads Brake pad spring into...

Page 223: ...l Below the minimum level mark a Add the specified brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 13 7 Check Brake pedal operation Soft or spongy feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS on page 3 15 EAS30193 REMOVING THE REAR BRAKE MASTER CYLINDER 1 Remove Brake hose union bolt 1 Brake hose gaskets 2 Brake hose 3 TIP To co...

Page 224: ...akage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake performance When refilling be careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock NOTICE ECA13540 Brake fluid...

Page 225: ...rake fluid Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS on page 3 15 1 Lean angle sensor coupler 1 Disconnect 2 Fuel tank bracket assembly 1 3 ABS ECU coupler 1 Disconnect 4 Brake hose union bolt Gasket 1 2 5 Rear brake hose hydraulic unit to rear brake caliper 1 Disconnect 6 Brake hose union bolt Gasket 1 2 7 Rear brake hose rear brake master cylinder to hydraulic unit 1 Disconnect 8 Br...

Page 226: ... Brake hose union bolt Gasket 1 2 11 Front brake hose front brake master cylinder to hydraulic unit 1 Disconnect 12 Bracket 1 13 Rear brake hose bracket 1 14 Hydraulic unit bracket 1 15 Hydraulic unit 1 7 Nm 0 7 m kgf 5 1 ft Ibf 30 Nm 3 0 m kgf 22 ft Ibf 7 Nm 0 7 m kgf 5 1 ft Ibf 7 Nm 0 7 m kgf 5 1 ft Ibf 11 Nm 1 1 m kgf 8 0 ft Ibf LT 30 Nm 3 0 m kgf 22 ft Ibf 10 11 12 13 14 15 9 ...

Page 227: ...heel sensor 5 Rear wheel sensor rotor 6 Front wheel sensor 7 Front wheel sensor rotor 8 ABS warning light 9 Fuse box 2 10 Rear brake hose hydraulic unit to rear brake caliper 11 Front brake hose front brake master cylinder to hydraulic unit 12 Front brake hose hydraulic unit to front brake caliper 13 Rear brake hose rear brake master cylinder to hydraulic unit ...

Page 228: ...connect ABS ECU coupler 1 TIP Pull the lock lever a of the ABS ECU coupler in the direction of the arrow shown and then dis connect the coupler 2 Remove Brake hoses TIP Do not operate the brake lever and brake pedal while removing the brake hoses NOTICE ECA18251 When removing the brake hoses cover the area around the hydraulic unit assembly to catch any spilt brake fluid Do not allow the brake flu...

Page 229: ...tion of the arrow shown Make sure that the ABS ECU coupler is con nected in the correct position as shown in illus tration A 5 Fill Brake master cylinder reservoir Brake fluid reservoir with the specified amount of the specified brake fluid WARNING EWA13090 Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Re...

Page 230: ...re is no danger of it falling over TIP For the brake line routing confirmation use the diagnosis mode of the Yamaha diagnostic tool Before performing the brake line routing confir mation make sure that no malfunctions have been detected in the ABS ECU and that the wheels are not rotating 1 Place the vehicle on the centerstand 2 Turn the main switch to OFF 3 Remove Passenger seat Rider seat Refer t...

Page 231: ...nit is normal delete all of the fault codes ABS reaction force confirmation WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over TIP For the ABS reaction force confirmation use the diagnosis mode of the Yamaha diagnostic tool For more information refer to the opera tion manual of the Yamaha diagnostic tool Before performing the ABS reaction force con firmatio...

Page 232: ... force pulsating action consists of quick pulses Be sure to continue operating the brake lever and brake pedal even after the pulsating action has stopped ON and OFF on the tool screen indicate when the brakes are being applied and re leased respectively 10 After the pulsating action has stopped in the brake lever it is generated in the brake pedal 1 and continues for a few seconds TIP The reactio...

Page 233: ...raulic unit assembly 12 Turn the main switch to OFF 13 Remove the Yamaha diagnostic tool coupler from the ABS test coupler and then install the protective cap 14 Turn the main switch to ON 15 Set the start engine stop switch to 16 Check for brake fluid leakage around the hy draulic unit Brake fluid leakage Replace the hydraulic unit brake pipes and related parts as a set 17 If the operation of the...

Page 234: ...end 2 2 4 Handlebar cover 2 5 Lever cover 2 6 Upper handguard bracket 2 7 Lower handguard bracket 2 1 2 3 4 5 6 7 7 Nm 0 7 m kgf 5 1 ft Ibf 17 Nm 1 7 m kgf 12 ft lbf 6 Nm 0 6 m kgf 4 3 ft Ibf 7 Nm 0 7 m kgf 5 1 ft Ibf 7 Nm 0 7 m kgf 5 1 ft Ibf 4 3 Nm 0 43 m kgf 3 1 ft lbf 17 Nm 1 7 m kgf 12 ft lbf 17 Nm 1 7 m kgf 12 ft lbf 4 3 Nm 0 43 m kgf 3 1 ft lbf 17 Nm 1 7 m kgf 12 ft lbf 6 7 2 3 5 4 1 ...

Page 235: ...nect 7 Grip end 2 8 Throttle grip 1 9 Clutch switch coupler 1 Disconnect 10 Handlebar switch left 1 11 Handlebar switch holder 2 12 Handlebar grip 1 13 Clutch switch 1 14 Clutch cable 1 Disconnect 15 Clutch lever holder 1 16 Upper handlebar holder 2 17 Handlebar 1 18 Lower handlebar holder 2 10 Nm 1 0 m kgf 7 2 ft lbf 40 Nm 4 0 m kgf 29 ft lbf 26 Nm 2 6 m kgf 19 ft lbf 22 Nm 2 2 m kgf 16 ft lbf 11...

Page 236: ...180 d Install the handlebar 2 and upper handlebar holders 1 NOTICE ECA19130 First tighten the bolts on the front side of the upper handlebar holder and then on the rear side Turn the handlebar all the way to the left and right If there is any contact with the fuel tank adjust the handlebar position TIP Align the punch mark a on the handlebar with the left side upper surface of the left lower han d...

Page 237: ...hten a bent handle bar as this may dangerously weaken it EAS30205 INSTALLING THE HANDLEBAR 1 Stand the vehicle on a level surface WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over 2 Install Lower handlebar holders temporarily Handlebar 1 Upper handlebar holders 2 NOTICE ECA19130 First tighten the bolts on the front side of the upper handlebar holder and th...

Page 238: ... handlebar 8 Install Handlebar switch screw left TIP Align the projection a on the left handlebar switch with the hole b in the handlebar 9 Install Handlebar grip 1 Grip end 2 a Apply a thin coat of rubber adhesive onto the end of the left handlebar b Side the handlebar grip over the end of the left handlebar c Wipe off any excess rubber adhesive with a clean rag Lower handlebar holder nut 40 Nm 4...

Page 239: ... Tighten the handguard bracket bolts 3 to specification c Tighten the rearview mirror locknut 4 to specification d Tighten the handguard bolt 5 to specifica tion e Tighten the handguard bracket nut 6 to specification 2 Install Handguard right 1 Rearview mirror right 2 a Install the handguard and rearview mirror TIP Temporarily tighten the handguard bracket bolts 3 rearview mirror locknut 4 handgua...

Page 240: ...on d Tighten the handguard bolt 5 to specifica tion e Tighten the handguard bracket nut 6 to specification Handguard bracket bolt 7 Nm 0 7 m kgf 5 1 ft lbf Rearview mirror locknut 17 Nm 1 7 m kgf 12 ft lbf Handguard bolt 17 Nm 1 7 m kgf 12 ft lbf Handguard bracket nut right 6 Nm 0 6 m kgf 4 3 ft lbf 1 2 4 5 6 3 T R T R T R T R ...

Page 241: ...oth of the front fork legs Front wheel Refer to FRONT WHEEL on page 4 19 1 Front fender 1 2 Upper bracket pinch bolt 1 Loosen 3 Cap bolt 1 Loosen 4 Lower bracket pinch bolt 2 Loosen 5 Front fork leg 1 1 2 3 4 5 10 Nm 1 0 m kgf 7 2 ft Ibf 26 Nm 2 6 m kgf 19 ft Ibf 10 Nm 1 0 m kgf 7 2 ft Ibf 23 Nm 2 3 m kgf 17 ft Ibf 23 Nm 2 3 m kgf 17 ft Ibf ...

Page 242: ...rks 1 Cap bolt 1 2 O ring 1 3 Washer 1 4 Spacer 1 5 Fork spring 1 6 Locknut 1 7 Dust seal 1 8 Oil seal clip 1 9 Outer tube 1 10 Oil seal 1 11 Washer 1 12 Outer tube bushing 1 13 Inner tube bushing 1 14 Damper rod assembly bolt 1 15 Copper washer 1 16 Damper rod assembly 1 17 Inner tube 1 LT ...

Page 243: ...t 1 2 O ring 1 3 Washer 1 4 Spacer 1 5 Fork spring 1 6 Locknut 1 7 Damper adjusting rod 1 8 Dust seal 1 9 Oil seal clip 1 10 Outer tube 1 11 Oil seal 1 12 Washer 1 13 Outer tube bushing 1 14 Inner tube bushing 1 15 Damper rod assembly bolt 1 16 Copper washer 1 17 Damper rod assembly 1 18 Inner tube 1 LT ...

Page 244: ...WA13640 Before loosening the upper and lower brack et pinch bolts support the front fork leg 4 Remove Front fork leg EAS30207 DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Remove Cap bolt 1 from the damper rod assembly Washer 2 Spacer 3 Locknut 4 a Press down on the spacer with the fork spring compressor 5 b Install the rod holder 6 between the ...

Page 245: ...or the damper rod assembly the right side is used for the rebound operation Pay atten tion not to mistake the right and left TIP While holding the damper rod with the damper rod holder 1 loosen the damper rod assembly bolt EAS30208 CHECKING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Check Inner tube 1 Outer tube 2 Bends damage scratches Replace WARNING EWA...

Page 246: ... front fork legs are not filled with the specified amount of the fork oil it may cause poor handling and a loss of stability TIP When assembling the front fork leg be sure to replace the following parts Inner tube bushing Outer tube bushing Oil seal Oil seal clip Dust seal Copper washer O ring Before assembling the front fork leg make sure all of the components are clean 1 Install Damper rod assem...

Page 247: ...he inner tube with fork oil Before installing the oil seal cover the top of the front fork leg with a plastic bag to protect the oil seal during installation 5 Install Outer tube to the inner tube 6 Install Outer tube bushing 1 Washer 2 with the fork seal driver 3 7 Install Oil seal 1 with the fork seal driver 2 Damper rod holder 90890 01582 Damper rod holder YM 01582 Recommended oil Suspension oi...

Page 248: ...o enter the front fork 12 After filling the front fork leg slowly stroke the damper rod 1 up and down at least ten times to distribute the fork oil TIP Be sure to stroke the damper rod slowly be cause the fork oil may spurt out 13 Before measuring the fork oil level wait ten minutes until the oil has settled and the air bubbles have dispersed Fork seal driver 90890 01442 Adjustable fork seal drive...

Page 249: ...nto the damper rod assembly d Install the rod puller and rod puller attach ment e Install the spacer f Install the fork spring compressor g Press down on the spacer with the fork spring compressor 1 h Pull up the rod puller and install the rod holder 2 between the locknut 3 and the spacer 4 TIP Use the side of the rod holder that is marked B i Remove the rod puller and rod puller attach Level left...

Page 250: ...knut all the way onto the damper rod assembly d Install the rod puller and rod puller attach ment e Install the spacer f Install the fork spring compressor g Press down on the spacer with the fork spring compressor 1 h Pull up the rod puller and install the rod holder 2 between the locknut 3 and the spacer 4 TIP Use the side of the rod holder that is marked B i Remove the rod puller and rod puller...

Page 251: ...he vehicle and tightening the lower bracket pinch bolts EAS30210 INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Install Front fork leg Temporarily tighten the upper and lower bracket pinch bolts TIP Make sure the outer tube is flush with the top of the upper bracket 2 Tighten Lower bracket pinch bolts 1 Cap bolt 2 Upper bracket pinch bolt 3 WARNING ...

Page 252: ...ASSIS 2 on page 4 6 Handlebar Refer to HANDLEBAR on page 4 69 Front fork legs Refer to FRONT FORK on page 4 76 1 Protector 1 2 Rivet 1 3 Coupler cover assembly 1 4 Clamp 1 5 Main switch coupler 2 Disconnect 6 Immobilizer coupler 1 Disconnect 7 Horn lead connector 2 Disconnect 8 Horn 1 9 Front brake hose 1 10 Front brake hose bracket 1 FWD 7 9 10 8 110 Nm 11 m kgf 80 ft Ibf 7 Nm 0 7 m kgf 5 1 ft Ib...

Page 253: ...t 1 15 Lock washer 1 16 Upper ring nut 1 17 Rubber washer 1 18 Lower ring nut 1 19 Lower bracket 1 20 Bearing cover 1 21 Lower bearing dust seal 1 22 Upper bearing 1 23 Lower bearing 1 FWD 110 Nm 11 m kgf 80 ft Ibf 7 Nm 0 7 m kgf 5 1 ft Ibf 52 Nm 5 2 m kgf 38 ft Ibf 1st 18 Nm 1 8 m kgf 13 ft Ibf 2nd 7 Nm 0 7 m kgf 5 1 ft Ibf 11 12 13 14 15 16 17 18 19 20 21 22 23 ...

Page 254: ...Wash Bearing Bearing race 2 Check Bearing 1 Bearing race 2 Damage pitting Replace the bearings and bearing races as a set 3 Replace Bearing Bearing race a Remove the bearing races from the steering head pipe 1 with a long rod 2 and hammer b Remove the bearing race 3 from the lower bracket with a floor chisel 4 and hammer c Install a new dust seal and new bearing rac es NOTICE ECA14270 If the beari...

Page 255: ... 2 Upper ring nut 3 Lock washer 4 Refer to CHECKING AND ADJUSTING THE STEERING HEAD on page 3 19 3 Install Upper bracket Steering stem nut TIP Temporarily tighten the steering stem nut 4 Install Front fork legs Refer to FRONT FORK on page 4 76 TIP Temporarily tighten the upper and lower bracket pinch bolts 5 Tighten Steering stem nut Recommended lubricant Lithium soap based grease Steering stem nu...

Page 256: ...er to FUEL TANK on page 7 1 Muffler assembly Refer to ENGINE REMOVAL on page 5 3 1 Connecting arm lower nut Bolt 1 1 2 Relay arm nut Collar Bolt 1 1 1 3 Rear shock absorber assembly upper nut Washer Bolt 1 1 1 4 Rear shock absorber assembly lower nut Washer Bolt 1 2 1 5 Rear shock absorber assembly 1 6 Connecting arm upper nut Bolt 1 1 7 Connecting arm 2 8 Relay arm 1 9 Collar Oil seal Bearing 1 2...

Page 257: ...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 Remove Connecting arm lower nut...

Page 258: ...sembly upper nut Relay arm bolt Relay arm nut Connecting arm lower bolt Connecting arm lower nut TIP Install the rear shock absorber assembly upper bolt relay arm bolt and connecting arm lower bolt from the left When installing the rear shock absorber as sembly lift up the swingarm Install the rear shock absorber assembly with the rebound damping adjusting screw facing the left side of the vehicle...

Page 259: ...REAR SHOCK ABSORBER ASSEMBLY 4 94 Rear shock absorber assembly nut upper 44 Nm 4 4 m kgf 32 ft lbf Relay arm nut 61 Nm 6 1 m kgf 44 ft lbf Connecting arm lower nut 55 Nm 5 5 m kgf 40 ft lbf T R ...

Page 260: ...chain Refer to CHAIN DRIVE on page 4 98 1 Connecting arm lower nut 1 2 Connecting arm lower bolt 1 3 Pivot shaft nut 1 4 Pivot shaft 1 5 Washer 1 6 Swingarm 1 7 Drive chain guard 1 8 Drive chain guide 1 9 Rear fender 1 10 Dust cover 4 11 Collar 3 12 Oil seal 4 13 Bearing 4 14 Washer 1 110 Nm 11 m kgf 80 ft Ibf 1 2 3 4 5 6 7 8 9 10 11 12 13 7 Nm 0 7 m kgf 5 1 ft Ibf 10 55 Nm 5 5 m kgf 40 ft Ibf 7 N...

Page 261: ...to side If the swingarm has side to side play check the collars bearings and dust covers c Check the swingarm vertical movement B by moving the swingarm up and down If the swingarm vertical movement is not smooth or if there is binding check the pivot shaft collars bearings and dust covers 4 Remove Drive chain Refer to REMOVING THE DRIVE CHAIN on page 4 99 Swingarm EAS30227 CHECKING THE SWINGARM 1...

Page 262: ...bolt Connecting arm lower nut Rear wheel Refer to REAR SHOCK ABSORBER AS SEMBLY on page 4 91 and REAR WHEEL on page 4 27 5 Adjust Drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3 18 Recommended lubricant Lithium soap based grease Installed depth a 2 0 mm 0 08 in Installed depth b 9 0 mm 0 35 in Installed depth c 0 5 1 5 mm 0 02 0 06 in Installed depth d 7 0 mm 0 28 in Installed...

Page 263: ...Remarks 1 Locknut 2 2 Shift rod 1 3 Shift arm 1 4 Drive sprocket cover 1 5 Drive chain guide 1 6 Drive sprocket nut 1 7 Washer 1 8 Drive sprocket 1 9 Drive chain 1 1 2 3 4 5 6 14 Nm 1 4 m kgf 10 ft Ibf 10 Nm 1 0 m kgf 7 2 ft Ibf 7 8 9 95 Nm 9 5 m kgf 69 ft Ibf E 1 8 Nm 0 8 m kgf 5 8 ft Ibf LT E ...

Page 264: ...ength c between the outer sides of the pins on a 15 link section of the drive chain as shown in the illustration b Calculate the length a of the 15 link section of the drive chain using the following formula Drive chain 15 link section length a length b between pin inner sides length c between pin outer sides 2 TIP When measuring a 15 link section of the drive chain make sure that the drive chain ...

Page 265: ... Check O rings 1 Damage Replace the drive chain Drive chain rollers 2 Damage wear Replace the drive chain Drive chain side plates 3 Damage wear cracks Replace the drive chain 5 Lubricate Drive chain EAS30231 CHECKING THE DRIVE SPROCKET 1 Check Drive sprocket More than 1 4 tooth a wear Replace the drive sprocket the rear wheel sprocket and the drive chain as a set Bent teeth Replace the drive sproc...

Page 266: ...nside of the connecting link 3 and inside of the connecting plate 1 is 14 1 14 3 mm 0 56 0 65 in 2 Lubricate Drive chain 3 Install Drive sprocket Washer 1 Drive sprocket nut 2 TIP While applying the rear brake tighten the drive sprocket nut Install washer 1 with the OUT mark a fac ing out Stake the drive sprocket nut 2 at cutouts b in the drive axle 4 Install Shift arm 1 TIP Before installing make...

Page 267: ...3 18 NOTICE ECA13550 A drive chain that is too tight will overload the engine and other vital parts and one that is too loose can skip and damage the swing arm or cause an accident Therefore keep the drive chain slack within the specified lim its Drive chain slack 5 0 15 0 mm 0 20 0 59 in 1 a b ...

Page 268: ...CHAIN DRIVE 4 103 ...

Page 269: ...EAD 5 20 INSTALLING THE CYLINDER HEAD 5 21 VALVES AND VALVE SPRINGS 5 22 REMOVING THE VALVES 5 23 CHECKING THE VALVES AND VALVE GUIDES 5 23 CHECKING THE VALVE SEATS 5 25 CHECKING THE VALVE SPRINGS 5 26 CHECKING THE VALVE LIFTERS 5 27 INSTALLING THE VALVES 5 27 GENERATOR AND STARTER CLUTCH 5 30 REMOVING THE GENERATOR 5 32 REMOVING THE STARTER CLUTCH 5 32 CHECKING THE STARTER CLUTCH 5 32 INSTALLING ...

Page 270: ... PAN 5 55 CHECKING THE OIL STRAINER 5 55 INSTALLING THE OIL PAN 5 55 CRANKCASE 5 56 DISASSEMBLING THE CRANKCASE 5 57 CHECKING THE CRANKCASE 5 57 ASSEMBLING THE CRANKCASE 5 57 CONNECTING RODS AND PISTONS 5 60 REMOVING THE CONNECTING RODS AND PISTONS 5 61 CHECKING THE CYLINDER AND PISTON 5 61 CHECKING THE PISTON RINGS 5 62 CHECKING THE PISTON PIN 5 63 CHECKING THE CONNECTING RODS 5 63 INSTALLING THE...

Page 271: ...CHECKING THE SHIFT DRUM ASSEMBLY 5 81 CHECKING THE TRANSMISSION 5 81 ASSEMBLING THE MAIN AXLE AND DRIVE AXLE 5 81 INSTALLING THE TRANSMISSION 5 82 ...

Page 272: ...y any dirt accumulat ed in the spark plug wells to prevent it from falling into the cylinders 4 Install Compression gauge 1 Extension 2 5 Measure Compression pressure Out of specification Refer to steps c and d a Set the main switch to ON b With the throttle wide open crank the engine until the reading on the compression gauge stabilizes WARNING EWA17100 To prevent sparking the plug remove all ig ...

Page 273: ...k Refer to FUEL TANK on page 7 1 Fuel tank cover Refer to GENERAL CHASSIS 3 on page 4 13 Rider seat Passenger seat Refer to GENERAL CHASSIS 1 on page 4 1 Front side cowling Front side panel Fuel tank front cover Refer to GENERAL CHASSIS 2 on page 4 6 Compression pressure with oil applied into the cylinder Reading Diagnosis Higher than without oil Piston ring s wear or damage Repair Same as without...

Page 274: ...ing 1 2 Centerstand 1 3 O2 sensor coupler bracket 1 4 O2 sensor coupler 1 Disconnect 5 Muffler assembly 1 6 Exhaust gasket 3 7 Muffler protector 1 3 4 5 6 7 6 10 Nm 1 0 m kgf 7 2 ft Ibf 10 Nm 1 0 m kgf 7 2 ft Ibf 20 Nm 2 0 m kgf 14 ft Ibf 20 Nm 2 0 m kgf 14 ft Ibf 12 Nm 1 2 m kgf 8 7 ft Ibf 48 Nm 4 8 m kgf 35 ft lbf LT LT 1 2 ...

Page 275: ...S 3 on page 4 13 Throttle bodies Refer to THROTTLE BODIES on page 7 4 Fuel rail Refer to THROTTLE BODIES on page 7 4 Radiator Refer to RADIATOR on page 6 1 Air cut off valve Refer to AIR INDUCTION SYSTEM on page 7 15 Right footrest assembly Refer to REAR BRAKE on page 4 48 Drive sprocket Refer to CHAIN DRIVE on page 4 98 1 Clutch cable 1 Disconnect 2 Starter motor lead 1 Disconnect 3 Negative batt...

Page 276: ...ads and hoses Order Job Parts to remove Q ty Remarks 7 Gear position switch coupler 2 Disconnect 8 Crankshaft position sensor coupler 1 Disconnect 9 Stator coil coupler 1 Disconnect 7 Nm 0 7 m kgf 5 1 ft Ibf 12 Nm 1 2 m kgf 8 7 ft Ibf 7 8 9 ...

Page 277: ...eft front upper side 1 1 1 4 Centerstand bracket bolt left 1 5 Engine mounting bolt rear lower side Engine mounting nut rear lower side 1 1 6 Engine mounting bolt rear upper side Engine mounting nut rear upper side 1 1 7 Engine 1 8 Engine mounting adjust bolt 3 1 2 3 4 5 6 7 8 45 Nm 4 5 m kgf 33 ft Ibf 7 Nm 0 7 m kgf 5 1 ft Ibf 45 Nm 4 5 m kgf 33 ft Ibf 12 Nm 1 2 m kgf 8 7 ft Ibf 7 Nm 0 7 m kgf 5 ...

Page 278: ...all Centerstand bracket bolt left 5 temporarily tighten 5 Install Engine mounting bolt left front upper side 6 Engine mounting bolt left front lower side 7 Engine mounting bolt right front lower side 8 TIP Temporarily tighten the engine mounting bolts 6 8 6 Tighten Engine mounting adjust bolt front 1 TIP Tighten the engine mounting adjust bolt to specification with the pivot shaft wrench Make sure...

Page 279: ...bolt right front upper side 10 Engine mounting bolt left front upper side 6 Engine mounting bolt left front lower side 7 Engine mounting bolt right front lower side 8 12 Tighten Centerstand bracket bolt left 5 Centerstand bracket bolt right 9 Engine mounting adjust bolt rear 7 Nm 0 7 m kgf 5 1 ft lbf Pivot shaft wrench 90890 01518 Frame spanner socket YM 01518 Pivot shaft wrench adapter 90890 0147...

Page 280: ... cover Refer to GENERAL CHASSIS 3 on page 4 13 Fuel tank Refer to FUEL TANK on page 7 1 Air filter case Refer to GENERAL CHASSIS 3 on page 4 13 Radiator Refer to RADIATOR on page 6 1 Air cut off valve Refer to AIR INDUCTION SYSTEM on page 7 15 1 Ignition coil coupler 3 Disconnect 2 Ignition coil 3 3 Spark plug 3 4 Cylinder head cover 1 5 Cylinder head cover gasket 1 6 Timing chain guide top side 1...

Page 281: ...asket 1 5 Intake camshaft cap 1 6 Exhaust camshaft cap 1 7 Camshaft cap 1 8 Intake camshaft 1 9 Exhaust camshaft 1 10 Intake camshaft sprocket 1 11 Exhaust camshaft sprocket 1 12 Timing chain bolt 1 13 Dowel pin 1 14 Timing chain guide intake side 1 15 Timing chain 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 10 Nm 1 0 m kgf 7 2 ft Ibf 24 Nm 2 4 m kgf 17 ft Ibf 7 Nm 0 7 m kgf 5 1 ft Ibf E E LT 10 Nm 1 0 ...

Page 282: ...hen the camshaft lobes are turned away from each other 3 Remove Timing chain tensioner 1 Timing chain tensioner gasket 4 Remove Camshaft cap 1 Intake camshaft cap 2 Exhaust camshaft cap 3 NOTICE ECA13720 To prevent damage to the cylinder head camshafts or camshaft caps loosen the camshaft cap bolts in stages and in a criss cross pattern working from the outside in 5 Remove Intake camshaft 1 Exhaus...

Page 283: ...d without the camshaft caps b Position strip of Plastigauge 1 onto the camshaft journal as shown Camshaft wrench 90890 04162 Camshaft wrench YM 04162 Camshaft lobe dimensions Lobe height Intake 36 290 36 390 mm 1 4287 1 4327 in Limit 36 190 mm 1 4248 in Base circle diameter Intake 27 950 28 050 mm 1 1004 1 1043 in Limit 27 850 mm 1 0965 in Lobe height Exhaust 35 720 35 820 mm 1 4063 1 4102 in Limi...

Page 284: ... as a set EAS30258 CHECKING THE TIMING CHAIN AND CAMSHAFT SPROCKET 1 Check Timing chain Damage stiffness Replace the timing chain and camshaft and camshaft sprocket as a set 2 Check Camshaft sprocket More than 1 4 tooth wear a Replace the camshaft sprockets and the timing chain as a set EAS30265 CHECKING THE TIMING CHAIN GUIDES The following procedure applies to all of the camshaft sprockets and t...

Page 285: ...ement re place the timing chain tensioner EAS30269 INSTALLING THE CAMSHAFTS 1 Remove Timing mark accessing bolt 1 Crankshaft end cover 2 2 Align Mark a on the generator rotor with the generator rotor cover mark b a Turn the crankshaft counterclockwise b When piston 1 is at BTDC125 align the mark a on the generator rotor with the gen erator rotor cover mark b 3 Install Intake camshaft sprocket 1 Ex...

Page 286: ...ft side camshaft cap mark Make sure the arrow mark a on each cam shaft points toward the right side of the engine 6 Tighten Camshaft cap bolts TIP Tighten the camshaft cap bolts in the tightening sequence as shown NOTICE ECA17430 Lubricate the camshaft cap bolts with the engine oil The camshaft cap bolts must be tightened evenly or damage to the cylinder head camshaft caps and camshafts will resul...

Page 287: ...ch mark a Make sure the punch mark a on the cam shaft is aligned with the camshaft cap align ment mark b 9 Install Timing chain tensioner Timing chain tensioner gasket a Apply a few drops of engine oil to the inside a of the timing chain tensioner b While lightly pressing the timing chain ten sioner rod by hand turn the timing chain ten sioner rod fully counterclockwise with a hexagon wrench 1 c K...

Page 288: ... g Remove the hexagon wrench and check the timing chain tension h Install the timing chain tensioner cap bolt and gasket and then tighten the timing chain ten sioner cap bolt to the specified torque 10 Turn Crankshaft several turns counterclockwise 11 Check Mark a Make sure the mark a on the generator rotor is aligned with the generator rotor cover mark b Camshaft punch mark c Make sure the punch ...

Page 289: ...e mating surfaces of the cylinder head cover and cylin der head cover gasket After installing the cylinder head cover gasket 1 to the cylinder head cover cut off the a section 15 Install Spark plugs Ignition coils 1 TIP Install the ignition coils 1 in the direction shown in the illustration Timing mark accessing bolt 15 Nm 1 5 m kgf 11 ft lbf Crankshaft end cover 10 Nm 1 0 m kgf 7 2 ft lbf Cylinde...

Page 290: ...er to CAMSHAFTS on page 5 9 Exhaust camshaft Refer to CAMSHAFTS on page 5 9 1 Coolant temperature sensor 1 2 Cylinder head 1 3 Cylinder head gasket 1 4 Dowel pin 2 5 Timing chain guide exhaust side 1 1 2 3 4 5 8 E 4 25 Nm 2 5 m kgf 18 ft Ibf Specified angle 1st 16 Nm 1 6 m kgf 12 ft Ibf 2nd 10 Nm 1 0 m kgf 7 2 ft Ibf 16 Nm 1 6 m kgf 12 ft Ibf 10 Nm 1 0 m kgf 7 2 ft Ibf ...

Page 291: ... TIP Do not use a sharp instrument to avoid damag ing or scratching Spark plug bore threads Valve seats 2 Check Cylinder head Damage scratches Replace Cylinder head water jacket Mineral deposits rust Eliminate 3 Measure Cylinder head warpage Out of specification Resurface the cylinder head a Place a straightedge 1 and a thickness gauge 2 across the cylinder head b Measure the warpage c If the limi...

Page 292: ... Cylinder head bolt 1 8 Cylinder head bolt 9 12 Following the tightening order loosen the bolt one by one and then retighten it to the specific torque and the specific angle TIP Tighten the cylinder head bolts 1 8 in the tightening sequence as shown and torque them in 2 stages 4 Install Exhaust camshaft Intake camshaft Refer to INSTALLING THE CAMSHAFTS on page 5 14 Cylinder head bolt 1 8 1st 25 Nm...

Page 293: ... 12 4 Intake valve spring retainer 6 5 Intake valve spring 6 6 Intake valve 6 7 Intake valve stem seal 6 8 Intake valve spring seat 6 9 Intake valve guide 6 10 Exhaust valve lifter 6 11 Exhaust valve pad 6 12 Exhaust valve cotter 12 13 Exhaust valve spring retainer 6 14 Exhaust valve spring 6 15 Exhaust valve 6 16 Exhaust valve stem seal 6 17 Exhaust valve spring seat 6 18 Exhaust valve guide 6 1 ...

Page 294: ...lean solvent a into the intake and exhaust ports b Check that the valves properly seal TIP There should be no leakage at the valve seat 1 3 Remove Valve cotters TIP Remove the valve cotters by compressing the valve spring with the valve spring compressor 1 and the valve spring compressor attachment 2 4 Remove Valve spring retainer 1 Valve spring 2 Valve 3 Valve stem seal 4 Valve spring seat 5 TIP ...

Page 295: ... 2 and valve guide remover 1 c After installing the valve guide bore the valve guide with the valve guide reamer 3 to ob tain the proper valve stem to valve guide clearance TIP After replacing the valve guide reface the valve seat Valve stem to valve guide clearance Valve guide inside diameter a Valve stem diameter b Valve stem to valve guide clear ance intake 0 010 0 037 mm 0 0004 0 0015 in Limit...

Page 296: ...d 3 Measure Valve seat contact width a Out of specification Replace the cylinder head a Apply blue layout fluid b onto the valve face b Install the valve into the cylinder head c Press the valve through the valve guide and onto the valve seat to make a clear impres sion d Measure the valve seat contact width TIP Where the valve seat and valve face contacted one another the blue layout fluid will h...

Page 297: ...th be tween your hands e Apply a fine lapping compound to the valve face and repeat the above steps f After every lapping procedure be sure to clean off all of the lapping compound from the valve face and valve seat g Apply blue layout fluid b onto the valve face h Install the valve into the cylinder head i Press the valve through the valve guide and onto the valve seat to make a clear impres sion...

Page 298: ... VALVES The following procedure applies to all of the valves and related components 1 Deburr Valve stem end with an oil stone 2 Lubricate Valve stem 1 Valve stem seal 2 with the recommended lubricant b Installed length Installed compression spring force intake 192 00 220 00 N 19 58 22 43 kgf 43 16 49 46 lbf Installed compression spring force exhaust 162 00 186 00 N 16 52 18 97 kgf 36 42 41 81 lbf ...

Page 299: ... valve spring compressor attachment 3 5 To secure the valve cotters onto the valve stem lightly tap the valve tip with a soft face hammer NOTICE ECA13800 Hitting the valve tip with excessive force could damage the valve 6 Lubricate Valve pad with the recommended lubricant Valve lifter with the recommended lubricant 7 Install Valve pad b Smaller pitch New Valve spring compressor 90890 04019 Valve s...

Page 300: ...VALVES AND VALVE SPRINGS 5 29 Valve lifter TIP The valve lifter must move smoothly when ro tated with a finger Each valve lifter and valve pad must be rein stalled in its original position ...

Page 301: ... WATER PUMP on page 6 8 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 25 1 Stator coil coupler 1 Disconnect 2 Crankshaft position sensor coupler 1 Disconnect 3 Holder fuel tank overflow hose and fuel tank breather hose 1 4 Generator cover 1 5 Generator cover gasket 1 6 Dowel pin 2 7 Stator coil lead holder 1 8 Stator coil assembly stator coil crankshaft posi tion sensor 1 1 2 3 5 6 7...

Page 302: ...lutch idle gear shaft 1 14 Starter clutch idle gear 1 15 Crankshaft end cover 1 16 Timing mark accessing bolt 1 17 Water pump outlet pipe 1 9 12 15 16 17 75 Nm 7 5 m kgf 54 ft Ibf 32 Nm 3 2 m kgf 23 ft Ibf 15 Nm 1 5 m kgf 11 ft Ibf 10 Nm 1 0 m kgf 7 2 ft Ibf 12 Nm 1 2 m kgf 8 7 ft Ibf 12 Nm 1 2 m kgf 8 7 ft Ibf 14 Nm 1 4 m kgf 10 ft Ibf 10 Nm 1 0 m kgf 7 2 ft Ibf E E 13 14 E 10 11 E 3 LT 6 3 LT 12...

Page 303: ...nerator rotor EAS30868 REMOVING THE STARTER CLUTCH 1 Remove Starter clutch bolts Starter clutch TIP While holding the generator rotor 1 with the sheave holder 2 loosen the starter clutch bolts EAS30869 CHECKING THE STARTER CLUTCH 1 Check Starter clutch rollers Damage wear Replace 2 Check Starter clutch idle gear Starter clutch gear Burrs chips roughness wear Replace the defective part s 3 Check St...

Page 304: ...ave holder 3 tighten the starter clutch bolts EAS30872 INSTALLING THE GENERATOR 1 Install Woodruff key Generator rotor Washer Generator rotor bolt TIP Clean the tapered portion of the crankshaft and the generator rotor hub When installing the generator rotor make sure the woodruff key is properly seated in the key way of the crankshaft Lubricate the washer with engine oil Lubricate the generator r...

Page 305: ...ator cover bolts in stages and in a crisscross pattern 5 Connect Stator coil coupler Crankshaft position sensor coupler TIP To route the stator coil lead refer to CABLE ROUTING on page 2 41 Yamaha bond No 1215 90890 85505 Three bond No 1215 Generator cover bolt 1 12 Nm 1 2 m kgf 8 7 ft lbf LOCTITE Generator cover bolt 2 12 Nm 1 2 m kgf 8 7 ft lbf New T R 1 2 2 2 ...

Page 306: ...senger seat Rider seat Refer to GENERAL CHASSIS 1 on page 4 1 Fuel tank cover Refer to GENERAL CHASSIS 3 on page 4 13 Fuel tank Refer to FUEL TANK on page 7 1 Air filter case Refer to GENERAL CHASSIS 3 on page 4 13 Throttle bodies Refer to THROTTLE BODIES on page 7 4 1 Starter motor lead 1 Disconnect 2 Negative battery lead 1 Disconnect 3 Starter motor 1 1 2 3 12 Nm 1 2 m kgf 8 7 ft Ibf 7 Nm 0 7 m...

Page 307: ...36 Disassembling the starter motor Order Job Parts to remove Q ty Remarks 1 O ring 1 2 Starter motor front cover 1 3 Starter motor yoke 1 4 Armature assembly 1 5 Gasket 2 6 Brush holder set 1 7 Starter motor rear cover 1 ...

Page 308: ...otor a Measure the armature assembly resistances with the digital circuit tester b If any resistance is out of specification re place the starter motor 4 Measure Brush length a Out of specification 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 90890 03174 Model 88 Multimeter wit...

Page 309: ...on 2 Install Starter motor rear cover 1 Starter motor yoke 2 Starter motor front cover 3 TIP Align the match marks a on the starter motor yoke with the match marks b on the front and rear cover EAS30327 INSTALLING THE STARTER MOTOR 1 Install Starter motor 1 Negative battery lead 2 Starter motor bolts 3 TIP Install the negative battery lead as shown in the illustration 2 Connect Starter motor lead ...

Page 310: ...fer to CHANGING THE ENGINE OIL on page 3 25 1 Clutch cable 1 Disconnect 2 Cover 1 3 O2 sensor coupler bracket 1 4 Clutch cover 1 5 Clutch cover gasket 1 6 Dowel pin 2 7 Oil filler cap 1 1 2 3 4 5 6 7 12 Nm 1 2 m kgf 8 7 ft Ibf 12 Nm 1 2 m kgf 8 7 ft Ibf 12 Nm 1 2 m kgf 8 7 ft Ibf 1 5 Nm 0 15 m kgf 1 1 ft Ibf 6 7 ...

Page 311: ... 40 Removing the pull lever shaft Order Job Parts to remove Q ty Remarks 1 Circlip 1 2 Pull lever 1 3 Pull lever spring 1 4 Circlip 1 5 Pull lever shaft 1 6 Oil seal 1 7 Bearing 1 8 Bearing 1 1 2 3 4 5 6 7 8 E ...

Page 312: ...1 5 Friction plate 1 7 6 Clutch plate 8 7 Friction plate 2 2 Green paint mark 8 Clutch boss nut 1 9 Conical spring washer 1 10 Washer 1 11 Clutch boss 1 12 Thrust plate 1 13 Clutch housing 1 14 Oil pump drive chain 1 15 Bearing 1 16 Spacer 1 17 Thrust plate 1 18 Thrust plate 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 LT 125 Nm 12 5 m kgf 90 ft Ibf 10 Nm 1 0 m kgf 7 2 ft Ibf 5 7 5 E E E E ...

Page 313: ...ocket 1 Refer to OIL PUMP on page 5 50 3 Remove Compression spring bolts 1 Compression springs Pressure plate 2 Pull rod 3 4 Remove Friction plates 1 1 5 Remove Clutch plates 1 Friction plates 2 6 Straighten the clutch boss nut rib a 7 Loosen Clutch boss nut 1 TIP While holding the clutch boss 2 with the univer sal clutch holder 3 loosen the clutch boss nut 1 2 1 1 2 1 3 Universal clutch holder 90...

Page 314: ...l of the clutch plates 1 Check Clutch plate Damage Replace the clutch plates as a set 2 Measure Clutch plate warpage with a surface plate and thickness gauge 1 Out of specification Replace the clutch plates as a set EAS30351 CHECKING THE CLUTCH SPRINGS The following procedure applies to all of the clutch springs 1 Check Clutch spring Damage Replace the clutch springs as a Friction plate 1 thicknes...

Page 315: ...ic clutch operation 2 Check Oil pump drive sprocket 1 Cracks damage wear Replace 3 Check Bearing Damage wear Replace the bearing and clutch housing EAS30353 CHECKING THE CLUTCH BOSS 1 Check Clutch boss splines Damage pitting wear Replace the clutch boss TIP Pitting on the clutch boss splines will cause er ratic clutch operation EAS30354 CHECKING THE PRESSURE PLATE 1 Check Pressure plate 1 Cracks d...

Page 316: ... teeth 2 Damage wear Replace the pull rod and pull lever shaft as a set 2 Check Pull rod bearing Damage wear Replace EAS30363 INSTALLING THE CLUTCH 1 Install Oil pump drive chain 1 Clutch housing 2 TIP Install the oil pump drive chain onto the oil pump drive sprocket a 2 Install Thrust plate Clutch boss 1 Washer Conical spring washer 2 Clutch boss nut 3 TIP Install the conical spring washer on the...

Page 317: ... and in a crisscross pattern Apply lithium soap based grease onto the pull rod Position the pull rod so that the teeth a face towards the hole b Then install the clutch cover 5 Install Dowel pins Clutch cover gasket Clutch cover Cover TIP Apply engine oil onto the bearing Tighten the clutch cover bolts in stages and in a crisscross pattern 6 Install Pull lever TIP Install the pull lever with the O...

Page 318: ... b on the clutch cover Make sure that the pull rod teeth and pull lever shaft pinion gear are engaged 7 Adjust Clutch lever free play Refer to ADJUSTING THE CLUTCH LEVER FREE PLAY on page 3 12 Clutch lever free play 10 0 15 0 mm 0 39 0 59 in a b ...

Page 319: ...to CLUTCH on page 5 39 Shift arm Refer to CHAIN DRIVE on page 4 98 1 Circlip 1 2 Washer 1 3 Shift shaft 1 4 Washer 1 5 Circlip 1 6 Washer 1 7 Stopper lever 1 8 Stopper lever spring 1 9 Collar 1 10 Shift shaft spring 1 11 Shift shaft spring stopper 1 12 Oil seal 1 13 Bearing 1 3 4 5 6 7 8 9 10 11 LT E 22 Nm 2 2 m kgf 16 ft Ibf E 1 2 12 13 E E ...

Page 320: ...hift shaft assembly Stopper lever spring 2 TIP Hook the end of the shift shaft spring 3 onto the shift shaft spring stopper 1 Hook the ends of the stopper lever spring 2 onto the stopper lever 4 and the crankcase boss 5 Mesh the stopper lever with the shift drum seg ment assembly 2 Install Bearing Oil seal Washer 1 Circlip 2 TIP Lubricate the oil seal lips with lithium soap based grease Lubricate ...

Page 321: ...oving the oil pump Order Job Parts to remove Q ty Remarks Clutch cover Refer to CLUTCH on page 5 39 1 Oil pump driven sprocket 1 2 Oil pump assembly 1 1 2 10 Nm 1 0 m kgf 7 2 ft Ibf 15 Nm 1 5 m kgf 11 ft Ibf 10 Nm 1 0 m kgf 7 2 ft Ibf LT ...

Page 322: ... Remarks 1 Oil pump cover 1 2 Oil pump shaft 1 3 Pin 1 4 Oil pump inner rotor 1 5 Oil pump outer rotor 1 6 Circlip 1 Hold down the washer when removing the circlip 7 Washer 1 8 Spring 1 9 Relief valve 1 10 Dowel pin 2 E 1 2 3 4 5 6 7 8 9 10 3 8 Nm 0 38 m kgf 2 8 ft Ibf 10 ...

Page 323: ... to outer rotor tip clearance a Outer rotor to oil pump housing clearance b Oil pump housing to inner rotor and outer rotor clearance c Out of specification Replace the defective part s 3 Check Oil pump operation Rough movement Repeat steps 1 and 2 or replace the defective part s 1 2 Inner rotor to outer rotor tip clearance Less than 0 120 mm 0 0047 in Limit 0 20 mm 0 0079 in Outer rotor to oil pu...

Page 324: ...ion Refer to CHECKING THE OIL PUMP on page 5 52 EAS30343 INSTALLING THE OIL PUMP 1 Install Oil pump 1 Oil pump bolts 2 Oil pump driven sprocket 3 NOTICE ECA20940 After installing the oil pump drive chain and driven sprocket make sure the oil pump turns smoothly TIP 1RC mark of the oil pump driven sprocket is in stalled at oil pump side Install the oil pump drive chain onto the oil pump driven spro...

Page 325: ...IS 1 on page 4 1 Fuel tank cover Refer to GENERAL CHASSIS 3 on page 4 13 Fuel tank Refer to FUEL TANK on page 7 1 Muffler assembly Refer to ENGINE REMOVAL on page 5 3 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 25 1 Oil level switch coupler 1 Disconnect 2 Oil level switch lead holder 1 3 Oil level switch 1 4 O2 sensor lead holder 1 5 Oil pan 1 6 Oil pan gasket 1 7 Oil strainer 1 1 ...

Page 326: ...Oil pan 1 Oil level switch 2 Engine oil drain bolt 3 WARNING EWA12820 Always use new copper washers TIP Tighten the oil pan bolts in stages and in a crisscross pattern Lubricate the oil level switch O ring with lithi um soap based grease A MT09TRA for Europe RN29F0011886 and after MT09TRAG for Oceania RN29K 0000556 and after 1 2 1 2 1 Oil pan bolt 10 Nm 1 0 m kgf 7 2 ft lbf Oil level switch bolt 1...

Page 327: ...rainer Refer to OIL PAN on page 5 54 1 Oil filter cartridge 1 2 Oil filter cartridge union bolt 1 3 Gear position switch 1 4 Clutch cable holder 1 5 Lower crankcase 1 6 Dowel pin 3 1 2 3 4 5 6 6 6 2 2 4 2 11 6 E E E E LT E LT 24 Nm 2 4 m kgf 17 ft Ibf 25 Nm 2 5 m kgf 18 ft Ibf Specified angle 60 1st 3rd 15 Nm 1 5 m kgf 11 ft Ibf 2nd 25 Nm 2 5 m kgf 18 ft Ibf Specified angle 60 1st 3rd 18 Nm 1 8 m ...

Page 328: ... shaft journal bearing from the lower crankcase TIP Identify the position of each part very carefully so that it can be reinstalled in its original place EAS30390 CHECKING THE CRANKCASE 1 Thoroughly wash the crankcase halves in a mild solvent 2 Thoroughly clean all the gasket surfaces and crankcase mating surfaces 3 Check Crankcase Cracks damage Replace Oil delivery passages Obstruction Blow out w...

Page 329: ...14 M6 85 mm 3 35 in bolt 18 M6 65 mm 2 56 in bolts 15 16 M6 65 mm 2 56 in bolt 26 M6 50 mm 1 97 in bolts 17 19 21 23 25 27 30 M6 40 mm 1 57 in bolt 22 7 Tighten Crankcase bolts 1 8 Following the tightening order loosen the bolt one by one and then retighten it to the specific torque WARNING EWA16610 If the bolt is tightened more than the speci fied angle do not loosen the bolt and then re tighten ...

Page 330: ...Tighten the bolts in the tightening sequence cast on the crankcase Crankcase bolts 9 14 24 Nm 2 4 m kgf 17 ft lbf Crankcase bolts 15 30 10 Nm 1 0 m kgf 7 2 ft lbf 8 1 2 3 4 5 6 7 8 T R 22 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 ...

Page 331: ...ve Q ty Remarks Lower crankcase Refer to CRANKCASE on page 5 56 1 Connecting rod cap 3 2 Big end lower bearing 3 3 Piston pin clip 6 4 Piston pin 3 5 Piston 3 6 Connecting rod 3 7 Big end upper bearing 3 8 Top ring 3 9 2nd ring 3 10 Oil ring 3 E 1 2 3 4 6 7 8 9 10 M M E E 3 20 Nm 2 0 m kgf 14 ft Ibf 1st Specified angle 2nd 175 185 E 5 ...

Page 332: ...in out TIP For reference during installation put identifica tion marks on the piston crown Before removing the piston pin deburr the pis ton pin clip groove and the piston pin bore ar ea If both areas are deburred and the piston pin is still difficult to remove remove it with the piston pin puller set 4 3 Remove Top ring 2nd ring Oil ring TIP When removing a piston ring open the end gap with your ...

Page 333: ...the piston and piston rings as a set TIP Before measuring the piston ring side clearance eliminate any carbon deposits from the piston ring grooves and piston rings 2 Install Piston ring into the cylinder Bore 78 000 78 010 mm 3 0709 3 0713 in Taper limit 0 050 mm 0 0020 in Out of round limit 0 050 mm 0 0020 in C maximum of D1 D6 Taper limit maximum of D1 or D2 maximum of D5 or D6 Out of round lim...

Page 334: ...side diameter b Out of specification Replace the piston 4 Calculate Piston pin to piston pin bore clearance Out of specification Replace the piston pin and piston as a set EAS30750 CHECKING THE CONNECTING RODS 1 Measure Crankshaft pin to big end bearing clearance Top ring End gap installed 0 15 0 25 mm 0 0059 0 0098 in Limit 0 50 mm 0 0197 in 2nd ring End gap installed 0 30 0 45 mm 0 0118 0 0177 i...

Page 335: ...egion tightening angle method Al ways install new bolts TIP Clean the connecting rod bolts and lubricate the bolt threads and seats with molybdenum disulfide oil Make sure that the projection a on the con necting rod cap faces the same direction as the Y mark b on the connecting rod After installing the big end bearing assemble the connecting rod and connecting rod cap without installing them onto...

Page 336: ...s further to reach the specified angle 175 185 WARNING EWA16610 If the bolt is tightened more than the speci fied angle do not loosen the bolt and then re tighten it Instead replace the bolt with a new one and perform the procedure again NOTICE ECA20890 Do not use a torque wrench to tighten the bolt to the specified angle j After the installation check that the section shown a is flush with each o...

Page 337: ...ting rod TIP Be sure to reinstall each big end bearing in its original place Align the projections a on the big end bear ings with the notches b in the connecting rods and connecting rod caps Make sure that the projection c on the con necting rod cap faces the same direction as the Y mark d on the connecting rod 2 Tighten Connecting rod bolts NOTICE ECA18390 Tighten the connecting rod bolts using ...

Page 338: ...e current condition 3 Install Oil ring expander 1 Lower oil ring rail 2 Upper oil ring rail 3 2nd ring 4 Top ring 5 into the piston TIP Be sure to install the piston rings so that the manufacturer s marks or numbers a face up 4 Install Piston 1 onto the respective connecting rod 2 Piston pin 3 Piston pin clips 4 TIP Apply engine oil onto the piston pin Make sure that the Y mark a on the connect in...

Page 339: ... cylinder 9 Install Connecting rod caps Connecting rod bolts TIP Make sure the Y marks a on the connecting rods face towards the left side of the crank shaft Make sure that the projection b on the con necting rod cap faces the same direction as the Y mark a on the connecting rod Apply Molybdenum disulfide oil to the bolt threads and seats 10 Tighten Connecting rod bolts 1 TIP Tighten the connectin...

Page 340: ...w one and perform the procedure again NOTICE ECA20890 Do not use a torque wrench to tighten the bolt to the specified angle d After the installation check that the section shown a is flush with each other by touching the surface WARNING EWA17120 If the connecting rod and cap are not flush with each other remove the connecting rod bolts and big end bearing and restart from step 1 In this case make ...

Page 341: ...Lower crankcase Refer to CRANKCASE on page 5 56 Connecting rod Refer to REMOVING THE CONNECTING RODS AND PISTONS on page 5 61 1 Balancer shaft 1 2 Balancer shaft journal lower bearing 2 3 Balancer shaft journal upper bearing 2 4 Crankshaft 1 5 Crankshaft journal lower bearing 4 6 Crankshaft journal upper bearing 4 7 Oil nozzle 3 1 2 3 4 5 6 7 E 2 3 E 7 E E ...

Page 342: ...pin surfaces Bearing surfaces Scratches wear Replace the crankshaft 3 Measure Crankshaft journal to crankshaft journal bearing clearance Out of specification Replace the crank shaft journal bearings NOTICE ECA13920 Do not interchange the crankshaft journal bearings To obtain the correct crankshaft journal to crankshaft journal bearing clear ance and prevent engine damage the crank shaft journal be...

Page 343: ...lower bearings h Measure the compressed Plastigauge width a on each crankshaft journal If the crankshaft journal to crankshaft jour nal bearing clearance is out of specification select replacement crankshaft journal bear ings 4 Select Crankshaft journal bearings J1 J4 TIP The numbers A stamped into the crankshaft web and the numbers B stamped into the lower crankcase are used to determine the re p...

Page 344: ...amage the balancer shaft journal bearings must be installed in their original positions a Clean the balancer shaft journal bearings balancer shaft journals and bearing portions of the crankcase b Place the upper crankcase upside down on a bench c Install the balancer shaft journal upper bear ings 1 and the balancer shaft into the upper crankcase TIP Align the projections a on the balancer shaft jo...

Page 345: ...lancer shaft journal bearings 4 Select Balancer shaft journal bearing J1 J2 TIP The numbers A stamped into the balancer shaft web and the numbers B stamped into the lower crankcase are used to determine the replacement balancer shaft journal bearing siz es J1 J2 refer to the bearings shown in the balancer shaft and lower crankcase illustration If J1 J2 are the same use the same size for all of the...

Page 346: ...rings into the upper crankcase Balancer shaft journal lower bearings into the lower crankcase TIP Align the projections a on the balancer shaft journal bearings 1 with the notches b in the crankcases Be sure to install each balancer shaft journal bearing in its original place 2 Install Balancer shaft TIP Install by aligning the crankshaft match mark a and the balancer shaft match mark b 1 a b 1 a ...

Page 347: ...SE on page 5 56 1 Drive axle assembly 1 2 Oil seal 1 3 Bearing 1 4 Washer 1 5 Shift drum retainer 2 6 Shift fork guide bar 2 7 Shift fork L 1 8 Shift fork R 1 9 Shift drum assembly 1 10 Shift fork C 1 11 Main axle assembly 1 12 Bearing 1 1 2 3 4 5 6 7 8 9 10 11 E LT 12 Nm 1 2 m kgf 8 7 ft Ibf 10 Nm 1 0 m kgf 7 2 ft Ibf LT LT E E E E E 5 6 10 Nm 1 0 m kgf 7 2 ft Ibf LT E 12 ...

Page 348: ... pinion gear 1 2 Toothed lock washer 1 3 Toothed lock washer retainer 1 4 6th pinion gear 1 5 Collar 1 6 Washer 1 7 Circlip 1 8 3rd pinion gear 1 9 Circlip 1 10 Washer 1 11 5th pinion gear 1 12 Collar 1 13 Bearing housing 1 14 Bearing 1 15 Main axle 1 9 10 12 15 13 14 7 8 6 5 4 3 2 1 11 E M M M M M M ...

Page 349: ...lar 1 5 5th wheel gear 1 6 Circlip 1 7 Washer 1 8 3rd wheel gear 1 9 Collar 1 10 Toothed lock washer 1 11 Toothed lock washer retainer 1 12 4th wheel gear 1 13 Collar 1 14 Washer 1 15 Circlip 1 16 6th wheel gear 1 17 Circlip 1 18 Washer 1 19 Collar 1 20 2nd wheel gear 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 M M E M E M M M M M M ...

Page 350: ...TRANSMISSION 5 79 Disassembling the drive axle assembly Order Job Parts to remove Q ty Remarks 21 Collar 1 22 Bearing 1 23 Circlip 1 24 Drive axle 1 21 M M E M E 22 23 24 M M M M M M ...

Page 351: ...ontinue tightening the bolts until the main axle assembly comes free from the upper crankcase 3 Remove Bearing 1 EAS30431 CHECKING THE SHIFT FORKS The following procedure applies to all of the shift forks 1 Check Shift fork cam follower 1 Shift fork pawl 2 Bends damage scoring wear Replace the shift fork 2 Check Shift fork guide bar Roll the shift fork guide bar on a flat surface Bends Replace WAR...

Page 352: ...of specification Replace the drive axle 3 Check Transmission gears Blue discoloration pitting wear Replace the defective gear s Transmission gear dogs Cracks damage rounded edges Replace the defective gear s 4 Check Transmission gear engagement each pinion gear to its respective wheel gear Incorrect Reassemble the transmission axle assemblies 5 Check Transmission gear movement Rough movement Repla...

Page 353: ...ve a in the axle align the projection on the retainer with an axle spline and then install the toothed lock washer Be sure to align the projection on the toothed lock washer that is between the alignment marks b with the alignment mark c on the re tainer EAS30438 INSTALLING THE TRANSMISSION 1 Install Bearing 1 TIP Face the seal side of bearing to the outside 2 Install Main axle assembly 1 Bearing ...

Page 354: ... Shift drum retainers 3 Bearing Oil seal Circlip 4 Drive axle assembly 5 TIP Install shift fork R into the groove a in the 5th wheel gear and shift fork L into the groove b in the 6th wheel gear on the drive axle Install the shift drum retainer with its OUT mark c facing outward Touch the protrusion d on the shift fork guide bar to the side of the shift drum retainer Make sure that the drive axle ...

Page 355: ...G THE RADIATOR 6 2 OIL COOLER 6 4 CHECKING THE OIL COOLER 6 5 INSTALLING THE OIL COOLER 6 5 THERMOSTAT 6 6 CHECKING THE THERMOSTAT 6 7 INSTALLING THE THERMOSTAT ASSEMBLY 6 7 WATER PUMP 6 8 DISASSEMBLING THE WATER PUMP 6 10 CHECKING THE WATER PUMP 6 10 ASSEMBLING THE WATER PUMP 6 10 ...

Page 356: ... reservoir cover 1 3 Coolant reservoir 1 4 Coolant reservoir cap 1 5 Radiator cap 1 6 Radiator fan motor coupler 1 Disconnect 7 Radiator hose cylinder head to radiator 1 Disconnect 8 Radiator inlet hose 1 Disconnect 9 Radiator outlet hose 1 Disconnect 10 Radiator 1 11 Radiator fan cover 1 12 Radiator fan 1 13 Radiator stay 1 1 2 3 4 5 6 7 8 9 10 LT 10 Nm 1 0 m kgf 7 2 ft Ibf 0 5 Nm 0 05 m kgf 0 36...

Page 357: ...eplace 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 27 2 Check Cooling system Leaks Repair or replace any faulty part a Attach the radiator cap tester 1 and radiator cap tester adapter 2 to the radiator b Apply 122 7 kPa 1 23 kgf ...

Page 358: ...DIATOR 6 3 pressure c Measure the indicated pressure with the gauge 3 Measure Radiator cap opening pressure Below the specified pressure Replace the radiator cap Refer to CHECKING THE RADIATOR on page 6 2 ...

Page 359: ...o ENGINE REMOVAL on page 5 3 Coolant Drain Refer to CHANGING THE COOLANT on page 3 27 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 25 1 Radiator inlet hose 1 2 Oil cooler inlet hose 1 3 Oil cooler outlet hose 1 4 Oil cooler union bolt 1 5 Washer 1 6 Oil cooler 1 7 Water jacket joint 1 10 Nm 1 0 m kgf 7 2 ft Ibf E 35 Nm 3 5 m kgf 25 ft Ibf LT 1 2 3 4 5 6 7 ...

Page 360: ... O ring is positioned properly Align the projection a on the oil cooler with the slot b in the crankcase After installing the oil cooler union bolt bend the tab c of the washer 3 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 27 Crankcase with the specified amount of the recom mended engine oil Refer to CHANGING THE ENGINE OIL on p...

Page 361: ...ts to remove Q ty Remarks Muffler assembly Refer to ENGINE REMOVAL on page 5 3 Coolant Drain Refer to CHANGING THE COOLANT on page 3 27 1 Radiator outlet hose 1 2 Water pump inlet hose 1 3 Oil cooler outlet hose 1 Disconnect 4 Thermostat assembly 1 1 2 3 4 10 Nm 1 0 m kgf 7 2 ft Ibf ...

Page 362: ...mbly 2 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 27 3 Check Cooling system Leaks Repair or replace any faulty part Refer to INSTALLING THE RADIATOR on page 6 2 4 Measure Radiator cap opening pressure Below the specified pressure Replace the radiator cap Refer to CHECKING THE RADIATOR on page 6 2 1 ...

Page 363: ...6 WATER PUMP Removing the water pump Order Job Parts to remove Q ty Remarks Coolant Drain Refer to CHANGING THE COOLANT on page 3 27 1 Water pump inlet hose 1 Disconnect 2 Water pump assembly 1 1 2 12 Nm 1 2 m kgf 8 7 ft Ibf ...

Page 364: ...r Job Parts to remove Q ty Remarks 1 Water pump housing cover 1 2 O ring 1 3 Circlip 1 4 Water pump driven gear 1 5 Pin 1 6 Washer 1 7 Impeller shaft 1 8 Mechanical seal 1 9 Bearing 1 10 Oil seal 1 E E 1 2 3 4 5 6 7 8 9 10 10 Nm 1 0 m kgf 7 2 ft Ibf ...

Page 365: ...EAS30447 CHECKING THE WATER PUMP 1 Check Water pump housing cover 1 Impeller shaft 2 Cracks damage wear Replace Water pump housing 3 Cracks damage wear Replace the water pump assembly 2 Check Bearing Rough movement Replace 3 Check Water pump inlet hose Cracks damage wear Replace EAS30448 ASSEMBLING THE WATER PUMP 1 Install Oil seal 1 Bearing 2 into the water pump housing 3 TIP Install the oil seal...

Page 366: ... the mechanical seal is dirty clean it 4 Measure Impeller shaft tilt Out of specification Repeat steps 3 and 4 NOTICE ECA20340 Make sure the mechanical seal impeller side is flush with the impeller Mechanical seal installer 90890 04078 Water pump seal installer YM 33221 A Middle driven shaft bearing driver 90890 04058 Middle drive bearing installer 40 50 mm YM 04058 2 Water pump housing 3 Mechanic...

Page 367: ... FUEL HOSE FUEL RAIL SIDE 7 7 REMOVING THE INJECTORS 7 7 CHECKING THE INJECTORS 7 7 CHECKING AND CLEANING THE THROTTLE BODIES 7 7 REPLACING THE THROTTLE BODIES 7 9 INSTALLING THE INJECTORS 7 9 CHECKING THE INJECTOR PRESSURE 7 9 CHECKING THE FUEL PRESSURE 7 10 INSTALLING THE FUEL HOSE FUEL RAIL SIDE 7 11 ADJUSTING THE THROTTLE POSITION SENSOR 7 11 ADJUSTING THE ACCELERATOR POSITION SENSOR 7 12 AIR ...

Page 368: ...NERAL CHASSIS 1 on page 4 1 Fuel tank cover Refer to GENERAL CHASSIS 3 on page 4 13 1 Fuel hose connector 1 Disconnect 2 Fuel pump coupler 1 Disconnect 3 Fuel tank breather hose 1 Disconnect 4 Fuel tank drain hose 1 Disconnect 5 Fuel tank 1 6 Fuel pump bracket 1 7 Fuel pump 1 8 Fuel pump gasket 1 1 2 3 4 5 5 6 7 8 2 4 2 2 7 Nm 0 7 m kgf 5 1 ft Ibf 7 Nm 0 7 m kgf 5 1 ft Ibf 7 Nm 0 7 m kgf 5 1 ft Ib...

Page 369: ...l be removed It is prohibited to wear the cotton work gloves or equivalent coverings 4 Remove Fuel tank TIP Do not set the fuel tank down so that the instal lation surface of the fuel pump is directly under the tank Be sure to lean the fuel tank in an up right position EAS30451 REMOVING THE FUEL PUMP 1 Remove Fuel pump NOTICE ECA14721 Do not drop the fuel pump or give it a strong shock Do not touc...

Page 370: ...rrect position otherwise the fuel hose will not be properly installed TIP Install the fuel hose securely onto the fuel pump until a distinct click is heard To install the fuel hose onto the fuel pump slide the fuel hose 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 2 Connect Fuel tank breather ho...

Page 371: ...ase Refer to GENERAL CHASSIS 3 on page 4 13 1 Fuel hose 1 2 Intake air pressure sensor 1 coupler 1 Disconnect 3 Intake air pressure sensor 2 coupler 1 Disconnect 4 Accelerator position sensor coupler 1 Disconnect 5 Throttle servo motor coupler 1 Disconnect 6 Throttle position sensor coupler 1 Disconnect 7 Throttle cable accelerator cable 1 Disconnect Black 8 Throttle cable decelerator cable 1 Disc...

Page 372: ...remove Q ty Remarks 1 Negative pressure hose 6 2 Hose joint 2 3 Intake air pressure sensor 2 1 4 Intake air pressure sensor 1 1 5 Throttle position sensor 1 6 Accelerator position sensor 1 3 5 Nm 0 35 m kgf 2 5 ft Ibf 1 1 1 2 3 4 5 6 3 5 Nm 0 35 m kgf 2 5 ft Ibf ...

Page 373: ...hrottle bodies Throttle body joint Refer to THROTTLE BODIES on page 7 4 1 Fuel rail 1 2 Injector 3 3 Injector coupler 2 Disconnect 4 Injector lead 1 5 Injector lead coupler 1 Disconnect 6 Wire harness 1 7 Adapter 1 3 5 6 1 4 2 3 2 5 Nm 0 5 m kgf 3 6 ft Ibf 7 12 Nm 1 2 m kgf 8 7 ft Ibf ...

Page 374: ...ted area free of combustible materials Make sure that there is no smoking or use of electric tools in the vicinity of the injectors Be careful when disconnecting the fuel hose Any remaining pressure in the fuel hose may cause the fuel to spray out Place a container or rag under the hose to catch any fuel that spills Always clean up any spilt fuel immediately Turn the main switch to OFF and discon ...

Page 375: ...tings a c Hold the throttle valves in the open position WARNING EWA15940 When cleaning the throttle bodies be careful not to injure yourself on the throttle valves or other components of the throttle bodies NOTICE ECA20380 Do not open the throttle valves by supply ing electrical power to the throttle bodies Do not use tools to open the throttle valves or to keep them in the open position Do not op...

Page 376: ...8 5 Place the vehicle on the centerstand so that the rear wheel is elevated 6 Check Engine idling speed Start the engine warm it up and then mea sure the engine idling speed EAS30480 INSTALLING THE INJECTORS NOTICE ECA21550 Always use new O rings When installing the injectors do not allow any foreign material to enter or adhere to the injectors fuel rails or O rings Be careful not to twist or pinc...

Page 377: ...ide cowling Refer to GENERAL CHASSIS 2 on page 4 6 Passenger seat Rider seat Refer to GENERAL CHASSIS 1 on page 4 1 Fuel tank cover Refer to GENERAL CHASSIS 3 on page 4 13 2 Check Fuel pressure a Remove the fuel tank bolts and hold up the fuel tank b Disconnect the fuel hose 1 from the fuel pump Refer to FUEL TANK on page 7 1 WARNING EWA17320 Cover fuel hose connections with a cloth when disconnec...

Page 378: ...ibited to wear the cotton work gloves or equivalent coverings EAS30485 ADJUSTING THE THROTTLE POSITION SENSOR WARNING EWA16690 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 1 Check Throttle position sensor Refer to CHECKING THE THROTTLE PO SITION SENSOR on page 8 144 2 Adjust T...

Page 379: ...elerator po sition sensor is dropped replace it 1 Check Accelerator position sensor Refer to CHECKING THE ACCELERATOR POSITION SENSOR on page 8 145 2 Adjust Accelerator position sensor angle TIP Before adjusting the accelerator position sensor the throttle bodies must be removed a Temporary tighten the accelerator position sensor b Check that the throttle valves are fully closed c Connect the acce...

Page 380: ...lly open position o Check the meter display value If the meter display value is not 97 107 adjust the accel erator position sensor angle p Select the diagnostic code number 15 q Turn the throttle grip to the fully closed posi tion r Check the meter display value If the meter display value is not 10 24 adjust the acceler ator position sensor angle s Turn the throttle grip to the fully open position...

Page 381: ...THROTTLE BODIES 7 14 ...

Page 382: ...AIR INDUCTION SYSTEM 7 15 EAS20071 AIR INDUCTION SYSTEM 1 2 3 2 3 4 4 ...

Page 383: ...AIR INDUCTION SYSTEM 7 16 1 Air filter case 2 Air induction system hose air filter case to air cut off valve 3 Air cut off valve 4 Air induction system hose air cut off valve to reed valve cover ...

Page 384: ...page 7 1 Air filter case Refer to GENERAL CHASSIS 3 on page 4 13 Radiator Refer to RADIATOR on page 6 1 1 Air cut off valve coupler 1 Disconnect 2 Air induction system hose air cut off valve to reed valve cover 1 3 Air induction system hose air cut off valve to reed valve cover 1 4 Air induction system hose air filter case to air cut off valve 1 5 Air cut off valve 1 6 Air cut off valve holder 1 7...

Page 385: ...EM 7 18 Removing the air cut off valve assembly and reed valves Order Job Parts to remove Q ty Remarks 11 Reed valve assembly 2 1 12 Reed valve plate 2 LT 10 Nm 1 0 m kgf 7 2 ft Ibf 11 LT LT 10 Nm 1 0 m kgf 7 2 ft Ibf 12 ...

Page 386: ...mperature is below the specified value the air cut off valve remains open and allows the air to flow into the exhaust pipe until the temperature becomes higher than the specified value 1 Check Hoses Loose connections Connect properly Cracks damage Replace 2 Check Reed valve Reed valve stopper Reed valve seat Cracks damage Replace the reed valve assembly 3 Measure Reed valve bending limit a Out of ...

Page 387: ... that the open side turns to the exhaust side of the en gine Install the reed valve assembly 2 so that the open side turns to the intake side of the engine 3 Install Reed valve cover A Reed valve assembly 1 B Reed valve assembly 2 C Exhaust side Reed valve cover bolt 10 Nm 1 0 m kgf 7 2 ft lbf LOCTITE 1 c d d A C B C T R ...

Page 388: ...AIR INDUCTION SYSTEM 7 21 ...

Page 389: ...G 8 19 SIGNALING SYSTEM 8 21 CIRCUIT DIAGRAM 8 21 TROUBLESHOOTING 8 23 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 35 DIAGNOSTIC MODE 8 36 YAMAHA DIAGNOSTIC TOOL 8 37 TROUBLESHOOTING DETAILS 8 38 FUEL PUMP SYSTEM 8 77 CIRCUIT DIAGRAM 8 77 TROUBLESHOOTING 8 79 IMMOBILIZER SYS...

Page 390: ...ontrol unit 8 132 CHECKING AND CHARGING THE BATTERY 8 132 CHECKING THE RELAYS 8 135 CHECKING THE TURN SIGNAL HAZARD RELAY 8 136 CHECKING THE RELAY UNIT DIODE 8 137 CHECKING THE IGNITION COILS 8 138 CHECKING THE IGNITION SPARK GAP 8 138 CHECKING THE CRANKSHAFT POSITION SENSOR 8 139 CHECKING THE LEAN ANGLE SENSOR 8 139 CHECKING THE STARTER MOTOR OPERATION 8 140 CHECKING THE STATOR COIL 8 140 CHECKIN...

Page 391: ......

Page 392: ...IGNITION SYSTEM 8 1 EAS20072 IGNITION SYSTEM EAS30490 CIRCUIT DIAGRAM ...

Page 393: ... system fuse 20 Joint connector 21 Joint coupler 22 Relay unit 25 Sidestand switch 27 ECU engine control unit 28 Ignition coil 1 29 Ignition coil 2 30 Ignition coil 3 31 Spark plug 39 Crankshaft position sensor 44 Lean angle sensor 66 Gear position switch 69 Handlebar switch right 71 Start engine stop switch ...

Page 394: ...park However the engine continues to run under the following con ditions The transmission is in gear the neutral circuit of the gear position switch is open and the sidestand is up the sidestand switch circuit is closed The transmission is in neutral the neutral circuit of the gear position switch is closed and the sides tand is down the sidestand switch circuit is open 1 Battery 2 Main fuse 3 Mai...

Page 395: ... replace the battery OK 3 Check the spark plugs Refer to CHECKING THE SPARK PLUGS on page 3 4 NG Re gap or replace the spark plug s OK 4 Check the ignition spark gap Refer to CHECKING THE IGNI TION SPARK GAP on page 8 138 OK Ignition system is OK NG 5 Check the ignition coils Refer to CHECKING THE IGNI TION COILS on page 8 138 NG Replace the ignition coil s OK 6 Check the crankshaft position sen s...

Page 396: ...OK 11 Check the relay unit diode Refer to CHECKING THE RELAY UNIT DIODE on page 8 137 NG Replace the relay unit OK 12 Check the lean angle sensor Refer to CHECKING THE LEAN ANGLE SENSOR on page 8 139 NG Replace the lean angle sensor OK 13 Check the entire ignition system s wiring Refer to CIRCUIT DIAGRAM on page 8 1 NG Properly connect or repair the ignition sys tem s wiring OK Replace the ECU Ref...

Page 397: ...IGNITION SYSTEM 8 6 ...

Page 398: ...ELECTRIC STARTING SYSTEM 8 7 EAS20073 ELECTRIC STARTING SYSTEM EAS30493 CIRCUIT DIAGRAM ...

Page 399: ...ground 17 Fuel injection system fuse 18 Starter relay 19 Starter motor 20 Joint connector 21 Joint coupler 22 Relay unit 23 Starting circuit cut off relay 25 Sidestand switch 66 Gear position switch 69 Handlebar switch right 71 Start engine stop switch 76 Handlebar switch left 77 Clutch switch ...

Page 400: ...losed The clutch lever is pulled to the handlebar the clutch switch is closed and the sidestand is up the sidestand switch is closed The starting circuit cut off relay prevents the starter motor from operating when neither of these condi tions has been met In this instance the starting circuit cut off relay is open so current cannot reach the starter motor When at least one of the above conditions...

Page 401: ...IS UP AND THE CLUTCH LEVER IS PULLED TO THE HAN DLEBAR 1 Battery 2 Main fuse 3 Main switch 4 Ignition fuse 5 Start engine stop switch 6 Starting circuit cut off relay 7 Diode 8 Clutch switch 9 Sidestand switch 10 Gear position switch neutral circuit 11 Diode 12 Starter relay 13 Starter motor ...

Page 402: ...Check the starter motor operation Refer to CHECKING THE START ER MOTOR OPERATION on page 8 140 OK Starter motor is OK Perform the electric starting system troubleshooting starting with step 5 NG 4 Check the starter motor Refer to CHECKING THE START ER MOTOR on page 5 37 NG Repair or replace the starter motor OK 5 Check the relay unit starting circuit cut off relay Refer to CHECKING THE RE LAYS on ...

Page 403: ...Replace the sidestand switch OK 11 Check the clutch switch Refer to CHECKING THE SWITCHES on page 8 127 NG Replace the clutch switch OK 12 Check the start engine stop switch Refer to CHECKING THE SWITCHES on page 8 127 NG Replace the right handlebar switch OK 13 Check the entire starting system s wiring Refer to CIRCUIT DIAGRAM on page 8 7 NG Properly connect or repair the starting sys tem s wirin...

Page 404: ...CHARGING SYSTEM 8 13 EAS20074 CHARGING SYSTEM EAS30496 CIRCUIT DIAGRAM ...

Page 405: ...CHARGING SYSTEM 8 14 1 AC magneto 2 Rectifier regulator 4 Main fuse 15 Battery 16 Engine ground ...

Page 406: ...ING AND CHARGING THE BATTERY on page 8 132 NG Clean the battery terminals Recharge or replace the battery OK 3 Check the stator coil Refer to CHECKING THE STA TOR COIL on page 8 140 NG Replace the stator coil assembly OK 4 Check the rectifier regulator Refer to CHECKING THE RECTI FIER REGULATOR on page 8 140 NG Replace the rectifier regulator OK 5 Check the entire charging system s wiring Refer to...

Page 407: ...CHARGING SYSTEM 8 16 ...

Page 408: ...LIGHTING SYSTEM 8 17 EAS20075 LIGHTING SYSTEM EAS30498 CIRCUIT DIAGRAM ...

Page 409: ...r 21 Joint coupler 27 ECU engine control unit 52 Meter assembly 55 Meter light 61 High beam indicator light 76 Handlebar switch left 83 Dimmer pass switch 88 Headlight control unit 89 Headlight high beam 90 Headlight low beam 91 Auxiliary light right 92 Auxiliary light left 93 License plate light 94 Tail brake light 100 Headlight fuse ...

Page 410: ...ignal ing system Refer to CHECKING THE FUSES on page 8 131 NG Replace the fuse s OK 3 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 132 NG Clean the battery terminals Recharge or replace the battery OK 4 Check the main switch Refer to CHECKING THE SWITCHES on page 8 127 NG Replace the main switch immobilizer unit OK 5 Check the dimmer pass switch Refer to CHECKING THE SWIT...

Page 411: ...LIGHTING SYSTEM 8 20 ...

Page 412: ...SIGNALING SYSTEM 8 21 EAS20076 SIGNALING SYSTEM EAS30500 CIRCUIT DIAGRAM ...

Page 413: ...er 58 Oil level warning light 59 Engine trouble warning light 62 Turn signal indicator light left 63 Turn signal indicator light right 65 Oil level switch 66 Gear position switch 67 Fuel sender 69 Handlebar switch right 72 Hazard switch 73 Front brake light switch 74 Rear brake light switch 75 Turn signal hazard relay 76 Handlebar switch left 80 Horn switch 81 Horn 82 Turn signal switch 84 Rear tu...

Page 414: ...ighting Refer to CHECKING THE FUSES on page 8 131 NG Replace the fuse s OK 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 132 NG Clean the battery terminals Recharge or replace the battery OK 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 127 NG Replace the main switch immobilizer unit OK 4 Check the entire signaling system s wiring Refer to CIRCUIT DIAG...

Page 415: ...rake light switch OK 3 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 8 21 NG Properly connect or repair the signaling system s wiring OK Replace the tail brake light 1 Check the turn signal light bulbs and sockets Refer to CHECKING THE BULBS AND BULB SOCKETS on page 8 130 NG Replace the turn signal light bulb socket or both OK 2 Check the turn signal switch Refer to C...

Page 416: ...OK 2 Check the relay unit diode Refer to CHECKING THE RELAY UNIT DIODE on page 8 137 NG Replace the relay unit OK 3 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 8 21 NG Properly connect or repair the signaling system s wiring OK Replace the meter assembly 1 Check the oil level switch Refer to CHECKING THE SWITCHES on page 8 127 NG Replace the oil level switch OK 2 Ch...

Page 417: ...he entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 8 21 NG Properly connect or repair the signaling system s wiring OK Replace the ECU or meter assembly Refer to REPLACING THE ECU en gine control unit on page 8 132 1 Check the rear wheel sensor Refer to MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR on page 4 32 NG Replace the rear wheel sensor OK 2 Check the entire wheel ...

Page 418: ...COOLING SYSTEM 8 27 EAS20077 COOLING SYSTEM EAS30502 CIRCUIT DIAGRAM ...

Page 419: ...itch 4 Main fuse 9 Radiator fan motor fuse 11 Ignition fuse 15 Battery 16 Engine ground 20 Joint connector 21 Joint coupler 27 ECU engine control unit 41 Coolant temperature sensor 95 Radiator fan motor relay 96 Radiator fan motor ...

Page 420: ...he main switch Refer to CHECKING THE SWITCHES on page 8 127 NG Replace the main switch immobilizer unit OK 4 Check the radiator fan motor Refer to CHECKING THE RADIA TOR FAN MOTOR on page 8 143 NG Replace the radiator fan motor OK 5 Check the radiator fan motor relay Refer to CHECKING THE RE LAYS on page 8 135 NG Replace the radiator fan motor relay OK 6 Check the coolant temperature sen sor Refer...

Page 421: ...COOLING SYSTEM 8 30 ...

Page 422: ...FUEL INJECTION SYSTEM 8 31 EAS20078 FUEL INJECTION SYSTEM EAS30504 CIRCUIT DIAGRAM ...

Page 423: ... Air induction system solenoid 38 O2 sensor 39 Crankshaft position sensor 40 Intake air temperature sensor 41 Coolant temperature sensor 42 Intake air pressure sensor 1 43 Intake air pressure sensor 2 44 Lean angle sensor 46 Rear wheel sensor 47 ABS ECU electronic control unit 48 Throttle servo motor 49 Accelerator position sensor 50 Throttle position sensor 51 Yamaha diagnostic tool coupler 52 Me...

Page 424: ...emains stored in the memory of the ECU until it is deleted Engine trouble warning light indication and fuel injection system operation The warning light flashes when any one of the following conditions is present and the side of the start engine stop switch is pushed Checking the engine trouble warning light The engine trouble warning light comes on for around 2 seconds after the main switch has b...

Page 425: ...ng light and provides the engine with alternate operating instructions that are appropriate for the type of malfunction When an abnormal signal is received from a sensor the ECU processes the specified values that are programmed for each sensor in order to provide the engine with alternate operating instructions that enable the engine to continue operating or stop operating depending on the condit...

Page 426: ...o OFF will not erase the malfunction history The engine operation is not normal but the engine trouble warning light does not come on 1 Check the operation of the following sensors and actuators in the diagnostic mode Refer to TROUBLESHOOTING DETAILS on page 8 38 If a malfunction is detected in the sensors or actuators repair or replace all faulty parts If no malfunction is detected in the sensors...

Page 427: ...played on the multi function meter right display simultaneously press the TCS button 1 and RESET button 2 for 2 seconds or more TIP Press the TCS button to switch the display between DIAG and CO 6 Select the diagnostic code number corresponding to the fault code number by pressing the TCS button or RESET button TIP To decrease the selected diagnostic code number press the RESET button Press the RE...

Page 428: ...efer to the operation manual that is included with the tool Features of the Yamaha diagnostic tool You can use the Yamaha diagnostic tool to identify malfunctions quicker than with conventional methods By connecting the adapter interface which is connected to the USB port of a computer to a vehicle s ECU using the communication cable you can display information that is necessary for identifying ma...

Page 429: ...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 operated Refer to DIAGNOSTIC MODE on page 8 36 CO adjustment mode Adjust the concentration of CO admissions during idling Monitoring mode Displays a graph of sensor output values for actual operating condi tions Logging mode Recor...

Page 430: ...n joint connector and ECU coupler black blue black blue Crank the engine Fault code number is not dis played Service is finished Fault code number is displayed Go to item 4 4 Installed condition of crankshaft position sensor Check for looseness or pinch ing Check the gap 0 85 mm 0 0335 in between the crank shaft position sensor and the generator rotor Improperly installed sensor Reinstall or repla...

Page 431: ...ken terminals and locking condition of the pins Improperly connected Con nect the coupler securely or replace the wire harness Turn the main switch to ON Fault code number is not dis played Service is finished Fault code number is displayed Go to item 3 3 Wire harness continuity Open or short circuit Replace the wire harness Between intake air pressure sensor 1 coupler and ECU cou pler pink pink B...

Page 432: ...number is not dis played Service is finished Fault code number is displayed Go to item 6 6 Malfunction in ECU Replace the ECU Refer to REPLACING THE ECU engine control unit on page 8 132 Fault code No 14 Item Intake air pressure sensor 1 hose system malfunction clogged or detached hose Fail safe system Able to start engine Able to drive vehicle Diagnostic code No 03 Meter display Displays the inta...

Page 433: ...ective Refer to CHECKING THE INTAKE AIR PRESSURE SEN SOR on page 8 146 Fault code No 15 Item Throttle position sensor open or short circuit detected Fail safe system Able Unable to start engine Able Unable to drive vehicle Diagnostic code No 01 13 01 Meter display Throttle position sensor signal 1 11 21 fully closed position 96 106 fully open position Procedure Check with throttle valves fully clo...

Page 434: ...ttle position sensor Check for looseness or pinch ing Improperly installed sensor Reinstall or adjust the sensor Refer to ADJUSTING THE THROTTLE POSITION SEN SOR on page 7 11 Turn the main switch to ON Fault code number is not dis played Service is finished Fault code number is displayed Go to item 5 5 Throttle position sensor resis tance Measure the throttle position sensor resistance black blue ...

Page 435: ...condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the coupler securely or replace the wire harness Turn the main switch to ON and then extend and retract the sidestand Fault code number is not dis played Service is finished Fault code number is displayed Go to item 3 3 Connection of relay unit...

Page 436: ...ide of the start engine stop switch If the display value changes the performance is OK 04 Meter display Displays the intake air pressure Procedure Operate the throttle while pushing the side of the start engine stop switch If the display value changes the performance is OK Item Probable cause of malfunction and check Maintenance job Confirmation of service com pletion 1 Defective intake air pressu...

Page 437: ...ed coolant temperature with the meter dis play value Item Probable cause of malfunction and check Maintenance job Confirmation of service com pletion 1 Connection of coolant tempera ture sensor coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the coupler securely or ...

Page 438: ...nsor Replace if defective Refer to CHECKING THE COOLANT TEMPERATURE SENSOR on page 8 144 Turn the main switch to ON Fault code number is not dis played Service is finished Fault code number is displayed Go to item 6 6 Malfunction in ECU Replace the ECU Refer to REPLACING THE ECU engine control unit on page 8 132 Fault code No 22 Item Intake air temperature sensor open or short circuit detected Fai...

Page 439: ...nch ing Improperly installed sensor Reinstall or replace the sensor Turn the main switch to ON Fault code number is not dis played Service is finished Fault code number is displayed Go to item 5 5 Defective intake air tempera ture sensor Execute the diagnostic mode Code No 05 When engine is cold Displayed temperature is close to the ambient temperature The displayed temperature is not close to the...

Page 440: ...Service is finished Fault code number is displayed Go to item 4 4 Wire harness continuity Open or short circuit Replace the wire harness Between O2 sensor coupler and ECU coupler gray green gray green pink black pink black Between O2 sensor coupler and joint connector black blue black blue red white red white Between joint connector and ECU coupler black blue black blue Between joint connector and...

Page 441: ... harness ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the coupler securely or replace the wire harness Turn the main switch to ON Fault code number is not dis played Service is finished Fault code number is displayed Go to item 3 3 Wire harness continuity Ope...

Page 442: ...es The value does not change when engine is cranking Check the intake air pressure sensor 2 Replace if defective Refer to CHECKING THE INTAKE AIR PRESSURE SEN SOR on page 8 146 Turn the main switch to ON Fault code number is not dis played Service is finished Fault code number is displayed Go to item 6 6 Malfunction in ECU Replace the ECU Refer to REPLACING THE ECU engine control unit on page 8 13...

Page 443: ... level Approx 101 kPa 757 6 mmHg 29 8 inHg 1000 m 3300 ft above sea level Approx 90 kPa 675 1 mmHg 26 6 inHg 2000 m 6700 ft above sea level Approx 80 kPa 600 0 mmHg 23 6 inHg 3000 m 9800 ft above sea level Approx 70 kPa 525 0 mmHg 20 7 inHg When engine is cranking Make sure that the indication value changes The value does not change when engine is cranking Check the intake air pressure sensor 2 Re...

Page 444: ... page 8 132 Fault code No 33 Item Cylinder 1 ignition coil open or short circuit detected in the pri mary lead of the cylinder 1 ignition coil Fail safe system Able to start engine depending on the number of faulty cylinders Able to drive vehicle depending on the number of faulty cylinders Diagnostic code No 30 Actuation Actuates the cylinder 1 ignition coil five times at one second intervals Illu...

Page 445: ...isplayed Go to item 5 5 Defective cylinder 1 ignition coil Measure the primary coil resis tance of the cylinder 1 ignition coil Replace if out of specification Refer to CHECKING THE IGNITION COILS on page 8 138 Start the engine and let it idle for approximately 5 seconds Fault code number is not dis played Service is finished Fault code number is displayed Go to item 6 6 Malfunction in ECU Execute...

Page 446: ...nder 2 ignition coil Check for looseness or pinch ing Improperly installed ignition coil Reinstall or replace the igni tion coil Start the engine and let it idle for approximately 5 seconds Fault code number is not dis played Service is finished Fault code number is displayed Go to item 5 5 Defective cylinder 2 ignition coil Measure the primary coil resis tance of the cylinder 2 ignition coil Repl...

Page 447: ...art the engine and let it idle for approximately 5 seconds Fault code number is not dis played Service is finished Fault code number is displayed Go to item 4 4 Installed condition of cylinder 3 ignition coil Check for looseness or pinch ing Improperly installed ignition coil Reinstall or replace the igni tion coil Start the engine and let it idle for approximately 5 seconds Fault code number is n...

Page 448: ...heck the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the coupler securely or replace the wire harness Execute the diagnostic mode Code Nos 36 37 38 No operating sound Go to item 3 Operating sound Go to item 8 3 Defective injector 1 2 and or injector 3 Measure the injector resistance Replace if out of specification Refer to CHECKING THE FUEL INJECTO...

Page 449: ...ned Procedure Remove the lean angle sensor and incline it more than 65 degrees Item Probable cause of malfunction and check Maintenance job Confirmation of service com pletion 1 Connection of lean angle sensor coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the coup...

Page 450: ...en to OFF and then back to ON Fault code number is not dis played Service is finished Fault code number is displayed Go to item 5 5 Malfunction in ECU Replace the ECU Refer to REPLACING THE ECU engine control unit on page 8 132 Fault code No 42 Item A Rear wheel sensor no normal signals are received from the rear wheel sensor B Neutral switch open or short circuit is detected C Clutch switch open ...

Page 451: ...n of the pins Improperly connected Con nect the coupler securely or replace the wire harness Execute the diagnostic mode Code No 07 Rotate the rear wheel by hand and check that the indicated value increases Value increases Go to item A 8 and delete the fault code Value does not increase Go to item A 4 A 4 Connection of wire harness ECU coupler Check the locking condition of the coupler Disconnect ...

Page 452: ... can also be deleted by activating the diag nostic mode and selecting diag nostic code number 63 Fault code No 42 Item A Rear wheel sensor no normal signals are received from the rear wheel sensor B Neutral switch open or short circuit is detected C Clutch switch open or short circuit is detected Fail safe system Able to start engine Able to drive vehicle Diagnostic code No 21 Meter display Neutra...

Page 453: ...ect indication Go to item B 9 Incorrect indication Go to item B 3 B 3 Connection of wire harness ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the coupler securely or replace the wire harness Execute the diagnostic mode Code No 21 When the transmission is in n...

Page 454: ...m neutral detec tion area Malfunction Replace the shift drum Refer to TRANSMISSION on page 5 76 Execute the diagnostic mode Code No 21 When the transmission is in neutral ON When the transmission is in gear with the clutch lever released OFF Correct indication Go to item B 9 Incorrect indication Go to item B 8 B 8 Malfunction in ECU Replace the ECU Refer to REPLACING THE ECU engine control unit on...

Page 455: ...nction Execute the diagnostic mode Code No 07 Rotate the rear wheel by hand and check that the indicated value increases Value does not increase Go to item A 2 for the rear wheel sensor Execute the diagnostic mode Code No 21 When the transmission is in neutral ON When the transmission is in gear with the clutch lever released OFF Incorrect indication Go to item B 2 for the neutral switch When the ...

Page 456: ...e sidestand is retracted ON Correct indication Go to item C 9 Incorrect indication Go to item C 5 C 5 Wire harness continuity Open or short circuit Replace the wire harness Between ECU coupler and relay unit coupler black yellow black yellow black red black red Between relay unit coupler and clutch switch coupler black yellow black yellow black red black red Execute the diagnostic mode Code No 21 ...

Page 457: ...ic mode and selecting diagnos tic code number 63 Fault code No 43 Item Fuel system voltage incorrect voltage supplied to the fuel injector and fuel pump Fail safe system Able to start engine Able to drive vehicle Diagnostic code No 09 50 09 Meter display Fuel system voltage battery voltage Approximately 12 0 Procedure Set the start engine stop switch to and then compare the actually measured batte...

Page 458: ...njec tion system fuse and relay unit coupler red red Between relay unit coupler and ECU coupler red blue red blue blue yellow blue yellow Start the engine and let it idle for approximately 5 seconds Fault code number is not dis played Service is finished Fault code number is displayed Go to item 4 4 Defective relay unit Execute the diagnostic mode Code No 50 No operating sound Replace the relay un...

Page 459: ...displayed Repeat item 1 If the same number is indicated go to item 6 3 02 is indicated in diagnostic mode code No 60 EEP ROM data error for adjustment of CO concentration of cylinder 2 Change the CO concentration of cylinder 2 and rewrite in EEPROM Refer to ADJUSTING THE EXHAUST GAS VOLUME on page 3 10 After this adjustment is made the memory is not recovered when the main switch is turned to OFF ...

Page 460: ... page 8 13 Defective rectifier regulator or AC magneto Replace Defective connection in the charging system circuit Prop erly connect or replace the wire harness Start the engine and let it idle for approximately 5 seconds Fault code number is not dis played Service is finished Fault code number is displayed Repeat the maintenance job Fault code No 50 Item Faulty ECU memory When this malfunction is...

Page 461: ... Connection of wire harness ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the coupler securely or replace the wire harness Turn the main switch to ON Fault code number is not dis played Service is finished Fault code number is displayed Go to item 3 3 Wire har...

Page 462: ...em malfunction detected Fail safe system Able Unable to start engine Able Unable to drive vehicle Diagnostic code No Meter display Procedure Item Probable cause of malfunction and check Maintenance job Confirmation of service com pletion 1 Connection of throttle servo motor coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and loc...

Page 463: ...e main switch to ON Fault code number is not dis played Service is finished Fault code number is displayed Go to item 6 6 Defective throttle bodies Check the throttle bodies Replace if defective Refer to CHECKING THE THROTTLE SERVO MOTOR on page 8 145 Turn the main switch to ON Fault code number is not dis played Service is finished Fault code number is displayed Go to item 7 7 Malfunction in ECU ...

Page 464: ...s Improperly connected Con nect the coupler securely or replace the wire harness Execute the diagnostic mode Code No 16 Rotate the front wheel by hand and check that the indicated value increases Value increases Go to item 9 and delete the fault code Value does not increase Go to item 4 4 Connection of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins...

Page 465: ...20 to 30 km h 19 mi h The fault code can also be deleted by activating the diag nostic mode and selecting diag nostic code number 63 Fault code No 89 Yamaha diagnostic tool Err multi function meter display Item Multi function meter signals cannot be transmitted between the ECU and the multi function meter Fail safe system Able to start engine Able to drive vehicle Diagnostic code No Meter display ...

Page 466: ...ght green blue light green white light green white Between joint coupler and meter assembly coupler light green blue light green blue light green white light green white Turn the main switch to ON Fault code number is not dis played Service is finished Fault code number is displayed Go to item 4 4 Defective meter assembly Replace the meter assembly Turn the main switch to ON Fault code number is n...

Page 467: ...FUEL INJECTION SYSTEM 8 76 ...

Page 468: ...FUEL PUMP SYSTEM 8 77 EAS20081 FUEL PUMP SYSTEM EAS30513 CIRCUIT DIAGRAM ...

Page 469: ... fuse 11 Ignition fuse 15 Battery 16 Engine ground 17 Fuel injection system fuse 20 Joint connector 21 Joint coupler 22 Relay unit 24 Fuel pump relay 27 ECU engine control unit 68 Fuel pump 69 Handlebar switch right 71 Start engine stop switch ...

Page 470: ...eplace the battery OK 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 127 NG Replace the main switch immobilizer unit OK 4 Check the start engine stop switch Refer to CHECKING THE SWITCHES on page 8 127 NG Replace the right handlebar switch OK 5 Check the relay unit fuel pump re lay Refer to CHECKING THE RE LAYS on page 8 135 NG Replace the relay unit OK 6 Check the fuel pump Refe...

Page 471: ...FUEL PUMP SYSTEM 8 80 ...

Page 472: ...IMMOBILIZER SYSTEM 8 81 EAS20084 IMMOBILIZER SYSTEM EAS30519 CIRCUIT DIAGRAM ...

Page 473: ...ch 4 Main fuse 8 Backup fuse 11 Ignition fuse 15 Battery 16 Engine ground 20 Joint connector 21 Joint coupler 26 Immobilizer unit 27 ECU engine control unit 52 Meter assembly 53 Immobilizer system indicator light 57 Multi function meter ...

Page 474: ... lost regis tering new codes in the standard keys is impossible The standard keys can still be used to start the vehicle However if code re registering is required e g if a new standard key is made or all keys are lost the entire immobilizer system must be replaced Therefore it is highly rec ommended to use either standard key for driving and to keep the code re registering key in a safe place Do ...

Page 475: ...he ignition key to OFF 30 seconds later the indicator light will start flashing continuously in the standby flashing mode pattern for up to 24 hours After that time the indicator light will stop flashing but the immobilizer system is still enabled Standby mode Parts to be replaced Key registration requirement Main switch immobilizer unit Standard key ECU Acces sory lock and key Main switch Immobi ...

Page 476: ...le the indicator light is flashing turn the main switch to OFF remove the key and within 5 sec onds insert the second standard key to be registered into the main switch TIP If he immobilizer system indicator light stops flashing 5 seconds after the first standard key is registered the registration mode is deactivated If this occurs the second standard key cannot be registered and steps 2 to 4 need...

Page 477: ...ain switch OFF c LED on d LED off e Less than 5 0 s f Code re registering key g Remaining standard key h Registration mode A If the immobilizer system indicator light stops flashing 5 seconds after the first standard key is registered the second standard key cannot be registered ...

Page 478: ...HECKING AND CHARGING THE BATTERY on page 8 132 NG Clean the battery terminals Recharge or replace the battery OK 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 127 NG Replace the main switch immobilizer unit OK 4 Check the entire immobilizer sys tem wiring Refer to CIRCUIT DIAGRAM on page 8 81 NG Properly connect or repair the immobilizer system wiring OK Check the condition of t...

Page 479: ...ard key 53 IMMOBILIZER UNIT Codes cannot be transmitted between the ECU and the immobilizer unit Noise interference or dis connected lead cable 1 Interference due to radio wave noise 2 Disconnected commu nication harness 3 Immobilizer unit mal function 4 ECU malfunction 1 Check the wire harness and con nector 2 Replace the main switch immobi lizer unit 3 Replace the ECU Refer to REPLACING THE ECU ...

Page 480: ...5 sec ON and 0 5 sec OFF Example fault code 52 56 ECU Unidentified code is received Noise interference or dis connected lead cable 1 Check the wire harness and con nector 2 Replace the main switch immobi lizer unit 3 Replace the ECU Refer to REPLACING THE ECU engine control unit on page 8 132 Fault code Part Symptom Cause Action a Light on b Light off ...

Page 481: ...IMMOBILIZER SYSTEM 8 90 ...

Page 482: ...ABS ANTI LOCK BRAKE SYSTEM 8 91 EAS20085 ABS ANTI LOCK BRAKE SYSTEM EAS30843 CIRCUIT DIAGRAM ...

Page 483: ...0 Joint connector 21 Joint coupler 22 Relay unit 23 Starting circuit cut off relay 27 ECU engine control unit 45 Front wheel sensor 46 Rear wheel sensor 47 ABS ECU electronic control unit 51 Yamaha diagnostic tool coupler 52 Meter assembly 57 Multi function meter 64 ABS warning light 69 Handlebar switch right 71 Start engine stop switch 73 Front brake light switch 74 Rear brake light switch ...

Page 484: ...ABS ANTI LOCK BRAKE SYSTEM 8 93 EAS30525 ABS COMPONENTS CHART 1 2 3 4 5 6 7 8 9 1 ...

Page 485: ...I LOCK BRAKE SYSTEM 8 94 1 Hydraulic unit assembly 2 Fuse box 3 3 ABS test coupler 4 Rear wheel sensor 5 Rear wheel sensor rotor 6 Front wheel sensor 7 Front wheel sensor rotor 8 ABS warning light 9 Fuse box 2 ...

Page 486: ...ABS ANTI LOCK BRAKE SYSTEM 8 95 EAS30844 ABS COUPLER LOCATION CHART 2 1 3 4 5 ...

Page 487: ...ABS ANTI LOCK BRAKE SYSTEM 8 96 1 Meter assembly coupler 2 Rear wheel sensor coupler 3 ABS ECU coupler 4 ABS test coupler 5 Front wheel sensor coupler ...

Page 488: ...llow the normal service method WARNING EWA16710 When maintenance or checks have been performed on components related to the ABS be sure to perform a final check before delivering the vehicle to the customer ABS operation when the ABS warning light comes on 1 The ABS warning light remains on ABS operates as a normal brake system A malfunction was detected using the ABS self diagnosis function The A...

Page 489: ...the memory of the ABS ECU Delete the fault codes when the ser vice is finished This is because the past fault codes will be displayed again if another malfunction occurs EAS30529 BASIC INSTRUCTIONS FOR TROUBLESHOOTING WARNING EWA17420 Perform the troubleshooting A B C in order Be sure to follow the order since a wrong diagnosis could result if the steps are followed in a different order or omitted...

Page 490: ...of the final checks completed normally Finished Yes No A Turn the main switch to ON and check the ABS warning light Fails to come on Comes on The ABS ECU fuse is blown The ABS ECU coupler is disconnected The wire harness is defective The hydraulic unit assembly is defective The connection with the Yamaha diagnostic tool is defective The wire harness is defective Cannot communicate Can communicate ...

Page 491: ... light comes on the ABS ECU is defective Replace the hydraulic unit assembly EAS30533 A 2 THE ABS WARNING LIGHT AND OTHER INDICATOR LIGHTS FAIL TO COME ON 1 Main switch Check the main switch for continuity Refer to CHECKING THE SWITCHES on page 8 127 If there is no continuity replace the main switch immobilizer unit 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BA...

Page 492: ...nd light green white terminal of the ABS test coupler CANL 4 ABS ECU malfunction Replace the hydraulic unit assembly EAS31164 A 5 ABS ECU AND FI ECU FAIL TO COMMUNICATE 1 Yamaha diagnostic tool Check that the Yamaha diagnostic tool is properly connected 2 Wire harness Open circuit in the wire harness between the ABS ECU coupler and the ABS test coupler Check for continuity between light green blue...

Page 493: ...th the Yamaha diagnostic tool and turning the main switch off Operation of the Yamaha diagnostic tool Fault diagnosis mode Malfunction results are displayed in the top part of the window area 1 Recovered The item list of the malfunction detected in the past already recovered are displayed 2 Detected The item list of the malfunction currently occurred are displayed 3 Code The following icons and th...

Page 494: ...lses or no pulses Front wheel sensor signal is not received properly Pulses are not received or are received intermittently while the vehicle is traveling Foreign material adhered around the front wheel sen sor Incorrect installation of the front wheel Defective sensor rotor or incorrect installation of the rotor Defective front wheel sen sor or incorrect installation of the sensor 12 Rear wheel s...

Page 495: ... circuit is detected in the front wheel sensor Defective coupler between the front wheel sensor and the hydraulic unit assembly Open or short circuit in the wire harness between the front wheel sensor and the hydraulic unit assembly Defective front wheel sen sor or hydraulic unit assembly 16 Rear wheel sensor open or short circuit Open or short circuit is detected in the rear wheel sensor Defectiv...

Page 496: ...ht or brake light switch and the hydraulic unit assembly Defective hydraulic unit assembly 31 Hydraulic unit assembly abnormal ABS solenoid power supply Power is not supplied to the solenoid circuit in the hydraulic unit assembly Blown ABS solenoid fuse Defective coupler between the battery and the hydrau lic unit assembly Open or short circuit in the wire harness between the battery and the hydra...

Page 497: ...en sor Incorrect installation of the front wheel Defective sensor rotor or incorrect installation of the rotor Defective front wheel sen sor or incorrect installation of the sensor 44 Rear wheel sensor missing pulses Rear wheel sensor signal is not received properly Miss ing pulses are detected in the signal while the vehicle is traveling Foreign material adhered around the rear wheel sen sor Inco...

Page 498: ...and the hydraulic unit assembly Defective front wheel sen sor Defective hydraulic unit assembly 64 Rear wheel sensor power supply voltage of power supply is low Power voltage supplied from the ABS ECU to the rear wheel sensor is too low Short circuit in the wire har ness between the rear wheel sensor and the hydraulic unit assembly Defective rear wheel sen sor Defective hydraulic unit assembly Fau...

Page 499: ...EAR WHEEL on page 4 31 3 Defective sensor rotor or incorrect instal lation of the rotor Check the surface of the sensor rotor for damage Replace the sensor rotor if there is visible damage Refer to MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR on page 4 32 4 Defective rear wheel sensor or incorrect installation of the sensor Check the wheel sensor for damage and the installed condition of ...

Page 500: ...ived properly The pulse period is abnormal while the vehicle is traveling Order Item components and probable cause Check or maintenance job 1 Foreign material adhered around the rear wheel sensor Check the surface of the sensor rotor and wheel sensor for foreign material such as metal particles Clean the sensor rotor and wheel sensor if necessary 2 Incorrect installation of the rear wheel Check th...

Page 501: ...ensor and the hydraulic unit assembly Check for continuity between the white terminal 1 and the white terminal 4 and between the black ter minal 2 and the black terminal 5 If there is no continuity the wire harness is defective Replace the wire harness Check that there is no short circuit between the white terminal 1 and the black terminal 2 and between the white terminal 4 and the black terminal ...

Page 502: ...the black ter minal 2 and the black terminal 5 If there is no continuity the wire harness is defective Replace the wire harness Check that there is no short circuit between the white terminal 1 and the black terminal 2 and between the white terminal 4 and the black terminal 5 If there is short circuit the wire harness is defective Replace the wire harness Check that there is no short circuit betwe...

Page 503: ...3 4 Defective front wheel sensor or incorrect installation of the sensor Check the wheel sensor for damage and the installed condition of the sensor Repair or replace the wheel sensor if necessary Refer to MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR on page 4 23 Fault code No 18 46 Item Rear wheel sensor missing pulses Symptom Rear wheel sensor signal is not received properly Missing pu...

Page 504: ...rake light and brake light switches Refer to CHECKING THE SWITCHES on page 8 127 2 Defective coupler between the signaling system tail brake light or brake light switch and the hydraulic unit assembly Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the cou pler securely 3 Open or short circuit in the w...

Page 505: ...nts and probable cause Check or maintenance job 1 Defective hydraulic unit assembly Replace the hydraulic unit assembly Refer to ABS ANTI LOCK BRAKE SYSTEM on page 4 60 Fault code No 33 Item Hydraulic unit assembly abnormal ABS motor power supply Symptom Power is not supplied to the motor circuit in the hydraulic unit assembly Order Item components and probable cause Check or maintenance job 1 Blo...

Page 506: ...ymptom Pulses from the front wheel sensor are received intermittently while the vehicle is traveling Front wheel will not recover from the locking tendency even though the signal is transmitted from the ABS ECU to reduce the hydraulic pressure Order Item components and probable cause Check or maintenance job 1 Incorrect installation of the front wheel sensor Check the components for looseness dist...

Page 507: ...ure is correctly transmit ted to the brake caliper when the brake pedal is oper ated and that the pressure decreases when the pedal is released Refer to CHECKING THE REAR BRAKE DISC on page 4 54 4 Defective hydraulic unit assembly If the above items were performed and no malfunctions were found replace the hydraulic unit assembly Refer to ABS ANTI LOCK BRAKE SYSTEM on page 4 60 Fault code No 43 It...

Page 508: ...aintenance job 1 Foreign material adhered around the rear wheel sensor Check the surface of the sensor rotor and wheel sensor for foreign material such as metal particles Clean the sensor rotor and wheel sensor if necessary 2 Incorrect installation of the rear wheel Check the components for looseness distortion and bends Refer to CHECKING THE REAR WHEEL on page 4 31 3 Defective sensor rotor or inc...

Page 509: ...STEM on page 8 13 Fault code No 53 Item Vehicle system power supply voltage of ABS ECU power supply is low Symptom Power voltage supplied to the ABS ECU in the hydraulic unit assem bly is too low Order Item components and probable cause Check or maintenance job 1 Defective battery Recharge or replace the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 132 2 Defective coupler between t...

Page 510: ...ABS ECU coupler and starter relay coupler ABS motor fuse red blue red blue Between ABS ECU coupler and ABS solenoid fuse red white red white 4 Defective charging system Check the charging system Refer to CHARGING SYSTEM on page 8 13 5 Defective hydraulic unit assembly If the above items were performed and no malfunctions were found replace the hydraulic unit assembly Refer to ABS ANTI LOCK BRAKE S...

Page 511: ...te terminal 1 and the black terminal 2 Check that there is no short circuit between the black yellow terminal 3 and the white terminal 1 If there is a short circuit the wire harness is defective Replace the wire harness 4 ABS ECU 5 Wheel sensor 2 Defective front wheel sensor Check that there is no short circuit between the gray terminal 1 and the white terminal 2 If there is a short circuit the wh...

Page 512: ...e terminal 1 and the black terminal 2 Check that there is no short circuit between the black yellow terminal 3 and the white terminal 1 If there is a short circuit the wire harness is defective Replace the wire harness 4 ABS ECU 5 Wheel sensor 2 Defective rear wheel sensor Check that there is no short circuit between the gray terminal 1 and the white terminal 2 If there is a short circuit the whee...

Page 513: ...he wheel sensors for proper installation Refer to INSTALLING THE FRONT WHEEL DISC BRAKE on page 4 25 and INSTALLING THE REAR WHEEL DISC BRAKE on page 4 32 3 Perform brake line routing confirmation Refer to HYDRAULIC UNIT OPERATION TESTS on page 4 65 If it does not have reaction force properly the brake hose is not properly routed or connected 4 Delete the fault codes Refer to B 3 DELETING THE FAUL...

Page 514: ...ELECTRICAL COMPONENTS 8 123 EAS20089 ELECTRICAL COMPONENTS ...

Page 515: ...ic unit assembly 5 Battery 6 Fuse box 3 7 Main fuse 8 Fuel injection system fuse 9 Starter relay 10 Rectifier regulator 11 Rear wheel sensor 12 Rear brake light switch 13 Gear position switch 14 Sidestand switch 15 O2 sensor 16 Oil level switch 17 Front wheel sensor 18 Ignition coil 19 Radiator fan motor 20 Horn ...

Page 516: ...ELECTRICAL COMPONENTS 8 125 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 ...

Page 517: ... relay 6 Turn signal hazard relay 7 Relay unit 8 Stator coil 9 Crankshaft position sensor 10 Coolant temperature sensor 11 Throttle servo motor 12 Accelerator position sensor 13 Throttle position sensor 14 Intake air pressure sensor 1 15 Intake air pressure sensor 2 16 Injector 17 Air induction system solenoid 18 Fuse box 1 19 Fuse box 2 ...

Page 518: ...ELECTRICAL COMPONENTS 8 127 EAS30549 CHECKING THE SWITCHES B Y W R B W G Br B R Dg Ch Y B Br W B W Y W L W G Dg Br W B W Ch R B R W B W L B L B L 2 1 3 4 6 5 7 8 12 13 14 9 10 11 ...

Page 519: ... Turn signal switch 3 Horn switch 4 Select switch 5 Menu switch 6 Clutch switch 7 Oil level switch 8 Sidestand switch 9 Hazard switch 10 Start engine stop switch 11 Drive mode switch 12 Front brake light switch 13 Main switch 14 Rear brake light switch ...

Page 520: ... 1 range When checking for continuity switch back and forth between the switch positions a few times The switches and their terminal connections are illustrated as in the following example of the main switch The switch positions a are shown in the far left column and the switch lead colors b are shown in the top row The continuity i e a closed circuit between switch terminals at a given switch pos...

Page 521: ...WARNING EWA13320 Since the headlight bulb gets extremely hot keep flammable products and your hands away from the bulb until it has 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 transparen...

Page 522: ... Blown fuse a Set the main switch to OFF b Install a new fuse of the correct amperage rating c Set on the switches to verify if the electrical circuit is operational d If the fuse immediately 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 dam...

Page 523: ... minutes and get immediate medical attention INTERNAL Drink large quantities of water or milk fol lowed with milk of magnesia beaten egg or vegetable oil Get immediate medical atten tion NOTICE ECA13661 This is a VRLA Valve Regulated Lead Acid battery Never remove the sealing caps be cause the balance between cells will not be maintained and battery performance will deteriorate Charging time charg...

Page 524: ...ected to the battery Before removing the battery charger lead clips from the battery terminals be sure to turn off the battery charger Make sure the battery charger lead clips are in full contact with the battery terminal and that they are not shorted A corroded bat tery charger lead clip may generate heat in the contact area and a weak clip spring may cause sparks If the battery becomes hot to th...

Page 525: ...d using a constant voltage charger a Measure the open circuit voltage prior to charging TIP Voltage should be measured 30 minutes after the engine is stopped b Connect a charger and ammeter to the bat tery and start charging c Make sure that the current is higher than the standard charging current written on the bat tery TIP If the current is lower than the standard charging current written on the...

Page 526: ...m the wire harness 2 Connect the pocket tester 1 and battery 12 V to the relay terminal as shown Check the relay operation Out of specification Replace Starter relay Relay unit starting circuit cut off relay Recommended lubricant Dielectric grease Pocket tester 90890 03112 Analog pocket tester YU 03112 C 1 2 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative...

Page 527: ...t of specification Replace a Connect the pocket tester DC 20 V to the turn signal hazard relay 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...

Page 528: ... Continuity Positive tester probe sky blue 1 Negative tester probe black yellow 2 No continuity Positive tester probe black yellow 2 Negative tester probe sky blue 1 Continuity Positive tester probe sky blue 1 Negative tester probe black red 3 No continuity Positive tester probe black red 3 Negative tester probe sky blue 1 Continuity Positive tester probe sky blue 1 Negative tester probe sky blue ...

Page 529: ...on spark gap Out of specification Perform the ignition system troubleshooting starting with step 5 Refer to TROUBLESHOOTING on page 8 4 TIP If the ignition spark gap is within specification the ignition system circuit is operating normally a Remove the ignition coil from the spark plug b Connect the ignition checker 1 as shown Primary coil resistance 1 19 1 61 Pocket tester 90890 03112 Analog pock...

Page 530: ...NSOR 1 Remove Lean angle sensor from the fuel tank bracket 2 Check Lean angle sensor output voltage Out of specification Replace a Connect the test harness lean angle sensor 6P 1 to the lean angle sensor and wire harness as shown b Connect the pocket tester DC 20 V to the test harness lean angle sensor 6P 2 Ignition coil Crankshaft position sensor resis tance 228 342 Gy B Pocket tester 90890 03112...

Page 531: ...e sure no flammable gas or fluid is in the vicinity b Check the starter motor operation EAS30566 CHECKING THE STATOR COIL 1 Disconnect Stator coil coupler from the wire harness 2 Check Stator coil resistance Out of specification Replace the stator coil a Connect the digital circuit tester to the stator coil coupler as shown b Measure the stator coil resistance EAS30680 CHECKING THE RECTIFIER REGUL...

Page 532: ...heck Horn resistance Out of specification Replace a Disconnect the horn leads from the horn ter minals b Connect the digital circuit tester to the horn terminals Rectifier regulator input voltage above 14 V at 5000 r min Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe white 1 Negative tester probe white 2 Positive tester probe white 1 Negative tester probe white 3 P...

Page 533: ...cification Replace the fuel pump assembly a Connect the pocket tester 10 100 to the fuel sender terminals as shown Oil level switch Oil level switch resistance maxi mum level position 484 0 536 0 Oil level switch resistance mini mum level position 114 0 126 0 Pocket tester 90890 03112 Analog pocket tester YU 03112 C Minimum level position A Positive tester probe Coupler gray 1 Negative tester prob...

Page 534: ...HE OIL LEVEL WARNING LIGHT This model is equipped with a self diagnosis de vice for the oil level detection circuit 1 Check Oil level warning light 1 Turn the main switch to ON Warning light comes on for a few seconds then goes off Warning light is OK Warning light does not come on Replace the meter assembly Warning light flashes ten times then goes off for 2 5 seconds in a repeated cycle malfunc ...

Page 535: ...ace a thermometer 3 in the coolant d Heat the coolant or let it cool down to the specified temperatures e Measure the coolant temperature sensor re sistance 3 Install Coolant temperature sensor EAS30581 CHECKING THE THROTTLE POSITION SENSOR 1 Remove Throttle position sensor from the throttle bodies NOTICE ECA17540 Handle the throttle position sensor with special care Never subject the throttle pos...

Page 536: ... a Connect the pocket tester 1 k to the ac celerator position sensor terminals as shown b Measure the accelerator position sensor maximum resistance 3 Install Accelerator position sensor TIP When installing the accelerator position sensor adjust its angle properly Refer to ADJUSTING THE ACCELERATOR POSITION SENSOR on page 7 12 EAS30592 CHECKING THE THROTTLE SERVO MOTOR 1 Remove Air filter case Ref...

Page 537: ...o the intake air pressure sensor and wire harness as shown NOTICE ECA20920 Pay attention to the installing direction of the test harness S pressure sensor 3P cou pler b Connect the digital circuit tester DCV to the test harness S pressure sensor 3P A Check that the throttle valves 2 open B Check that the throttle valves 2 fully close Solenoid resistance 20 24 Pocket tester 90890 03112 Analog pocke...

Page 538: ...ensor terminals do not get wet c Place a thermometer 3 in the water d Slowly heat the water then let it cool down to the specified temperature e Measure the intake air temperature sensor resistance 3 Install Intake air temperature sensor EAS31088 CHECKING THE GEAR POSITION SWITCH 1 Remove Fuel tank Refer to FUEL TANK on page 7 1 Gear position switch Refer to CRANKCASE on page 5 56 2 Check Gear pos...

Page 539: ...ative tester probe Sensor terminal a 1st position Continuity Positive tester probe white 2 Negative tester probe Sensor terminal b 2nd position Continuity Positive tester probe pink 3 Negative tester probe Sensor terminal c 3rd position Continuity Positive tester probe yellow white 4 Negative tester probe Sensor terminal d 4th position Continuity Positive tester probe white red 5 Negative tester p...

Page 540: ...ELECTRICAL COMPONENTS 8 149 ...

Page 541: ...2 FAULTY CLUTCH 9 2 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 3 TROUBLESHOOTING AT THE ABS WARNING LIGHT 9 4 SELF DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE 9 5 SELF DIAGNOSTIC FUNCTION TABLE 9 5 COMMUNICATION ERROR WITH THE METER 9 6 DIAGNOSTIC CODE SENSOR OPERATION TABLE 9 6 DIAGNOSTIC CO...

Page 542: ...or contaminated fuel Sucked in air Electrical system 1 Battery Discharged battery Faulty battery 2 Fuse s Blown damaged or incorrect fuse Improperly installed fuse 3 Spark plug s Incorrect spark plug gap Incorrect spark plug heat range Fouled spark plug Worn or damaged electrode Worn or damaged insulator 4 Ignition coil s Cracked or broken ignition coil body Broken or shorted primary or secondary ...

Page 543: ...opper lever Shift forks Worn shift fork Shift drum Incorrect axial play Worn shift drum groove Transmission Worn gear dog EAS30849 FAULTY CLUTCH Clutch slips 1 Clutch Improperly assembled clutch Improperly adjusted clutch cable Loose or fatigued clutch spring Worn friction plate Worn clutch plate 2 Engine oil Incorrect oil level Incorrect oil viscosity low Deteriorated oil Clutch drags 1 Clutch Un...

Page 544: ...ube bushing Bent or damaged damper rod Incorrect oil viscosity Incorrect oil level EAS30611 UNSTABLE HANDLING Handlebar Bent or improperly installed handlebar Steering head components Improperly installed upper bracket Improperly installed lower bracket improperly tightened ring nut Bent steering stem Damaged ball bearing or bearing race Front fork leg s Uneven oil levels both front fork legs Unev...

Page 545: ... turn signal hazard relay Faulty main switch Faulty turn signal switch Incorrect turn signal bulb Turn signal remains lit Faulty turn signal hazard relay Burnt out turn signal bulb Turn signal blinks quickly Incorrect turn signal bulb Faulty turn signal hazard relay Burnt out turn signal bulb Horn does not sound Damaged or faulty horn Faulty main switch Faulty horn switch Faulty battery Blown dama...

Page 546: ...O2 sensor no normal signals are received from the O2 sensor 25 Intake air pressure sensor 2 open or short circuit detected 26 Intake air pressure sensor 2 hose system malfunction clogged or detached hose 30 Latch up detected 33 Cylinder 1 ignition coil open or short circuit detected in the primary lead of the cylinder 1 ignition coil 34 Cylinder 2 ignition coil open or short circuit detected in th...

Page 547: ... multi function meter Diagnostic code No Item Meter display Procedure 01 Throttle position sensor sig nal 1 Fully closed position 11 21 Check with throttle valves fully closed Fully open position 96 106 Check with throttle valves fully open 03 Intake air pressure 1 Displays the intake air pres sure Operate the throttle while pushing the side of the start engine stop switch If the display value cha...

Page 548: ...on sensor sig nal 2 Fully closed position 9 23 Check with throttle valves fully closed Fully open position 94 108 Check with throttle valves fully open 14 Accelerator position sensor signal 1 Fully closed position 12 22 Check with throttle grip fully closed position Fully open position 97 107 Check with throttle grip fully open position 15 Accelerator position sensor signal 2 Fully closed position...

Page 549: ...play alter nates every two seconds to show all the detected cylin der numbers When all cylinder numbers are shown the display repeats the same process 11 Data error for ISC idle speed control learning val ues 61 Malfunction history code dis play No history 00 History exists Fault codes 12 89 If more than one code number is detected the display alternates every two seconds to show all the detected ...

Page 550: ... Actuation Procedure 30 Cylinder 1 ignition coil Actuates the cylinder 1 igni tion coil five times at one second intervals Illuminates the engine trou ble warning light Check that a spark is gener ated five times Connect an ignition checker 31 Cylinder 2 ignition coil Actuates the cylinder 2 igni tion coil five times at one second intervals Illuminates the engine trou ble warning light Check that ...

Page 551: ...tening for the operating sound 50 Relay unit Actuates the relay unit five times at one second inter vals Illuminates the engine trou ble warning light Check that the relay unit is actuated five times by listen ing for the operating sound 51 Radiator fan motor relay Actuates the radiator fan motor relay five times at five second intervals Illuminates the engine trou ble warning light Check that the...

Page 552: ... abnormality detected in the intake air pressure sensor 2 Same as fault code 25 Perform the inspection items listed for fault code No 25 203 Lean angle sen sor Brief abnormality detected in the lean angle sensor Same as fault code 41 Perform the inspection items listed for fault code No 41 207 Accelerator posi tion sensor Brief abnormality detected in the accel erator position sensor Same as fault...

Page 553: ...able Malfunction in the fuel injection system Dirty or worn spark plug Malfunction in the battery Malfunction in ECU If a fault code is occur ring respond to that first Rarely Code 243 occurs even when the system is functioning properly 244 Poor start ing inability to start Poor starting inability to start detected No gasoline Malfunction in the fuel injection system Dirty or worn spark plug Malfu...

Page 554: ...EVENT CODE TABLE 9 13 ...

Page 555: ...witch 67 Fuel sender 68 Fuel pump 69 Handlebar switch right 70 Drive mode switch 71 Start engine stop switch 72 Hazard switch 73 Front brake light switch 74 Rear brake light switch 75 Turn signal hazard relay 76 Handlebar switch left 77 Clutch switch 78 Select switch 79 Menu switch 80 Horn switch 81 Horn 82 Turn signal switch 83 Dimmer pass switch 84 Rear turn signal light right 85 Rear turn signa...

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Page 559: ...TRAF 2015 WIRING DIAGRAM MT09TRA MT09TRAF 2015 SCHÉMA DE CÂBLAGE MT09TRA MT09TRAF 2015 SCHALTPLAN MT09TRA MT09TRAF 2015 SCHEMA ELETTRICO MT09TRA MT09TRAF 2015 DIAGRAMA ELÉCTRICO W D_S2PPE0 indd 1 2014 06 05 9 52 03 ...

Page 560: ...TRAF 2015 WIRING DIAGRAM MT09TRA MT09TRAF 2015 SCHÉMA DE CÂBLAGE MT09TRA MT09TRAF 2015 SCHALTPLAN MT09TRA MT09TRAF 2015 SCHEMA ELETTRICO MT09TRA MT09TRAF 2015 DIAGRAMA ELÉCTRICO W D_S2PPE0 indd 2 2014 06 05 9 52 03 ...

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