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Yamaha XP560D, Service Manual

The Yamaha XP560D Service Manual is an essential tool for owners of this high-performance product. Easily download this comprehensive manual for free from manualshive.com, enabling you to service and maintain your XP560D with confidence. Take advantage of detailed instructions and diagrams to ensure optimal performance and longevity.

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FRONT BRAKE ............................................................................................. 4-38

INTRODUCTION ..................................................................................... 4-43
CHECKING THE FRONT BRAKE DISCS............................................... 4-43
REPLACING THE FRONT BRAKE PADS .............................................. 4-43
REMOVING THE FRONT BRAKE CALIPERS ....................................... 4-45
DISASSEMBLING THE FRONT BRAKE CALIPERS.............................. 4-45
CHECKING THE FRONT BRAKE CALIPERS ........................................ 4-45
ASSEMBLING THE FRONT BRAKE CALIPERS.................................... 4-46
INSTALLING THE FRONT BRAKE CALIPERS ...................................... 4-46
REMOVING THE FRONT BRAKE MASTER CYLINDER ....................... 4-47
CHECKING THE FRONT BRAKE MASTER CYLINDER........................ 4-47
ASSEMBLING THE FRONT BRAKE MASTER CYLINDER ................... 4-47
INSTALLING THE FRONT BRAKE MASTER CYLINDER...................... 4-47

REAR BRAKE ............................................................................................... 4-50

INTRODUCTION ..................................................................................... 4-58
CHECKING THE REAR BRAKE DISC.................................................... 4-58
REPLACING THE REAR BRAKE PADS................................................. 4-58
REMOVING THE REAR BRAKE CALIPER ............................................ 4-59
DISASSEMBLING THE REAR BRAKE CALIPER .................................. 4-59
CHECKING THE REAR BRAKE CALIPER............................................. 4-60
ASSEMBLING THE REAR BRAKE CALIPER ........................................ 4-60
INSTALLING THE REAR BRAKE CALIPER........................................... 4-60
REMOVING THE REAR BRAKE MASTER CYLINDER ......................... 4-61
CHECKING THE REAR BRAKE MASTER CYLINDER .......................... 4-61
ASSEMBLING THE REAR BRAKE MASTER CYLINDER...................... 4-61
INSTALLING THE REAR BRAKE MASTER CYLINDER ........................ 4-62
REPLACING THE REAR BRAKE LOCK PADS...................................... 4-63
REPLACING THE REAR BRAKE LOCK CABLE.................................... 4-64
REMOVING THE REAR BRAKE LOCK CALIPER ................................. 4-64
CHECKING THE REAR BRAKE LOCK CALIPER .................................. 4-64
ASSEMBLING THE REAR BRAKE LOCK CALIPER.............................. 4-65
INSTALLING THE REAR BRAKE LOCK CALIPER ................................ 4-66

ABS (Anti-lock Brake System) .................................................................... 4-67

REMOVING THE HYDRAULIC UNIT ASSEMBLY ................................. 4-68
CHECKING THE HYDRAULIC UNIT ASSEMBLY .................................. 4-69
INSTALLING THE HYDRAULIC UNIT ASSEMBLY ................................ 4-69
HYDRAULIC UNIT OPERATION TEST .................................................. 4-70
CHECKING THE ABS WARNING LIGHT ............................................... 4-73

HANDLEBAR ................................................................................................ 4-74

REMOVING THE HANDLEBAR.............................................................. 4-78
CHECKING THE HANDLEBAR .............................................................. 4-78
INSTALLING THE HANDLEBAR ............................................................ 4-78
ADJUSTING THE ACCELERATOR POSITION SENSOR...................... 4-80

Summary of Contents for XP560D

Page 1: ...2020 SERVICE MANUAL TMAX TMAX TECH MAX XP560EL XP560D B3T 28197 20 ...

Page 2: ......

Page 3: ...will appear in future editions of this manual where applicable TIP If the contents of the manual are revised the last digit of the manual number will be increased by one 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 EAS20002 This is the safety alert ...

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

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

Page 6: ......

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

Page 8: ......

Page 9: ...1 GENERAL INFORMATION IDENTIFICATION 1 1 VEHICLE IDENTIFICATION NUMBER 1 1 MODEL LABEL 1 1 FEATURES 1 2 MULTI FUNCTION DISPLAY 1 2 CANCELING THE SIDESTAND ALARM BEEPER 1 11 SPECIAL TOOLS 1 12 ...

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

Page 11: ... is detected in the fuel meter electri cal circuit the fuel meter will flash repeatedly Check the vehicle Coolant temperature meter The coolant temperature varies with changes in the weather and engine load If the top segment starts flashing the information display automati cally changes to C TEMP and Hi flashes Stop the vehicle and let the engine cool TIP The information display cannot be changed...

Page 12: ... before the V belt re placement indicator flashes the indicator must be reset in order for the next periodic V belt change to be indicated at the correct time Oil change indicator This indicator flashes at the initial 1000 km 600 mi then at 5000 km 3000 mi and every 5000 km 3000 mi thereafter to indicate that the en gine oil should be changed After changing the engine oil reset the oil change indi...

Page 13: ... the handlebar grip or throttle grip be comes worn or damaged stop using the grip warmers and replace the grips Adjusting the seat heater This vehicle can be equipped with a seat heater which can only be used when the vehicle is run ning There are 4 seat heater settings To increase the seat heater temperature push the side of the select switch To decrease the seat heater temperature push the side ...

Page 14: ... traveled from that point In this case push the select switch to switch the display in the following order F TRIP Display 1 Display 2 Dis play 3 F TRIP If you do not reset the fuel reserve tripmeter manually it will reset automatically after refuel ing and traveling 5 km 3 mi TIP You cannot enter setting mode while F TRIP is on Estimated traveling range The estimated distance that can be traveled ...

Page 15: ...ettings 1 Use the select switch to highlight Grip Warmer 1 Setting mode display 1 Display Description Grip Warmer This function allows you to set the low middle and high settings to 10 temperature levels Seat Heater This function allows you to set the low middle and high settings to 10 temperature levels Traction Con trol This function allows you to turn the traction control sys tem on or off Main...

Page 16: ...to return to the menu screen Seat heater settings 1 Use the select switch to highlight Seat Heat er 2 Push the MENU switch The seat heater setting display will be shown 3 Push the MENU switch The temperature level for the high setting will be highlighted Use the select switch to set the temperature level and then push the MENU switch 4 Use the select switch to highlight Mid or Low and then change ...

Page 17: ...When you finished changing the settings push the MENU switch to return to the menu screen Resetting the maintenance counters 1 Use the select switch to highlight Mainte nance 2 Push the MENU switch and then use the select switch to select the item to reset 3 Push the MENU switch and after the se lected item is highlighted push the select switch for one second 4 When you finished resetting use the ...

Page 18: ...he display to change and then push the MENU switch again 3 Use the select switch to highlight the item to change and then push the MENU switch TIP Display item order is as follows 4 Use the select switch to select the item to show and then push the MENU switch 5 When you finished changing the settings use the select switch to highlight and then push the MENU switch to return to the pre vious displ...

Page 19: ...the clock TIP The clock uses a 12 hour time system 1 Use the select switch to highlight Clock 2 Push the MENU switch 3 When the hour digits are highlighted use the select switch to set the hours 4 Push the MENU switch and the minute dig its are highlighted 5 Use the select switch to set the minutes 6 Push the MENU switch to return to the menu screen Resetting all of the display items 1 Use the sel...

Page 20: ...ne will stop and the beeper will sound to prevent you from forgetting to turn off the vehicle power The sidestand alarm beeper can be set to not activate Setting procedure 1 Set the engine stop switch 1 to 2 While the smart key is on press and hold down the Parking Unlock switch 1 and the Power on Starter switch 2 at the same time TIP The vehicle s power turns on but continue to press and hold tho...

Page 21: ... provided below to avoid any mistakes TIP For U S A and Canada use part numbers starting with YM YU or ACC For others use part numbers starting with 90890 Tool name Tool No Illustration Reference pages Yamaha diagnostic tool USB 90890 03267 3 4 3 12 4 70 4 71 7 13 9 3 9 36 9 37 Yamaha diagnostic tool A I 90890 03264 3 4 3 12 4 70 4 71 7 13 9 3 9 36 9 37 Thickness gauge 90890 03268 Feeler gauge set...

Page 22: ...h 90890 01426 Oil filter wrench YU 38411 3 27 6 8 Oil pressure gauge set 90890 03120 3 29 Oil pressure adapter B 90890 03124 3 29 Pressure gauge 90890 03153 Pressure gauge YU 03153 3 29 7 12 7 13 Fork spring compressor 90890 01441 Fork spring compressor YM 01441 4 83 4 88 Rod holder 90890 01434 Damper rod holder double ended YM 01434 4 83 4 88 Tool name Tool No Illustration Reference pages ...

Page 23: ... 90890 01437 Universal damping rod bleeding tool set YM A8703 4 87 Rod puller attachment M10 90890 01436 Universal damping rod bleeding tool set YM A8703 4 87 Compression gauge 90890 03081 Engine compression tester YU 33223 5 6 Valve spring compressor 90890 04019 Valve spring compressor YM 04019 5 24 5 28 Tool name Tool No Illustration Reference pages YM A8703 YM A8703 90890 03081 YU 33223 ...

Page 24: ...e guide installer 4 0 mm YM 04112 5 25 Valve guide reamer ø4 90890 04113 Valve guide reamer 4 0 mm YM 04113 5 25 Piston pin puller set 90890 01304 Piston pin puller YU 01304 5 31 Digital circuit tester CD732 90890 03243 Model 88 Multimeter with tachometer YU A1927 5 37 8 93 8 94 8 101 8 102 8 103 8 103 8 104 8 104 8 105 8 105 8 106 8 107 8 108 8 108 8 109 8 110 8 110 8 111 8 111 8 112 Tool name To...

Page 25: ...ave spring compressor 90890 04134 Sheave spring compressor YM 04134 5 43 5 46 Sheave fixed block 90890 04135 Sheave fixed bracket YM 04135 5 43 5 46 Yamaha bond No 1215 90890 85505 Three bond No 1215 5 47 5 54 5 71 Sheave holder 90890 01701 Primary clutch holder YS 01880 A 5 52 5 52 5 53 5 54 Tool name Tool No Illustration Reference pages ...

Page 26: ... holder YU 01235 5 58 5 61 Clutch spring compressor 90890 01482 5 58 5 61 Universal clutch holder 90890 04086 Universal clutch holder YM 91042 5 58 5 60 Plane bearing installer 90890 04139 5 75 5 79 Radiator cap tester 90890 01325 Mityvac cooling system tester kit YU 24460 A 6 5 6 5 Tool name Tool No Illustration Reference pages YU 24460 A ...

Page 27: ...8 6 14 Fuel injector pressure adapter 90890 03210 Fuel injector pressure adapter YU 03210 7 12 Fuel pressure adapter 90890 03186 Fuel pressure adapter YM 03186 7 13 Ignition checker 90890 06754 Oppama pet 4000 spark checker YM 34487 8 103 Test harness lean angle sensor 6P 90890 03209 Test harness lean angle sensor 6P YU 03209 8 104 Test harness S pressure sensor 3P 90890 03207 Test harness S press...

Page 28: ...ostic tool A I 90890 03264 This special tool includes the YDT sub harness 6P 90890 03266 TIP YDT sub harness 6P 90890 03266 If you already have Yamaha diagnostic tool A I 90890 03262 YDT sub harness 6P 90890 03266 is separately required ...

Page 29: ...S GENERAL SPECIFICATIONS 2 1 ENGINE SPECIFICATIONS 2 2 CHASSIS SPECIFICATIONS 2 7 ELECTRICAL SPECIFICATIONS 2 9 TIGHTENING TORQUES 2 11 ENGINE TIGHTENING TORQUES 2 11 CHASSIS TIGHTENING TORQUES 2 11 CABLE ROUTING 2 13 ...

Page 30: ...in Overall width 765 mm 30 1 in Overall height 1420 1475 mm 55 9 58 1 in XP560E 1420 1555 mm 55 9 61 2 in XP560D Wheelbase 1575 mm 62 0 in Ground clearance 125 mm 4 92 in Minimum turning radius 2 8 m 9 19 ft Weight Curb weight 218 kg 481 lb XP560E 220 kg 485 lb XP560D Loading Maximum load 195 kg 430 lb XP560D 197 kg 434 lb XP560E Riding capacity 2 person ...

Page 31: ... gal Engine oil Recommended brand YAMALUBE SAE viscosity grades 10W 40 Recommended engine oil grade API service SG type or higher JASO standard MA Lubrication system Dry sump Engine oil quantity Oil change 2 60 L 2 75 US qt With oil filter removal 2 90 L 3 07 US qt Quantity disassembled 3 50 L 3 70 US qt Cooling system Coolant quantity Radiator including all routes 1 54 L 1 63 US qt Coolant reserv...

Page 32: ...h intake 0 90 1 10 mm 0 0354 0 0433 in Limit 1 6 mm 0 06 in Valve seat contact width exhaust 0 90 1 10 mm 0 0354 0 0433 in Limit 1 6 mm 0 06 in Valve stem diameter intake 3 975 3 990 mm 0 1565 0 1571 in Limit 3 945 mm 0 1553 in Valve stem diameter exhaust 3 960 3 975 mm 0 1559 0 1565 in Limit 3 930 mm 0 1547 in Valve guide inside diameter intake 4 000 4 012 mm 0 1575 0 1580 in Valve guide inside d...

Page 33: ... 0 0026 in Side clearance limit 0 115 mm 0 0045 in 2nd ring End gap limit 0 85 mm 0 0335 in Ring side clearance 0 020 0 055 mm 0 0008 0 0022 in Side clearance limit 0 115 mm 0 0045 in Connecting rod Oil clearance 0 039 0 063 mm 0 0015 0 0025 in Bearing color code Code 1 Blue Code 2 Black Code 3 Brown Code 4 Green Crankshaft Runout limit 0 030 mm 0 0012 in Crankshaft journal diameter 54 984 55 000 ...

Page 34: ...tity 7 pcs Clutch spring plate height 4 70 mm 0 19 in Minimum height 4 40 mm 0 17 in Spring quantity 1 pcs Clutch in revolution 1650 2250 r min Clutch stall revolution 3500 4500 r min V belt V belt width limit 31 4 mm 1 24 in Drivetrain Primary reduction ratio 1 000 Transmission type V belt automatic Transmission ratio 2 041 0 758 1 Weight outside diameter 25 0 mm 0 98 in Limit 24 5 mm 0 96 in Dri...

Page 35: ...O2 feedback control Active Coolant temperature 85 105 C 185 221 F Intake vacuum 34 0 kPa 255 mmHg 10 0 inHg Difference in vacuum pressure between the cylinders 0 kPa 1 3 kPa 0 mmHg 10 mmHg 0 inHg 0 4 inHg CO 0 0 2 0 Fuel line pressure at idle 220 300 kPa 2 2 3 0 kgf cm 31 9 43 5 psi Throttle grip free play 1 0 3 0 mm 0 04 0 12 in ...

Page 36: ...TTLAX SCF Rear tire Type Tubeless Size 160 60R15M C 67H Manufacturer model BRIDGESTONE BATTLAX SCR Tire air pressure measured on cold tires 1 person Front 225 kPa 2 25 kgf cm 33 psi Rear 250 kPa 2 50 kgf cm 36 psi 2 persons Front 225 kPa 2 25 kgf cm 33 psi Rear 280 kPa 2 80 kgf cm 41 psi Front brake Type Hydraulic dual disc brake Disc outside diameter thickness 267 0 4 0 mm 10 51 0 16 in Brake dis...

Page 37: ... 2 mm 0 01 in Recommended oil Yamaha Suspension Oil 01 Quantity left 444 0 cm 15 01 US oz Quantity right 434 0 cm 14 67 US oz Level left 114 mm 4 5 in Level right 118 mm 4 6 in Rear suspension Type Swingarm link suspension Spring Coil spring Shock absorber Gas hydraulic damper Wheel travel 117 mm 4 6 in Spring preload Adjusting system Mechanical adjustable type XP560D Unit for adjustment Cam posit...

Page 38: ...age up to operating angle 0 4 1 4 V Output voltage over operating angle 3 7 4 4 V Charging system Charging system AC magneto Standard output 14 0 V 25 0 A at 5000 r min Stator coil resistance 0 224 0 336 Rectifier regulator Regulator type Three phase Regulated voltage DC 14 1 14 9 V Battery Model YTZ12S Voltage capacity 12 V 11 0 Ah 10 HR Bulb wattage Headlight LED Brake tail light LED Front turn ...

Page 39: ...e air temperature sensor resistance 5400 6600 at 0 C 5400 6600 at 32 F Intake air temperature sensor resistance 290 390 at 80 C 290 390 at 176 F Atmospheric pressure sensor output voltage 3 59 3 67 V at 101 3 kPa 3 59 3 67 V at 1 01 kgf cm 3 59 3 67 V at 14 7 psi Coolant temperature sensor resistance 2513 2777 at 20 C 2513 2777 at 68 F Coolant temperature sensor resistance 210 221 at 100 C 210 221...

Page 40: ... kgf m 30 lb ft Coolant drain bolt M12 1 1 6 N m 0 16 kgf m 1 2 lb ft Engine oil drain bolt M14 1 43 N m 4 3 kgf m 32 lb ft Item Thread size Q ty Tightening torque Remarks Front wheel axle M14 1 91 N m 9 1 kgf m 67 lb ft Front wheel axle pinch bolt M8 4 21 N m 2 1 kgf m 15 lb ft See TIP Rear wheel pulley bolt M10 5 64 N m 6 4 kgf m 47 lb ft Rear wheel axle nut M24 1 160 N m 16 kgf m 118 lb ft Fron...

Page 41: ...th a soft hammer until its end is flush with the front fork However if the surface of the front axle end is not parallel to the surface of the front fork align a point on the outer edge of the axle with the fork making sure that the axle does not protrude past the fork 4 Tighten the pinch bolt 5 pinch bolt 4 and pinch bolt 5 to 21 N m 2 1 kgf m 15 lb ft in this order TIP Lower ring nut 1 Tighten t...

Page 42: ...2 13 CABLE ROUTING EAS20021 CABLE ROUTING Headlight bracket front view ...

Page 43: ...ite handle bar switch coupler 3 left white rear brake light switch coupler white for XP560D front brake light switch cou pler black for XP560D handlebar switch coupler 3 right black for XP560E han dlebar switch coupler 4 left white for XP560E The order of arrangement of the coupler above does not matter E Refer to Handlebar top and left side view for XP560D or Handlebar front view for XP560D F Rou...

Page 44: ...2 15 CABLE ROUTING Front cowling assembly rear view ...

Page 45: ...clamp does not matter D Route the headlight sub wire harness going to the right turn signal light in front of the headlight assembly lead E Fully push in the blue tape section of the headlight sub wire harness all the way to the back of the rib section of the headlight assembly F Install the green tape section of the head light sub wire harness to the rib section of the headlight assembly G Instal...

Page 46: ...2 17 CABLE ROUTING Frame right side view front ...

Page 47: ...e cooling sys tem air bleed hose G Insert the injector couplers separately into 1 and 2 H Route the radiator fan motor lead on the inside of the radiator inlet hose I Fasten the radiator fan motor lead with the clamp and install it into the hole in the radi ator bracket J Fasten the wire harness with the clamp and install it into the hole in the bracket K Route the wire harness on the inside of th...

Page 48: ...2 19 CABLE ROUTING Frame right side view rear ...

Page 49: ...ock cylinder E To seat heater for XP560D F Fasten the storage box light switch lead with the clamp G It does not matter whether the storage box light leads are installed on the left or right of the storage box light H Install the clamp of the seat heater lead against the rib of the storage box I Around the starter motor J Push in the starter motor lead underneath the V belt case air duct K Install...

Page 50: ...2 21 CABLE ROUTING Frame left side view front Q ...

Page 51: ...lead cou pler D Pass it outside the starter motor lead E Make sure the spark plug leads after this clamp are not twisted F Make sure there is no slack in the spark plug lead when installed within this range as shown in the illustration G Install the wire harness clamp into the hole on the battery box H Push in the buzzer coupler up to the inside of the wire harness branch lead and relay The couple...

Page 52: ...2 23 CABLE ROUTING Rear frame left side view center ...

Page 53: ...the illustration Point the end of the plastic locking tie rearward and place it inside of the footboard I Assemble the wire harness clamp to the round area of the rib J Install the plastic locking tie between the wire harness clamp and the centerstand lock solenoid coupler Make sure the plas tic locking tie does not come into contact with the bare wire The end of the plastic locking tie should fac...

Page 54: ...2 25 CABLE ROUTING Frame left side view rear ...

Page 55: ...XP560D B The order of arrangement of the lead does not matter as long as it is installed within this range C Install the plastic locking tie within this range D Fasten the tape portion of each lead with the clamp White tape Wire harness seat heater lead for XP560D Yellow tape Mudguard assembly lead It should be okay as long as the clamp is aligned roughly to the tape section of each lead E The end...

Page 56: ...2 27 CABLE ROUTING Frame top view front ...

Page 57: ...Front brake hose hydraulic unit to front brake caliper 16 Windshield drive unit cable for XP560D A After connecting the coupler to the meter insert it until the coupler cover contacts the bottom of the meter B Insert the clamp into the hole in the fuel tank bracket C Insert the coolant temperature sensor lead into the notch in the air filter case duct D To canister E To fuel pump F Pass the canist...

Page 58: ...2 29 CABLE ROUTING Frame top view rear ...

Page 59: ... relay control for XP560D 11 Seat heater relay power for XP560D 12 Radiator fan motor relay 13 Turn signal hazard relay 14 Wire harness 15 Storage box light switch lead A Route the lead along the edge of the filler cover B Make sure the seat lock cable does not get caught C Pass the tail brake light lead right through the hole D Install the seat fuel lid lock solenoid lead to the rib of the filler...

Page 60: ...2 31 CABLE ROUTING Handlebar top and left side view for XP560E ...

Page 61: ...ke hose holder A Route the rear brake lock cable through the hole in the handlebar cover B Route through the cable guide in the order of the throttle cable decelerator cable fol lowed by throttle cable accelerator cable C Turn the rear brake lock lever up to the position shown in the illustration before installing the rear brake lock cable D Route the handlebar switch lead right on top of and at t...

Page 62: ...2 33 CABLE ROUTING Handlebar front view for XP560E ...

Page 63: ...front brake hose with the white paint mark on the metal part facing the front L Route the metal part of the rear brake hose between the guides of the rear brake mas ter cylinder M Attach the rear brake hose with the yellow paint mark on the metal part facing the front N Consolidate the leads around the handle bar and fasten them with the clamp Refer to P Clamp A fixed position details O Face the e...

Page 64: ...2 35 CABLE ROUTING Handlebar top and left side view for XP560D ...

Page 65: ...by throttle cable accelerator cable C Install the grip warmer lead left into the slot in the handlebar switch left D Turn the rear brake lock lever up to the position shown in the illustration before installing the rear brake lock cable E 87 93 F Case mating surface of the handlebar switch left G The end of the clamp should face the front without being cut H Route the grip warmer lead handlebar sw...

Page 66: ...2 37 CABLE ROUTING Handlebar front view for XP560D ...

Page 67: ... right to assemble it N The metal part of the front brake hose should come into contact with the guide section of the front brake master cylinder O Install the front brake hose with the white paint mark on the metal part facing the front P Route the metal part of the rear brake hose between the guides of the rear brake mas ter cylinder Q Install the rear brake hose with the yellow paint mark on th...

Page 68: ...2 39 CABLE ROUTING Front brake front left side and right side view Q ...

Page 69: ...stic locking tie The plastic locking tie should face downward with the end cut to 5 mm 0 2 in or less J Install the bracket with the identification mark facing the front K Install the front brake hose left brake cali per to right brake caliper with the metal part in contact with the positioning stopper of the brake caliper Install the front brake hose hydraulic unit to front brake caliper by align...

Page 70: ...2 41 CABLE ROUTING Frame right side view front ...

Page 71: ...ake lock cable in front of the section where the electrical compo nents tray and frame are fastened D Route the rear brake hose along the guide of the electrical components tray E Make sure there is no slack in the rear wheel sensor lead within this interval F Arrange the rear wheel sensor lead either on top of below or outside the rear brake hose G The end of the plastic locking tie should face d...

Page 72: ...2 43 CABLE ROUTING Rear brake right side view rear ...

Page 73: ...tation stopper against the rear frame C Install the clamp with the clamp in contact with the protector end of the rear wheel sensor lead D Install the rear brake hose with the rear brake hose in contact with the stopper of the rear brake caliper E Route the rear brake lock cable between the bracket F Route the rear brake hose through the guide portion of the bracket G Fasten the rear brake hose hy...

Page 74: ...2 45 CABLE ROUTING Fuel tank right side view ...

Page 75: ...and fuel tank breather hose with the clamp Install the clamp with the longer side of the fixed sec tion facing downward and adjust the posi tion so that the intersection of the rear brake hose and fuel tank breather hose is in contact with the clamp C To hose joint D Install the fuel tank breather hose with the mark facing the outside The end of the fuel tank breather hose should come into contact...

Page 76: ...2 47 CABLE ROUTING Fuel tank left side view ...

Page 77: ...tall the fuel tank overflow hose with the mark facing the outside B Route the fuel tank overflow hose between the sidestand bracket and the frame C Align the mark on the fuel tank with the mark on the fuel pump to install the fuel pump D Assemble the filler cover to match the shape of the fuel tank The filler cover should not ride up on the round end of the fuel tank E Round end of the fuel tank ...

Page 78: ...2 49 CABLE ROUTING Fuel tank top view ...

Page 79: ...the hose mounting area G Insert the canister purge hose until it butts against the throttle body assembly H Do not allow the bolt head of the clamp that is holding the throttle body joint to touch the clip of the canister purge hose I The end of the clip should face downward 2 pieces J Face the tip of the clip knob toward the back of the vehicle so it does not interfere with other parts K Do not a...

Page 80: ...2 51 CABLE ROUTING Air filter case and throttle body left side view ...

Page 81: ...until it butts against the throttle body assembly E Do not allow the intake air pressure sensor hose to be twisted F Pass the intake air pressure sensor hose under the brim of the air filter case duct left G Mate the intake air pressure sensor hose to the clamp on the air filter case duct left H 10 I Align the projection on the air filter case duct right to the indent on the clamp J Align the proj...

Page 82: ...2 53 CABLE ROUTING Radiator right side view ...

Page 83: ...olant reservoir hose to the bottom of the radiator filler hose O 2 mm 0 08 in or more P Insert the oil cooler inlet hose all the way to the paint mark on the end Q Make sure the clamp does not ride on top of the bulge in the hose mounting area R Insert the radiator inlet hose into the radia tor until it reaches the end of the punch mark S Face the screw head of the hose clamp to the right side of ...

Page 84: ...2 55 CABLE ROUTING Radiator left side view ...

Page 85: ...n contact with it 0 10 mm 0 0 39 in J Align the clamp with the paint mark on the coolant reservoir hose K Make sure the clamp does not ride on top of the bulge in the hose installing area L Make sure the hose does not contact the rounded end of the oil cooler inlet pipe M 2 mm 0 08 in or more N Install the clamp so that the joint section is at a position relative to the screw head of the hose clam...

Page 86: ...2 57 CABLE ROUTING Radiator top view ...

Page 87: ...se clamp does not ride on top of the bulge in the hose mounting area C Install the clip with its end facing the down D Insert the coolant reservoir hose until it comes into contact with the rib of the radia tor filler pipe E Insert the cooling system air bleed hose until it comes into contact with the rib of the radiator filler pipe F Install the clamp with its end facing the right G Pass the cool...

Page 88: ...2 59 CABLE ROUTING Hydraulic unit assembly top and front view ...

Page 89: ...e front brake hose 3 with the L shaped pin in contact with the side of the hydraulic unit The installation order of rear brake hose 1 and front brake hose 3 does not matter 2 Install the front brake hose 4 with the protrusion in contact with the metal part of front brake hose 3 Install the rear brake hose 2 with the protrusion in contact with the metal part of rear brake hose 1 The installation or...

Page 90: ...2 61 CABLE ROUTING ...

Page 91: ...ENT AND CLEANING THE CHECK HOSE 3 12 CLEANING THE V BELT CASE AIR FILTER ELEMENT 3 13 CHECKING THE BRAKE OPERATION 3 14 CHECKING THE BRAKE FLUID LEVEL 3 14 ADJUSTING THE FRONT DISC BRAKE 3 14 CHECKING THE FRONT BRAKE PADS 3 15 ADJUSTING THE REAR DISC BRAKE 3 15 CHECKING THE REAR BRAKE PADS 3 16 CHECKING THE FRONT BRAKE HOSES 3 16 CHECKING THE REAR BRAKE HOSE 3 16 BLEEDING THE HYDRAULIC BRAKE SYSTE...

Page 92: ... SHOCK ABSORBER ASSEMBLY for XP560D 3 25 CHECKING THE CONNECTING ARM AND RELAY ARM 3 26 CHECKING THE ENGINE OIL LEVEL 3 27 CHANGING THE ENGINE OIL 3 27 MEASURING THE ENGINE OIL PRESSURE 3 29 CHECKING THE COOLANT LEVEL 3 29 CHECKING THE COOLING SYSTEM 3 30 CHANGING THE COOLANT 3 31 REPLACING THE V BELT 3 32 CHECKING THE BRAKE LIGHT SWITCHES 3 33 CHECKING AND LUBRICATING THE CABLES 3 33 CHECKING THE...

Page 93: ...MISSION CONTROL SYSTEM EAS30615 GENERAL MAINTENANCE AND LUBRICATION CHART No ITEM CHECK OR MAINTENANCE JOB ODOMETER READINGS ANNUAL CHECK 1000 km 600 mi 10000 km 6000 mi 20000 km 12000 mi 30000 km 18000 mi 40000 km 24000 mi 1 Fuel line Check fuel hoses for cracks or damage Replace if necessary 2 Spark plugs Check condition Adjust gap and clean Replace 3 Valve clearance Check and adjust Every 40000...

Page 94: ...ies for looseness Moderately repack with lithi um soap based grease 17 Chassis fasteners Make sure that all nuts bolts and screws are properly tight ened 18 Front and rear brake lever pivot shaft Lubricate with silicone grease 19 Sidestand center stand Check operation Lubricate with lithium soap based grease 20 Sidestand switch Check operation and replace if necessary 21 Front fork Check operation...

Page 95: ...nternal components of the brake master cylinders and calipers and change the brake fluid every 2 years Replace the brake hoses every 4 years or sooner if cracked or damaged 28 Front and rear brake switches Check operation 29 Moving parts and cables Lubricate 30 Throttle grip housing and cable Check operation and free play Adjust the throttle cable free play if necessary Lubricate the throttle grip...

Page 96: ...N AND DIAGNOSTIC CODE TABLE on page 9 38 4 Perform Dynamic inspection TIP Use the Dynamic inspection function of the YDT version 3 0 and after to perform the dynam ic inspection For information about using the YDT refer to the operation manual that is includ ed with the tool 5 Install Battery cover Refer to GENERAL CHASSIS 1 on page 4 1 EAS30619 CHECKING THE FUEL LINE The following procedure appli...

Page 97: ...k plug Insulator 2 Abnormal color Replace the spark plug Normal color is medium to light tan 6 Clean Spark plug with a spark plug cleaner or wire brush 7 Measure Spark plug gap a with a wire thickness gauge Out of specification Regap 8 Install Spark plug TIP Before installing the spark plug clean the spark plug and gasket surface 9 Connect Spark plug cap 10 Install Radiator cover Side panel Bottom...

Page 98: ...he generator rotor with the mark b on the generator cover TIP TDC on the compression stroke can be found when the cylinder 1 camshaft lobes are turned away from each other In order to be sure that the piston is at TDC the alignment mark c on the intake camshaft sprocket and the alignment mark d on the ex haust camshaft sprocket must align with the cylinder head mating surface as shown in the illus...

Page 99: ...d valve clearance Example Specified valve clearance 0 15 0 22 mm 0 0059 0 0087 in Measured valve clearance 0 25 mm 0 0098 in 0 25 mm 0 0098 in 0 22 mm 0 0087 in 0 03 mm 0 001 in c Check the thickness of the current valve pad TIP The thickness a of each valve pad is marked in hundredths of millimeters on the side that touch es the valve lifter Example If the valve pad is marked 155 the pad thicknes...

Page 100: ...he specified clearance is obtained 8 Install All removed part TIP For installation reverse the removal procedure 9 Adjust Throttle grip free play Refer to CHECKING THE THROTTLE GRIP on page 3 33 EAS31017 CHECKING THE ENGINE IDLING SPEED TIP Prior to checking the engine idling speed the throttle body synchronization should be adjusted properly the air filter element should be clean and the engine s...

Page 101: ... Footboard Refer to GENERAL CHASSIS 2 on page 4 11 Fuel tank Refer to FUEL TANK on page 7 1 3 Remove Intake air pressure sensor hose 1 Cap 2 4 Install Hose 1 Parts No 5JW 24311 00 3 way joint 2 Parts No 68V 24376 00 Intake air pressure sensor hose 3 Vacuum gauge 4 5 Install Fuel tank Refer to FUEL TANK on page 7 1 6 Check Throttle body synchronization a Start the engine warm it up for several min ...

Page 102: ...lace the throttle bodies The difference in vacuum pressure between the throttle bodies should not exceed 1 33 kPa 10 mmHg 2 Stop the engine and remove the measuring equipment 3 Install Intake air pressure sensor hose Cap 4 Install Fuel tank Refer to FUEL TANK on page 7 1 Footboard Rear side cowling assembly Side cover Fuel tank cover assembly Center cover Refer to GENERAL CHASSIS 2 on page 4 11 Bo...

Page 103: ...ar 5 4 Install Footboard right Rear side cowling assembly right Side cover right Fuel tank cover assembly Center cover Refer to GENERAL CHASSIS 2 on page 4 11 Bottom center cowling Side panel Bottom side cowling Refer to GENERAL CHASSIS 1 on page 4 1 EAS30623 CHECKING THE CYLINDER HEAD BREATHER HOSE 1 Remove Bottom side cowling Side panel Bottom center cowling Refer to GENERAL CHASSIS 1 on page 4 ...

Page 104: ...volume use the CO adjustment mode of the YDT For more infor mation refer to the operation manual of the YDT 1 Remove the protective cap and then connect the YDT to coupler Refer to YDT on page 9 3 TIP Yamaha diagnostic tool A I 90890 03264 in cludes YDT sub harness 6P 90890 03266 If you already have Yamaha diagnostic tool A I 90890 03262 YDT sub harness 6P 90890 03266 is separately required EAS311...

Page 105: ...THE V BELT CASE AIR FILTER ELEMENT 1 Remove Bottom side cowling Side panel Bottom center cowling Refer to GENERAL CHASSIS 1 on page 4 1 Center cover Fuel tank cover assembly Side cover Rear side cowling assembly Footboard Refer to GENERAL CHASSIS 2 on page 4 11 2 Remove V belt case air filter element left Refer to WATER PUMP on page 6 11 3 Remove V belt case air filter case cover V belt case air f...

Page 106: ...te causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake performance When refilling be careful that water does not enter the brake master cylinder reser voir Water will significantly lower the boil ing point of the brake fluid and could cause vapor lock NO...

Page 107: ... the brake pads as a set Refer to FRONT BRAKE on page 4 38 EAS30631 ADJUSTING THE REAR DISC BRAKE 1 Adjust Rear brake lever position distance a from the left side grip to the brake lever a Push the brake lever forward b Turn the adjusting dial 1 until the brake le ver is in the desired position c Align the appropriate setting on the adjust ing dial with the mark a on the brake lever WARNING EWA170...

Page 108: ...EAR BRAKE on page 4 50 EAS30893 BLEEDING THE HYDRAULIC BRAKE SYSTEM WARNING EWA14000 Always bleed the brake system when the brake related parts are removed NOTICE ECA18050 Bleed the brake system in the following or der 1st step Front brake calipers 2nd step Rear brake caliper WARNING EWA15740 Bleed the ABS whenever the system is disassembled a brake hose is loosened disconnected or replaced the br...

Page 109: ...oir to the proper level with the speci fied brake fluid l Tighten the bleed screw to specification m Fill the brake master cylinder reservoir to the proper level with the specified brake flu id Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 14 WARNING EWA13110 After bleeding the hydraulic brake system check the brake operation EAS31425 ADJUSTING THE REAR BRAKE LOCK CABLE WARNING EWA18100 Do not...

Page 110: ...K 1 Check Rear brake lock operation Apply the rear brake lock and then pushing the vehicle for properly locks the rear brake lock Rear brake lock not working properly Check the rear brake lock cable and rear brake lock pads Refer to ADJUSTING THE REAR BRAKE LOCK CABLE on page 3 17 and CHECK ING THE REAR BRAKE LOCK PADS on page 3 18 2 Check Rear brake lock cable length Out of specification Adjust R...

Page 111: ...tires listed below have been approved by Yamaha Motor Co Ltd for this model The front and rear tires should always be by the same manufacturer and of the same design No guarantee con cerning handling characteristics can be giv en if a tire combination other than one approved by Yamaha is used on this vehicle WARNING EWA13210 New tires have a relatively low grip on the road surface until they have ...

Page 112: ...E on page 4 94 2 Clean Drive belt a Wipe the drive belt with a clean cloth b Put the drive belt in a mixture of mild deter gent and water Then remove any dirt from the drive belt c Remove the drive belt from the mixture and rinse it off with clean water Then let the drive belt thoroughly dry 3 Check Drive belt Exposed cogs or external cracks A Replace Missing teeth B Replace Hook wear C Replace St...

Page 113: ...at room temperature and when the drive belt is dry 1 Stand the vehicle on a level surface TIP Place the vehicle on the centerstand 2 Remove the drive belt upper guard Refer to REAR WHEEL on page 4 30 3 Tap the drive belt and measure the vibration frequency Drive belt tension vibration frequency Out of specification Adjust TIP Before using the tension meter read the instruc tion manual a Face the m...

Page 114: ... tween the left and right sides is within 0 8 mm 0 03 in 7 Use the tension meter and measure the drive belt tension again 8 Measure and adjust until proper drive belt tension within specification value is obtained EAS31433 LUBRICATING THE DRIVE PULLEY AND DRIVE AXLE 1 Remove Drive belt upper guard and lower guard Refer to REAR WHEEL on page 4 30 2 Remove Drive belt Refer to BELT DRIVE on page 4 94...

Page 115: ...you put in too much grease the grease will come out of the holder which could cause grease to get on the drive belt TIP Use a scale to weigh the grease and inject 38 g into the drive pulley assembly inner part 8 Install All removed part 9 Adjust Drive belt tension Refer to DRIVE BELT TENSION on page 3 21 EAS30645 CHECKING AND ADJUSTING THE STEERING HEAD 1 Stand the vehicle on a level surface WARNI...

Page 116: ...y turning the front fork all the way in both directions If any binding is felt re move the lower bracket and check the up per and lower bearings Refer to STEERING HEAD on page 4 90 e Install the rubber washer 3 f Install the upper ring nut 2 g Finger tighten the upper ring nut 2 then align the slots of both ring nuts If neces sary hold the lower ring nut and tighten the upper ring nut until their ...

Page 117: ...face WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over 2 Check Inner tube Damage scratches Replace Front fork leg Oil leaks between inner tube and outer tube Replace the oil seal 3 Hold the vehicle upright and apply the front brake 4 Check Front fork operation Push down hard on the handlebar several times and check if the front fork rebounds smoothly Rough...

Page 118: ...his ad justment range may not exactly match the spec ifications listed due to small differences in production EAS30809 CHECKING THE CONNECTING ARM AND RELAY ARM 1 Check Rear shock absorber assembly operation Rough movement Repair Refer to REAR SHOCK ABSORBER AS SEMBLY on page 4 96 Direction a Spring preload is increased suspension is harder Direction b Spring preload is decreased suspension is sof...

Page 119: ...rankcase TIP Before checking the engine oil level wait a few minutes until the oil has settled 4 Start the engine warm it up for several min utes and then turn it off 5 Check the engine oil level again TIP Before checking the engine oil level wait a few minutes until the oil has settled EAS30657 CHANGING THE ENGINE OIL 1 Start the engine warm it up for several min utes and then turn it off 2 Place...

Page 120: ...ng and bot tom center cowling Refer to GENERAL CHASSIS 1 on page 4 1 b Slightly loosen the engine oil check bolt 1 c Start the engine and keep it idling until en gine oil starts to seep from the oil check bolt If no engine oil comes out after one minute turn the engine off so that it will not seize d Check the engine oil passages the oil filter cartridge and the oil pump for damage or leakage Refe...

Page 121: ... point plug TIP Lubricate the O ring of the engine oil pressure check point plug with a thin coat of lithium soap based grease EAS30811 CHECKING THE COOLANT LEVEL 1 Stand the vehicle on a level surface TIP Place the vehicle on the centerstand Make sure the vehicle is upright 2 Check Coolant level The coolant level should be between the maximum level mark a and minimum level mark b Oil pressure gau...

Page 122: ...ECKING THE COOLING SYSTEM 1 Remove Bottom side cowling Side panel Radiator cover Bottom center cowling Refer to GENERAL CHASSIS 1 on page 4 1 Center cover Fuel tank cover assembly Side cover Rear side cowling assembly Footboard Refer to GENERAL CHASSIS 2 on page 4 11 2 Check Radiator 1 Radiator inlet hose 2 Radiator outlet hose 3 Radiator filler pipe 4 Radiator filler hose 5 Oil cooler outlet hose...

Page 123: ...steam may be blown out which could cause serious in jury When the engine has cooled open the radiator cap as follows Place a thick rag or a towel over the radiator cap and slowly turn the radiator cap counter clockwise toward the detent to allow any re sidual pressure to escape When the hissing sound has stopped press down on the radi ator cap and turn it counterclockwise to re move TIP When remov...

Page 124: ...olant to the maxi mum level mark a 12 Install Coolant reservoir cap 13 Start the engine warm it up for one minute and then stop it TIP Place the vehicle on the centerstand 14 Check Coolant level Refer to CHECKING THE COOLANT LEV EL on page 3 29 TIP Before checking the coolant level wait a few minutes until the coolant has settled 15 Install Footboard Rear side cowling assembly Side cover Fuel tank...

Page 125: ...o all of the in ner and outer cables WARNING EWA13270 Damaged outer cable may cause the cable to corrode and interfere with its movement Re place damaged outer cable and inner cables as soon as possible 1 Check Outer cable Damage Replace 2 Check Cable operation Rough movement Lubricate TIP Hold the cable end upright and pour a few drops of lubricant into the cable sheath or use a suit able lubrica...

Page 126: ... CHARGING THE BATTERY Refer to CHECKING AND CHARGING THE BATTERY on page 8 94 EAS30662 CHECKING THE FUSES Refer to CHECKING THE FUSES on page 8 93 EAS30664 ADJUSTING THE HEADLIGHT BEAMS 1 Adjust Headlight beam vertically a Turn the adjusting screw 1 TIP Other than the socket wrench the adjusting screws can be turned with a screwdriver Phillips No 2 2 as shown in the illustration 2 Adjust Headlight...

Page 127: ...EEL 4 22 REMOVING THE FRONT WHEEL 4 24 DISASSEMBLING THE FRONT WHEEL 4 24 CHECKING THE FRONT WHEEL 4 24 ASSEMBLING THE FRONT WHEEL 4 25 MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR 4 26 ADJUSTING THE FRONT WHEEL STATIC BALANCE 4 27 INSTALLING THE FRONT WHEEL DISC BRAKE 4 27 REAR WHEEL 4 30 REMOVING THE REAR WHEEL 4 33 DISASSEMBLING THE REAR WHEEL 4 33 CHECKING THE REAR WHEEL 4 33 CHECKIN...

Page 128: ...CALIPER 4 60 ASSEMBLING THE REAR BRAKE CALIPER 4 60 INSTALLING THE REAR BRAKE CALIPER 4 60 REMOVING THE REAR BRAKE MASTER CYLINDER 4 61 CHECKING THE REAR BRAKE MASTER CYLINDER 4 61 ASSEMBLING THE REAR BRAKE MASTER CYLINDER 4 61 INSTALLING THE REAR BRAKE MASTER CYLINDER 4 62 REPLACING THE REAR BRAKE LOCK PADS 4 63 REPLACING THE REAR BRAKE LOCK CABLE 4 64 REMOVING THE REAR BRAKE LOCK CALIPER 4 64 CH...

Page 129: ...G THE DRIVE BELT 4 95 INSTALLING THE DRIVE BELT AND DRIVE PULLEY 4 95 REAR SHOCK ABSORBER ASSEMBLY 4 96 HANDLING THE REAR SHOCK ABSORBER 4 97 DISPOSING OF A REAR SHOCK ABSORBER 4 97 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 4 97 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 4 98 CHECKING THE CONNECTING ARM AND RELAY ARM 4 98 ASSEMBLING THE CONNECTING ARM 4 98 INSTALLING THE RELAY ARM 4 98 INSTALLING T...

Page 130: ...er 1 6 Rearview mirror 2 7 Windshield inner panel 1 8 Meter assembly coupler 1 Disconnect 9 Meter assembly 1 10 Meter panel assembly 1 3 1 1 3 4 5 7 8 10 9 6 6 2 2 1 6 N m 0 16 kgf m 1 2 lb ft 1 5 N m 0 15 kgf m 1 1 lb ft 1 5 N m 0 15 kgf m 1 1 lb ft 4 0 N m 0 40 kgf m 3 0 lb ft 2 5 N m 0 25 kgf m 1 8 lb ft 2 5 N m 0 25 kgf m 1 8 lb ft 1 3 N m 0 13 kgf m 0 95 lb ft 10 N m 1 0 kgf m 7 4 lb ft 10 N ...

Page 131: ...2 6 Windshield inner panel 1 7 Meter assembly coupler 1 Disconnect 8 Meter assembly 1 9 Meter panel assembly 1 3 1 1 3 4 6 7 9 8 5 5 2 2 1 6 N m 0 16 kgf m 1 2 lb ft 1 5 N m 0 15 kgf m 1 1 lb ft 1 5 N m 0 15 kgf m 1 1 lb ft 4 0 N m 0 40 kgf m 3 0 lb ft 2 5 N m 0 25 kgf m 1 8 lb ft 2 5 N m 0 25 kgf m 1 8 lb ft 1 3 N m 0 13 kgf m 0 95 lb ft 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft ...

Page 132: ...ect 2 Front turn signal light 2 3 Headlight assembly coupler 2 Disconnect 4 Front cowling assembly 1 5 Side cowling 2 6 Front turn signal light bracket 2 7 Headlight under panel 1 8 Headlight sub wire harness 1 9 Headlight 1 10 Plate 2 11 Rearview mirror adaptor 2 1 2 1 2 3 4 5 5 6 6 7 8 9 10 11 10 11 1 5 N m 0 15 kgf m 1 1 lb ft 4 0 N m 0 40 kgf m 3 0 lb ft 1 5 N m 0 15 kgf m 1 1 lb ft 1 5 N m 0 ...

Page 133: ...arts to remove Q ty Remarks 1 Footboard mat 4 2 Bottom side cowling 2 3 Side panel 2 4 Radiator cover 1 5 Bottom center cowling 1 3 1 1 1 2 3 2 3 4 5 1 5 N m 0 15 kgf m 1 1 lb ft 1 5 N m 0 15 kgf m 1 1 lb ft 1 5 N m 0 15 kgf m 1 1 lb ft 7 N m 0 7 kgf m 5 2 lb ft ...

Page 134: ...SSIS 2 on page 4 11 1 Battery cover 1 2 Negative battery lead 1 Disconnect 3 Positive battery lead 1 Disconnect 4 Battery band 1 5 Battery 1 6 Storage compartment lid lock solenoid coupler 1 Disconnect for XP560D 7 Remote control unit coupler 1 Disconnect 8 Auxiliary DC jack coupler 1 Disconnect 9 Inner panel 2 10 Leg shield assembly 1 11 Holder 1 12 Remote control unit 1 FWD FWD 1 2 3 4 5 6 7 8 9...

Page 135: ... 13 Auxiliary DC jack 1 14 Storage box 1 15 Protector 1 16 Storage compartment lid lock solenoid 1 17 Cover 1 FWD FWD 13 14 15 16 17 1 5 N m 0 15 kgf m 1 1 lb ft 4 0 N m 0 40 kgf m 3 0 lb ft 1 5 N m 0 15 kgf m 1 1 lb ft 4 3 N m 0 43 kgf m 3 2 lb ft 4 0 N m 0 40 kgf m 3 0 lb ft 2 8 N m 0 28 kgf m 2 1 lb ft ...

Page 136: ...dshield by removing the screws 3 d Install the windshield to the desired position by installing the screws 3 e Tighten the screws to the specified torque f Install the caps 1 g Place the windshield covers 1 and then install the quick fasteners EAS31398 REMOVING THE FRONT COVER 1 Remove Front cover 1 a Remove the front cover bolts 2 2 1 2 1 3 3 3 3 Windshield screw 10 N m 1 0 kgf m 7 4 lb ft T R 1 ...

Page 137: ...ets b EAS30821 REMOVING THE SIDE PANEL The following procedure applies to both of the side panels 1 Remove Bottom side cowling 2 Remove Side panel 1 a Remove the side panel screws 2 b Remove the quick fasteners 3 and the side panel bolt 4 c Remove the side panel 1 TIP Remove the side panel by removing the lower part a and upper part b 3 1 a b 1 2 3 3 4 a b 1 ...

Page 138: ...eners 3 c Install the side panel screws 4 2 Install Bottom side cowling EAS30819 REMOVING THE INNER PANEL The following procedure applies to both of the in ner panels 1 Remove Inner panel 1 a Remove the part a of the inner panel and slide the inner panel 1 to the upper side TIP When removing the part a of the inner panel use a commercially available cover removal tool b Side panel bolt 1 5 N m 0 1...

Page 139: ...1 by moving it in the arrow direction EAS31677 REMOVING THE BATTERY COVER 1 Remove Battery cover 1 a Remove the battery cover screw 2 b Remove the part a of the battery cover c Remove the battery cover 1 by sliding it to the upper side b a 1 1 2 1 a ...

Page 140: ...r 1 2 Fuel tank cover assembly 1 3 Seat fuel lid lock solenoid coupler 1 Disconnect 4 Seat lock cable 1 Disconnect 5 Side cover 2 6 Footboard 4 7 Seat fuel button cover 1 8 Cover 2 9 Seat fuel lid lock solenoid 1 10 Fuel tank cover 1 FWD FWD 1 3 4 2 5 6 5 6 6 7 9 8 8 10 4 0 N m 0 40 kgf m 3 0 lb ft 4 0 N m 0 40 kgf m 3 0 lb ft 1 5 N m 0 15 kgf m 1 1 lb ft 3 8 N m 0 38 kgf m 2 8 lb ft LT LT 1 5 N m...

Page 141: ...ssembly Side cover Refer to GENERAL CHASSIS 2 on page 4 11 1 Grab bar 2 2 Rubber cover 1 3 Rear side cowling assembly 2 4 Rear side cowling 2 5 Inner panel 2 6 Rear turn signal light coupler 2 Disconnect 7 License plate light coupler 2 Disconnect 8 Mudguard assembly 1 2 8 1 4 5 5 4 1 7 6 6 3 3 22 N m 2 2 kgf m 16 lb ft 10 N m 1 0 kgf m 7 4 lb ft 1 5 N m 0 15 kgf m 1 1 lb ft 1 5 N m 0 15 kgf m 1 1 ...

Page 142: ...on page 4 11 1 Rear cover 1 2 Tail brake light coupler 1 Disconnect 3 Seat lock cable 1 Disconnect 4 Rear cowling assembly 1 5 Lid 1 6 Tail brake light 1 7 Seat lock key cylinder 1 8 Tail brake light cover 1 9 Seat heater coupler 1 Disconnect for XP560D 10 Seat switch lead coupler 1 Disconnect 11 Seat assembly 1 6 1 4 8 5 7 9 3 2 10 11 7 N m 0 7 kgf m 5 2 lb ft 1 5 N m 0 15 kgf m 1 1 lb ft 4 0 N m...

Page 143: ...y Refer to GENERAL CHASSIS 2 on page 4 11 1 Storage box inner mat 1 2 Storage box light switch connector 2 Disconnect 3 Wire harness 1 Disconnect 4 Storage box 1 5 Rear panel 2 6 Storage box light 1 7 Seat lock assembly 1 8 Bracket 1 9 Seat hinge assembly 1 10 Storage box light switch 1 11 Stopper 2 10 9 2 3 5 11 11 6 7 5 1 4 8 0 7 N m 0 07 kgf m 0 52 lb ft 16 N m 1 6 kgf m 12 lb ft 16 N m 1 6 kgf...

Page 144: ... Remove Side cover Rear cover Grab bar Refer to GENERAL CHASSIS 2 on page 4 11 2 Remove Rear side cowling assembly 1 a Remove the rear side cowling assembly screw bolt and quick fastener EAS31523 REMOVING THE FOOTBOARD The following procedure applies to both of the footboards 1 Remove Bottom side cowling Side panel Refer to GENERAL CHASSIS 1 on page 4 1 Rear side cowling assembly Fuel tank cover a...

Page 145: ...sliding it to the upper side EAS31193 REMOVING THE REAR COVER 1 Remove Rubber cover 1 2 Remove Grab bar Rear side cowling assembly GENERAL CHASSIS 2 on page 4 11 3 Remove Tail brake light cover 1 a Remove the quick fasteners 2 and screws 3 1 1 1 3 3 2 2 ...

Page 146: ...uel tank cover assembly Side cover Rear side cowling assembly Footboard Refer to GENERAL CHASSIS 2 on page 4 11 1 Ignition coil connector 2 Disconnect 2 Ignition coil 1 3 Buzzer coupler 1 Disconnect 4 Intake air temperature sensor coupler 1 Disconnect 5 ECU coupler 3 Disconnect 6 Wire harness 1 7 YDT coupler 1 Disconnect 8 Battery box 1 9 Band 1 10 ECU Engine Control Unit 1 11 Buzzer 1 12 Intake a...

Page 147: ...er cover Fuel tank cover assembly Side cover Rear side cowling assembly Footboard Refer to GENERAL CHASSIS 2 on page 4 11 1 Handlebar switch coupler 2 2 Rectifier regulator coupler 1 Disconnect 3 Rectifier regulator 1 4 Plastic locking tie 1 5 Wire harness 1 6 Rear brake hose 1 7 Electrical components tray 1 8 Meter bracket 1 9 Windshield bracket 2 FWD FWD 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf...

Page 148: ...assembly Footboard Refer to GENERAL CHASSIS 2 on page 4 11 Brake hose holder Refer to HANDLEBAR on page 4 74 1 Handlebar switch coupler 2 2 Rectifier regulator coupler 1 Disconnect 3 Rectifier regulator 1 4 Windshield drive unit coupler 1 Disconnect 5 Plastic locking tie 1 6 Wire harness 1 7 Rear brake hose 1 8 Electrical components tray 1 9 Meter bracket 1 10 Windshield drive unit 1 10 N m 1 0 kg...

Page 149: ...bly Footboard Refer to GENERAL CHASSIS 2 on page 4 11 Battery box Electrical components tray Meter bracket Windshield bracket XP560E Wind shield drive unit XP560D Refer to GENERAL CHASSIS 3 on page 4 17 Hydraulic unit Refer to ABS Anti lock Brake System on page 4 67 1 Brake hose holder 1 2 Wire harness 1 3 Clamp 2 4 Cover 2 5 Plate 1 6 Headlight bracket 1 1 7 Wire harness bracket 1 8 Headlight bra...

Page 150: ...d drive unit coupler to the wire harness b Adjust the distances at the top a and bot tom b of the rails so they are the same TIP Refer to the illustration below for the positions to measure c c After installing the windshield 1 operate the windshield drive unit to check that the arm of the windshield drive unit can move fully up and down within the prescribed time Rail dimensions top and bottom 40...

Page 151: ...wheel axle bolt 1 8 Front wheel axle 1 9 Front wheel 1 10 Collar 1 Length 22 mm 0 87 in 11 Collar 1 Length 18 mm 0 71 in 12 Front brake disc 2 LT LT 1 2 3 3 3 3 4 5 5 6 6 7 8 9 10 11 12 12 1 2 2 5 N m 0 25 kgf m 1 8 lb ft 9 N m 0 9 kgf m 6 6 lb ft 21 N m 2 1 kgf m 15 lb ft 35 N m 3 5 kgf m 26 lb ft 35 N m 3 5 kgf m 26 lb ft 7 N m 0 7 kgf m 5 2 lb ft 23 N m 2 3 kgf m 17 lb ft 23 N m 2 3 kgf m 17 lb...

Page 152: ...ing 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 Collar 1 LT 8 N m 0 8 kgf m 5 9 lb ft 2 0 N m 0 20 kgf m 1 5 lb ft 3 0 N m 0 30 kgf m 2 2 lb ft 1 2 3 4 2 3 ...

Page 153: ...housing 3 Elevate Front wheel TIP Place the vehicle on the centerstand so that the front wheel is elevated 4 Loosen Wheel axle pinch bolt 5 Remove Front wheel axle bolt Front 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 sea...

Page 154: ... 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 between the socket 2 and the bearing so that both the inner race 3 and outer race 4 are pressed at the same time and then press the bearing until the inner race makes contact with the spacer 5 d Install the new oil seals 2 Install Front wheel sen...

Page 155: ...ce they have been accurately adjusted Keep them away from dirt and do not sub ject them to shocks The front wheel sensor cannot be disas sembled Do not attempt to disassemble it If faulty replace with a new one Keep any type of magnets including mag netic pick up tools magnetic screwdrivers etc away from the front wheel sensor or front wheel sensor rotor Do not drop or shock the wheel sensor or th...

Page 156: ...ONT WHEEL STATIC BALANCE TIP After replacing the tire wheel or both the front wheel static balance should be adjusted Adjust the front wheel static balance with the brake disc installed Refer to ADJUSTING THE WHELL STATIC BALANCE in BASIC INFORMATION sepa rate volume 1 Remove Balancing weight s 2 Find Front wheel s heavy spot 3 Adjust Front wheel static balance 4 Check Front wheel static balance E...

Page 157: ...l sensor rotor and front wheel sensor TIP When installing the front wheel sensor check the front wheel sensor lead for twists To route the front wheel sensor lead refer to CABLE ROUTING on page 2 13 7 Measure Distance a between the wheel sensor rotor 1 and front wheel sensor 2 Out of specification Check the wheel bear ing for looseness and the front wheel sensor and sensor rotor installation condi...

Page 158: ...e holder WARNING EWA13500 Make sure the brake hose is routed properly Front brake caliper bolt 35 N m 3 5 kgf m 26 lb ft Front brake hose holder bolt left 9 N m 0 9 kgf m 6 6 lb ft Front brake hose holder bolt right 7 N m 0 7 kgf m 5 2 lb ft 1 1 2 2 a G088903 T R ...

Page 159: ...2 Loosen 6 Adjusting bolt 2 Loosen 7 Rear wheel axle nut 1 8 Washer 1 9 Rear wheel axle 1 10 Adjusting block left 1 11 Adjusting block right 1 12 Rear wheel 1 13 Rear wheel sensor housing 1 14 Brake caliper bracket 1 15 Collar right 1 Length 18 mm 0 71 in 16 Collar left 1 Length 23 9 mm 0 94 in 1 2 3 4 7 8 5 6 9 10 11 12 13 14 15 16 6 5 7 N m 0 7 kgf m 5 2 lb ft 10 N m 1 0 kgf m 7 4 lb ft 16 N m 1...

Page 160: ...rder Job Parts to remove Q ty Remarks 1 Rear brake disc 1 2 Rear wheel sensor rotor 1 3 Drive belt guide 1 4 Rear wheel pulley 1 5 Rear wheel 1 1 2 3 4 5 LT LT LT LT 8 N m 0 8 kgf m 5 9 lb ft 10 N m 1 0 kgf m 7 4 lb ft 30 N m 3 0 kgf m 22 lb ft 64 N m 6 4 kgf m 47 lb ft ...

Page 161: ...4 32 REAR WHEEL Disassembling the rear wheel assembly Order Job Parts to remove Q ty Remarks 1 Oil seal 2 2 Wheel bearing left 1 3 Collar 1 4 Wheel bearing right 1 1 4 3 2 1 ...

Page 162: ... wheel axle Rear wheel Rear brake caliper bracket Rear wheel sensor housing Collar NOTICE ECA21400 Be sure to remove the rear wheel sensor be fore removing the brake caliper bracket oth erwise the sensor could be damaged TIP Push the rear wheel forward and remove the drive belt from the rear wheel pulley EAS31154 DISASSEMBLING THE REAR WHEEL NOTICE ECA21340 Do not drop the wheel sensor rotor or su...

Page 163: ...th care since they have been accurately adjusted Keep them away from dirt and do not sub ject them to shocks The rear wheel sensor cannot be disassem bled Do not attempt to disassemble it If faulty replace with a new one Keep any type of magnets including mag netic pick up tools magnetic screwdrivers etc away from the rear wheel sensor or rear wheel sensor rotor Do not drop or shock the wheel sens...

Page 164: ...housing Rear brake caliper bracket Rear wheel Adjusting block Rear wheel axle Washer Wheel axle nut TIP Do not install the brake caliper and brake lock caliper Fit the brake torque stop pin a on the swing arm into the slot b on the rear brake caliper bracket When installing the rear brake caliper bracket and the rear wheel sensor housing align the projection c on the rear brake caliper bracket wit...

Page 165: ... 1 and adjusting bolt 2 9 Install Rear wheel sensor 1 NOTICE ECA21080 Make sure there are no foreign materials in the rear wheel sensor rotor and rear wheel sensor Foreign materials cause damage to the rear wheel sensor rotor and rear wheel sensor TIP When installing the rear wheel sensor check the rear wheel sensor lead for twists A Left side B Right side a b c d f e g h Rear wheel axle nut 160 N...

Page 166: ...act 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 sensor rotor and rear wheel sensor in several places in one rotation of the rear wheel Do not turn the rear wheel while the thickness gauge is installed This may damage the rear wheel sen sor rotor and the rear wheel sensor 11 Adjust ...

Page 167: ...Brake pad 2 5 Front brake hose holder bolt 1 The tightening torque of the front brake hose holder bolt on the right side is 7 N m 0 7 kgf m 5 2 lb ft 6 Front brake hose holder 1 7 Front reflector 1 8 Front brake caliper 1 9 Bleed screw 1 Left brake caliper side 10 Bleed screw 1 Right brake caliper side FWD FWD 10 9 6 7 2 8 3 4 1 5 6 N m 0 6 kgf m 4 4 lb ft 35 N m 3 5 kgf m 26 lb ft 35 N m 3 5 kgf ...

Page 168: ...eservoir diaphragm holder 1 3 Brake master cylinder reservoir diaphragm 1 4 Front brake lever 1 5 Front brake light switch connector 2 Disconnect For XP560E 6 Brake hose union bolt 1 7 Brake hose gasket 2 8 Front brake hose 1 9 Front brake master cylinder holder 1 10 Front brake master cylinder 1 11 Front brake light switch 1 For XP560E 12 Front brake light switch 1 For XP560D FWD FWD S S 11 12 1 ...

Page 169: ...4 40 FRONT BRAKE 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 1 2 ...

Page 170: ... brake hose holder bolt 1 The tightening torque of the front brake hose holder bolt on the right side is 7 N m 0 7 kgf m 5 2 lb ft 2 Front brake hose holder 1 3 Front reflector 1 4 Brake hose union bolt 1 5 Brake hose gasket 1 Left side only 6 Front brake hose 1 Left side only 7 Brake hose gasket 2 8 Brake hose 1 9 Front brake caliper 1 FWD FWD 1 4 5 7 9 3 8 6 2 35 N m 3 5 kgf m 26 lb ft 30 N m 3 ...

Page 171: ...alipers 1 Brake pad clip 2 2 Brake pad pin 1 3 Brake pad spring 1 4 Front brake pad 2 5 Brake caliper piston 4 6 Brake caliper piston dust seal 4 7 Brake caliper piston seal 4 8 Bleed screw 1 Left brake caliper side 9 Bleed screw 1 Right brake caliper side BF BF BF BF FWD FWD 2 1 5 8 9 3 4 6 6 6 5 7 6 7 6 N m 0 6 kgf m 4 4 lb ft 6 N m 0 6 kgf m 4 4 lb ft ...

Page 172: ...lace the brake disc a Place the vehicle on the centerstand so that the front wheel is elevated b Remove the brake caliper c Hold the dial gauge at a right angle against the brake disc surface d Measure the runout 1 5 mm 0 06 in below the edge of the brake disc 3 Measure Brake disc thickness Measure the brake disc thickness at a few dif ferent locations Out of specification Replace 4 Adjust Brake d...

Page 173: ...n the bleed screw and push the brake caliper pistons into the brake caliper with your finger 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 clip Front brake caliper 7 Check Brake fluid level Below the minimum level mark Add the specified brake fluid t...

Page 174: ... the brake caliper WARNING EWA17060 Never try to pry out the brake caliper pis tons Do not loosen the bolts 4 c Remove the brake caliper piston dust seals and brake caliper piston seals d Repeat the previous steps to force out the right side pistons from the brake caliper EAS30173 CHECKING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers 1 Check Brake caliper ...

Page 175: ... Brake hose gasket Brake hose 2 Brake hose union bolt 3 WARNING EWA13531 Proper brake hose routing is essential to in sure safe vehicle operation NOTICE ECA21410 When installing the brake hose onto the brake caliper 1 make sure the brake pipe a touches the projection b on the brake caliper Install the brake pipe c so that it is aligned with the brake pipe a 2 Remove Front brake caliper 3 Install B...

Page 176: ... master cylinder drain the brake fluid from the entire brake sys tem 1 Disconnect Brake light switch connector from the front brake light switch 2 Remove Brake hose union bolt Brake hose gasket Brake hose TIP To collect any remaining brake fluid place a container under the master cylinder and the end of the brake hose EAS30725 CHECKING THE FRONT BRAKE MASTER CYLINDER 1 Check Brake master cylinder ...

Page 177: ...ster cylinder reservoir with the specified amount of the specified brake fluid WARNING EWA13540 Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake performan...

Page 178: ...inimum level mark Add the specified brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 14 6 Check Brake lever operation Soft or spongy feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 16 ...

Page 179: ... the rear brake pads Order Job Parts to remove Q ty Remarks 1 Rear brake caliper bolt 2 2 Rear brake caliper 1 3 Rear brake pad 2 4 Brake pad support 2 5 Bleed screw 1 S 3 4 3 4 2 5 1 1 FWD FWD 27 N m 2 7 kgf m 20 lb ft 6 N m 0 6 kgf m 4 4 lb ft ...

Page 180: ...nder reservoir diaphragm holder 1 3 Brake master cylinder reservoir diaphragm 1 4 Rear brake lever 1 5 Rear brake light switch connector 2 Disconnect For XP560E 6 Brake hose union bolt 1 7 Brake hose gasket 2 8 Rear brake hose 1 9 Rear brake master cylinder holder 1 10 Rear brake master cylinder 1 11 Rear brake light switch 1 For XP560E 12 Rear brake light switch 1 For XP560D S S 11 12 1 2 3 4 5 6...

Page 181: ...4 52 REAR BRAKE Disassembling the rear brake master cylinder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder kit 1 2 Brake master cylinder body 1 S BF 1 2 ...

Page 182: ...LEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 16 1 Brake hose union bolt 1 2 Brake hose gasket 2 3 Rear brake hose 1 4 Rear brake caliper bolt 2 5 Rear brake caliper 1 6 Rear brake pad 2 7 Brake pad support 2 8 Caliper bolt boot 2 1 3 4 4 5 8 6 6 7 2 7 S S S FWD FWD 27 N m 2 7 kgf m 20 lb ft 30 N m 3 0 kgf m 22 lb ft ...

Page 183: ...rear brake caliper Order Job Parts to remove Q ty Remarks 1 Brake caliper piston 1 2 Brake caliper piston dust seal 1 3 Brake caliper piston seal 1 4 Bleed screw 1 5 Brake caliper body 1 6 N m 0 6 kgf m 4 4 lb ft S BF 5 4 3 2 1 FWD FWD ...

Page 184: ...rear brake lock pads Order Job Parts to remove Q ty Remarks 1 Rear brake lock cable adjusting nut 1 2 Pin 1 3 Rear brake lock spring 1 4 Rear brake lock caliper 1 5 Rear brake lock pad 2 5 3 2 1 4 FWD FWD 23 N m 2 3 kgf m 17 lb ft ...

Page 185: ...emoving the rear brake lock caliper Order Job Parts to remove Q ty Remarks 1 Rear brake lock cable adjusting nut 1 2 Pin 1 3 Rear brake lock spring 1 4 Rear brake lock caliper 1 3 2 1 4 FWD FWD 23 N m 2 3 kgf m 17 lb ft ...

Page 186: ...ar brake lock pad 2 6 Caliper piston assembly 1 Locknut Left hand thread 7 Rear brake lock caliper bracket bolt 1 8 Rear brake lock caliper bracket 1 9 Sleeve 1 10 Boot 2 11 Boot 1 12 Slide pin bolt 1 13 Rear brake lock caliper 1 S S S S LT FWD FWD 1 2 3 4 5 6 7 8 9 10 10 11 12 13 22 N m 2 2 kgf m 16 lb ft 15 N m 1 5 kgf m 11 lb ft 17 N m 1 7 kgf m 13 lb ft 22 N m 2 2 kgf m 16 lb ft ...

Page 187: ...ing Replace 3 Measure Brake disc runout Out of specification Correct the brake disc deflection or replace the brake disc Refer to CHECKING THE FRONT BRAKE DISCS on page 4 43 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 43 5 Adjust Brake disc deflection Refer to CHECKING T...

Page 188: ...TEM on page 3 16 EAS30186 REMOVING THE REAR BRAKE CALIPER TIP Before removing the brake caliper drain the brake fluid from the entire brake system 1 Remove Brake hose union bolt Brake hose gasket Rear brake hose TIP Put the end of the brake hose into a container and pump out the brake fluid carefully EAS30187 DISASSEMBLING THE REAR BRAKE CALIPER 1 Remove Brake caliper piston Brake caliper piston d...

Page 189: ...rake caliper is disassembled replace the brake caliper piston dust seal and brake caliper piston seal EAS30190 INSTALLING THE REAR BRAKE CALIPER 1 Install Rear brake caliper 1 temporarily Brake hose gasket Rear brake hose 2 Brake hose union bolt 3 WARNING EWA13531 Proper brake hose routing is essential to in sure safe vehicle operation NOTICE ECA14170 When installing the brake hose onto the brake ...

Page 190: ...RAKE SYSTEM on page 3 16 EAS30193 REMOVING THE REAR BRAKE MASTER CYLINDER TIP Before removing the rear brake master cylinder drain the brake fluid from the entire brake sys tem 1 Remove Brake hose union bolt Brake hose gasket Rear brake hose TIP To collect any remaining brake fluid place a container under the master cylinder and the end of the brake hose EAS30194 CHECKING THE REAR BRAKE MASTER CYL...

Page 191: ... brake hose does not touch other parts e g wire harness cables leads Correct if necessary 3 Fill Brake master cylinder reservoir with the specified amount of the specified brake fluid WARNING EWA13540 Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in...

Page 192: ...BRAKE LOCK PADS 1 Remove Rear brake lock cable adjusting nut Pin Rear brake lock spring 2 Remove Rear brake lock caliper bolt Rear brake lock caliper 3 Remove Rear brake lock pad left side 1 TIP Push on the back of the pad using a rod with a round end 4 Remove Rear brake lock pad right side 1 a Remove the bolt 2 and then slide the rear brake lock caliper bracket 3 b Insert a flathead screwdriver i...

Page 193: ...cable 3 Install Rear brake lock cable WARNING EWA13490 Make sure the brake cable is routed properly 4 Adjust Rear brake lock cable length a Adjust the clearance for the rear brake lock pad Refer to ADJUSTING THE REAR BRAKE LOCK CABLE on page 3 17 b Activate the rear brake lock cable 10 times c Carry out adjustment using rear brake lock cable adjusting nut 1 so that dimension a is 38 40 mm 1 50 1 5...

Page 194: ...hes the locknut b With shaft L fastened turn and adjust the piston adjusting bolt so that the length a between the end of shaft L and the end of the piston adjusting bolt is changed to 19 mm 0 75 in Rear brake lock caliper slide pin bolt 17 N m 1 7 kgf m 13 lb ft Recommended lubricant Silicone grease Rear brake lock caliper bracket bolt 22 N m 2 2 kgf m 16 lb ft LOCTITE Recommended lubricant Silic...

Page 195: ...fter installing the rear brake lock pad to the caliper check that the pad rotates smoothly EAS31422 INSTALLING THE REAR BRAKE LOCK CALIPER 1 Install Rear brake lock caliper Rear brake lock caliper bolt Rear brake lock spring Pin Rear brake lock cable adjusting nut 2 Adjust Rear brake lock cable length Refer to ADJUSTING THE REAR BRAKE LOCK CABLE on page 3 17 Rear brake lock adjusting nut 15 N m 1 ...

Page 196: ...SYSTEM on page 3 16 1 ABS ECU coupler 1 Disconnect 2 Brake hose union bolt 4 3 Brake hose gasket 8 4 Rear brake hose rear brake master cylinder to hydraulic unit 1 Disconnect 5 Front brake hose hydraulic unit to front brake caliper 1 Disconnect 6 Front brake hose front brake master cylinder to hydraulic unit 1 Disconnect 7 Rear brake hose hydraulic unit to rear brake caliper 1 Disconnect 8 Hydraul...

Page 197: ... cou plers and cause bad contacts If the union bolts for the hydraulic unit as sembly have been removed be sure to tighten them to the specified torque and bleed the brake system 1 Disconnect ABS ECU coupler 1 TIP While pushing the portion a of the ABS ECU coupler pull the lock lever up to release the lock NOTICE ECA20080 Do not use a tool to disconnect the ABS ECU coupler 2 Remove Brake hose TIP ...

Page 198: ...ydraulic unit 4 Gasket Brake hose union bolt NOTICE ECA21121 If the brake hose union bolt does not turn easily replace the hydraulic unit assembly brake hoses and related parts as a set TIP To route the brake hose refer to CABLE ROUTING on page 2 13 4 Connect ABS ECU coupler 1 TIP Connect the ABS ECU coupler and then push the lock lever of the coupler in the direction of the arrow shown 5 Fill Bra...

Page 199: ...line routing confirmation use the diagnosis of function of the YDT 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 Push the OFF LOCK switch 3 Remove Battery cover Refer to GENERAL CHASSIS 1 on page 4 1 4 Check Battery voltage Lower than 12 8 V Charge...

Page 200: ...no danger of it falling over TIP For the ABS reaction force confirmation use the diagnosis of function of the YDT For more information refer to the operation manual of the YDT Before performing the ABS reaction force con firmation make sure that no malfunctions have been detected in the ABS ECU and that the wheels are not rotating 1 Place the vehicle on a centerstand 2 Push the OFF LOCK switch 3 R...

Page 201: ...TIP The reaction force pulsating action consists of quick pulses Be sure to continue operating the front brake lever and rear brake lever even after the pul sating action has stopped ON and OFF on the tool screen indicate when the brakes are being applied and re leased respectively 11 After the pulsating action has stopped in the rear brake lever it is generated in the front brake lever and contin...

Page 202: ...nit brake pipes and related parts as a set 17 If the operation of the hydraulic unit is normal delete all of the DTC EAS30202 CHECKING THE ABS WARNING LIGHT After all checks and servicing are completed en sure that the ABS warning light goes off by walk ing the vehicle at a speed of faster than 7 km h 4 4 mi h or performing a trial run ...

Page 203: ...ver front 1 3 Parking Unlock switch coupler 1 Disconnect 4 OFF LOCK switch coupler 1 Disconnect 5 Lower handlebar cover 1 6 Accelerator position sensor coupler 1 Disconnect 7 Handlebar cover rear 1 8 Parking Unlock switch 1 9 OFF LOCK switch 1 FWD FWD 1 2 3 4 5 6 7 8 9 1 5 N m 0 15 kgf m 1 1 lb ft 1 5 N m 0 15 kgf m 1 1 lb ft 1 5 N m 0 15 kgf m 1 1 lb ft 1 5 N m 0 15 kgf m 1 1 lb ft 1 5 N m 0 15 k...

Page 204: ...er Footboard Refer to GENERAL CHASSIS 2 on page 4 11 Handlebar cover Refer to HANDLEBAR on page 4 74 1 Front brake light switch connector 2 Disconnect for XP560E 2 Front brake master cylinder holder 1 3 Front brake master cylinder assembly 1 4 Handlebar switch right 1 5 Throttle cable 2 Disconnect 6 Throttle cable throttle grip side 2 Disconnect 7 Grip end 2 8 Throttle grip 1 FWD FWD 1 1 2 3 4 5 6...

Page 205: ...ever 1 13 Rear brake lock cable 1 Disconnect 14 Rear brake master cylinder assembly 1 15 Handlebar switch left 1 16 Handlebar switch holder 2 17 Handlebar grip 1 FWD FWD 10 9 11 12 13 14 15 17 16 16 3 5 N m 0 35 kgf m 2 6 lb ft 3 8 N m 0 38 kgf m 2 8 lb ft 3 8 N m 0 38 kgf m 2 8 lb ft 3 5 N m 0 35 kgf m 2 6 lb ft 10 N m 1 0 kgf m 7 4 lb ft 1 8 N m 0 18 kgf m 1 3 lb ft 26 N m 2 6 kgf m 19 lb ft 26 ...

Page 206: ...tboard Refer to GENERAL CHASSIS 2 on page 4 11 Handlebar cover Brake master cylinder Handle bar switch Refer to HANDLEBAR on page 4 74 1 Clamp 2 2 Bracket 1 3 Upper handlebar holder 2 4 Handlebar 1 5 Lower handlebar holder 1 6 Brake hose holder 1 7 Brake hose bracket 1 8 Throttle cable pulley 1 9 Grip cancel switch 1 10 Accelerator position sensor 1 FWD FWD 1 2 3 3 4 5 6 7 8 9 10 3 5 N m 0 35 kgf ...

Page 207: ...vehicle so that there is no danger of it falling over 2 Install Brake hose bracket Lower handlebar holder Handlebar 1 Upper handlebar holder 2 Bracket 3 NOTICE ECA18300 First tighten the bolts on the front side of the handlebar holder and then on the rear side TIP Align the punch mark a on the handlebar with the right side upper surface of the lower handle bar holder 3 Install Throttle grip 1 Thro...

Page 208: ...Refer to INSTALLING THE REAR BRAKE MASTER CYLINDER on page 4 62 9 Install Handlebar grip Grip end 1 a Apply a thin coat of rubber adhesive onto the end of the left handlebar b Slide the handlebar grip over the end of the left handlebar c Wipe off any excess rubber adhesive with a clean rag WARNING EWA13700 Do not touch the handlebar grip until the rub ber adhesive has fully dried TIP There should ...

Page 209: ...f Diagnostic code No 14 is selected g Turn the throttle grip to the fully closed po sition h Adjust the position of the accelerator posi tion sensor angle so that 11 20 can appear in the YDT screen i After adjusting the accelerator position sen sor angle tighten the accelerator position sensor screws 1 j Turn the throttle grip to the fully open posi tion k Check the YDT screen value If the YDT scr...

Page 210: ...anel Meter assembly Bottom side cowling Side panel Front cowling assembly Refer to GENERAL CHASSIS 1 on page 4 1 Front wheel Refer to FRONT WHEEL on page 4 22 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 4 3 5 14 N m 1 4 kgf m 10 lb ft 14 N m 1 4 kgf m 10 lb ft 23 N m 2 3 kgf m 17 lb ft 23 N m 2 3 kgf m 17 lb ft...

Page 211: ... Damper rod locknut 1 4 Spacer 1 5 Fork spring 1 6 Damper rod assembly bolt 1 7 Copper washer 1 8 Damper rod assembly 1 9 Dust seal 1 10 Oil seal clip 1 11 Outer tube 1 12 Oil seal 1 13 Washer 1 14 Outer tube bushing 1 15 Inner tube bushing 1 16 Inner tube 1 1 2 3 4 5 7 6 9 10 15 16 8 12 14 13 11 LT 15 N m 1 5 kgf m 11 lb ft 23 N m 2 3 kgf m 17 lb ft 23 N m 2 3 kgf m 17 lb ft ...

Page 212: ...he front fork legs NOTICE ECA22020 Because the left and right damper rod as semblies are different be sure to install them in the correct positions 1 Remove Cap bolt 1 Spacer 2 Damper rod locknut 3 a Press down on the spacer with the fork spring compressor 4 b Install the rod holder 5 between the damp er rod locknut 3 and the spacer 2 TIP Use the side of the rod holder that is marked B c Hold the ...

Page 213: ...ld the front fork leg horizontally b Securely clamp the brake caliper bracket in a vise with soft jaws c Separate the outer tube from the inner tube by pulling the outer tube forcefully but care fully NOTICE ECA19880 Excessive force will damage the bushings Damaged bushings must be replaced EAS30208 CHECKING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Check...

Page 214: ...the following parts Inner tube bushing Outer tube bushing Oil seal Dust seal Oil seal clip O ring Copper washer Before assembling the front fork leg make sure all of the components are clean 1 Lubricate Inner tube outer surface 2 Install Dust seal 1 Oil seal clip 2 Oil seal 3 Washer 4 Outer tube bushing 5 Inner tube bushing 6 NOTICE ECA14220 Make sure the numbered side of the oil seal faces up TIP...

Page 215: ...ht side is used for the rebound operation and left side for the compression Pay attention not to mistake the right and left TIP The left side for the compression damper rod assembly has the holes a of oil path unlike the right side Fork seal driver 90890 01442 Adjustable fork seal driver 36 46 mm YM 01442 Fork seal driver 90890 01442 Adjustable fork seal driver 36 46 mm YM 01442 1 2 3 G088923 1 2 ...

Page 216: ...t allow any foreign ma terial to enter the front fork 12 After filling the front fork leg slowly stroke the damper rod assembly 1 up and down at least ten times to distribute the fork oil TIP Be sure to stroke the damper rod assembly slowly because 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 TIP Be ...

Page 217: ...e rod puller and install the rod holder 2 between the damper rod locknut 3 and the spacer 4 TIP Use the side of the rod holder that is marked B f Remove the rod puller and the rod puller at tachment g Install the damper rod locknut 3 onto the damper rod and turn it until it stops h Install the cap bolt 5 and then tighten the damper rod locknut 3 until it contacts the bolt i Hold the cap bolt and t...

Page 218: ...ly 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 bolt 1 Cap bolt 2 Upper bracket pinch bolt 3 Lower bracket pinch bolt 23 N m 2 3 kgf m 17 lb ft Front fork cap bolt 23 N m 2 3 kgf m 17 lb ft Upper bracket pinch bolt 30 N m 3 0 kgf m 22 lb ft T R 2 3 1 ...

Page 219: ...GENERAL CHASSIS 1 on page 4 1 Center cover Fuel tank cover assembly Rear side cowling assembly Side cover Footboard Refer to GENERAL CHASSIS 2 on page 4 11 Handlebar cover Handlebar Lower handlebar holder Refer to HANDLEBAR on page 4 74 Front wheel Refer to FRONT WHEEL on page 4 22 1 Bracket 2 2 Steering stem nut 1 3 Upper bracket 1 4 Lock washer 1 5 Upper ring nut 1 6 Rubber washer 1 7 Lower ring...

Page 220: ... remove Q ty Remarks 8 Lower bracket 1 9 Upper bearing cover 1 10 Upper bearing 1 11 Lower bearing 1 12 Dust seal 1 13 Steering lock unit coupler 1 Disconnect 14 Steering lock unit 1 15 Stay 1 FWD LT LT LT 8 9 10 11 12 13 14 15 7 N m 0 7 kgf m 5 2 lb ft 130 N m 13 kgf m 96 lb ft 1st 2nd 52 N m 5 2 kgf m 38 lb ft 16 N m 1 6 kgf m 12 lb ft ...

Page 221: ...ove the bearing races from the steer ing head pipe 1 with a long rod 2 and hammer b Remove the bearing race from the lower bracket 3 with a floor chisel 4 and ham mer c Install a new rubber seal and new bearing races NOTICE ECA14270 If the bearing race is not installed properly the steering head pipe could be damaged TIP Always replace the bearings and bearing races as a set Whenever the steering ...

Page 222: ...E STEERING HEAD on page 3 23 3 Install Upper bracket Washer Steering stem nut TIP Temporarily tighten the steering stem nut 4 Install Front fork leg Refer to FRONT FORK on page 4 81 TIP Temporarily tighten the upper and lower bracket pinch bolts 5 Tighten Steering stem nut Steering stem nut 130 N m 13 kgf m 96 lb ft G088935 T R ...

Page 223: ...iper Rear brake lock caliper Refer to REAR BRAKE on page 4 50 Rear wheel Refer to REAR WHEEL on page 4 30 1 Drive pulley cover 1 2 Dust cover 1 3 Holder 1 4 Collar 2 5 Circlip 1 6 Drive pulley 1 7 O ring 1 8 Circlip 1 9 Bearing 1 10 Oil seal 1 11 Drive belt 1 FWD FWD 1 2 3 8 9 10 6 4 11 7 5 10 N m 1 0 kgf m 7 4 lb ft 48 N m 4 8 kgf m 35 lb ft 48 N m 4 8 kgf m 35 lb ft ...

Page 224: ...IVE BELT AND DRIVE PULLEY 1 Install Drive belt NOTICE ECA22720 Align the mark of the drive belt with the prog ress direction A Do not twist the drive belt when installing it 2 Lubricate Drive pulley assembly inner part Refer to LUBRICATING THE DRIVE PUL LEY AND DRIVE AXLE on page 3 22 3 Install Drive pulley assembly Drive pulley assembly bolt 4 Tighten Drive pulley assembly bolt TIP Tighten the dr...

Page 225: ...r nut Rear shock absorber assembly lower bolt 1 1 3 Washer 1 4 Collar 1 5 Collar 1 6 Rear shock absorber assembly upper nut Washer Rear shock absorber assembly upper bolt 1 2 1 7 Rear shock absorber assembly 1 8 Connecting arm bolt Connecting arm nut 1 1 9 Connecting arm 2 10 Relay arm 1 11 Collar Oil seal Bearing 1 2 1 12 Collar Oil seal Bearing 1 2 1 13 Collar Oil seal Bearing 1 2 2 14 Oil seal ...

Page 226: ...SORBER 1 Gas pressure must be released before dis posing of a rear shock absorber To release the gas pressure drill a 2 3 mm 0 08 0 12 in hole through the rear shock absorber as shown WARNING EWA13760 Wear eye protection to prevent eye damage from released gas or metal chips TIP Drill a hole at a point 50 mm 1 97 in from the center of the installation hole EAS30219 REMOVING THE REAR SHOCK ABSORBER...

Page 227: ... Lubricate Collar Oil seal 2 Install Bearing 1 Oil seal 2 TIP When installing the oil seals 2 to the connect ing arms 3 face the character stamp of the oil seals outside Install the bearing to the connecting arm by pressing the character stamped side EAS30222 INSTALLING THE RELAY ARM 1 Lubricate Collar Oil seal 2 Install Bearing 1 to the relay arm Oil seal 2 to the relay arm Recommended lubricant ...

Page 228: ... the rear shock absorber assembly so that the label is facing downward Install the rear shock absorber assembly so that the rebound damping adjusting screw b is facing downward for XP560D EAS30225 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 1 Install Rear shock absorber assembly TIP Install the rear shock absorber assembly lower bolt and relay arm bolt from the right Install the rear shock absorbe...

Page 229: ...ER ASSEMBLY on page 4 96 Drive belt Refer to BELT DRIVE on page 4 94 1 Holder 1 2 Holder 1 3 Drive belt inner guard 1 4 Swingarm left 1 5 Swingarm right 1 6 Dowel pin 2 7 Pivot shaft 1 8 Oil seal 1 9 Oil seal 1 10 Outer race 1 FWD FWD LT 1 2 3 4 5 6 7 8 9 10 6 7 N m 0 7 kgf m 5 2 lb ft 6 N m 0 6 kgf m 4 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft 30 N m 3 0 kgf m 22 lb ft 40 N m ...

Page 230: ... housing 1 13 O ring 1 14 Collar 1 15 Oil seal 1 16 Bearing 1 FWD FWD LT 11 12 13 14 15 16 7 N m 0 7 kgf m 5 2 lb ft 6 N m 0 6 kgf m 4 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft 30 N m 3 0 kgf m 22 lb ft 40 N m 4 0 kgf m 30 lb ft 40 N m 4 0 kgf m 30 lb ft 100 N m 10 kgf m 74 lb ft ...

Page 231: ... Refer to BELT DRIVE on page 4 94 4 Remove Drive pulley assembly bolt Swingarm bolt Pivot shaft nut EAS30227 CHECKING THE SWINGARM 1 Check Swingarm left Swingarm right Bends cracks damage Replace 2 Check Drive pulley assembly bolt Swingarm bolt Damage wear Replace EAS30228 INSTALLING THE SWINGARM 1 Lubricate Taper roller bearing TIP Lubricate the space in the swingarm with lithium soap based greas...

Page 232: ...ouches the collar and then tighten the pivot shaft to the specified torque b Tighten the pivot shaft nut to the specified torque Swingarm bolt 40 N m 4 0 kgf m 30 lb ft Drive pulley assembly bolt 48 N m 4 8 kgf m 35 lb ft Pivot shaft 6 N m 0 6 kgf m 4 4 lb ft Pivot shaft nut 100 N m 10 kgf m 74 lb ft T R T R ...

Page 233: ... HEAD 5 20 REMOVING THE CYLINDER HEAD 5 21 CHECKING THE CYLINDER HEAD 5 21 INSTALLING THE CYLINDER HEAD 5 21 VALVES AND VALVE SPRINGS 5 23 REMOVING THE VALVES 5 24 CHECKING THE VALVES AND VALVE GUIDES 5 24 CHECKING THE VALVE SEATS 5 26 CHECKING THE VALVE SPRINGS 5 27 CHECKING THE VALVE LIFTERS 5 28 INSTALLING THE VALVES 5 28 CYLINDER AND PISTONS 5 30 REMOVING THE PISTON 5 31 CHECKING THE CYLINDERS...

Page 234: ... STARTER CLUTCH 5 52 CHECKING THE STARTER CLUTCH 5 53 CHECKING THE OIL STRAINER 5 53 ASSEMBLING THE OIL TANK 5 53 INSTALLING THE STARTER CLUTCH 5 53 INSTALLING THE GENERATOR 5 53 CLUTCH 5 55 REMOVING THE CLUTCH 5 58 DISASSEMBLING THE CLUTCH 5 58 CHECKING THE FRICTION PLATES 5 59 CHECKING THE CLUTCH PLATES 5 59 CHECKING THE CLUTCH DAMPER SPRINGS 5 59 CHECKING THE CLUTCH SPRING PLATE 5 60 CHECKING T...

Page 235: ...EMBLING THE CRANKCASE 5 71 CRANKSHAFT 5 73 REMOVING THE CONNECTING RODS 5 75 REMOVING THE CRANKSHAFT JOURNAL BEARINGS 5 75 CHECKING THE CRANKSHAFT AND CONNECTING RODS 5 75 INSTALLING THE CRANKSHAFT JOURNAL BEARINGS 5 79 INSTALLING THE CONNECTING RODS 5 79 INSTALLING THE CRANKSHAFT ASSEMBLY 5 81 TRANSMISSION 5 83 CHECKING THE TRANSMISSION 5 84 ...

Page 236: ...e camshaft 2 Exhaust camshaft 3 Timing chain tensioner 4 Connecting rod 5 To piston 6 Starter clutch gear 7 Crankshaft 8 Balancer connecting rod 9 To balancer piston 10 Oil pipe 11 Check valve 12 Relief valve 13 Oil filter 14 Oil cooler 15 Oil tank 16 Oil strainer 17 Feed pump 18 Oil delivery pipe 19 Scavenge pump 20 Oil strainer 21 To starter idle gear 22 Clutch 23 Secondary shaft 24 To transmiss...

Page 237: ... LUBRICATION DIAGRAMS 2 8 9 1 3 7 7 6 5 4 7 11 10 12 4 1 Exhaust camshaft 2 Intake camshaft 3 Oil delivery pipe 4 Oil pump assembly 5 Scavenge pump 6 Feed pump 7 Oil pipe 8 Oil cooler 9 Oil filter 10 Engine oil check bolt 11 Relief valve 12 Check valve ...

Page 238: ...5 3 LUBRICATION SYSTEM CHART AND DIAGRAMS 1 2 3 4 5 1 Crankshaft 2 Secondary shaft 3 Drive axle 4 Clutch 5 Generator cover ...

Page 239: ...5 4 LUBRICATION SYSTEM CHART AND DIAGRAMS 1 3 2 1 Oil strainer 2 Intake camshaft 3 Exhaust camshaft ...

Page 240: ...5 5 LUBRICATION SYSTEM CHART AND DIAGRAMS 2 4 3 A A 1 1 Generator cover 2 Oil strainer 3 Main gallery 4 Crankcase right A Forward ...

Page 241: ...ank the en gine until the reading on the compression gauge stabilizes TIP The difference in compression pressure be tween cylinders should not exceed 100 kPa 1 kgf cm 14 psi c If the compression pressure is above the maximum specification check the cylinder head valve surfaces and piston crown for carbon deposits Carbon deposits Eliminate d If the compression pressure is below the minimum specific...

Page 242: ...bly right Footboard right Refer to GENERAL CHASSIS 2 on page 4 11 1 O2 sensor coupler 1 Disconnect 2 O2 sensor 1 3 Exhaust assembly 1 4 Gasket 2 5 Front muffler protector 1 6 Muffler protector 1 7 Muffler end 1 8 Muffler end bracket 1 FWD FWD 10 N m 1 0 kgf m 7 4 lb ft 7 N m 0 7 kgf m 5 2 lb ft 8 N m 0 8 kgf m 5 9 lb ft 8 N m 0 8 kgf m 5 9 lb ft 20 N m 2 0 kgf m 15 lb ft 25 N m 2 5 kgf m 18 lb ft ...

Page 243: ...ssembly Seat assembly Storage box Refer to GENERAL CHASSIS 2 on page 4 11 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 27 Coolant Drain Refer to CHANGING THE COOLANT on page 3 31 Exhaust assembly Refer to ENGINE REMOVAL on page 5 7 Fuel tank Rollover valve Refer to FUEL TANK on page 7 1 Front wheel Refer to FRONT WHEEL on page 4 22 Front fender Refer to FRONT FORK on page 4 81 Rear ...

Page 244: ...S SION on page 5 39 Radiator inlet hose Cooling system air bleed hose Radiator outlet hose Refer to RADIATOR on page 6 3 1 Spark plug cap 2 Disconnect 2 Sidestand switch coupler 1 Disconnect 3 Centerstand lock solenoid coupler 1 Disconnect 4 Stator coil coupler 1 Disconnect 5 Crankshaft position sensor coupler 1 Disconnect 6 Starter motor lead 1 Disconnect 7 Coolant temperature sensor coupler 1 Di...

Page 245: ... Rear frame 2 6 Engine mounting bolt front left lower side 2 7 Sidestand 1 8 Engine mounting bolt front right lower side 1 9 Engine mounting bolt front upper side 2 10 Engine 1 LT LT LT LT LT LT 78 N m 7 8 kgf m 58 lb ft T R 83 N m 8 3 kgf m 61 lb ft T R 105 N m 10 5 kgf m 77 lb ft T R 70 N m 7 0 kgf m 52 lb ft T R 77 N m 7 7 kgf m 57 lb ft T R FWD FWD 1 2 2 3 4 5 6 6 7 8 9 9 10 ...

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

Page 247: ...RAL CHASSIS 1 on page 4 1 Center cover Fuel tank cover assembly Side cover Rear side cowling assembly Footboard Refer to GENERAL CHASSIS 2 on page 4 11 Radiator bracket Refer to RADIATOR on page 6 3 1 Spark plug cap 2 Disconnect 2 Spark plug 2 3 Cylinder head breather hose 1 4 Cylinder head cover 1 5 Cylinder head cover gasket 1 6 Dowel pin 2 7 Timing chain guide upper side 1 New 4 3 1 2 7 5 6 6 1...

Page 248: ...on page 5 12 1 Timing mark accessing plug 1 2 Timing chain tensioner 1 3 Timing chain tensioner gasket 1 4 Intake camshaft cap 1 5 Exhaust camshaft cap 1 6 Dowel pin 4 TIP During removal the dowel pins may still be connected to the camshaft caps 7 Intake camshaft 1 8 Exhaust camshaft 1 New New 2 2 1 3 6 4 6 7 6 6 8 5 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft ...

Page 249: ...ent marks d on the exhaust camshaft sprocket must align with the cylinder head mating surface as shown in the illustration 2 Remove Timing chain tensioner 1 Timing chain tensioner gasket 3 Remove Intake camshaft cap Exhaust camshaft cap Dowel pin 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 wo...

Page 250: ...the specified torque To prevent the camshaft cap from cracking tighten the camshaft cap carefully by tapping the camshaft using a soft face hammer both for temporary and final tightening Do not turn the camshaft when measuring the camshaft journal to camshaft cap clearance with the Plastigauge d Remove the camshaft caps and then mea sure the width of the Plastigauge 1 5 Measure Camshaft journal di...

Page 251: ... CHAIN TENSIONER 1 Check Timing chain tensioner Cracks damage rough movement Replace a Using the valve spring compressor 1 push and insert timing chain tensioner rod 2 into the timing chain tensioner housing TIP Push the timing chain tensioner rod in direction a and turn the timing chain tensioner body 3 in direction b until the circlip fits into the groove b Lock the timing chain tensioner rod by...

Page 252: ...y pointer b on the generator cover c Install the timing chain onto both camshaft sprockets and then install the camshafts onto the cylinder head TIP Lubricate the camshaft journal with the molyb denum disulfide oil When installing the timing chain start with the exhaust camshaft and be sure to keep the tim ing chain as tight as possible on the exhaust side The camshafts should be installed onto th...

Page 253: ...event the camshaft cap from cracking tighten the camshaft cap carefully by tapping the camshaft using a soft face hammer both for temporary and final tightening 4 Install Timing chain tensioner gasket Timing chain tensioner a Using the valve spring compressor 1 push and insert timing chain tensioner rod 2 into the timing chain tensioner housing TIP Push the timing chain tensioner rod in direction ...

Page 254: ...ng surface Out of alignment Correct Refer to the installation steps above 8 Measure Valve clearance Out of specification Adjust Refer to ADJUSTING THE VALVE CLEAR ANCE on page 3 5 9 Install Timing chain guide upper side Cylinder head cover gasket to the cylinder head cover TIP Apply Three bond No 1541C 1 onto the mating surfaces of the cylinder head cover and gasket 10 Install Cylinder head cover ...

Page 255: ... on page 5 12 Thermostat Refer to THERMOSTAT on page 6 9 1 Coolant temperature sensor coupler 1 Disconnect 2 Coolant temperature sensor 1 3 Gasket 1 4 Cylinder head 1 5 Cylinder head gasket 1 6 Dowel pin 2 7 Engine oil check bolt 1 8 Gasket 1 New New E E 1st 3rd 4th 2nd 10 N m 1 0 kgf m 7 4 lb ft 20 N m 2 0 kgf m 15 lb ft 28 N m 2 8 kgf m 21 lb ft 6 N m 0 6 kgf m 4 4 lb ft Specified angle 180 10 N...

Page 256: ...r head a Place a straightedge 1 and a thickness gauge 2 across the cylinder head b Measure the warpage c If the limit is exceeded resurface the cylin der head as follows d Place a 400 600 grit wet sandpaper on the surface plate and resurface the cylinder head using a figure eight sanding pattern TIP To ensure an even surface rotate the cylinder head several times EAS30282 INSTALLING THE CYLINDER H...

Page 257: ...t when the cylinder head and cylinder are cold Use four steps to tighten the cylinder head nuts 4 Install Exhaust camshaft Intake camshaft Refer to INSTALLING THE CAMSHAFTS on page 5 17 Cylinder head nut 1st 10 N m 1 0 kgf m 7 4 lb ft 2nd 20 N m 2 0 kgf m 15 lb ft 3rd 28 N m 2 8 kgf m 21 lb ft 4th 6 N m 0 6 kgf m 4 4 lb ft Specified angle 180 Cylinder head bolt 10 N m 1 0 kgf m 7 4 lb ft Cylinder ...

Page 258: ... remove Q ty Remarks Cylinder head Refer to CYLINDER HEAD on page 5 20 1 Valve lifter 8 2 Valve pad 8 3 Valve cotter 16 4 Valve spring retainer 8 5 Valve spring 8 6 Intake valve 4 7 Exhaust valve 4 8 Valve stem seal 8 9 Valve spring seat 8 10 Valve guide 8 New New New New M E E M M M 1 1 2 3 4 5 2 3 4 5 8 8 9 6 7 10 10 9 ...

Page 259: ...ere should be no leakage at the valve seat 1 3 Remove Valve cotter 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 Valve spring Valve Valve stem seal Valve spring seat TIP Identify the position of each part very carefully so that it can be reinstalled in its original place EA...

Page 260: ...e clearance TIP After replacing the valve guide reface the valve seat Valve stem to valve guide clear ance intake 0 010 0 037 mm 0 0004 0 0015 in Limit 0 080 mm 0 0032 in Valve stem to valve guide clear ance exhaust 0 025 0 052 mm 0 0010 0 0020 in Limit 0 100 mm 0 0039 in G088960 G088961 G088962 Valve guide position intake 12 2 12 6 mm 0 48 0 50 in Valve guide position exhaust 12 2 12 6 mm 0 48 0 ...

Page 261: ...e seat Pitting wear Replace the cylinder head 3 Measure Valve seat width a Out of specification Replace the cylinder head a Apply blue layout fluid b onto the valve face b Install the valve into the cylinder head c Press the valve through the valve guide and onto the valve seat to make a clear impres sion d Measure the valve seat width TIP Where the valve seat and valve face contacted one another ...

Page 262: ...nd 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 j Measure the valve seat width c again If the valve seat width is out of ...

Page 263: ...er head TIP Make sure each valve is installed in its original place Install the valve springs with the larger pitch a facing up 4 Install Valve cotter TIP Install the valve cotters by compressing the valve spring with the valve spring compressor 1 and the valve spring compressor attachment 2 5 To secure the valve cotters onto the valve stem lightly tap the valve tip with a soft face hammer NOTICE ...

Page 264: ...NOTICE ECA22150 After making sure that the valve pads are ful ly inserted install the valve lifter taking care so that the pads do not fall TIP The valve lifter must move smoothly when ro tated with a finger Each valve lifter and valve pad must be rein stalled in its original position Recommended lubricant Molybdenum disulfide oil Recommended lubricant Engine oil G088975 ...

Page 265: ...arks Cylinder head Refer to CYLINDER HEAD on page 5 20 1 Coolant hose 1 Disconnect 2 Timing chain guide exhaust side 1 3 Cylinder 1 4 Cylinder gasket 1 5 Dowel pin 2 6 Piston pin clip 4 7 Piston pin 2 8 Piston 2 9 Top ring 2 10 2nd ring 2 11 Oil ring 2 5 4 2 7 8 6 6 11 10 9 3 1 5 New New New E E E 10 N m 1 0 kgf m 7 4 lb ft ...

Page 266: ...p ring 2nd ring Oil ring TIP When removing a piston ring open the end gap with your fingers and lift the other side of the ring over the piston crown EAS30291 CHECKING THE CYLINDERS AND PISTONS The following procedure applies to all of the cyl inders and pistons 1 Check Piston wall Cylinder wall Vertical scratches Replace the cylinder piston and piston rings as a set 2 Measure Piston to cylinder c...

Page 267: ...m of the cylinder where the cylinder wear is lowest 3 Measure Piston ring end gap Out of specification Replace the piston ring set TIP The oil ring expander spacer s end gap cannot be measured If the oil ring rail s gap is exces sive replace all three piston rings a 8 0 mm 0 31 in from the bottom edge of the piston Piston Diameter 69 975 69 990 mm 2 7549 2 7555 in Piston to cylinder clearance Cyli...

Page 268: ... following procedure applies to all of the pis tons and cylinders 1 Install Oil ring expander 1 Lower oil ring rail 2 Upper oil ring rail 3 2nd ring 4 Top ring 5 into the piston TIP Be sure to install the top and 2nd rings so that the manufacturer marks or numbers a face up 2 Install Piston 1 Piston pin 2 Piston pin clip 3 a Bottom of cylinder b Upper of cylinder Piston pin outside diameter 16 995...

Page 269: ...he cutout c in the piston as shown in the illustration 3 Install Dowel pin Cylinder gasket 4 Lubricate Piston Piston ring Cylinder with the recommended lubricant 5 Offset Piston ring end gap 6 Install Cylinder Cylinder bolt TIP While compressing the piston rings install the cylinder Pass the timing chain and timing chain guide intake side through the timing chain cavity 7 Tighten Cylinder bolt Rec...

Page 270: ...er cowling Refer to GENERAL CHASSIS 1 on page 4 1 Center cover Fuel tank cover assembly Side cover Rear side cowling assembly Footboard Refer to GENERAL CHASSIS 2 on page 4 11 Fuel tank Refer to FUEL TANK on page 7 1 1 Starter motor lead 1 Disconnect 2 Starter motor assembly 1 FWD FWD 1 2 New 10 N m 1 0 kgf m 7 4 lb ft T R 7 N m 0 7 kgf m 5 2 lb ft T R LS ...

Page 271: ...ulator and starter motor rear cover replace the starter motor assembly Order Job Parts to remove Q ty Remarks 1 Starter motor front cover 1 2 Armature assembly 1 3 Starter motor yoke 1 4 O ring 2 5 Brush holder set 1 6 Insulator 1 7 Starter motor rear cover 1 1 2 3 4 4 6 7 5 New New New 11 N m 1 1 kgf m 8 1 lb ft T R 5 N m 0 5 kgf m 3 7 lb ft T R ...

Page 272: ...uit tester and check the continuity b If there is no continuity replace 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 6 Check Gear teeth Damage wear Replace the starter motor assembly 7 Check Bearing Damage pitting Replace the starter motor assembly Mica undercut depth 0 70...

Page 273: ...motor front cover 3 TIP Align the match mark a on the starter motor rear cover with the match mark b on the start er motor yoke Align the match mark c on the starter motor yoke with the match mark d on the starter mo tor front cover EAS30327 INSTALLING THE STARTER MOTOR 1 Install Starter motor 1 Starter motor lead 2 TIP Connect the starter motor lead to the starter mo tor in the direction shown in...

Page 274: ...ENERAL CHASSIS 2 on page 4 11 1 Crankshaft end access cover 1 2 Damper 1 3 V belt case air filter case cover 1 4 O2 sensor lead 1 5 V belt case air filter case 1 6 V belt case air filter element right 1 7 Outer V belt case 1 8 Outer V belt case gasket 1 9 Bearing retainer 1 10 Bearing 1 11 Circlip 1 12 Oil seal 1 13 Bearing 1 FWD FWD 3 2 4 6 3 1 2 3 4 5 6 7 8 9 10 11 12 13 New New New New LS LT LT...

Page 275: ...ve nut 1 6 Secondary sheave assembly 1 7 V belt 1 8 Primary fixed sheave 1 9 V belt case air duct joint clamp 1 Loosen 10 V belt case air duct 1 11 Inner V belt case plate 1 12 Inner V belt case 1 13 Dowel pin 2 14 Plate 1 15 Inner V belt case seal 1 FWD FWD 3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 13 New New 2 2 1 1 1 10 N m 1 0 kgf m 7 4 lb ft T R 18 N m 1 8 kgf m 13 lb ft T R 3 0 N m 0 30 kgf m 2 ...

Page 276: ...Apply YAMAHA GREASE F 2 When replacing the primary sliding sheave or collar replace them as a set Order Job Parts to remove Q ty Remarks 1 Cam 1 2 Slider 8 3 Primary sheave weight 8 4 Primary sliding sheave 1 5 Collar 1 6 Oil seal 2 1 2 5 2 3 4 2 6 6 New New FW FWD 1 1 1 ...

Page 277: ...r Job Parts to remove Q ty Remarks 1 Secondary sheave spring seat nut 1 2 Upper spring seat 1 3 Secondary sheave compression spring 1 4 Spring seat 1 5 Guide pin 6 6 Secondary sliding sheave 1 7 O ring 2 8 Oil seal 2 9 Secondary fixed sheave 1 FWD FWD 1 2 3 4 5 6 7 8 8 9 New New New 90 N m 9 0 kgf m 66 lb ft T R ...

Page 278: ... with the sheave holder 3 loosen the second ary sheave spring seat nut with the locknut wrench 4 Do not loosen the secondary sheave spring seat nut 1 more than 1 4 turn 2 Remove Secondary sheave spring seat nut 1 TIP Install the sheave spring compressor 2 and sheave fixed block 3 onto the secondary sheave assembly as shown Then compress the spring and remove the secondary sheave spring seat nut wi...

Page 279: ...re applies to all of the pri mary sheave weights 1 Check Primary sheave weight Cracks damage wear Replace 2 Measure Primary sheave weight outside diameter Out of specification Replace EAS30318 CHECKING THE SLIDERS The following procedure applies to all of the slid ers 1 Check Slider Cracks damage wear Replace EAS30319 CHECKING THE SECONDARY SHEAVE 1 Check Secondary fixed sheave Secondary sliding s...

Page 280: ...NDARY SHEAVE 1 Lubricate Secondary fixed sheave inner surface 1 Secondary sliding sheave inner surface 2 Oil seals with the recommended lubricant 2 Install Guide pin TIP Before installing the guide pin align the position where fixed sheave rivet head a and guide pin hole b are in alignment with each other with alignment mark c of the sliding sheave Install the guide pin Then make sure that the sli...

Page 281: ...rarily tighten the secondary sheave spring seat nut 5 Tighten Secondary sheave spring seat nut 1 TIP While holding the secondary fixed sheave 2 with the sheave holder 3 tighten the second ary sheave spring seat nut 1 with the locknut wrench 4 Recommended lubricant YAMAHA GREASE H Poly urea Grease New Sheave spring compressor 90890 04134 Sheave spring compressor YM 04134 Sheave fixed block 90890 04...

Page 282: ...CA22160 Do not allow grease to contact the V belt pri mary and secondary sheave TIP When installing the belt screw M6 more than 45 mm 1 77 in bolts 4 to spread apart the secondary sheave and then install the V belt Make sure to install the V belt with the arrow facing in the direction shown Install the V belt and secondary sheave as sembly then pass the V belt the primary sheave side Align the a a...

Page 283: ...ut EAS31235 INSTALLING THE V BELT CASE 1 Install Oil seal 1 into outer V belt case 2 Fill the space b shown in the illustration with 10 g 0 35 oz or more of lithium soap based grease 3 Install Bearing retainer 1 TIP Install the bearing retainer 1 with its mark a facing outward Apply locking agent LOCTITE to the threads of the bearing retainer screw Recommended lubricant YAMAHA GREASE G Shell Sunli...

Page 284: ...r assembly Side cover left Rear side cowling assembly left Footboard left Refer to GENERAL CHASSIS 2 on page 4 11 V belt case air filter element left Generator cover protector Water pump inlet pipe Water pump outlet pipe Water pump assembly Refer to WATER PUMP on page 6 11 1 Centerstand lock solenoid coupler 1 Disconnect 2 Crankshaft position sensor coupler 1 Disconnect 3 Stator coil coupler 1 Dis...

Page 285: ...tch idle gear shaft 1 8 Starter clutch idle gear 1 9 Generator rotor nut 1 10 Spacer 1 11 Generator rotor 1 12 Woodruff key 1 13 Washer 1 14 Starter clutch gear 1 15 Starter clutch 1 13 15 5 6 7 8 6 11 12 10 9 3 17 14 New New Specified angle 120 E E LT E E E 10 N m 1 0 kgf m 7 4 lb ft T R 32 N m 3 2 kgf m 24 lb ft T R 65 N m 6 5 kgf m 48 lb ft 1st 2nd T R Specified angle 120 ...

Page 286: ...215 Three bond No 1215 Order Job Parts to remove Q ty Remarks 1 Oil tank 1 2 Oil tank gasket 1 3 Dowel pin 2 4 Oil strainer 1 5 Crankshaft position sensor 1 6 Stator coil 1 7 Bearing cover 1 8 Oil seal 1 9 Bearing 1 10 Bearing 1 7 2 3 3 5 10 6 3 8 9 4 7 3 1 2 1 1 New New LS E E 2 LT LT LT 10 N m 1 0 kgf m 7 4 lb ft T R 10 N m 1 0 kgf m 7 4 lb ft T R 12 N m 1 2 kgf m 8 9 lb ft T R ...

Page 287: ...tion on the generator rotor 3 Remove Generator rotor 1 with the flywheel puller 2 Woodruff key TIP Make sure the flywheel puller is centered over the generator rotor EAS30868 REMOVING THE STARTER CLUTCH 1 Remove Starter clutch bolt 1 Starter clutch TIP While holding the generator rotor 2 with the sheave holder 3 remove the starter clutch bolts Do not allow the sheave holder to touch the projection...

Page 288: ...en turning the starter clutch gear clock wise B it should turn freely otherwise the starter clutch is faulty and must be re placed EAS31439 CHECKING THE OIL STRAINER 1 Check Oil strainer Damage Replace Contaminants Clean with solvent EAS31440 ASSEMBLING THE OIL TANK 1 Install Bearing TIP Seal a is adhered only on one side of the bear ing Note the press in orientation EAS30871 INSTALLING THE STARTE...

Page 289: ...ut Do not allow the sheave holder to touch the projection on the generator rotor TIP Tighten the nut until it is at the specified angle 3 Apply Sealant onto the crankshaft position sensor stator lead grommet 4 Install Generator cover gasket Generator cover TIP Tighten the generator cover bolts in stages and in a crisscross pattern Generator rotor nut 1st 65 N m 6 5 kgf m 48 lb ft Sheave holder 908...

Page 290: ...t Refer to GENERAL CHASSIS 2 on page 4 11 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 27 Coolant Drain Refer to CHANGING THE COOLANT on page 3 31 V belt case air filter element left Generator cover protector Water pump inlet pipe Water pump outlet pipe Water pump assembly Refer to WATER PUMP on page 6 11 Generator cover Refer to GENERATOR AND STARTER CLUTCH on page 5 49 1 Clutch as...

Page 291: ...te 1 4 Pressure plate 1 5 Clutch plate 2 2 6 Clutch damper spring 7 7 Friction plate 6 8 Clutch plate 1 5 9 Clutch spring 6 10 Thrust plate 1 11 Clutch boss nut 1 12 Primary drive gear 1 13 Bearing 2 14 Clutch boss 1 15 Collar 1 1 2 3 4 5 5 6 6 6 6 6 6 6 7 7 7 7 7 7 8 9 6 10 11 12 13 14 15 8 8 8 8 E 130 N m 13 kgf m 96 lb ft T R ...

Page 292: ...5 57 CLUTCH Disassembling the clutch Order Job Parts to remove Q ty Remarks 16 Washer 1 17 Clutch weight 12 18 Clutch housing 1 16 17 12 18 E 130 N m 13 kgf m 96 lb ft T R ...

Page 293: ...r plate 1 TIP To ensure proper balance of the clutch assem bly one to three holes a or no hole at all may have been drilled in the spring stopper plate Be fore removing the spring stopper plate make alignment marks on both the plate and the clutch housing so that the plate can be reinstalled in its original position 3 Loosen Clutch boss nut 1 TIP While holding the clutch boss 2 with the univer sal...

Page 294: ...n plates as a set Clutch plate thickness Out of specification Replace the clutch plates and friction plates as a set TIP Measure the clutch plate 2 at four places EAS31442 CHECKING THE CLUTCH DAMPER SPRINGS The following procedure applies to all of the clutch damper springs 1 Check Clutch damper spring Damage Replace 2 Measure Clutch damper spring free height a Out of specification Replace the clu...

Page 295: ...h housing dogs will cause er ratic clutch operation EAS30353 CHECKING THE CLUTCH BOSS 1 Check Clutch boss spline Damage pitting wear Replace the clutch boss TIP Pitting on the clutch boss splines will cause er ratic clutch operation EAS31443 CHECKING THE PRESSURE PLATE AND THRUST PLATE 1 Check Pressure plate 1 Thrust plate 2 Cracks damage Replace EAS31444 ASSEMBLING THE CLUTCH 1 Install Clutch bos...

Page 296: ...st plate 1 can be identified by punch mark b on the pressure plate 4 Install Clip 1 TIP While compressing the clutch springs with the clutch spring compressor 2 install the clip EAS30363 INSTALLING THE CLUTCH 1 Install Clutch assembly 1 Clutch assembly nut 2 TIP Align the a and b during reassembly While holding the clutch assembly with the ro tor holding tool 3 tighten the clutch assembly nut 1 2 ...

Page 297: ...5 62 CLUTCH 1 3 2 ...

Page 298: ...CHASSIS 2 on page 4 11 V belt case air filter element left Generator cover protector Water pump inlet pipe Water pump outlet pipe Water pump assembly Refer to WATER PUMP on page 6 11 Generator cover Generator rotor Starter clutch gear Refer to GENERATOR AND STARTER CLUTCH on page 5 49 1 Oil pump assembly 1 2 Oil pump drive chain 1 3 Gasket 2 4 Oil delivery pipe 1 5 Oil pipe 1 6 Relief valve assemb...

Page 299: ...1 Oil pump housing 1 1 2 Dowel pin 2 3 Oil pump outer rotor 1 1 4 Oil pump inner rotor 1 1 5 Pin 1 6 Washer 1 7 Oil pump housing center 1 8 Oil pump outer rotor 2 1 9 Oil pump inner rotor 2 1 10 Pin 1 11 Oil pump driven gear 1 12 Oil pump housing 2 1 1 2 3 4 5 6 7 8 9 10 11 12 FWD FWD E E E 6 N m 0 6 kgf m 4 4 lb ft T R 6 N m 0 6 kgf m 4 4 lb ft T R ...

Page 300: ...CKING THE OIL PUMP DRIVE CHAIN 1 Check Oil pump drive chain Cracks stiffness Replace the oil pump chain and oil pump assembly as a set EAS30342 ASSEMBLING THE OIL PUMP 1 Lubricate Inner rotor Outer rotor Oil pump shaft with the recommended lubricant 2 Install Inner rotor TIP When installing the inner rotor align the pins 1 in the oil pump shaft with the grooves a in the inner rotor 3 Check Oil pum...

Page 301: ...n page 6 11 Generator cover Generator rotor Starter clutch gear Refer to GENERATOR AND STARTER CLUTCH on page 5 49 Clutch assembly Refer to CLUTCH on page 5 55 Oil pump assembly Refer to OIL PUMP on page 5 63 Outer V belt case Primary sheave assembly Secondary sheave assembly Inner V belt case Refer to V BELT AUTOMATIC TRANSMIS SION on page 5 39 Bearing housing Refer to SWINGARM on page 4 100 3 3 ...

Page 302: ...e 1 4 Crankcase left 1 5 Dowel pin 2 6 Oil strainer 1 7 Crankcase right 1 8 Centerstand lock solenoid cover 1 9 Centerstand lock solenoid 1 3 3 6 6 8 5 2 New New 1 2 3 4 5 6 7 8 9 5 LT LT LT LS LS 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft 24 N m 2 4 kgf m 18 lb ft 43 N m 4 3 kgf m 32 lb ft 55 N m 5 5 kgf m 41 lb ft 7 N m 0 7 kgf m 5 2 lb ft ...

Page 303: ...CRANKCASE Disassembling the Centerstand assembly Order Job Parts to remove Q ty Remarks 1 Spring 1 2 Spring tube 1 3 Centerstand bracket 2 4 Centerstand 1 68 N m 6 8 kgf m 50 lb ft T R 3 1 2 4 3 LS LS LS LS ...

Page 304: ... Order Job Parts to remove Q ty Remarks Crankshaft assembly Refer to CRANKSHAFT on page 5 73 Transmission Refer to TRANSMISSION on page 5 83 1 Bearing retainer 2 2 Oil seal 2 3 Bearing 5 1 2 2 3 3 3 3 New New E E LS LS 12 N m 1 2 kgf m 8 9 lb ft T R LT ...

Page 305: ...lt 4 Tighten Centerstand nut 5 Lubricate Centerstand 1 Centerstand bracket 2 TIP Apply grease to the sliding surfaces of the cen terstand and centerstand bracket After applying grease while the centerstand is extended apply grease while the centerstand is retracted Apply the grease so it is pressed in between the centerstand and the centerstand bracket Operate the centerstand several times so the ...

Page 306: ... a mild solvent 2 Thoroughly clean all the gasket surfaces and crankcase mating surfaces 3 Check Crankcase Cracks damage Replace Oil delivery passage Obstruction Blow out with compressed air EAS31445 CHECKING THE TIMING CHAIN 1 Check Timing chain Damage stiffness Replace the timing chain camshafts and crankshaft assembly as a set EAS30397 ASSEMBLING THE CRANKCASE 1 Install Cylinder stud bolt 1 TIP...

Page 307: ...at a time in stag es and in a crisscross pattern M8 120 mm 4 72 in bolts 1 M8 110 mm 4 33 in bolts 2 M6 50 mm 1 97 in bolts 3 M6 35 mm 1 38 in bolts 4 6 Check Crankshaft and transmission operation Rough movement Repair Crankcase bolt M8 24 N m 2 4 kgf m 18 lb ft Crankcase bolt M6 10 N m 1 0 kgf m 7 4 lb ft T R 4 4 3 3 3 3 2 2 2 2 1 ...

Page 308: ...b Parts to remove Q ty Remarks Crankcase Separate Refer to CRANKCASE on page 5 66 1 Dowel pin 2 2 Balancer cylinder 1 3 Crankshaft assembly 1 4 Oil seal 1 5 Crankshaft journal bearing 2 3 5 4 2 1 4 5 New E E E E E LT LS 1st 2nd 16 N m 1 6 kgf m 12 lb ft 58 N m 5 8 kgf m 43 lb ft ...

Page 309: ... piston pin 1 7 Balancer piston 1 8 Balancer connecting rod cap 1 9 Balancer big end lower bearing 1 10 Balancer connecting rod 1 11 Balancer big end upper bearing 1 1 1 2 2 3 3 4 4 5 5 6 7 8 9 10 11 New New New New New New New New New New M M M M E E E E E E E E M M M M M E 60 N m 6 0 kgf m 44 lb ft 1st 2nd 16 N m 1 6 kgf m 12 lb ft Specified angle 120 1st 2nd 16 N m 1 6 kgf m 12 lb ft Specified ...

Page 310: ...nkshaft journal bearings 1 Remove Crankshaft assembly Crankshaft journal bearing 1 TIP Remove the crankshaft journal bearing using the plane bearing installer 2 TIP Identify the position of each crankshaft journal bearing so that it can be reinstalled in its original place EAS30423 CHECKING THE CRANKSHAFT AND CONNECTING RODS 1 Measure Crankshaft runout Out of specification Replace the crank shaft ...

Page 311: ...t a piece of Plastigauge 1 on the crankshaft pin d Assemble the connecting rod halves TIP Do not move the connecting rod or crankshaft until the clearance measurement has been completed Lubricate the bolts threads and nut seats with molybdenum disulfide grease Make sure the Y mark c on the connecting rod faces towards the left side of the crank shaft Make sure the characters d on both the con nect...

Page 312: ...g the smaller value is used The following procedure applies to all of the crankshaft journal bearings NOTICE ECA13920 Do not interchange the crankshaft journal bearings To obtain the correct crankshaft journal to crankshaft journal bearing clear ance and prevent engine damage the crank shaft journal bearings must be installed in their original positions a Clean the crankshaft journal bearings cran...

Page 313: ...earance is If the oil clearance is out of specification select replacement bearings 6 Select Crankshaft journal bearing J1 J2 TIP The numbers A is stamped onto the crank shaft web the number B on the left crank case and the number C on the right crankcase The numbers A B and C are used to de termine the replacement crankshaft journal bearing size J1 J2 refer to the bearings as shown in the cranksh...

Page 314: ...ce an iron plate 3 beneath the crankcase and press fit until the end of the plain bearing installer touches the iron plate EAS30426 INSTALLING THE CONNECTING RODS 1 Lubricate Bolt thread Nut seat with the recommended lubricant 2 Lubricate Crankshaft pin Big end bearings inner surface Balancer big end bearings inner surface with the recommended lubricant 3 Install Big end bearing Connecting rod Con...

Page 315: ...wrench b Put a mark 1 on the corner of the connect ing rod nut 2 and the connecting rod cap 3 c Tighten the connecting rod nuts further to reach the specified angle 120 WARNING EWA13400 If the connecting rod nut is tightened more than the specified angle do not loosen the nut and then retighten it Instead replace the connecting rod bolt and nut with a new one and perform the procedure again NOTICE...

Page 316: ...interrupted between 30 N m 3 0 kgf m 22 lb ft and 60 N m 6 0 kgf m 44 lb ft loosen the nut to less than 30 N m 3 0 kgf m 22 lb ft and start again 7 Install Balancer piston 1 Balancer piston pin Piston pin clip 2 TIP Apply engine oil onto the balancer piston pin Make sure that the clip ends a are positioned away from the cutout b in the balancer piston as shown in the illustration EAS30428 INSTALLI...

Page 317: ...5 82 CRANKSHAFT 2 1 2 1 2 4 3 ...

Page 318: ...Grease R0 Order Job Parts to remove Q ty Remarks Crankcase Separate Refer to CRANKCASE on page 5 66 1 Secondary shaft 1 2 Collar 1 3 O ring 1 4 Primary driven gear 1 5 Main axle 1 6 1st pinion gear 1 7 Drive axle 1 8 1st wheel gear 1 9 Circlip 1 10 O ring 1 3 5 1 4 5 6 2 8 9 7 4 New New 3 10 New LS E E E E ...

Page 319: ...ve part s 3 Check Main axle Cracks damage wear Replace the main axle 4 Measure Drive axle runout with a centering device and dial gauge Out of specification Replace the drive axle 5 Measure Secondary shaft runout with a centering device and dial gauge Out of specification Replace the second ary shaft Drive axle runout limit 0 08 mm 0 0032 in Secondary shaft runout limit 0 12 mm 0 0047 in ...

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

Page 321: ...TOR 6 5 OIL COOLER 6 7 CHECKING THE OIL COOLER 6 8 INSTALLING THE OIL COOLER 6 8 THERMOSTAT 6 9 CHECKING THE THERMOSTAT 6 10 INSTALLING THE THERMOSTAT ASSEMBLY 6 10 WATER PUMP 6 11 DISASSEMBLING THE WATER PUMP 6 13 CHECKING THE WATER PUMP 6 13 ASSEMBLING THE WATER PUMP 6 13 INSTALLING THE WATER PUMP 6 14 ...

Page 322: ...iller hose 3 Cooling system air bleed hose 4 Coolant reservoir hose 5 Radiator inlet hose 6 Thermostat 7 Oil cooler inlet hose 8 Oil cooler 9 Oil cooler outlet hose 10 Coolant hose 11 Water pump outlet pipe 12 Radiator outlet hose 13 Radiator bracket 14 Coolant reservoir 15 Coolant reservoir breather hose 16 Radiator 17 Water pump 18 Water pump inlet pipe ...

Page 323: ...RAMS 1 2 3 4 5 3 6 10 9 8 7 1 Thermostat 2 Cooling system air bleed hose 3 Coolant reservoir hose 4 Radiator cap 5 Radiator filler hose 6 Radiator 7 Radiator bracket 8 Radiator inlet hose 9 Oil cooler 10 Oil cooler inlet hose ...

Page 324: ...ootboard Refer to GENERAL CHASSIS 2 on page 4 11 Coolant Drain Refer to CHANGING THE COOLANT on page 3 31 1 Coolant reservoir hose 1 2 Coolant reservoir 1 3 Coolant reservoir cap 1 4 Coolant reservoir breather hose 1 5 Radiator cap 1 TIP Remove Install it with the radiator filler pipe held 6 Cooling system air bleed hose 1 Disconnect FWD LT 1 1 2 3 4 5 6 7 N m 0 7 kgf m 5 2 lb ft 7 N m 0 7 kgf m 5...

Page 325: ... hose 1 10 Radiator inlet hose 1 11 Radiator fan motor coupler 1 Disconnect 12 Radiator 1 13 Radiator fan 1 14 Radiator bracket 1 FWD LT 7 8 9 10 11 12 13 14 7 N m 0 7 kgf m 5 2 lb ft 7 N m 0 7 kgf m 5 2 lb ft 13 N m 1 3 kgf m 9 6 lb ft 13 N m 1 3 kgf m 9 6 lb ft 9 N m 0 9 kgf m 6 6 lb ft 9 N m 0 9 kgf m 6 6 lb ft 13 N m 1 3 kgf m 9 6 lb ft ...

Page 326: ...mage Replace Malfunction Check and repair Refer to COOLING SYSTEM on page 8 39 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 31 2 Check Cooling system Leaks Repair or replace any faulty part a Attach the radiator cap tester 1 and radia tor cap tester adapter 2 to the radiator Radiator cap valve o...

Page 327: ...6 6 RADIATOR b Apply 137 3 kPa 1 37 kgf cm2 19 9 psi of pressure c Measure the indicated pressure with the gauge ...

Page 328: ...ssembly Side cover Rear side cowling assembly Footboard Refer to GENERAL CHASSIS 2 on page 4 11 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 27 Coolant Drain Refer to CHANGING THE COOLANT on page 3 31 1 Oil filter cartridge 1 2 Oil cooler outlet hose 1 3 Oil cooler inlet hose 1 4 Oil filter cartridge union bolt 1 5 Oil cooler 1 6 Gasket 1 New New 1 2 3 5 6 FWD FWD 4 E 17 N m 1 7 kgf...

Page 329: ... the slot b in the crankcase 3 Install Oil filter cartridge Refer to CHANGING THE ENGINE OIL on page 3 27 4 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 31 Crankcase with the specified amount of the recom mended engine oil Refer to CHANGING THE ENGINE OIL on page 3 27 5 Check Cooling system Leaks Repair or replace any faulty part...

Page 330: ...ide panel Bottom center cowling Refer to GENERAL CHASSIS 1 on page 4 1 Center cover Fuel tank cover assembly Side cover Rear side cowling assembly Footboard Refer to GENERAL CHASSIS 2 on page 4 11 Coolant Drain Refer to CHANGING THE COOLANT on page 3 31 1 Thermostat cover 1 2 Thermostat 1 1 2 10 N m 1 0 kgf m 7 4 lb ft ...

Page 331: ...cooling 2 Check Thermostat cover Cracks damage Replace EAS30445 INSTALLING THE THERMOSTAT ASSEMBLY 1 Install Thermostat TIP Install the thermostat with its jiggle valve a facing upward 2 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 31 3 Check Cooling system Leaks Repair or replace any faulty part Refer to INSTALLING THE RADIATOR ...

Page 332: ...olant Drain Refer to CHANGING THE COOLANT on page 3 31 1 V belt case air filter element joint clamp 1 Loosen 2 V belt case air filter element left 1 3 Oil filler cap 1 4 Generator cover protector 1 5 Oil cooler outlet hose 1 Disconnect 6 Coolant hose 1 Disconnect 7 Radiator outlet hose 1 Disconnect 8 Water pump inlet pipe 1 9 Water pump outlet pipe 1 10 Water pump assembly 1 New New 7 5 3 4 9 10 6...

Page 333: ...pump Order Job Parts to remove Q ty Remarks 1 Water pump housing cover 1 2 Circlip 1 3 Impeller shaft 1 4 Mechanical seal 1 5 Bearing 1 6 Oil seal 1 7 Water pump housing 1 M E New New New New New 1 2 2 3 4 5 6 7 10 N m 1 0 kgf m 7 4 lb ft T R ...

Page 334: ...ck Water pump inlet pipe Water pump outlet pipe Cracks damage wear Replace EAS30448 ASSEMBLING THE WATER PUMP 1 Install Oil seal 1 Bearing 2 into the water pump housing TIP Before installing the oil seal apply tap water or coolant onto its outer surface Install the oil seal with a socket that matches its outside diameter Install the oil seal from the inside of the water pump housing 2 Install Mech...

Page 335: ...e specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 31 3 Check Cooling system Leaks Repair or replace any faulty part Refer to INSTALLING THE RADIATOR on page 6 5 4 Measure Radiator cap valve opening pressure Below the specified pressure Replace the radiator cap Refer to CHECKING THE RADIATOR on page 6 5 Mechanical seal installer ø33 90890 04132 Water pump seal i...

Page 336: ...6 15 WATER PUMP ...

Page 337: ...TANK 7 4 THROTTLE BODY 7 5 CHECKING THE INJECTORS BEFORE REMOVING 7 9 REMOVING THE FUEL HOSE FUEL RAIL SIDE 7 9 REMOVING THE INJECTORS 7 9 CHECKING THE INJECTORS 7 9 CHECKING AND CLEANING THE THROTTLE BODIES 7 10 REPLACING THE THROTTLE BODIES 7 11 INSTALLING THE INJECTORS 7 11 CHECKING THE INJECTOR PRESSURE 7 12 CHECKING THE FUEL PRESSURE 7 12 INSTALLING THE FUEL HOSE FUEL RAIL SIDE 7 13 ADJUSTING...

Page 338: ...ling assembly Footboard Refer to GENERAL CHASSIS 2 on page 4 11 1 Fuel tank overflow hose 1 2 Fuel tank breather hose 1 Disconnect 3 Fuel pump coupler 1 Disconnect 4 Fuel hose connector 1 Disconnect 5 Fuel tank 1 6 Fuel pump bracket 1 7 Fuel pump 1 8 Fuel pump gasket 1 9 Fuel tank cap 1 10 Filler cover 1 FWD FWD 1 2 3 4 5 6 7 8 9 10 New 4 0 N m 0 40 kgf m 3 0 lb ft 10 N m 1 0 kgf m 7 4 lb ft 10 N ...

Page 339: ... cover Rear side cowling assembly Footboard Refer to GENERAL CHASSIS 2 on page 4 11 Fuel tank Refer to FUEL TANK on page 7 1 1 Canister breather hose 1 2 Canister purge hose hose joint to canister 1 3 Fuel tank breather hose rollover valve to canis ter 1 4 Rollover valve 1 5 Fuel tank breather hose fuel tank to rollover valve 1 6 Canister bracket 1 7 Canister holder 1 8 Canister 1 1 6 2 5 3 4 8 7 ...

Page 340: ...uel pump slide the fuel hose connector cover 1 on the end of the hose in the direction of the arrow shown press the two buttons 2 on the sides of the connector and then remove the hose Before removing the hose place a few rags in the area under where it will be removed It is prohibited to wear the cotton work gloves or equivalent coverings 4 Remove Fuel tank TIP Do not set the fuel tank down so th...

Page 341: ... tight ening sequence as shown EAS30457 INSTALLING THE FUEL TANK 1 Connect Fuel hose fuel tank side NOTICE ECA17500 When installing the fuel hose make sure that it is securely connected and that the fuel hose connector cover on the fuel hose is in the correct position otherwise the fuel hose will not be properly installed TIP Install the fuel hose securely onto the fuel pump until a distinct click...

Page 342: ...Footboard Refer to GENERAL CHASSIS 2 on page 4 11 Fuel tank Refer to FUEL TANK on page 7 1 Throttle body assembly Refer to THROTTLE BODY on page 7 5 Cylinder head cover Refer to CAMSHAFTS on page 5 12 Front wheel Refer to FRONT WHEEL on page 4 22 Front fender Refer to FRONT FORK on page 4 81 1 Plate 1 2 Cylinder head breather hose 1 3 Air filter case joint clamp 2 Loosen 4 Air filter case cover 1 ...

Page 343: ...K on page 7 1 Air filter case Disconnect Refer to THROTTLE BODY on page 7 5 Canister purge hose hose joint to canister Disconnect Refer to FUEL TANK on page 7 1 1 Throttle servo motor coupler 1 Disconnect 2 Throttle position sensor coupler 1 Disconnect 3 Intake air pressure sensor coupler 1 Disconnect 4 Injector coupler 2 Disconnect 5 Throttle body joint clamp screw 2 Loosen 6 Intake air pressure ...

Page 344: ...tle body Order Job Parts to remove Q ty Remarks 9 Throttle body joint 1 10 Fuel hose 1 11 Fuel rail 1 12 Injector 2 New New New New New New 9 10 12 12 11 10 N m 1 0 kgf m 7 4 lb ft 3 8 N m 0 38 kgf m 2 8 lb ft 3 5 N m 0 35 kgf m 2 6 lb ft ...

Page 345: ...7 8 THROTTLE BODY Disassembling the throttle body assembly Order Job Parts to remove Q ty Remarks 1 Throttle position sensor 1 2 Canister purge hose 2 3 Hose joint 1 3 2 2 1 3 5 N m 0 35 kgf m 2 6 lb ft ...

Page 346: ... be removed It is prohibited to wear the cotton work gloves or equivalent coverings EAS30476 REMOVING THE INJECTORS WARNING EWA20210 Check the injectors in a well ventilated 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 ...

Page 347: ...ution Do not apply cleaning solvent directly to any plastic parts sensors or seals Be careful not to remove the white paint mark that identifies the standard throttle body Do not turn the bypass air screws a oth erwise the throttle body synchronization will be affected a Place the throttle bodies on a flat surface with the air filter case side facing up b Install the caps 895 14169 00 onto the hos...

Page 348: ...le bodies synchronizing Out of specification Replace the throttle bodies Refer to SYNCHRONIZING THE THROT TLE BODIES on page 3 9 EAS31160 REPLACING THE THROTTLE BODIES 1 Remove the throttle bodies from the vehicle 2 Install a new throttle bodies to the vehicle 3 Reset ISC idle speed control learning values Use the diagnostic code number 67 Refer to DIAGNOSTIC CODE SENSOR OPERATION TABLE on page 9 ...

Page 349: ...sure drops Check the pressure gauge and adapter Check the seals and O rings and then rein stall Out of specification Replace the fuel in jectors EAS30482 CHECKING THE FUEL PRESSURE 1 Check Fuel pressure a Remove the bottom side cowling side pan el and bottom center cowling Refer to GENERAL CHASSIS 1 on page 4 1 b Remove the center cover fuel tank cover assembly side cover rear side cowling as semb...

Page 350: ...LE POSITION SENSOR NOTICE ECA17540 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 8 107 2 Adjust Throttle position sensor angle TIP Before adjusting the throttle position sensor the throttle...

Page 351: ...uired For information about using the YDT refer to the operation manual that is included with the tool e Diagnostic code number 01 is selected f Adjust the position of the throttle position sensor angle so that 11 20 can appear in the YDT screen g After adjusting the throttle position sensor angle tighten the throttle position sensor screws 2 Throttle position sensor screw 3 5 N m 0 35 kgf m 2 6 l...

Page 352: ...7 15 THROTTLE BODY ...

Page 353: ...EM 8 23 CIRCUIT DIAGRAM 8 23 TROUBLESHOOTING 8 27 SIGNALING SYSTEM 8 29 CIRCUIT DIAGRAM 8 29 TROUBLESHOOTING 8 33 COOLING SYSTEM 8 39 CIRCUIT DIAGRAM 8 39 TROUBLESHOOTING 8 43 FUEL PUMP SYSTEM 8 45 CIRCUIT DIAGRAM 8 45 TROUBLESHOOTING 8 49 WINDSHIELD DRIVE SYSTEM for XP560D 8 51 CIRCUIT DIAGRAM 8 51 TROUBLESHOOTING 8 53 GRIP WARMER SYSTEM for XP560D 8 55 CIRCUIT DIAGRAM 8 55 TROUBLESHOOTING 8 57 S...

Page 354: ...FT POSITION SENSOR 8 104 CHECKING THE LEAN ANGLE SENSOR 8 104 CHECKING THE STARTER MOTOR OPERATION 8 105 CHECKING THE STATOR COIL 8 105 CHECKING THE RECTIFIER REGULATOR 8 105 CHECKING THE FUEL SENDER 8 106 CHECKING THE FUEL METER FUEL LEVEL WARNING INDICATOR 8 106 CHECKING THE RADIATOR FAN MOTOR 8 106 CHECKING THE COOLANT TEMPERATURE SENSOR 8 107 CHECKING THE THROTTLE POSITION SENSOR 8 107 CHECKIN...

Page 355: ......

Page 356: ...L L Y Y W R R W Y R L Lg L W W R B L B Lg B L B B B B B W B B B W B B B W B W B W B W B B B B B B W B B B Lg B B B B B G B B G B L Y L Y R B R B R B R B R B R W R W B L L L R R L Y L Y B B Br L Br B Br B Br L Br L Br L B B O O B B R W R W G R G R Lg B B Lg Lg Lg B B B R W R W B L Gy B L B L B L B L B W B W B Y G Y G B B B Br Br Y L Y L L B L Lg B Y B Y R R R R R R R R R R R R R R G Y G Y B B B B B...

Page 357: ...tion fuse 22 Battery 23 Engine ground 24 Main fuse 27 Diode 1 28 Sidestand relay 29 Diode 2 31 Starting circuit cut off relay 32 Sidestand switch 34 Handlebar switch right 35 Engine stop switch 57 ECU Engine Control Unit 58 Ignition coil 59 Spark plug 66 Lean angle sensor A Wire harness B Negative battery sub wire harness ...

Page 358: ...L Lg L W W R B L B Lg B L B Y L Y G P Lg L O W W G Y L Lg W B L Br W Gy G G L R G Lg L W G W Y G R Lg B L W Lg B B B B B W B B B W B B B W B W B W B W B B B B B B W B B B Br Y R W Br W R B R W Br Y R B Br W Lg B B B B B G B B G B L Y L Y R B R B R B R B R B R W R W B L L L R R L Y L Y B Br L Br B Br B Br L Br L Br L B B O O R W R W G R G R Lg B B Lg Lg B B B R W R W B L Gy B L B L B L B L B W B W ...

Page 359: ...tion fuse 22 Battery 23 Engine ground 24 Main fuse 27 Diode 1 28 Sidestand relay 29 Diode 2 31 Starting circuit cut off relay 32 Sidestand switch 34 Handlebar switch right 35 Engine stop switch 70 ECU Engine Control Unit 71 Ignition coil 72 Spark plug 79 Lean angle sensor A Wire harness B Negative battery sub wire harness ...

Page 360: ...Y on page 8 94 NG Clean the battery terminals Recharge or replace the battery OK 3 Check the spark plugs Refer to CHECKING THE SPARK PLUGS on page 3 5 NG Re gap or replace the spark plugs OK 4 Check the ignition spark gap Refer to CHECKING THE IGNI TION SPARK GAP on page 8 103 OK Ignition system is OK NG 5 Check the spark plug caps Refer to CHECKING THE SPARK PLUG CAPS on page 8 102 NG Replace the...

Page 361: ... on page 8 91 NG Replace the sidestand switch OK 12 Check the engine stop switch Refer to CHECKING THE SWITCHES on page 8 91 NG The engine stop switch is faulty Replace the handlebar switch right OK 13 Check the lean angle sensor Refer to CHECKING THE LEAN ANGLE SENSOR on page 8 104 NG Replace the lean angle sensor OK 14 Check the crankshaft position sen sor Refer to CHECKING THE CRANKSHAFT POSITI...

Page 362: ...B B W B B B W B B B W B W B W B W B B B B B B W B B B Y W Y Br Y BL B Sb G Y Lg B B B B B G B B G B L Y L Y R B R B R B R W R W B R R L Y L Y B B B Br L Br B Br B Br L Br L Br L B Br Br Br B B Br L W L W L W L W G R G Y G Y G Y Lg B B B Lg Br Br B Br R W R W B W B W B G Y Sb Sb Lg R R R R R R R R R R R R G Y G Y B B G R Br G Y G Y Lg L GLg W R B G L L R Br B W YL W G YLg L Y L B L R G L Y Br Br Y ...

Page 363: ...24 Main fuse 25 Starter relay 26 Starter motor 28 Sidestand relay 29 Diode 2 31 Starting circuit cut off relay 32 Sidestand switch 33 Diode 4 34 Handlebar switch right 35 Engine stop switch 36 ON start switch 39 Front brake light switch 40 Headlight relay dimmer 82 Handlebar switch left 83 Rear brake light switch A Wire harness B Negative battery sub wire harness ...

Page 364: ... B B W B B B W B W B W B W B B B B B B W B B B Y W Y Br Y BL B Br Lg B G Y B Br Y R W Br W R B L W B W G B W L W W G B W R W Br Y R B Br W B Sb G Y Lg B B B B B G B B G B L Y L Y R B R B R B R W R W B R R L Y L Y B B B Br L Br B Br B Br L Br L Br L B B B Br Br Br G W Y W Y W B Br Lg B Lg B L W L W L W L W G R Br Br Lg B B B Lg Br Br B B R W R W B W B W B B B B G Y G Y Sb Sb Lg R R R R R R R R R R ...

Page 365: ...fuse 25 Starter relay 26 Starter motor 28 Sidestand relay 29 Diode 2 31 Starting circuit cut off relay 32 Sidestand switch 33 Diode 4 34 Handlebar switch right 35 Engine stop switch 36 ON start switch 39 Headlight relay dimmer 40 Brake light relay 41 Brake light fuse 42 Front brake light switch 43 Rear brake light switch A Wire harness B Negative battery sub wire harness ...

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

Page 367: ...t brake light switch 8 Rear brake light switch 9 Diode 4 10 Starting circuit cut off relay 11 ON start switch 12 ECU Engine Control Unit 13 Fuel injection system relay 14 Engine stop switch 15 Fuel injection system fuse 16 Spark plug 17 Ignition coil 18 Diode 2 19 Sidestand switch 20 Sidestand relay 21 Diode 1 22 Starter relay 23 Starter motor ...

Page 368: ...lace the battery OK 3 Check the starter motor operation Refer to CHECKING THE START ER MOTOR OPERATION on page 8 105 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 ignition system relay Refer to CHECKING THE RE LAYS o...

Page 369: ...stand switch Refer to CHECKING THE SWITCHES on page 8 91 NG Replace the sidestand switch OK 13 Check the front brake light switch Refer to CHECKING THE SWITCHES on page 8 91 NG Replace the front brake light switch OK 14 Check the rear brake light switch Refer to CHECKING THE SWITCHES on page 8 91 NG Replace the rear brake light switch OK 15 Check the ON start switch Refer to CHECKING THE SWITCHES ...

Page 370: ...8 15 ELECTRIC STARTING SYSTEM OK Replace the remote control unit Refer to SMART KEY SYSTEM on page 8 67 ...

Page 371: ...8 16 ELECTRIC STARTING SYSTEM ...

Page 372: ...8 17 CHARGING SYSTEM EAS20074 CHARGING SYSTEM EAS30496 CIRCUIT DIAGRAM XP560E 22 23 24 10 12 13 B B A A A W W W W W W R B W W W R R R R R R R Br G R B B G B B G W W W B B R R R B B B B Gy R R R R R ...

Page 373: ...8 18 CHARGING SYSTEM 10 Joint coupler 12 AC magneto 13 Rectifier regulator 22 Battery 23 Engine ground 24 Main fuse A Wire harness B Negative battery sub wire harness ...

Page 374: ...8 19 CHARGING SYSTEM XP560D 22 23 24 10 12 13 B B A A A W W W W W W R B W W W R R R R R R R Br G R B B G B B G W W W B B R R R B B B B Gy R R R R R ...

Page 375: ...8 20 CHARGING SYSTEM 10 Joint coupler 12 AC magneto 13 Rectifier regulator 22 Battery 23 Engine ground 24 Main fuse A Wire harness B Negative battery sub wire harness ...

Page 376: ...ry Refer to CHECKING AND CHARGING THE BATTERY on page 8 94 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 8 105 NG Replace the stator coil OK 4 Check the rectifier regulator Refer to CHECKING THE RECTI FIER REGULATOR on page 8 105 NG Replace the rectifier regulator OK 5 Check the entire charging system s wiring R...

Page 377: ...8 22 CHARGING SYSTEM ...

Page 378: ... B Lg L B W R G Lg W B W B W B W B W B B B B B B W B B B R W B W Y W Y Br Y BL B B B G B B G B R W R W R W L L B Y Y B B R R L Y L Y L B L B Y L L Lg W Lg W Lg L Lg L Lg W Lg W L G L G R G R G B W B W L L L B B B B B B Br L Br L Br L Br L Br L Br L B B B W B W Br Br B R G L L L R G R G B B L G L G Br Br B B B B B R G R W R W B W B W B W B W B W B W Lg L Lg L Y Y Y Y Y B B B B B R Y R Y R Y R Y R Y...

Page 379: ...immer 41 Smart key system relay unlock 44 Meter assembly 46 Meter light 55 High beam indicator light 56 Multi function display 57 ECU Engine Control Unit 78 YDT coupler 82 Handlebar switch left 84 Dimmer pass switch 89 Tail brake light 90 License plate light 95 Auxiliary light 96 Headlight high 97 Headlight low 98 Headlight control unit 103 Headlight fuse 106 Storage box light switch A Wire harnes...

Page 380: ...B B W B B Lg L B W R G Lg W B W B W B W B W B B B B B B W B B B R W B W Y W Y Br Y BL B B B G B B G R Y V Y L Gy Y B R Y Ch Y L B B Dg Y B B R W R W R W L L B Y Y Y B Y B B B R R Y B Y B L Y L Y L B L B Y L L Lg W Lg W Lg L Lg L Lg W Lg W L G L G R G R G B W B W L L L B B B B B B Br L Br B Br B Br L Br L Br L Br L Br L B B B W B W Br Br B R G L L L R G R G R G Br L B B L G L G Br Br B B B B B R G ...

Page 381: ...er 45 Smart key system relay unlock 55 Meter assembly 57 Meter light 68 High beam indicator light 69 Multi function display 70 ECU Engine Control Unit 91 YDT coupler 95 Handlebar switch left 98 Dimmer pass switch 103 Tail brake light 104 License plate light 109 Auxiliary light 110 Headlight high 111 Headlight low 112 Headlight control unit 118 Headlight fuse 121 Storage box light switch A Wire har...

Page 382: ...tion signaling system and taillight Refer to CHECKING THE FUS ES on page 8 93 NG Replace the fuse s OK 3 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 94 NG Clean the battery terminals Recharge or replace the battery OK 4 Check the ignition system relay Refer to CHECKING THE RE LAYS on page 8 94 NG Replace the ignition system relay OK 5 Check the diode Diode 3 Refer to CHE...

Page 383: ...OK 9 Check the storage box light switch Refer to CHECKING THE SWITCHES on page 8 91 NG Replace the storage box light switch OK 10 Check the entire lighting system s wiring Refer to CIRCUIT DIAGRAM on page 8 23 NG Properly connect or replace the wire har ness OK Replace the ECU headlight assem bly remote control unit and or meter assembly ...

Page 384: ...Lg L Lg L Lg W Lg W R G B B B B B B B B B B B B Br L Br L Br L Br L Br L Br L B W B W Ch Ch Ch Gy W Gy W V V Gy Gy R G R G R G R G R G R G R G R G Br Br Br B B Br Br Br P R B R B R G Br Br R G R G R G R G Dg Dg Ch Ch G Y G Y G Y G Y G Y B L B L Lg Lg Lg Br Br B B Br R G R G R G R G Br W Br W Br W Br W B L B L B L R L R L R W R W G Y B W B W B W B W B W B W Lg L Lg L R G G G W Y W Y Br W Br W B B B...

Page 385: ... Turn signal indicator light left 52 Turn signal indicator light right 56 Multi function display 57 ECU Engine Control Unit 63 Coolant temperature sensor 64 Intake air temperature sensor 73 Fuel sender 76 Rear wheel sensor 77 ABS ECU Electronic Control Unit 78 YDT coupler 81 Horn 82 Handlebar switch left 83 Rear brake light switch 85 Horn switch 88 Turn signal switch 89 Tail brake light 91 Front t...

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

Page 387: ...ndicator light 61 Traction control system indicator light 62 Turn signal indicator light left 63 Turn signal indicator light right 69 Multi function display 70 ECU Engine Control Unit 76 Coolant temperature sensor 77 Intake air temperature sensor 86 Fuel sender 89 Rear wheel sensor 90 ABS ECU Electronic Control Unit 91 YDT coupler 94 Horn 95 Handlebar switch left 99 Horn switch 102 Turn signal swi...

Page 388: ...rt s 1 Front cowling assembly 2 Storage box 3 Fuel tank 4 Footboards 5 Rear side cowling assembly right 1 Check the fuses Main signaling system ABS mo tor ABS solenoid ABS ECU brake light and backup Refer to CHECKING THE FUS ES on page 8 93 NG Replace the fuse s OK 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 94 NG Clean the battery terminals Recharge or replace the bat...

Page 389: ...lace the front brake light switch OK 2 Check the rear brake light switch Refer to CHECKING THE SWITCHES on page 8 91 NG Replace the rear brake light switch OK 3 Check the entire signaling sys tem s wiring Refer to CIRCUIT DIAGRAM on page 8 29 NG Properly connect or replace the wire har ness OK Replace the tail brake light assembly and or remote control unit The turn signal light turn signal indica...

Page 390: ...ECKING THE FUEL SENDER on page 8 106 NG Replace the fuel pump assembly OK 2 Check the entire signaling sys tem s wiring Refer to CIRCUIT DIAGRAM on page 8 29 NG Properly connect or replace the wire har ness OK Replace the meter assembly The coolant temperature meter fails to operate 1 Check the coolant temperature sensor Refer to CHECKING THE COOL ANT TEMPERATURE SENSOR on page 8 107 NG Replace th...

Page 391: ...l sensor OK 2 Check the entire wheel sensor wir ing Refer to TIP NG Properly connect or replace the wire har ness OK Replace the hydraulic unit assembly ECU and or meter assembly The tachometer fails to operate 1 Check the crankshaft position sen sor Refer to CHECKING THE CRANKSHAFT POSITION SEN SOR on page 8 104 NG Replace the stator coil OK 2 Check the entire signaling system wiring Refer to CIR...

Page 392: ...or replace the wire har ness OK Replace the meter assembly The oil change indicator fails to come on 1 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 8 29 NG Properly connect or replace the wire har ness OK Replace the meter assembly The buzzer does not sound 1 Check the buzzer Refer to CHECKING THE BUZZ ER on page 8 112 NG Replace the buzzer OK 2 Check the entire signal...

Page 393: ...8 38 SIGNALING SYSTEM ...

Page 394: ... W W R B L B Lg B L Lg L B W R G Lg W B W B W B W B W B B B B B B W B B B B L B L Br B L R W Y R B B G B B G B R W R W R W R W B R R L Y L Y Y R Y R Lg W Lg W Lg L Lg L Lg W Lg W B Br L Br B Br B Br L Br L Br L B W R G R G R G R G R G R G R G R G R G R G R G B R G R W B R G B L B L B W B W B W B W L L Br B Br B B W B W Lg L Lg L R G B B R G R G B L B L G R G R R R R R R R R R R R R R R B B B B B B...

Page 395: ...e 18 Radiator fan motor fuse 20 Backup fuse 22 Battery 23 Engine ground 24 Main fuse 44 Meter assembly 56 Multi function display 57 ECU Engine Control Unit 63 Coolant temperature sensor 78 YDT coupler 79 Radiator fan motor 80 Radiator fan motor relay A Wire harness B Negative battery sub wire harness ...

Page 396: ...L W G W Y G R Lg B L W Lg Lg L B W R G Lg W B W B W B W B W B B B B B B W B B B B L B L Br B L R W Y R B B G B B G B R W R W R W R W B R R L Y L Y Y R Y R Lg W Lg W Lg L Lg L Lg W Lg W B Br L Br B Br B Br L Br L Br L B W R G R G R G R G R G R G R G R G R G R G R G B R G R W B R G B L B L B W B W B W B W L Br B Br B B W B W Lg L Lg L R G B B R G R G B L B L G R G R R R R R R R R R R R R R R R R R B...

Page 397: ...e 18 Radiator fan motor fuse 20 Backup fuse 22 Battery 23 Engine ground 24 Main fuse 55 Meter assembly 69 Multi function display 70 ECU Engine Control Unit 76 Coolant temperature sensor 91 YDT coupler 92 Radiator fan motor 93 Radiator fan motor relay A Wire harness B Negative battery sub wire harness ...

Page 398: ...e battery OK 3 Check the ignition system relay Refer to CHECKING THE RE LAYS on page 8 94 NG Replace the ignition system relay OK 4 Check the radiator fan motor Refer to CHECKING THE RADIA TOR FAN MOTOR on page 8 106 NG Replace the radiator fan motor OK 5 Check the radiator fan motor relay Refer to CHECKING THE RE LAYS on page 8 94 NG Replace the radiator fan motor relay OK 6 Check the coolant tem...

Page 399: ...8 44 COOLING SYSTEM Replace the ECU and or meter as sembly ...

Page 400: ... B W B W B W B W B B B B B B W B B B B B G B B G B R B R B R B R B R W R W B R R R R L Y L Y Lg W Lg W Lg L Lg L Lg W Lg W B B B Br L Br L Br L Br L L Y L Y R G R G R G R G R G R G R G R L R L B B R G R W R W B W B W B W B W Lg L Lg L R L R L R G R G Y L Y L R R R R R R R R R R R R R R R R B B B B B B Lg L GLg W R B G L L R Br B W YL W G YLg L Y L B L R G L Y Br Br Y R W Br W R B Br Y Br W R W R B...

Page 401: ...16 Ignition fuse 19 Fuel injection system fuse 20 Backup fuse 22 Battery 23 Engine ground 24 Main fuse 30 Fuel injection system relay 34 Handlebar switch right 35 Engine stop switch 57 ECU Engine Control Unit 74 Fuel pump 78 YDT coupler A Wire harness B Negative battery sub wire harness ...

Page 402: ... B B B B W B B B Br Y R W Br W R B R W Br Y R B Br W B B G B B G B R B R B R B R B R W R W B R R R R L Y L Y Lg W Lg W Lg L Lg L Lg W Lg W B B B Br L Br B Br B Br L Br L Br L L Y L Y R G R G R G R G R G R G R G R L R L B B R G R W R W B W B W B W B W R L R L R G R G Y L Y L R R R R R R R R R R R R R R R R B B B B B B Lg L GLg W R B G L L R Br B W YL W G G YLg L Y L B L R G L Y Br B O B G Y R B R B...

Page 403: ...16 Ignition fuse 19 Fuel injection system fuse 20 Backup fuse 22 Battery 23 Engine ground 24 Main fuse 30 Fuel injection system relay 34 Handlebar switch right 35 Engine stop switch 70 ECU Engine Control Unit 87 Fuel pump 91 YDT coupler A Wire harness B Negative battery sub wire harness ...

Page 404: ...e engine stop switch Refer to CHECKING THE SWITCHES on page 8 91 NG The engine stop switch is faulty Replace the handlebar switch right OK 4 Check the ignition system relay Refer to CHECKING THE RE LAYS on page 8 94 NG Replace the ignition system relay OK 5 Check the fuel injection system re lay Refer to CHECKING THE RE LAYS on page 8 94 NG Replace the fuel injection system relay OK 6 Check the fu...

Page 405: ...8 50 FUEL PUMP SYSTEM ...

Page 406: ... W R W B R R L Y L Y W L W L R W R W R W G W G P B P B Br B Br L Br B Br B Br L Br L Br L B W P W P W R G R G R G R G R G R G R G R G R G R G Br L R B R B R B R B R B R B R B R B B R G R W R W B W B W B W B W B W B W R G Br Br Br B B B B B R G R G R R R R R R R R R R R R R R B B W G P B L B W R Br O W B W W L G L Br L Br W Y B Ch Dg Br W R W G L B B P O W Y B Ch Dg B W W L G L R G Br W Lg L GLg W ...

Page 407: ...lay 16 Ignition fuse 20 Backup fuse 22 Battery 23 Engine ground 24 Main fuse 49 Windshield drive unit relay down 50 Windshield drive unit 51 Windshield drive unit relay up 55 Meter assembly 69 Multi function display 95 Handlebar switch left 100 Menu switch 101 Select switch A Wire harness B Negative battery sub wire harness ...

Page 408: ... to CHECKING THE FUS ES on page 8 93 NG Replace the fuse s OK 4 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 94 NG Clean the battery terminals Recharge or replace the battery OK 5 Check the ignition system relay Refer to CHECKING THE SWITCHES on page 8 91 NG Replace the ignition system relay OK 6 Check the menu switch Refer to CHECKING THE SWITCHES on page 8 91 NG The men...

Page 409: ...ve unit relay down OK 10 Check the windshield drive motor Refer to CHECKING THE WIND SHIELD DRIVE UNIT for XP560D on page 8 109 NG Replace the windshield drive unit OK 11 Check the entire windshield drive system wiring Refer to CIRCUIT DIAGRAM on page 8 51 NG Properly connect or replace the wire har ness OK Replace the remote control unit and or meter assembly ...

Page 410: ... W G Lg W Lg W Lg L Lg L Lg W Lg W B Br L Br B Br B Br L Br L Br L R G R G R G R G R G R G R G R G R G R G R G R G Br L B B B B B B B Y R Y R R G R W R W B W B W B W B W B W B W Lg L Lg L R G Y R R G R G Y L Y L R R R R R R R R R R R R R R B B B B B B W G P B L B W R Br O W B W W L G L Br L Br W Y B Ch Dg Br W R W G L B B P O W Y B Ch Dg B W W L G L R G Br W Lg L GLg W R B G L L R Br B W YL W G G ...

Page 411: ...20 Backup fuse 22 Battery 23 Engine ground 24 Main fuse 55 Meter assembly 69 Multi function display 70 ECU Engine Control Unit 73 Grip warmer connector 74 Grip warmer left 75 Grip warmer right 91 YDT coupler 95 Handlebar switch left 100 Menu switch 101 Select switch A Wire harness B Negative battery sub wire harness ...

Page 412: ...e grip warmer settings OK 3 Check the fuses Main ignition and backup Refer to CHECKING THE FUS ES on page 8 93 NG Replace the fuse s OK 4 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 94 NG Clean the battery terminals Recharge or replace the battery OK 5 Check the ignition system relay Refer to CHECKING THE RE LAYS on page 8 94 NG Replace the ignition system relay OK 6 Che...

Page 413: ...ature level of the high grip warmer setting is set to highest temperature NG Adjust the temperature levels of the grip warmer settings OK 2 Check that the MIL is on and that DTC No P0500 is displayed in the YDT display NG Perform the troubleshooting for DTC No P0500 Refer to P0500 on page 9 115 OK Replace the ECU Refer to REPLAC ING THE ECU Engine Control Unit on page 8 93 The temperature levels o...

Page 414: ...8 59 GRIP WARMER SYSTEM for XP560D OK Replace the meter assembly ...

Page 415: ...8 60 GRIP WARMER SYSTEM for XP560D ...

Page 416: ... L W Lg B W B W B W B W B B B B B B W B B B B B G B B G B B R R L Y L Y W L W L W R W R W G W G G B G B Br Y Br Y B W B W B B B Br L Br B Br B Br L Br L Br L R G R G R G R G R G R G R G R G R G R G Br L Br Br B Br Br Br Y Y L Y Y Y Y G G R G B W B W B W B W R G Br B B B R G R G Y L Y L R R R R R R R R R R R R R R R R R R B B B B B B W G P B L B W R Br O W B W W L G L Br L Br W Y B Ch Dg Br W R W G...

Page 417: ...tem fuse 20 Backup fuse 22 Battery 23 Engine ground 24 Main fuse 52 Seat heater relay control 53 Seat heater relay power 54 Seat heater 55 Meter assembly 69 Multi function display 70 ECU Engine Control Unit 95 Handlebar switch left 100 Menu switch 101 Select switch A Wire harness B Negative battery sub wire harness ...

Page 418: ... that the engine is started NG Start the engine OK 4 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 94 NG Clean the battery terminals Recharge or replace the battery OK 5 Check the ignition system relay Refer to CHECKING THE RE LAYS on page 8 94 NG Replace the ignition system relay OK 6 Check the seat heater relay power Refer to CHECKING THE RE LAYS on page 8 94 NG Replace ...

Page 419: ...r to CHECKING THE RE LAYS on page 8 94 NG Replace the seat heater relay power OK 3 Check the seat heater Refer to CHECKING THE SEAT HEATER for XP560D on page 8 110 NG Replace the seat assembly OK Replace the meter assembly The seat heater does not become very warm while the vehicle is traveling 1 Check that the temperature level of the high seat heater setting is set to highest temperature NG Adju...

Page 420: ...hanged 1 Check the menu switch Refer to CHECKING THE SWITCHES on page 8 91 NG The menu switch is faulty Replace the handlebar switch left OK 2 Check the select switch Refer to CHECKING THE SWITCHES on page 8 91 NG The select switch is faulty Replace the handlebar switch left OK 3 Check the wire harness between the handlebar switch left and the meter assembly NG Properly connect or replace the wiri...

Page 421: ...8 66 SEAT HEATER SYSTEM for XP560D ...

Page 422: ...W Y W Y L L L G Y G Y L Y L Y L R L R V W V W Br Y Br Y R L R L O L O L Lg L Lg L Lg W Lg W Lg L Lg L Lg L Lg L Lg W Lg W Lg W Lg W L G L G L G L G R G R G R G B B B B B B B B B R L R R R B Br L Br B Br B Br L Br L Br L R G Br R Br R Br R R G B B B Ch Ch Ch Gy W Gy W V V Gy Gy R G R G R G B Br R B R B Br Br R W R W B R G B B R G R G L W L W L W L W R G Dg Dg Ch Ch Br Br B Br R L G L G Br Br Br B B...

Page 423: ...m relay unlock 42 Seat fuel lid lock solenoid 43 Smart key system relay lock 44 Meter assembly 45 Smart key system indicator light 51 Turn signal indicator light left 52 Turn signal indicator light right 56 Multi function display 57 ECU Engine Control Unit 78 YDT coupler 82 Handlebar switch left 88 Turn signal switch 91 Rear turn signal light right 92 Rear turn signal light left 93 Front turn sign...

Page 424: ...g B G Y B Br Y R W Br W R B L W B W G B W L W W G B W R W Br Y R B Br W B B B G B B G R Y V Y L Gy Y B R Y Ch Y L Dg Y B B R W R W Dg Dg Br G Dg B R R W Y W Y L L L G Y G Y L Y L Y L R L R V W Br Y Br Y R L R L O L O L Lg W Lg L Lg L Lg W Lg W Lg L Lg L Lg L Lg L Lg W Lg W Lg W Lg W L G L G L G L G R G R G R G B B B B B B B B R L R R R B Br L Br B Br B Br L Br L Br L R G R G B B B B B W B W Ch Ch ...

Page 425: ...nlock 46 Storage compartment lid lock solenoid 47 Seat fuel lid lock solenoid 48 Smart key system relay lock 55 Meter assembly 56 Smart key system indicator light 62 Turn signal indicator light left 63 Turn signal indicator light right 69 Multi function display 70 ECU Engine Control Unit 91 YDT coupler 95 Handlebar switch left 102 Turn signal switch 105 Rear turn signal light right 106 Rear turn s...

Page 426: ...ART KEY BATTERY on page 8 112 NG Replace the button cell battery of the smart key Standard battery CR2025 OK 2 Check the fuses Main backup ignition and signal ing system Refer to CHECKING THE FUS ES on page 8 93 NG Replace the fuse s OK 3 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 94 NG Clean the battery terminals Recharge or replace the battery OK 4 Check the ON start ...

Page 427: ...8 72 SMART KEY SYSTEM Replace the remote control unit ...

Page 428: ... Replace the smart key or remote control unit The vehicle cannot be turned on in the emergency mode but the storage box light comes on when the seat is opened Replace the remote control unit The storage box light does not come on when the seat is opened Replace the seat or storage box light NO 3 The smart key system indicator light flashes The indicator light flashes once every 2 seconds and then ...

Page 429: ... not flash There are sources of strong electro magnetic waves in the vicinity Move the vehicle Smart key malfunction Register and use a different smart key Remote control unit malfunction Replace the remote control unit Engine does not start even though vehicle power is turned on 1 When the vehicle power is turned on the smart key system indicator light flashes Refer to SMART KEY SYSTEM SELF DIAGN...

Page 430: ...ossible Check the wire harness Light green White Light green White and or replace the remote control unit and or meter NO The seat fuel lid cannot be opened Check the mechanical components of the lock for malfunctions Repair or replace any defective parts Check the seat fuel lid lock solenoid Refer to CHECKING THE SEAT FUEL LID LOCK SOLENOID on page 8 112 Replace the remote control unit and or met...

Page 431: ...orage compartment lid solenoid for XP560D Refer to CHECKING THE STOR AGE COMPARTMENT LID LOCK SOLENOID for XP560D on page 8 112 Replace the remote control unit and or meter assembly 1 Check the turn signal hazard relay Refer to CHECKING THE RE LAYS on page 8 94 NG Replace the turn signal hazard relay OK 2 Check for open or short circuit be tween the remote control unit and turn signal hazard relay...

Page 432: ...n between the remote con trol unit and centerstand lock unit is not possible Check the wire harness Light green White Light green White and or replace the remote control unit and or cen terstand lock unit NO The centerstand cannot be un locked Check the mechanical components of the lock for malfunctions Repair or replace any defective parts Replace the remote control unit and or centerstand lock u...

Page 433: ...8 67 Vehicle power off ver ification error a LED on b LED off 10 seconds The smart key cannot be recognized Check that there are no sources of strong electromagnetic waves in the vicinity the smart key is not lost and the battery is not discharged Running detection er ror a LED on b LED off Flashes continuously until the error is re solved The smart key cannot be recognized Check that there are no...

Page 434: ...ng lock unit ECU communica tion error Data error ECU malfunction a LED on b LED off Flashes continuously until the error is re solved flashes 4 times in a repeating cycle Check the wire har ness Check the ECU Check the remote control unit Steering lock abnor mal or centerstand lock abnormal end position contact a LED on b LED off 10 seconds Check whether the steering lock is stuck Steering lock ab...

Page 435: ...nserting the mechanical key into the lock located right side of body and turn it counter clockwise 3 Open the seat and check that the trunk light comes on 4 Push the ON start switch once 5 Without completely shutting the seat raise and lower it three times within 10 seconds TIP Use the rear storage compartment light as a guide when raising and lowering the seat The smart key system indicator light...

Page 436: ...y system indicator light flashes twice The second digit has been set as 2 Repeat the above procedure until all digits of the identification number have been set The smart key system indicator light will flash for 10 seconds if the correct identification number was entered TIP Emergency mode will be terminated when either one of the following situations apply In this case start over again from step...

Page 437: ...emote control unit Be sure to register the smart keys one at a time Do not register multiple smart keys at the same time 1 Place the smart key 1 that will be registered within 80 cm 31 5 in a of the remote control unit 2 Perform steps 1 to 7 in SMART KEY SYSTEM EMERGENCY MODE on page 8 80 3 While the smart key system indicator light is on for 10 seconds push the Parking Unlock switch 1 and OFF LOC...

Page 438: ...y system indicator light will come on for 3 seconds and then the smart key system will turn off If the smart key was not registered successfully the smart key system indicator light will flash for 3 seconds and then the smart key system will turn off TIP If this registration procedure is performed for a smart key that is already registered the smart key sys tem indicator light will flash for 7 sec...

Page 439: ...le mode is activat ed 5 Turn on unlocked setting the smart keys that you want to enable and place them within 80 cm 31 5 in of the remote control unit 6 Push the OFF LOCK switch 1 time to start the communication between the remote control unit and the smart keys that are located within 80 cm 31 5 in of the unit TIP The number of smart keys that currently can be used will be indicated Number of fla...

Page 440: ...fication number on the smart key with the new number EAS31556 REPLACING THE STEERING LOCK UNIT 1 Replace the steering lock unit and then place the previously used smart key within 80 cm 31 5 in of the remote control unit 2 Push the ON start switch 3 Push the OFF LOCK switch and then push the ON start switch to check that the operation is correct TIP An identification number is not written to the s...

Page 441: ...number in the emergency mode Remote control unit When the vehicle system is turned on the smart key identifi cation number is automatically registered to the remote control unit Steering lock unit When the vehicle system is turned on the smart key identifi cation number is automatically registered to the steering lock unit ECU When the vehicle system is turned on the smart key identifi cation numb...

Page 442: ...nd ECU as a set Smart key Remote control unit Steer ing lock unit Replace the smart key remote control unit steering lock unit and ECU as a set Smart key Remote control unit ECU Replace the smart key remote control unit steering lock unit and ECU as a set Smart key Steering lock unit ECU Register the smart key identifica tion number in the emergency mode When the vehicle system is turned on the sm...

Page 443: ...tery 8 Steering lock unit 9 Diode 3 10 Diode 1 11 Injector 12 Coolant temperature sensor 13 Spark plug 14 Spark plug cap 15 Radiator fan motor 16 Throttle position sensor 17 Throttle servo motor 18 Front wheel sensor 19 Ignition coil 20 Smart key system relay unlock Smart key system relay lock Headlight relay dim mer Brake light relay for XP560D Fuel injection system relay Steering lock relay Star...

Page 444: ...and relay Turn signal hazard relay Radiator fan motor relay Seat heater relay power for XP560D Seat heater relay control for XP560D Windshield drive unit relay down for XP560D Windshield drive unit relay up for XP560D 6 Rear wheel sensor 7 Centerstand lock solenoid 8 Starter motor 9 O2 sensor 10 Stator coil 11 Crankshaft position sensor 12 Sidestand switch ...

Page 445: ...brake light switch for XP560E 7 Rear brake light switch for XP560D 8 Starter relay 9 Fuse box 4 Brake light fuse for XP560D Fuse box 5 Cruise control fuse for XP560D 10 Fuse box 1 11 Fuse box 2 12 Fuse box 3 13 Remote control unit 14 Auxiliary DC jack 15 Windshield drive unit 16 Horn 17 Rectifier regulator 18 Intake air pressure sensor 19 Lean angle sensor 20 Storage compartment lid lock solenoid ...

Page 446: ...P N DOWN B L B B PASS HI LO Br W R W G L B B P Br G Y Dg Ch Br W W L B W L B L B L B L B Br Y R W Br W R B Br G Y L G R R L G L W W G B W B Br P PUSH FREE B R B R W RUN OFF L W B OFF ON Br WBr Y OFF ON B B W W G FREE PUSH 1 2 3 4 5 6 12 B B B B 7 13 14 8 9 10 11 15 1 Dimmer pass switch 2 Horn switch 3 Menu switch 4 Select switch 5 Turn signal switch 6 Rear brake light switch 7 Sidestand switch 8 E...

Page 447: ... W W G UP N DOWN B B B B B L B B PASS HI LO Br P PUSH FREE B R B R W RUN OFF L W B OFF ON Br WBr Y OFF ON 1 2 3 4 5 6 7 8 9 10 11 12 15 16 18 13 14 17 1 Cruise control power switch 2 Cruise control setting switch 3 Dimmer pass switch 4 Horn switch 5 Menu switch 6 Select switch 7 Turn signal switch 8 Sidestand switch 9 Front brake light switch 10 Rear brake light switch 11 Engine stop switch 12 ON ...

Page 448: ...nd ignition systems to malfunction and could possibly cause a fire 4 Install Front cover Refer to GENERAL CHASSIS 1 on page 4 1 EAS31006 REPLACING THE ECU Engine Control Unit 1 Push the ON start switch to OFF 2 Replace the ECU Engine Control Unit 3 Clean the throttle bodies and reset the ISC Idle Speed Control learning value Refer to CHECKING AND CLEANING THE THROTTLE BODIES on page 7 10 4 Check E...

Page 449: ...tery terminal Dirt Clean with a wire brush Loose connection Connect properly 8 Lubricate Battery terminal 9 Install Battery band Battery cover Refer to GENERAL CHASSIS 1 on page 4 1 EAS30553 CHECKING THE RELAYS Check each switch for continuity with the digital circuit tester If the continuity reading is incor rect replace the relay 1 Disconnect the relay from the wire harness 2 Connect the digital...

Page 450: ... Negative tester probe Result Continuity between 1 and 2 No continuity between 1 and 3 1 2 G R Br Y W Y Y B Br L B 2 1 3 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe 5 Negative tester probe Result Continuity between 3 and 5 No continuity between 3 and 4 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negat...

Page 451: ...ive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 R R L R B L Y G R G Y L Y Lg 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 prob...

Page 452: ... Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result No continuity between 3 and 4 R Br L R L Y Br G Y Lg B B 1 Positive tester probe 2 Negative tester probe 3 Negative tester probe Result Continuity between 1 and 2 No continuity between 1 and 3 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe 5 Negative tester pro...

Page 453: ...een 1 and 3 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe 5 Negative tester probe Result No continuity between 3 and 4 Continuity between 3 and 5 R B Br P B 1 3 2 R B 1 2 3 5 4 R B Br P B R B 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 1 Positive t...

Page 454: ...Negative tester probe 3 Negative tester probe A XP560E B XP560D 1 2 3 4 G Y Y Br R B Br R R G O L A 1 2 3 R B R B R G O L 1 2 3 B Result Continuity between 1 and 2 No continuity between 1 and 3 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe 5 Negative tester probe A XP560E B XP560D Result No continuity between 3 and 4 Continuity between 3 an...

Page 455: ... Continuity between 1 and 2 No continuity between 1 and 3 Br B Br R R L R G 1 2 3 A Br B R B R L R G 1 2 3 B 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe 5 Negative tester probe A XP560E B XP560D Result No continuity between 3 and 4 Continuity between 3 and 5 Br B Br R R L R G 3 4 2 1 5 A Br B R B R L R G 3 4 2 1 5 B ...

Page 456: ...er probe Brown 2 Negative tester probe Green Red Blue White 1 Diode 2 Continuity Positive tester probe Red Black 3 Negative tester probe Blue Yellow 4 No continuity Positive tester probe Blue Yellow 4 Negative tester probe Red Black 3 Diode 3 Continuity Positive tester probe Black White 5 Negative tester probe Red White 6 No continuity Positive tester probe Red White 6 Negative tester probe Black ...

Page 457: ...f specification Replace a Remove the spark plug cap from the spark plug lead b Connect the digital circuit tester to the spark plug cap as shown c Measure the spark plug cap resistance EAS30558 CHECKING THE IGNITION COIL 1 Check Primary coil resistance Out of specification Replace a Disconnect the ignition coil connectors from the ignition coil terminals b Connect the digital circuit tester to the...

Page 458: ...isconnect the spark plug cap from the spark plug b Connect the ignition checker 1 as shown c Push the ON start switch and the engine stop switch to d Measure the ignition spark gap a e Crank the engine by pushing the ON start switch and gradually increase the spark gap until a misfire occurs Digital circuit tester CD732 90890 03243 Model 88 Multimeter with tachometer YU A1927 Positive tester probe...

Page 459: ...angle sensor and wire harness as shown b Connect the digital circuit tester DC V to the test harness lean angle sensor 6P c Push the ON start switch d When turn the lean angle sensor to 65 e Measure the lean angle sensor output volt age Crankshaft position sensor resistance 228 342 Digital circuit tester CD732 90890 03243 Model 88 Multimeter with tachometer YU A1927 Positive tester probe Gray 1 Ne...

Page 460: ...a Connect the digital circuit tester to the stator coil coupler as shown b Measure the stator coil resistance EAS30680 CHECKING THE RECTIFIER REGULATOR 1 Check Battery charging voltage Out of specification Check the stator coil condition If the stator coil does not have a problem replace the rectifier regulator Refer to CHECKING THE STATOR COIL on page 8 105 a Connect the digital circuit tester AC...

Page 461: ...l detection circuit 1 Check Fuel meter fuel level warning indicator 1 Push the ON start switch Fuel meter fuel level warning indicator comes on for a few seconds then goes off Fuel meter fuel level warning indicator is OK Fuel meter fuel level warning indicator does not come on Replace the meter assembly Fuel meter fuel level warning indicator flash es eight times then goes off for 3 seconds in a ...

Page 462: ...fied temperature e Measure the coolant temperature sensor resistance 3 Install Coolant temperature sensor EAS30581 CHECKING THE THROTTLE POSITION SENSOR 1 Remove Throttle position sensor from the throttle bodies 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 2 C...

Page 463: ...r position sensor terminals as shown b Measure the accelerator position sensor maximum resistance 3 Install Accelerator position sensor EAS30592 CHECKING THE THROTTLE SERVO MOTOR 1 Remove Air filter case Refer to GENERAL CHASSIS 3 on page 4 17 2 Check Throttle valve operation Throttle valves do not fully close Replace the throttle bodies a Connect two C size batteries to the throttle servo motor t...

Page 464: ... 1 Check Grip warmer resistance Out of specification Replace the grip warmer a Disconnect the grip warmer coupler from the wire harness b Connect the digital circuit tester to the grip warmer coupler as shown A Check that the throttle valves 2 fully close B Check that the throttle valves 2 open 1 1 3V 2 A 1 1 3V 1 3V B 2 R Br A 1 1 A 2 2 A Check that the windshield drive unit arms 2 up B Check tha...

Page 465: ...he test harness S pressure sensor 3P coupler a b Connect the digital circuit tester to the test harness S pressure sensor 3P c Push the ON start switch d Measure the intake air pressure sensor out put voltage Positive tester probe Black 1 Negative tester probe Black 2 Rider seat resistance 8 8 10 8 Digital circuit tester CD732 90890 03243 Model 88 Multimeter with tachometer YU A1927 Positive teste...

Page 466: ...ol down to the specified temperatures e Measure the intake air temperature sensor resistance 3 Install Intake air temperature sensor EAS30681 CHECKING THE FUEL INJECTOR 1 Check Fuel injector resistance Out of specification Replace the fuel injec tor a Disconnect the fuel injector coupler from wire harness b Connect the digital circuit tester to the fuel injector coupler c Measure the fuel injector...

Page 467: ...ace a Disconnect the seat fuel lid lock solenoid from the wire harness b Connect the battery DC 12 V as shown c Check the seat fuel lid lock solenoid move ment EAS32450 CHECKING THE STORAGE COMPARTMENT LID LOCK SOLENOID for XP560D 1 Check Storage compartment lid lock solenoid Faulty rough movement Replace a Disconnect the storage compartment lid lock solenoid from the wire harness b Connect the ba...

Page 468: ...8 113 ELECTRICAL COMPONENTS c Check the storage compartment lid lock so lenoid movement B Br 1 2 ...

Page 469: ... OPERATION 9 20 BASIC INSTRUCTIONS FOR TROUBLESHOOTING 9 21 BASIC PROCESS FOR TROUBLESHOOTING 9 22 A CHECKING THE CRUISE CONTROL SYSTEM INDICATOR LIGHT 9 23 B 1 DIAGNOSIS USING THE DTC 9 23 B 2 DIAGNOSIS USING THE MALFUNCTION HISTORY CODES 9 23 B 3 MALFUNCTION HISTORY IS NOT DISPLAYED 9 23 C 1 ERASING THE DTC 9 25 C 2 FINAL CHECK 9 25 ABS Anti lock Brake System 9 26 CIRCUIT DIAGRAM 9 26 ABS COMPON...

Page 470: ...ABLE FOR ABS Anti lock Brake System 9 53 COMMUNICATION ERROR WITH THE METER 9 58 DIAGNOSTIC CODE SENSOR OPERATION TABLE 9 58 DIAGNOSTIC CODE ACTUATOR OPERATION TABLE 9 62 EVENT CODE TABLE 9 63 30_EVENT 9 66 TROUBLESHOOTING 9 66 70_EVENT 9 68 TROUBLESHOOTING 9 68 P0030 9 69 TROUBLESHOOTING 9 69 P00D1 P2195 9 73 TROUBLESHOOTING 9 73 P0107 P0108 9 77 TROUBLESHOOTING 9 77 P0112 P0113 9 81 TROUBLESHOOT...

Page 471: ... 9 112 TROUBLESHOOTING 9 112 P0500 9 115 TROUBLESHOOTING 9 115 P0507 9 119 TROUBLESHOOTING 9 119 P0560 P0563 9 121 TROUBLESHOOTING 9 121 P0564 9 122 TROUBLESHOOTING 9 122 P056C 9 128 TROUBLESHOOTING 9 128 P0601 9 136 TROUBLESHOOTING 9 136 P0606 9 137 TROUBLESHOOTING 9 137 P062F 9 138 TROUBLESHOOTING 9 138 P0638 9 140 TROUBLESHOOTING 9 140 ...

Page 472: ... P2138 9 158 TROUBLESHOOTING 9 158 P2158 9 162 TROUBLESHOOTING 9 162 U0155 or Err 9 166 TROUBLESHOOTING 9 166 11 25_ABS 9 169 TROUBLESHOOTING 9 169 12_ABS 9 170 TROUBLESHOOTING 9 170 13 26_ABS 9 171 TROUBLESHOOTING 9 171 14 27_ABS 9 172 TROUBLESHOOTING 9 172 15_ABS 9 173 TROUBLESHOOTING 9 173 16_ABS 9 175 TROUBLESHOOTING 9 175 17 45_ABS 9 177 TROUBLESHOOTING 9 177 ...

Page 473: ...S 9 186 TROUBLESHOOTING 9 186 33_ABS 9 187 TROUBLESHOOTING 9 187 34_ABS 9 189 TROUBLESHOOTING 9 189 41_ABS 9 190 TROUBLESHOOTING 9 190 42 47_ABS 9 191 TROUBLESHOOTING 9 191 43_ABS 9 192 TROUBLESHOOTING 9 192 44_ABS 9 193 TROUBLESHOOTING 9 193 51 52_ABS 9 194 TROUBLESHOOTING 9 194 53_ABS 9 195 TROUBLESHOOTING 9 195 54_ABS 9 197 TROUBLESHOOTING 9 197 ...

Page 474: ...55_ABS 9 199 TROUBLESHOOTING 9 199 56_ABS 9 200 TROUBLESHOOTING 9 200 63_ABS 9 201 TROUBLESHOOTING 9 201 64_ABS 9 203 TROUBLESHOOTING 9 203 ...

Page 475: ...DTC is a code that is saved within a control unit s memory when the control unit detects an abnormal condition If the abnormal condition continues a malfunction may be determined Driving cycle Driving cycle is the duration from the ON start switch is pushed OBD requirements are met and until the OFF lock switch is pushed FFD Freeze frame data FFD is the data of all signal sensors saved at the mome...

Page 476: ... cause the occurrence of the warning light coming on without malfunction Reprogramming of the ECU software Using the electrical accessory which may affect the ECU Using the incorrect specification of spark plug and fuel injector Using the third party accessories such as suspension and exhaust system Change of specifications of drive belt drive pulley wheel and tire Removing or modifying the O2 sen...

Page 477: ...e protective cap 1 and then connect the YDT to the coupler EAS32864 PARTS CONNECTED TO THE ECU The following parts are connected to the ECU When checking for a power short circuit the couplers must be disconnected from all of the following parts beforehand Yamaha diagnostic tool USB 90890 03267 Yamaha diagnostic tool A I 90890 03264 Crankshaft position sensor Fuel pump Injector 1 Lean angle sensor...

Page 478: ...ing for a power short circuit the couplers must be disconnected from all of the following parts beforehand EAS33137 PRECAUTIONS FOR ROAD TEST WARNING EWA20860 When test riding the vehicle always comply with local traffic regulations ABS solenoid fuse Rear wheel sensor ABS motor fuse Meter assembly ABS ECU fuse ECU Engine Control Unit Front wheel sensor ...

Page 479: ...ise control power switch 29 Cruise control setting switch RES 28 Cruise control setting switch SET 25 Front brake light switch 26 Rear brake light switch 31 Crankshaft position sensor 32 Intake air pressure sensor 33 Coolant temperature sensor 34 Intake air temperature sensor 36 Lean angle sensor 35 O2 sensor 30 Grip cancel switch 12 ON start switch 11 Starting circuit cut off relay 24 Brake light...

Page 480: ...ccelerator position sensor 38 Accelerator position sensor 37 Throttle position sensor 37 Throttle position sensor 50 Headlight control unit 47 Radiator fan motor relay 45 Grip warmer left 1 ECU Engine Control Unit 46 Grip warmer right 52 CAN communication circuit 37 40 19 28 77 61 43 56 49 35 42 51 54 105 107 ...

Page 481: ... 24 Brake light fuse 25 Front brake light switch 26 Rear brake light switch 27 Cruise control power switch 28 Cruise control setting switch SET 29 Cruise control setting switch RES 30 Grip cancel switch 31 Crankshaft position sensor 32 Intake air pressure sensor 33 Coolant temperature sensor 34 Intake air temperature sensor 35 O2 sensor 36 Lean angle sensor 37 Throttle position sensor 38 Accelerat...

Page 482: ...B 16 Injector 1 R B 17 Joint coupler B 18 Electronic throttle valve fuse R L 19 Radiator fan motor relay Y R 20 21 22 23 24 25 Joint coupler B 26 Battery charger ter minal seat heater relay power wind shield motor fuse joint coupler igni tion system relay radiator fan motor fuse fuel injection system fuse back up fuse electronic throttle valve fuse R 27 28 Diode 1 Y W 29 Fuel injection sys tem rel...

Page 483: ... 70 Lean angle sensor Y G 71 72 Joint coupler L 73 74 75 No Connected parts Wireharness color 76 Crankshaft position sensor B Y 77 Joint coupler Lg L 78 79 80 81 82 Handlebar switch left R G 83 Handlebar switch left G L 84 O2 sensor Gy G 85 86 Intake air tempera ture sensor Br W 87 88 Joint coupler B L 89 90 91 92 93 94 95 Remote control unit sidestand relay sidestand switch Lg 96 Diode 1 sidestan...

Page 484: ...9 10 SYSTEM DIAGRAM 107 ABS ECU Electron ic Control Unit W G 108 No Connected parts Wireharness color ...

Page 485: ...9 11 SYSTEM DIAGRAM ...

Page 486: ... B B B B L B L Br B L R W Y R Y W Y Br Y BL B Lg B B B B B G B B G B R B R B R B R B R B R B R W B R R B B L L L L Y Y Y B Y B B B W W R R R R Y B Y B L Y L Y R R B L B L W W Gy G Gy G Y R Y R Y Y Lg W Lg W Lg L Lg L Lg W Lg W B B B B Br L Br L Br L Br L Br L Br L B W B W O O L Y L Y R G R G R G R G R G R G Br B B R G R G R G B R L R L R G R W R L R L R L R L R L R L R L R L B G B G B B B B B B B ...

Page 487: ... 57 ECU Engine Control Unit 58 Ignition coil 59 Spark plug 60 Grip warmer connector 61 Grip warmer left OPTION 62 Grip warmer right OPTION 63 Coolant temperature sensor 64 Intake air temperature sensor 65 Intake air pressure sensor 66 Lean angle sensor 67 O2 sensor 68 Injector 1 69 Injector 2 70 Throttle servo motor 71 Accelerator position sensor 72 Throttle position sensor 74 Fuel pump 76 Rear wh...

Page 488: ...B W R G Lg W B W B W B W B W B B B B B B W B B B B L B L Br B L R W Y R Y W Y Br Y BL B Br Lg B G Y B Br Y R W Br W R B R W Br Y R B Br W Lg B B B B B G B B G R Y V Y L Gy Y B R Y Ch Y L B B Dg Y B B R B R B R B R B R B R B R W R W R W R W B R R B B L L L L Y Y Y B Y B B B W W R R R R Y B Y B L Y L Y R R B L B L W W Gy G Gy G Y R Y R Y Y Lg W Lg W Lg L Lg L Lg W Lg W B B B B Br L Br B Br B Br L Br...

Page 489: ...68 High beam indicator light 69 Multi function display 70 ECU Engine Control Unit 71 Ignition coil 72 Spark plug 73 Grip warmer connector 74 Grip warmer left 75 Grip warmer right 76 Coolant temperature sensor 77 Intake air temperature sensor 78 Intake air pressure sensor 79 Lean angle sensor 80 O2 sensor 81 Injector 1 82 Injector 2 83 Throttle servo motor 84 Accelerator position sensor 85 Throttle...

Page 490: ...eck and repair it according to applicable troubleshooting When pushing the ON start switch does the MIL come on Does the MIL LED work properly B Perform the checking with the diagnostic mode Check the MIL LED The MIL goes off after 2 seconds Still on flash A Check the DTC Do the troubleshooting according to the DTCs of malfunction Check the DTCs of malfunction are not displayed on the screen Finis...

Page 491: ... MIL DOES NOT COME ON BUT THE ENGINE OPERATION IS NOT NORMAL 1 Monitor the operation of these sensors and actuators by using the YDT in the diagnostic mode Refer to DIAGNOSTIC CODE SENSOR OPERATION TABLE on page 9 58 and DIAGNOSTIC CODE ACTUATOR OPERATION TABLE on page 9 62 If a malfunction is detected in the sensors or actuators repair or replace all faulty parts If no malfunction is detected in ...

Page 492: ...W Gy G G L R G Lg L W G W Y G R Lg B L W Lg Lg L B W R G Lg W B W B W B W B W B B B B B B W B B B B B G B B G B R W R W B R R L Y L Y W L W L W R W R W G W G Lg W Lg W Lg L Lg L Lg W Lg W B Br L Br B Br B Br L Br L Br L B R B W B W R G R G R G R G R G R G G W Y W Y W R G R G R G Y W Y W R G Br Br G L G L R G Br L R G R G Y B Y B B W B W B W B W B W Lg L Lg L R G R W R W Lg L Lg L Y L Y L O W O W R...

Page 493: ...ake light switch 43 Rear brake light switch 44 Grip cancel switch 55 Meter assembly 64 Cruise control system indicator light 65 Cruise control setting indicator light 69 Multi function display 70 ECU Engine Control Unit 91 YDT coupler 95 Handlebar switch left 96 Cruise control power switch 97 Cruise control setting switch 100 Menu switch 101 Select switch 113 Cruise control fuse A Wire harness B N...

Page 494: ...on meter 14 Grip cancel switch 17 ECU Engine Control Unit 19 Cruise control system indicator light 20 Cruise control setting indicator light 1 Battery 2 Main fuse 3 Ignition system relay 4 Backup fuse 5 Fuel injection system fuse 6 Signaling system fuse 7 Brake light fuse 8 Ignition fuse 9 Cruise control system fuse 10 Cruise control power switch 11 Cruise control setting switch 12 Front brake lig...

Page 495: ...tart switch and then check the DTC of mal function is not displayed TIP If another DTC is displayed repeat steps 1 to 3 until no DTC is displayed Push the OFF LOCK switch will not erase the malfunction history 4 Do the final check 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 ord...

Page 496: ... control system to the customer Finished Is there automatic deactivation history for the cruise control system Check the malfunction history using the malfunction mode of the YDT Is there any malfunction history Diagnosis using the DTC Yes Yes OK The cruise control power switch is defective The cruise control system fuse is blown The ECU is defective Delete the DTC Final check Return to A Return t...

Page 497: ...unction mode of the YDT Malfunction history is displayed on the YDT B 1 Malfunction history is not displayed on the YDT B 3 EAS32882 B 3 MALFUNCTION HISTORY IS NOT DISPLAYED Use the YDT to check whether automatic deactivation history for the cruise control system exists 1 There is automatic deactivation history for the cruise control system Explain the conditions for automatically deactivating the...

Page 498: ...m may not be able to maintain the set cruising speed When going uphill the actual traveling speed may become lower than the set cruising speed If this occurs accelerate to the desired traveling speed using the throttle When going downhill the actual traveling speed may become higher than the set cruising speed If this occurs the setting switch cannot be used to adjust the set cruising speed To red...

Page 499: ...he rear brake light switches Refer to CHECKING THE SWITCHES on page 8 91 3 Execute the diagnostic mode DTC No 82 and 83 to check the operation of the front brake light switch rear brake light switch and grip cancel switch Refer to DIAGNOSTIC CODE SENSOR OPERATION TABLE on page 9 58 4 Execute the diagnostic mode DTC No 80 and 81 to check the operation of the cruise control set ting switch Refer to ...

Page 500: ...B B B B B B W B B B Y W Y Br Y BL B B B G B B G B R W R W B W W W B B B B B G W W R R R R L Y L Y Lg W Lg W Lg W Lg W Lg L Lg L Lg W Lg W B B B Br L Br B Br B Br L Br L Br L Br L Br L B W R G R G R G R G R G R G R G R G Br Br Br Br R G R G R G R G G Y G Y G Y G Y G Y B L B L Br Br B Br Lg L Lg L R G R W R W G R G R R L R L R W R W G Y B W B W B G B G B W B W B W B W Lg L Lg L R G W Y W Y B B B R G...

Page 501: ... 39 Front brake light switch 40 Headlight relay dimmer 44 Meter assembly 54 ABS warning light 56 Multi function display 57 ECU Engine Control Unit 75 Front wheel sensor 76 Rear wheel sensor 77 ABS ECU Electronic Control Unit 78 YDT coupler 82 Handlebar switch left 83 Rear brake light switch 89 Tail brake light 100 ABS solenoid fuse 101 ABS motor fuse 105 ABS ECU fuse A Wire harness B Negative batt...

Page 502: ... W B W B W B W B B B B B B W B B B Y W Y Br Y BL B Br Lg B G Y B B B G B B G B R W R W B W W W B B B B B G W W R R R R L Y L Y Lg W Lg W Lg W Lg W Lg L Lg L Lg W Lg W B B B Br L Br B Br B Br L Br L Br L Br L Br L B W R G R G R G R G R G R G R G R G Br Br Br G W Y W Y W Br Lg B Lg B R G R G R G R G Br Br G Y G Y B L B L Br Br B Lg L Lg L R G R W R W G R G R R L R L R W R W G Y B W B W B G B G B W B...

Page 503: ...immer 40 Brake light relay 41 Brake light fuse 42 Front brake light switch 43 Rear brake light switch 55 Meter assembly 67 ABS warning light 69 Multi function display 70 ECU Engine Control Unit 88 Front wheel sensor 89 Rear wheel sensor 90 ABS ECU Electronic Control Unit 91 YDT coupler 103 Tail brake light 115 ABS solenoid fuse 116 ABS motor fuse 120 ABS ECU fuse A Wire harness B Negative battery ...

Page 504: ... 6 7 2 8 10 9 1 4 4 3 1 YDT coupler 2 ABS warning light 3 Fuse box ABS motor fuse ABS solenoid fuse and ABS ECU fuse 4 ABS ECU 5 Front wheel sensor rotor 6 Front wheel sensor 7 Front brake caliper 8 Rear brake caliper 9 Rear wheel sensor 10 Rear wheel sensor rotor ...

Page 505: ...L B WR GR G W B B W G W W Y G R Lg Lg B L B Lg LLg W B B G W B W B Gy W Gy W 5 6 1 2 3 4 R W R L G Y Br W R Lg LB W R GLg W Gy O L R L Br Y Ch Dg R GR W Gy V Gy WV W G RG L G W GW R W L Y B WLg WLg L B W R GR G 1 Rear wheel sensor coupler 2 Meter assembly coupler for XP560E 3 Meter assembly coupler for XP560D 4 YDT coupler 5 Front wheel sensor coupler 6 ABS ECU coupler ...

Page 506: ...final check before delivering the vehicle to the customer TIP To final check refer to C 1 FINAL CHECK on page 9 37 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 ABS self diagnosis has not been completed The ABS self diagnosis starts when the ON start swi...

Page 507: ...t to damage components by subjecting them to shocks or pulling on them with too much force since the ABS components are precisely adjusted The ABS ECU and hydraulic unit are united assemblies and cannot be disassembled The malfunction history is stored in the memory of the ABS ECU Delete the DTC when the service is finished This is because the past DTC will be displayed again if another malfunctio...

Page 508: ...Were all of the final checks completed normally The reaction force generated during brake line routing confirmation is incorrect Refer to C 1 FINAL CHECK The brake hoses and brake pipes are not connected correctly The ABS warning light does not go off when the light is checked Refer to C 1 FINAL CHECK The malfunction is not corrected There is a break in the wire harness between the ABS ECU and the...

Page 509: ...N start switch for continuity Refer to CHECKING THE SWITCHES on page 8 91 If there is no continuity replace the handlebar switch right 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 94 If the battery is defective clean the battery terminals and recharge it or replace the battery 3 Main fuse Check the fuse for continuity Refer to CHECKING THE FUSES...

Page 510: ...ly EAS32902 A 5 ABS ECU AND FI ECU FAIL TO COMMUNICATE 1 YDT Check that the YDT is properly connected 2 Wire harness Open circuit in the wire harness between the ABS ECU coupler and the YDT coupler Check for continuity between light green blue terminal of the ABS ECU coupler and light green blue terminal of the YDT coupler CANH Check for continuity between light green white terminal of the ABS ECU...

Page 511: ...brake master cylinder reservoir Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 14 2 Check the wheel sensors for proper installation Refer to INSTALLING THE FRONT WHEEL DISC BRAKE on page 4 27 and INSTALLING THE REAR WHEEL DISC BRAKE on page 4 35 3 Perform brake line routing confirmation Refer to HYDRAULIC UNIT OPERATION TEST on page 4 70 If it does not have reaction force properly the brake hos...

Page 512: ...ssembly defective sole noid drive circuit 24_ABS Brake light switch or tail brake light 30_EVENT Latch up detected Unable Unable D08 31_ABS Hydraulic unit assembly abnormal ABS solenoid power supply 32_ABS Hydraulic unit assembly short circuit in ABS solenoid power supply circuit 33_ABS Hydraulic unit assembly abnormal ABS motor power supply 34_ABS Hydraulic unit assembly short circuit in ABS moto...

Page 513: ...essure sensor ground short circuit detected P0108 Intake air pressure sensor open or power short circuit detected Able Able P0112 P0113 P0112 Intake air temperature sensor ground short circuit detected P0113 Intake air temperature sensor open or power short circuit detected Able Able D05 P0117 P0118 P0117 Coolant temperature sensor ground short circuit detected P0118 Coolant temperature sensor ope...

Page 514: ...g voltage is abnormal P0563 Vehicle system power voltage out of range Able Able P0564 Cruise control setting switch RES open or short circuit is detected Cruise control setting switch SET open or short circuit is detected Able Able D80 D81 P056C Front brake light switch open or short circuit is detected Rear brake light switch open or short circuit is detected Able Able D82 D83 P0601 Internal malf...

Page 515: ...tor position sensor open or ground short circuit detected P2123 Accelerator position sensor power short circuit detected P2127 Accelerator position sensor ground short circuit detected P2128 Accelerator position sensor open or power short circuit detected P2138 Accelerator position sensor output voltage deviation error Able Unable Able Unable D14 D15 P2158 Front wheel sensor no normal signals are ...

Page 516: ...tected Open or short cir cuit in wire har ness Disconnected cou pler Defective O2 sen sor heater control ler Malfunction in ECU Broken or discon nected lead in O2 sensor heater When the O2 sen sor does not oper ate because the exhaust tempera ture is low Increased exhaust emissions Fuellearningcannot be carried out Display only If the O2 sensor does not operate O2 feed back is not carried out Crui...

Page 517: ...C learning is not carried out Cruise control sys tem cannot be oper ated P0112 P0113 P0112 Intake air temperaturesensor ground short circuit detected P0113 Intake air temperaturesensor open or power short circuit detected P0112 Lowvoltage of the intake air tem perature sensor cir cuit 0 1 V or less P0113 High volt age of the intake air temperature sensor circuit 4 8 V or more Defective coupler bet...

Page 518: ...r short cir cuit in wire har ness between coolant tempera ture sensor and ECU Improperly in stalled coolant temperature sen sor Defective coolant temperature sen sor Malfunction in ECU Engine is difficult to start Increased exhaust emissions Engine idling speed is unstable The radiator fan mo tor relay is on only when the vehicle is traveling at low speeds O2 feedback is not carried out ISC feedba...

Page 519: ... speed is high Engine idling speed is unstable Engine response is poor Loss of engine pow er Deceleration is poor Increased exhaust emissions Vehicle cannot be driven Change in the throt tle opening is 0 transient control is not carried out D j is fixed Throttle opening is fixed to 125 Intake air pressure is fixed to 101 3 kPa O2 feedback is not carried out Fuel is not cut off due to the throttle ...

Page 520: ...rankshaftposition sensor and ECU Improperly in stalled crankshaft position sensor Malfunction in generator rotor Defective crank shaft position sen sor Malfunction in ECU Engine cannot be started Does not operate ISC feedback is not carried out ISC learning is not carried out Cruise control sys tem cannot be oper ated P0351 Ignition coil open or short circuit detect ed in the primary lead of the i...

Page 521: ...not displayed on the meter Engine idling speed is unstable Traction control does not work Vehicle speed dis played on the meter 0 km h O2 feedback is not carried out Fuel cut off control when the rear wheel sensor or neutral switch malfunctions is carried out ISC feedback is not carried out ISC learning is not carried out Traction control does not work Cruise control sys tem cannot be oper ated P0...

Page 522: ...ess Defective cruise control setting switch Malfunction in ECU Cruise control sys tem cannot be oper ated Cruise control sys tem cannot be oper ated P056C Front brake light switch open or short circuit is de tected Rear brake light switch open or short circuit is de tected Open or short cir cuit in wire har ness Defective cruise control setting switch Malfunction in ECU Cruise control sys tem cann...

Page 523: ...ut is restricted Cruise control sys tem cannot be oper ated P062F EEPROM DTC an error is detected while reading or writing on EE PROM CO adjustment value is not prop erly written ISC learning value is not properly writ ten O2 feedback learn ing value is not properly written OBD memory val ue is not properly written Malfunction in ECU Increased exhaust emissions Engine cannot be started or is diffi...

Page 524: ...uit in wire har ness between fuel injection system relay and ECU Open circuit in wire harness between battery and ECU Defective fuel in jection system re lay Malfunction in ECU Engine is difficult to start Increased exhaust emissions Monitor voltage 12 V O2 feedback is not carried out Cruise control sys tem cannot be oper ated P1601 Sidestand switch open or short circuit of the light green lead of...

Page 525: ...is not carried out O2 feedback learn ing value is not writ ten Cruise control sys tem cannot be oper ated P1604 P1605 P1604 Lean angle sensor ground short circuit detect ed P1605 Lean angle sensor open or power short circuit P1604 Lowvoltage of the lean angle sensor circuit 0 2 V or less P1605 High volt age of the lean an gle sensor circuit 4 8 V or more Open or short cir cuit in wire har ness bet...

Page 526: ...CU Engine response is poor Loss of engine pow er Engine idling speed is unstable No change in accel erator opening transient control is not carried out Accelerator open ing is fixed to 0 O2 feedback is not carried out YCC T evacuation is activated Fuel cut is prohibit ed by accelerator opening Output is restricted ISC feedback is not carried out ISC learning is not carried out Cruise control sys t...

Page 527: ...y while the vehicle is traveling Foreign material ad hered around the rear wheel sensor Incorrect installation of the rear wheel Defective sensor rotor or incorrect installation of the rotor Defective rear wheel sensor or incorrect in stallation of the sensor 13 26 Front wheel sensor ab normal pulse period Front wheel sensor signal is not received properly The pulse period is ab normal while the v...

Page 528: ...sor miss ing pulses Front wheel sensor signal is not received properly Missing pulses are de tected in the signal while the vehicle is traveling Foreign material ad hered around the front wheel sensor Incorrect installation of the front wheel Defective sensor rotor or incorrect installation of the rotor Defective front wheel sensor or incorrect in stallation of the sensor 18 46 Rear wheel sensor m...

Page 529: ...coupler be tween the battery and the hydraulic unit assembly Open or short circuit in the wire harness be tween the battery and the hydraulic unit assembly Defective hydraulic unit assembly 32 Hydraulic unit assembly short circuit in ABS sole noid power supply circuit Short circuit is detected in the solenoid power supply circuit in the hydraulic unit assembly Defective hydraulic unit assembly 33 ...

Page 530: ...Front wheel sensor miss ing pulses Front wheel sensor signal is not received properly Missing pulses are de tected in the signal while the vehicle is traveling Foreign material ad hered around the front wheel sensor Incorrect installation of the front wheel Defective sensor rotor or incorrect installation of the rotor Defective front wheel sensor or incorrect in stallation of the sensor 44 Rear wh...

Page 531: ...aulic unit assembly Defective charging sys tem Defective hydraulic unit assembly 55 Hydraulic unit assembly defective ABS ECU Abnormal data is detected in the hydraulic unit as sembly Defective hydraulic unit assembly 56 Hydraulic unit assembly abnormal internal power supply Abnormality is detected in the power supply circuit in the hydraulic unit assem bly Defective hydraulic unit assembly 63 Fro...

Page 532: ...rol sys tem cannot be oper ated Diagnostic code No Item Tool display Procedure D01 Throttle position sensor signal 1 Fully closed position 11 20 Check with throttle valves fully closed Fully open position 95 106 Check with throttle valves fully open D03 Intake air pressure Displays the intake air pressure Operate the throttle while pushing the ON start switch If the display value changes the perfo...

Page 533: ... position 93 109 Check with throttle valves fully open D14 Accelerator position sen sor signal 1 Fully closed position 11 20 Check with throttle grip fully closed position Fully open position 95 106 Check with throttle grip fully open position D15 Accelerator position sen sor signal 2 Fully closed position 9 23 Check with throttle grip fully closed position Fully open position 93 109 Check with th...

Page 534: ...ion display ISC Idle Speed Control learning data erasure 00 ISC Idle Speed Control learning data has been erased 01 It is not necessary to erase the ISC Idle Speed Con trol learning data 02 It is necessary to erase the ISC Idle Speed Control learning data To erase the ISC Idle Speed Control learning data set the engine stop switch from to 3 times in 5 seconds D70 Control number 0 254 D80 Cruise co...

Page 535: ...direc tion ON Throttle grip is released OFF D83 Front brake light switch and rear brake light switch Operate the front brake lever and rear brake lever Front brake lever is squeezed ON Front brake lever is re leased OFF Rear brake lever is squeezed ON Rear brake lever is re leased OFF D87 O2 feedback learning data erasure 00 O2 feedback learning data has been erased 01 O2 feedback learning data ha...

Page 536: ...uel pump coupler before doing this procedure Check that injector 2 is actuated five times by lis tening for the operating sound D50 Fuel injection system relay Actuates the fuel injection system relay five times at one second intervals The check indicator on the YDT screen come on each time the relay is actu ated Check that the fuel injec tion system relay is actuat ed five times by listening for ...

Page 537: ...d P0118 Perform the inspection items listed for DTC No P0117 and P0118 197 Intake air tem perature sensor Brief abnormality detected in the in takeairtemperature sensor Same as for DTC No P0112 and P0113 Perform the inspection items listed for DTC No P0112 and P0113 203 Lean angle sen sor Brief abnormality detected in the lean angle sensor Same as for DTC No P1604 and P1605 Perform the checks and ...

Page 538: ...the sys tem is functioning properly 243 ISC Stuck at the lower limit for adjustment During idling the adjustment is main tained at the lower limit Idling engine speed is fast Poorly adjusted throt tle cable Malfunction in the fuel injection system Dirty or worn spark plug Malfunction in the battery Malfunction in ECU If a DTC is occurring respond to that first Rarely Code 243 oc curs even when the...

Page 539: ...rn off under the fol lowing conditions Unable to maintain the set cruising speed when traveling up a steep slope Wheel slip detected Engine stalls Sidestand is extend ed Engine stop switch is set to the posi tion The automatic turning off of the cruise control sys tem does not indicate a malfunction in the sys tem No Item Symptom Possible causes Note ...

Page 540: ... of the sensor 3 Defective lean angle sensor Execute the diagnostic mode Code D08 Check the lean angle sensor output voltage Is the MIL on YES Go to step 2 NO Service is completed Is check result OK YES Go to step 3 NO a Fix the lean angle sensor installation condition b Push the ON start switch then push the OFF LOCK switch and then push the ON start switch Is the MIL on YES Go to step 3 NO Servi...

Page 541: ...9 67 30_EVENT 4 Malfunction in ECU Replace the ECU and complete the service Refer to REPLACING THE ECU Engine Control Unit on page 8 93 Is the MIL on YES Go to step 4 NO Service is completed ...

Page 542: ...is displayed at the same time check the other error code first and repair it 1 Allow to idle for a long period Push the OFF LOCK switch Check whether it is possible to start the engine 2 Malfunction in ECU Replace the ECU and complete the service Refer to REPLACING THE ECU Engine Control Unit on page 8 93 Can the engine starting YES Service is completed NO Go to step 2 ...

Page 543: ...ition of the pins TIP For this check also set the engine stop switch to ON 2 Connection of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Push the ON start switch and then check ...

Page 544: ...ed condition YES Go to step 6 and complete the service NO Start the engine and then check the condition of the DTC Is it in the Recovered condition YES Go to step 6 and complete the service NO Go to step 3 Between O2 sensor coupler 1 and ECU cou pler 2 black green black green Between O2 sensor coupler 1 and fuel injec tion system relay coupler 3 red blue red blue Is resistance 0 YES Go to Short ci...

Page 545: ...tep 6 and complete the service NO Go to Short circuit check Between O2 sensor coupler 1 and ground red blue ground black green ground O2 sensor coupler 1 red blue any other coupler terminal black green any other coupler terminal ECU coupler 2 black green any other coupler terminal Fuel injection system relay coupler 3 red blue any other coupler terminal Is resistance YES Go to step 4 NO a Replace ...

Page 546: ...ontrol Unit on page 8 93 6 Delete the DTC and check that the MIL goes off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC Is it in the Recovered condition YES Go to step 6 and complete the service NO Start the engine and then check the condition of the DTC Is it in the Recovered condition YES Go to step 6 and complete the service NO Go to step 4 Is it in the...

Page 547: ...s bent or broken terminals and locking condition of the pins Is check result OK YES Go to step 2 NO a Reinstall or replace the O2 sensor Refer to ENGINE REMOVAL on page 5 7 b Start the engine and let it idle for approximately 1 minute c Check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 8 and complete the service NO Go to step 2 Is ...

Page 548: ...YDT Is it in the Recovered condition YES Go to step 8 and complete the service NO Go to step 4 Between O2 sensor coupler 1 and ECU cou pler 2 black green black green gray green gray green black blue black blue Between O2 sensor coupler 1 and fuel injec tion system relay coupler 3 red blue red blue O B G Y R B R B G B Y W B Y R R L B B R L L Y Y W R B Y L Y G P Lg L O W W G Y L Lg W B L Br W Gy G G...

Page 549: ...r coupler terminal black blue any other coupler terminal ECU coupler 2 black green any other coupler terminal gray green any other coupler terminal black blue any other coupler terminal Fuel injection system relay coupler 3 red blue any other coupler terminal R L B G Gy GB L O B G Y R B R B G B Y W B Y R R L B B R L L Y Y W R B Y L Y G P Lg L O W W G Y L Lg W B L Br W Gy G G L R G Lg L W G W Y G R...

Page 550: ...e service NO Go to step 5 Is check result OK YES Go to step 6 NO a Replace the fuel pump Refer to REMOVING THE FUEL PUMP on page 7 3 b Start the engine and let it idle for approximately 1 minute c Check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 8 and complete the service NO Go to step 6 Is check result OK YES Go to step 7 NO a Re...

Page 551: ...ent or broken terminals and locking condition of the pins 3 Wire harness continuity Disconnect the intake air pressure sensor coupler and ECU coupler Open circuit check Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Push the ON start switch and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Re...

Page 552: ...s resistance 0 YES Go to Short circuit check NO a Replace the wire harness b Push the ON start switch and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to Short circuit check Between intake air pressure sensor coupler 1 and ground P0108 black blue ground P0107 P0108 pink ground P0108 blue g...

Page 553: ...S Go to step 4 NO a Replace the wire harness b Push the ON start switch and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to step 4 Is check result OK YES Go to step 5 NO a Reinstall or replace the sensor b Push the ON start switch and then check the condition of the DTC using the malfuncti...

Page 554: ...ition of Recovered using the YDT and then delete the DTC At sea level Approx 101 kPa 757 6 mmHg 29 8 inHg approx 3 64 V 1000 m 3300 ft above sea level Approx 90 kPa 675 1 mmHg 26 6 inHg approx 3 30 V 2000 m 6700 ft above sea level Approx 80 kPa 600 0 mmHg 23 6 inHg approx 3 00 V 3000 m 9800 ft above sea level Approx 70 kPa 525 0 mmHg 20 7 inHg approx 2 70 V Is check result OK YES Go to step 6 NO a...

Page 555: ...king condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness and or sub wire harness b Push the ON start switch and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condit...

Page 556: ...Y L Y G P W G Y L Lg W B L Br W Gy G Lg L W G W Y G R L W Lg B L Br W 1 2 2 XP560D XP560E Is resistance 0 YES Go to Short circuit check NO a Replace the wire harness b Push the ON start switch and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to Short circuit check Between intake air temper...

Page 557: ...L O W W G Y L Lg W B L Br W Gy G G L R G Lg L W G W Y G R Lg B L W Lg B Y L Y G P W G Y L Lg W B L Br W Gy G Lg L W G W Y G R L W Lg B L Br W B L Br W A B 1 1 2 2 XP560D XP560E Is resistance YES Go to step 4 NO a Replace the wire harness b Push the ON start switch and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and com...

Page 558: ...that the DTC has a condition of Recovered using the YDT and then delete the DTC Is check result OK YES Go to step 6 NO a Replace the intake air temperature sensor Refer to GENERAL CHASSIS 3 on page 4 17 b Push the ON start switch and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to step 6 ...

Page 559: ... the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Push the ON start switch and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to st...

Page 560: ... Y G P W G Y L Lg W B L Br W Gy G Lg L W G W Y G R L W Lg B L G R 2 2 1 XP560D XP560E Is resistance 0 YES Go to step Short circuit check NO a Replace the wire harness b Push the ON start switch and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to step Short circuit check Between coolant tem...

Page 561: ... G Y L Lg W B L Br W Gy G G L R G Lg L W G W Y G R Lg B L W Lg B Y L Y G P W G Y L Lg W B L Br W Gy G Lg L W G W Y G R L W Lg B L G R B L G R A B 1 1 2 2 XP560D XP560E Is resistance YES Go to step 4 NO a Replace the wire harness b Push the ON start switch and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the...

Page 562: ...rm that the DTC has a condition of Recovered using the YDT and then delete the DTC Is check result OK YES Go to step 6 NO a Replace the coolant temperature sensor Refer to CYLINDER HEAD on page 5 20 b Push the ON start switch and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to step 6 ...

Page 563: ...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 2 Connection of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Is the coupler condition normal YES Go to step 2 NO a Connect the coupler se...

Page 564: ...0222 blue blue P0122 P0123 P0222 P0223 P2135 white white P0123 P0223 black blue black blue P0122 P0123 P0222 P0223 P2135 black black Is resistance 0 YES Go to Short circuit check NO a Replace the wire harness b Push the ON start switch and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 9 and complete the service NO Go to Sh...

Page 565: ...22 P0222 blue any other coupler terminal P0122 P0123 P0222 P0223 P2135 white any other coupler terminal P0123 P0223 black blue any other coupler terminal P0122 P0123 P0222 P0223 P2135 black any other coupler terminal Is resistance YES Go to step 4 NO a Replace the wire harness b Push the ON start switch and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Reco...

Page 566: ... the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 9 and complete the service NO Go to step 5 Is check result OK YES Go to step 6 NO a Replace the throttle position sensor b Push the ON start switch and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 9 and complete...

Page 567: ...ecovered using the YDT and then delete the DTC Is it in the Recovered condition YES Go to step 9 and complete the service NO Go to step 7 When the throttle valves are fully closed 9 23 When throttle valves are fully open 93 109 Is check result OK YES Go to step 8 NO a Replace the throttle position sensor Refer to ADJUSTING THE THROTTLE POSITION SENSOR on page 7 13 b Push the ON start switch and th...

Page 568: ...erminals and locking condition of the pins Is check result OK YES Go to step 2 NO a Reinstall or replace the sensor b Push the ON start switch and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to step 2 Is the coupler condition normal YES Go to step 3 NO a Connect the coupler securely or re...

Page 569: ...then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to step 4 Between O2 sensor coupler 1 and ECU cou pler 2 black blue black blue gray green gray green B Y L Y G P Lg L O W W G Y L Lg W B L Br W Gy G G L R G Lg L W G W Y G R Lg B L W Lg B Y L Y G P W G Y L Lg W B L Br W Gy G Lg L W G W Y G R L W...

Page 570: ...rt circuit check Between O2 sensor coupler 1 and ground gray green ground black blue ground O2 sensor coupler 1 black blue any other coupler terminal gray green any other coupler terminal ECU coupler 2 black blue any other coupler terminal gray green any other coupler terminal R L B G Gy GB L B Y L Y G P Lg L O W W G Y L Lg W B L Br W Gy G G L R G Lg L W G W Y G R Lg B L W Lg B Y L Y G P W G Y L L...

Page 571: ...s resistance YES Go to step 5 NO a Replace the wire harness b Push the ON start switch and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to step 5 Is check result OK YES Go to step 6 NO a Replace the O2 sensor Refer to ENGINE REMOVAL on page 5 7 b Push the ON start switch and then check the...

Page 572: ... bent or broken terminals and locking condition of the pins 2 Defective injector 1 Measure the injector resistance Refer to CHECKING THE FUEL INJECTOR on page 8 111 Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Execute the diagnostic mode Code D36 Is it hear operating sound YES Go to step 6 NO Go to step 2 Is check result OK YES Go...

Page 573: ...ect the coupler securely or replace the wire harness b Execute the diagnostic mode Code D36 Is it hear operating sound YES Go to step 6 NO Go to step 4 Between injector 1 coupler 1 and ECU cou pler 2 red black red black Between injector 1 coupler and fuel injection system relay coupler 3 red blue red blue Is resistance 0 YES Go to Short circuit check NO a Replace the wire harness b Execute the dia...

Page 574: ...the DTC has a condition of Recovered using the malfunction mode of the YDT and then delete the DTC Between injector 1 coupler 1 and ground red black ground red blue ground Injector 1 coupler 1 red black any other coupler terminal red blue any other coupler terminal ECU coupler 2 red black any other coupler terminal Fuel injection system relay coupler 3 red blue any other coupler terminal Is resist...

Page 575: ... bent or broken terminals and locking condition of the pins 2 Defective injector 2 Measure the injector resistance Refer to CHECKING THE FUEL INJECTOR on page 8 111 Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Execute the diagnostic mode Code D37 Is it hear operating sound YES Go to step 6 NO Go to step 2 Is check result OK YES Go...

Page 576: ... the coupler securely or replace the wire harness b Execute the diagnostic mode Code D37 Is it hear operating sound YES Go to step 6 NO Go to step 4 Between injector 2 coupler 1 and ECU cou pler 2 green black green black Between injector 2 coupler 1 and fuel injec tion system relay coupler 3 red blue red blue Is resistance 0 YES Go to Short circuit check NO a Replace the wire harness b Execute the...

Page 577: ... DTC has a condition of Recovered using the malfunction mode of the YDT and then delete the DTC Between injector 2 coupler 1 and ground green black ground red blue ground Injector 2 coupler 1 green black any other coupler terminal red blue any other coupler terminal ECU coupler 2 green black any other coupler terminal Fuel injection system relay coupler 3 red blue any other coupler terminal Is res...

Page 578: ... harness continuity Disconnect the crankshaft position sensor coupler and ECU coupler Open circuit check Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Crank the engine and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to ste...

Page 579: ... resistance 0 YES Go to Short circuit check NO a Replace the wire harness b Crank the engine and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to Short circuit check Between crankshaft position sensor coupler 1 and ground black yellow ground black blue ground Crankshaft position sensor coup...

Page 580: ...L B Y B L 2 2 1 1 A B XP560D XP560E Is resistance YES Go to step 4 NO a Replace the wire harness b Crank the engine and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to step 4 Is check result OK YES Go to step 5 NO a Reinstall or replace the sensor b Crank the engine and then check the cond...

Page 581: ...U Engine Control Unit on page 8 93 7 Delete the DTC and check that the MIL goes off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC Is check result OK YES Go to step 6 NO a Replace the crankshaft position sensor b Crank the engine and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 a...

Page 582: ...nnect the ignition coil coupler and ECU coupler Open circuit check Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Start the engine and let it idle for approximately 5 seconds c Check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to step...

Page 583: ...let it idle for approximately 5 seconds c Check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to Short circuit check Between ignition coil coupler 1 and ground orange ground Ignition coil coupler 1 orange any other coupler terminal ECU coupler 2 orange any other coupler terminal O B G Y R B R B G B Y ...

Page 584: ...plete the service NO Go to step 4 Is check result OK YES Go to step 5 NO a Reinstall or replace the ignition coil b Start the engine and let it idle for approximately 5 seconds c Check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to step 5 Is check result OK YES Go to step 6 NO a Replace the ignition...

Page 585: ...irm that spark plug does not sparking Replace the ECU and complete the service Refer to REPLACING THE ECU Engine Control Unit on page 8 93 7 Delete the DTC and check that the MIL goes off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC ...

Page 586: ...the pins bent or broken terminals and locking condition of the pins Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Push the ON start switch and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 6 and complete the service NO Go to step 2 Is the coupler condition ...

Page 587: ...1 and ECU coupler 2 yellow red yellow red Is resistance 0 YES Go to Short circuit check NO a Replace the wire harness b Push the ON start switch and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 6 and complete the service NO Go to Short circuit check Between radiator fan motor relay coupler 1 and ground yellow red ground r...

Page 588: ...the MIL goes off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC Is resistance YES Go to step 4 NO a Replace the wire harness b Push the ON start switch and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 6 and complete the service NO Go to step 4 Is it in the Recovered condition YES G...

Page 589: ...n of the pins 3 Connection of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Execute the diagnostic mode Code D07 c Rotate the rear wheel by hand and check that the indicated val...

Page 590: ...l sensor coupler 1 and ABS ECU coupler 2 black black white white Between ABS ECU coupler 2 and ECU cou pler 3 white green white green B Y L Y G P Lg L O W W G Y L Lg W B L Br W Gy G G L R G Lg L W G W Y G R Lg B L W Lg B Y L Y G P W G Y L Lg W B L Br W Gy G Lg L W G W Y G R L W Lg B W G G R W Y W B B W R W B G B L Lg W Lg L Br W Lg Lg G Y R L B W 1 2 3 3 XP560D XP560E Is resistance 0 YES Go to Sho...

Page 591: ...white any other coupler terminal ABS ECU coupler 2 black any other coupler terminal white any other coupler terminal white green any other coupler terminal ECU coupler 3 white green any other coupler terminal B Y L Y G P Lg L O W W G Y L Lg W B L Br W Gy G G L R G Lg L W G W Y G R Lg B L W Lg B Y L Y G P W G Y L Lg W B L Br W Gy G Lg L W G W Y G R L W Lg B W B W G G R W Y W B B W R W B G B L Lg W ...

Page 592: ...otate the rear wheel by hand Start the engine and input the vehicle speed signals by operating the vehicle at 20 to 30 km h 12 to 19 mph Confirm that the DTC has a condition of Recovered using the malfunction mode of the YDT and then delete the DTC Delete this DTC even if it has a condition of Detected Is that value increased YES Go to step 7 NO Go to step 6 ...

Page 593: ...ODIES on page 7 10 Is check result OK YES Go to step 2 NO a Replace the throttle bodies b Start the engine and let it idle for approximately 5 minutes c Push the ON start switch and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 4 and complete the service NO Go to step 2 Is check result OK YES Go to step 3 NO a Execute the ...

Page 594: ...0 P0507 3 Malfunction in ECU Replace the ECU and complete the service 4 Delete the DTC and check that the MIL goes off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC ...

Page 595: ...efer to CHARGING SYSTEM on page 8 17 2 Delete the DTC and check that the MIL goes off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC Is check result OK YES Repeat step 1 NO a Defective rectifier regulator or AC magneto Replace b Defective connection in the charging system circuit Properly connect or replace the wire har ness c Start the engine and let it id...

Page 596: ...re from step 3 to step 5 and from step 9 to step 10 b Execute the diagnostic mode Code 81 c Confirm that it is defective d Go to step 6 Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Push the ON start switch and then push the RES side and SET side of the cruise control setting switch c Check the condition of the DTC using the malfun...

Page 597: ...uise control setting switch and then check the condi tion of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 10 and complete the service NO Go to step 4 Between ignition system relay coupler 1 and ignition fuse holder 2 brown blue brown blue Between ignition fuse holder 2 and handlebar switch coupler left 3 yellow black yellow black Between left handle...

Page 598: ...red condition YES Go to step 10 and complete the service NO Go to Short circuit check Between ignition system relay coupler 1 and ground brown blue ground Between handlebar switch coupler left 3 and ground red green ground yellow black ground Ignition system relay coupler 1 brown blue any other coupler terminal Handlebar switch coupler left 3 red green any other coupler terminal yellow black any o...

Page 599: ...RES side of the cruise control setting switch and then check the condi tion of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 10 and complete the service NO Go to step 5 Is it in the Recovered condition YES Go to step 10 and complete the service NO Go to step 9 Is check result OK YES Go to step 7 NO a Replace the fuse b Push the ON start switch c Push...

Page 600: ...handlebar switch coupler left 3 and ECU coupler 4 green blue green blue Is resistance 0 YES Go to Short circuit check NO a Replace the wire harness b Push the ON start switch c Push and SET side of the cruise control setting switch and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 10 and complete the service NO Go to Short...

Page 601: ... any other coupler terminal Handlebar switch coupler left 3 green blue any other coupler terminal yellow black any other coupler terminal ECU coupler 4 green blue any other coupler terminal Is resistance YES Go to step 8 NO a Replace the wire harness b Push the ON start switch c Push and SET side of the cruise control setting switch and then check the condition of the DTC using the malfunction mod...

Page 602: ...p 11 2 Connection of ECU coupler front brake light switch coupler brake light relay coupler and handlebar switch coupler right Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins When the front brake is applied ON When the front brake is not applied OFF Is check result OK YES Go to step b NO Go to step 2 Wh...

Page 603: ...ing the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 11 and complete the service NO Go to step 4 Between ignition system relay coupler 1 and signaling system fuse holder 2 brown blue brown blue Between signaling system fuse holder 2 and front brake light switch coupler 3 brown green white Between front brake light switch coupler 3 and brake light relay coupler 4 gree...

Page 604: ...o to step 11 and complete the service NO Go to Short circuit check Between ignition system relay coupler 1 and ground brown blue ground Between front brake light switch 3 and ground green white ground green yellow ground Between brake light relay coupler 4 and ground light green black ground Ignition system relay coupler 1 brown blue any other coupler terminal Front brake light switch coupler 3 gr...

Page 605: ...pler and check the pins bent or broken terminals and locking condition of the pins Is resistance YES Go to step 5 NO a Replace the wire harness b Push the ON start switch c Operate the front brake lever and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 11 and complete the service NO Go to step 5 Is it in the Recovered cond...

Page 606: ... YES Go to step 11 and complete the service NO Go to step 7 Is check result OK YES Go to step 8 NO a Replace the fuse b Push the ON start switch c Operate the rear brake lever and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 11 and complete the service NO Go to step 8 Between ignition system relay coupler 1 and signaling ...

Page 607: ...t check Between ignition system relay coupler 1 and ground brown blue ground Between rear brake light switch coupler 3 and ground green yellow ground light green black ground Between brake light relay coupler 4 and ground light green black ground Ignition system relay coupler 1 brown blue any other coupler terminal Rear brake light switch coupler 3 green yellow any other coupler terminal light gre...

Page 608: ...vered condition YES Go to step 11 and complete the service NO Go to step 9 Is check result OK YES Go to step 10 NO a Push the ON start switch b Operate the rear brake lever and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 11 and complete the service NO Go to step 10 R Br L R L Y Br Lg BG Y B R Br L R L Y Br Lg BG Y B B Y ...

Page 609: ...eplace the ECU and complete the service Refer to REPLACING THE ECU Engine Control Unit on page 8 93 11 Delete the DTC and check that the MIL goes off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC ...

Page 610: ...tion is detected in the ECU the DTC might not appear on the tool display Fail safe system Unable to start engine Unable to drive vehicle Procedure 1 Malfunction in ECU Replace the ECU Refer to REPLACING THE ECU Engine Control Unit on page 8 93 Push the ON start switch Check that the MIL does not come on ...

Page 611: ...y are detected at the same time correct the P0122 P0123 P0222 P0223 and P2135 first Push the ON start switch and then check the condition of the DTC using the malfunction mode of the YDT 2 Malfunction in ECU Replace the ECU Refer to REPLACING THE ECU Engine Control Unit on page 8 93 Push the ON start switch Check that the MIL does not come on 3 Delete the DTC and check that the MIL goes off Confir...

Page 612: ...ade push the OFF LOCK switch Push the ON start switch and then check the condition of the DTC using the malfunction mode of the YDT 3 02 is indicated in diagnostic mode code D60 EEPROM data error for adjustment of CO concen tration of cylinder 2 Change the CO concentration of cylinder 2 and rewrite in EEPROM Refer to ADJUSTING THE EXHAUST GAS VOLUME on page 3 12 After this adjustment is made push ...

Page 613: ... malfunction mode of the YDT 5 Malfunction in ECU Replace the ECU and complete the service Refer to REPLACING THE ECU Engine Control Unit on page 8 93 6 Delete the DTC and check that the MIL goes off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC Is it in the Recovered condition YES Go to step 6 and complete the service NO a Repeat step 1 b If the same numb...

Page 614: ... pins bent or broken terminals and locking condition of the pins Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Push the ON start switch and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 8 and complete the service NO Go to step 2 Is the coupler condition nor...

Page 615: ... using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 8 and complete the service NO Go to step 4 Between throttle servo motor coupler 1 and ECU coupler 2 yellow red yellow red yellow white yellow white Between ECU coupler 2 and electronic throttle valve fuse holder 3 red blue red blue Is resistance 0 YES Go to Short circuit check NO a Replace the wire harness b Pus...

Page 616: ...er coupler terminal red blue any other coupler terminal Is resistance YES Go to step 5 NO a Replace the wire harness b Push the ON start switch and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 8 and complete the service NO Go to step 5 Is check result OK YES Go to step 6 NO a Replace the throttle bodies Refer to REPLACING...

Page 617: ...Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC Is it in the Recovered condition YES Go to step 8 and complete the service NO Go to step 6 Is check result OK YES Go to step 7 NO a Replace the throttle bodies Refer to REPLACING THE THROTTLE BODIES on page 7 11 b Push the ON start switch and then check the condition of the DTC using the malfunction mode of the...

Page 618: ...pler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Start the engine and let it idle for approximately 5 seconds c Check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7...

Page 619: ...d fuel injection system relay coupler 2 red black red black Between fuel injection system relay coupler 2 and ECU coupler 5 red blue red blue blue yellow blue yellow Is resistance 0 YES Go to Short circuit check NO a Replace the wire harness b Start the engine and let it idle for approximately 5 seconds c Check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered c...

Page 620: ...pler terminal blue yellow any other coupler terminal Is resistance YES Go to step 4 NO a Replace the wire harness b Start the engine and let it idle for approximately 5 seconds c Check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to step 4 Is check result OK YES Go to step 5 NO a Replace the fuel inj...

Page 621: ...as a condition of Recovered using the YDT and then delete the DTC Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to step 5 Is the fuel system voltage less than 3V YES a Replace the fuel injection system relay b Start the engine and let it idle for approximately 5 seconds c Check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered ...

Page 622: ...the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Push the ON start switch and then extend and retract the sidestand c Check the condition of the DTC using the malfunction mode of the YDT Is it in th...

Page 623: ... 4 Between sidestand relay coupler 1 and ECU coupler 2 light green light green Between sidestand relay coupler 1 and side stand switch coupler 3 light green light green B Y L Y G P Lg L O W W G Y L Lg W B L Br W Gy G G L R G Lg L W G W Y G R Lg B L W Lg B Y L Y G P W G Y L Lg W B L Br W Gy G Lg L W G W Y G R L W Lg Lg B G R G Y L Y Lg 2 1 3 2 XP560D XP560E Is resistance 0 YES Go to Short circuit c...

Page 624: ... green any other coupler terminal Sidestand switch coupler 3 light green any other coupler terminal B Y L Y G P Lg L O W W G Y L Lg W B L Br W Gy G G L R G Lg L W G W Y G R Lg B L W Lg B Y L Y G P W G Y L Lg W B L Br W Gy G Lg L W G W Y G R L W Lg Lg B G R G Y L Y Lg Lg B G R G Y L Y Lg B A 2 1 3 1 3 2 XP560D XP560E Is resistance YES Go to step 5 NO a Replace the wire harness b Push the ON start s...

Page 625: ...oes off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC Sidestand retracted ON Sidestand extended OFF Is check result OK YES Go to step 6 NO a Replace the sidestand switch b Push the ON start switch and then extend and retract the sidestand c Check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step ...

Page 626: ...he pins bent or broken terminals and locking condition of the pins Is check result OK YES Go to step 2 NO a Reinstall or replace the battery leads b Push the ON start switch and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 6 and complete the service NO Go to step 2 Is the coupler condition normal YES Go to step 3 NO a Con...

Page 627: ... condition YES Go to step 6 and complete the service NO Go to step 4 Between battery 1 and starter relay terminal 2 red red Between starter relay coupler 3 and ECU cou pler 4 red red Is resistance 0 YES Go to Short circuit check NO a Replace the wire harness b Push the ON start switch and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES...

Page 628: ...DTC has a condition of Recovered using the YDT and then delete the DTC Between starter relay coupler 3 and ground red ground Starter relay coupler 3 red any other coupler terminal ECU coupler 4 red any other coupler terminal Is resistance YES Go to step 5 NO a Replace the wire harness b Push the ON start switch and then check the condition of the DTC using the malfunction mode of the YDT Is it in ...

Page 629: ...condition of the pins 3 Wire harness continuity Disconnect the lean angle sensor coupler and ECU coupler Open circuit check Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Push the ON start switch then to OFF and then back to ON c Check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YE...

Page 630: ...L Lg W B L Br W Gy G Lg L W G W Y G R L W Lg B L Y G L 2 2 1 XP560D XP560E Is resistance 0 YES Go to Short circuit check NO a Replace the wire harness b Push the ON start switch then to OFF and then back to ON c Check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 6 and complete the service NO Go to Short circuit check Between lean an...

Page 631: ...Lg B Y L Y G P W G Y L Lg W B L Br W Gy G Lg L W G W Y G R L W Lg B L Y G L B A 2 2 1 XP560D XP560E Is resistance YES Go to step 4 NO a Replace the wire harness b Push the ON start switch then to OFF and then back to ON c Check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 6 and complete the service NO Go to step 4 Is check result OK...

Page 632: ...upler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins 2 Connection of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Is the coupler condition normal YES Go to step 2 NO a Connect the coupler secu...

Page 633: ...2122 P2123 P2127 P2128 P2138 white white P2123 P2128 black blue black blue P2122 P2127 blue blue P2122 P2123 P2127 P2128 P2138 red red Is resistance 0 YES Go to Short circuit check NO a Replace the wire harness b Push the ON start switch and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 6 and complete the service NO Go to ...

Page 634: ...2122 P2123 P2127 P2128 P2138 white any other coupler terminal P2123 P2128 black blue any other coupler terminal P2122 P2127 blue any other coupler terminal P2122 P2123 P2127 P2128 P2138 red any other coupler terminal Is resistance YES Go to step 4 NO a Replace the wire harness b Push the ON start switch and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Reco...

Page 635: ... page 8 93 6 Delete the DTC and check that the MIL goes off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC Is check result OK YES Go to step 5 NO Replace the accelerator position sensor Refer to HANDLEBAR on page 4 74 Is it in the Recovered condition YES Go to step 6 and complete the service NO Go to step 5 ...

Page 636: ... check the pins bent or broken terminals and locking condition of the pins Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Execute the diagnostic mode Code D16 c Rotate the front wheel by hand and check that the indicated value increases Is that value increased YES Go to step 8 and complete the service NO Go to step 2 Is the coupler ...

Page 637: ...hat the indicated value increases Is that value increased YES Go to step 8 and complete the service NO Go to step 4 Between front wheel sensor coupler 1 and ABS ECU coupler 2 black black white white Between ABS ECU coupler 2 and ECU cou pler 3 white yellow white yellow B Y L Y G P Lg L O W W G Y L Lg W B L Br W Gy G G L R G Lg L W G W Y G R Lg B L W Lg B Y L Y G P W G Y L Lg W B L Br W Gy G Lg L W...

Page 638: ... ground white yellow ground Front wheel sensor coupler 1 black any other coupler terminal white any other coupler terminal ABS ECU coupler 2 black any other coupler terminal white any other coupler terminal white yellow any other coupler terminal ECU coupler 3 white yellow any other coupler terminal B Y L Y G P Lg L O W W G Y L Lg W B L Br W Gy G G L R G Lg L W G W Y G R Lg B L W Lg B Y L Y G P W ...

Page 639: ...firm that the DTC has a condition of Recovered using the malfunction mode of the YDT and then delete the DTC Delete this DTC even if it has a condition of Detected Is resistance YES Go to step 5 NO a Replace the wire harness b Execute the diagnostic mode Code D16 c Rotate the front wheel by hand and check that the indicated value increases Is that value increased YES Go to step 8 and complete the ...

Page 640: ...k the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Push the ON start switch and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to s...

Page 641: ...Gy G Lg L W G W Y G R L W Lg G B P WP B O L R LB W Br Y L R Br YChDgR GR W Gy V Gy WV WG RG L G W GW RW L Y B WLg WLg LB WR GR G 2 2 1 XP560D XP560E Is resistance 0 YES Go to Short circuit check NO a Replace the wire harness b Push the ON start switch and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 6 and complete the ser...

Page 642: ...G Y L Lg W B L Br W Gy G G L R G Lg L W G W Y G R Lg B L W Lg B Y L Y G P W G Y L Lg W B L Br W Gy G Lg L W G W Y G R L W Lg G B P WP B O L R LB W Br Y L R Br YChDgR GR W Gy V Gy WV WG RG L G W GW RW L Y B WLg WLg LB WR GR G G B P WP B O L R LB W Br Y L R Br YChDgR GR W Gy V Gy WV WG RG L G W GW RW L Y B WLg WLg LB WR GR G B A 2 2 1 1 XP560D XP560E Is resistance YES Go to step 4 NO a Replace the w...

Page 643: ... 4 24 3 Defective sensor rotor or incorrect installation of the rotor Check the surface of the sensor rotor for damage Refer to MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR on page 4 26 4 Defective front wheel sensor or incorrect installation of the sensor Check the wheel sensor for damage and the installed condition of the sensor Refer to MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR...

Page 644: ...he surface of the sensor rotor for damage Refer to MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR on page 4 34 4 Defective rear wheel sensor or incorrect installation of the sensor Check the wheel sensor for damage and the installed condition of the sensor Refer to MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR on page 4 34 Is check result OK YES Go to step 2 NO Clean the sensor roto...

Page 645: ...er to CHECKING THE FRONT WHEEL on page 4 24 3 Defective sensor rotor or incorrect installation of the rotor Check the surface of the sensor rotor for damage Refer to MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR on page 4 26 4 Defective front wheel sensor or incorrect installation of the sensor Check the wheel sensor for damage and the installed condition of the sensor Refer to MAINTENANC...

Page 646: ...er to CHECKING THE REAR WHEEL on page 4 33 3 Defective sensor rotor or incorrect installation of the rotor Check the surface of the sensor rotor for damage Refer to MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR on page 4 34 4 Defective rear wheel sensor or incorrect installation of the sensor Check the wheel sensor for damage and the installed condition of the sensor Refer to MAINTENANCE O...

Page 647: ...upler and front wheel sensor coupler Open circuit check Short circuit check TIP Disconnect the ABS ECU related connectors before checking Refer to PARTS CONNECTED TO THE ABS ECU on page 9 4 Ground short circuit check A Is check result OK YES Go to step 2 NO If there is a malfunction repair it and connect the coupler securely Between ABS ECU coupler 1 and front wheel sensor coupler 2 white white bl...

Page 648: ...unit assembly Refer to FRONT WHEEL on page 4 22 and ABS Anti lock Brake System on page 4 67 ABS ECU coupler 1 white any other coupler terminal black any other coupler terminal Front wheel sensor 2 white any other coupler terminal black any other coupler terminal Is resistance YES Go to step 3 NO Replace the wire harness W B B W G G R W Y W B B W R W B G B L Lg W Lg L Br W Lg Lg G Y R L B W G G R W...

Page 649: ...upler and rear wheel sensor coupler Open circuit check Short circuit check TIP Disconnect the ABS ECU related connectors before checking Refer to PARTS CONNECTED TO THE ABS ECU on page 9 4 Ground short circuit check A Is check result OK YES Go to step 2 NO If there is a malfunction repair it and connect the coupler securely Between ABS ECU coupler 1 and rear wheel sensor coupler 2 white white blac...

Page 650: ...unit assembly Refer to REAR WHEEL on page 4 30 and ABS Anti lock Brake System on page 4 67 ABS ECU coupler 1 white any other coupler terminal black any other coupler terminal Rear wheel sensor 2 white any other coupler terminal black any other coupler terminal Is resistance YES Go to step 3 NO Replace the wire harness B W G G R W Y W B B W R W B G B L Lg W Lg L Br W Lg Lg G Y R L B W G G R W Y W B...

Page 651: ...tortion and bends Refer to CHECKING THE FRONT WHEEL on page 4 24 3 Defective sensor rotor or incorrect installation of the rotor Check the surface of the sensor rotor for damage Refer to MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR on page 4 26 4 Defective front wheel sensor or incorrect installation of the sensor Check the wheel sensor for damage and the installed condition of the senso...

Page 652: ...stortion and bends Refer to CHECKING THE REAR WHEEL on page 4 33 3 Defective sensor rotor or incorrect installation of the rotor Check the surface of the sensor rotor for damage Refer to MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR on page 4 34 4 Defective rear wheel sensor or incorrect installation of the sensor Check the wheel sensor for damage and the installed condition of the sensor ...

Page 653: ...21_ABS EAS33320 TROUBLESHOOTING Item Hydraulic unit assembly defective solenoid drive circuit Procedure 1 Defective hydraulic unit assembly Replace the hydraulic unit assembly Refer to ABS Anti lock Brake System on page 4 67 ...

Page 654: ... OFF LOCK switch before disconnecting or connecting a coupler 3 Wire harness continuity XP560E Disconnect the handlebar switch coupler right handlebar switch coupler left and ABS ECU cou pler Open circuit check Is check result OK YES Go to step 2 NO Replace the brake light switches Is check result OK YES XP560E Go to step 3 XP560D Go to step 4 NO If there is a malfunction repair it and connect the...

Page 655: ... 1 green yellow any other coupler terminal Handlebar switch coupler left 2 green yellow any other coupler terminal ABS ECU coupler 3 green yellow any other coupler terminal Is resistance YES Go to step 4 NO Replace the wire harness Between signaling system fuse holder 1 and brake light relay coupler 4 brown brown Between front brake light switch coupler 2 and rear brake light switch coupler 3 gree...

Page 656: ... coupler 2 green yellow any other coupler terminal Rear brake light switch coupler 3 green yellow any other coupler terminal light green black any other coupler terminal Brake light relay coupler 4 brown any other coupler terminal light green black any other coupler terminal green yellow any other coupler terminal black any other coupler terminal ABS ECU coupler 5 green yellow any other coupler te...

Page 657: ...9 183 24_ABS 5 Defective hydraulic unit assembly Replace the hydraulic unit assembly Refer to CHECKING THE FUEL PRESSURE on page 7 12 Is resistance YES Go to step 5 NO Replace the wire harness ...

Page 658: ...ush the OFF LOCK switch before disconnecting or connecting a coupler 3 Wire harness continuity Disconnect the ABS solenoid fuse and ABS ECU coupler Open circuit check Short circuit check Is check result OK YES Go to step 2 NO Replace the fuse and check the wire harness Is check result OK YES Go to step 3 NO If there is a malfunction repair it and connect the coupler securely Between ABS solenoid f...

Page 659: ...lic unit assembly Replace the hydraulic unit assembly Refer to ABS Anti lock Brake System on page 4 67 Between ABS ECU coupler 2 and ground red white ground ABS ECU coupler 2 red white any other coupler terminal Is resistance YES Go to step 4 NO Replace the wire harness B W G G R W Y W B B W R W B G B L Lg W Lg L Br W Lg Lg G Y R L B W G G R W Y W B B W R W B G B L Lg W Lg L Br W Lg Lg G Y R L A B...

Page 660: ...S33376 TROUBLESHOOTING Item Hydraulic unit assembly short circuit in ABS solenoid power supply circuit Procedure 1 Defective hydraulic unit assembly Replace the hydraulic unit assembly Refer to ABS Anti lock Brake System on page 4 67 ...

Page 661: ...upler TIP Push the OFF LOCK switch before disconnecting or connecting a coupler 3 Wire harness continuity Disconnect the ABS motor fuse and ABS ECU coupler Open circuit check Is check result OK YES Go to step 2 NO Replace the fuse and check the wire harness Is check result OK YES Go to step 3 NO If there is a malfunction repair it and connect the coupler securely Between ABS motor fuse holder 1 an...

Page 662: ...assembly Replace the hydraulic unit assembly Refer to ABS Anti lock Brake System on page 4 67 Between ABS ECU coupler 2 and ground red blue ground ABS ECU coupler 2 red blue any other coupler terminal black green any other coupler terminal Is resistance YES Go to step 4 NO Replace the wire harness B W G G R W Y W B B W R W B G B L Lg W Lg L Br W Lg Lg G Y R L B W G G R W Y W B B W R W B G B L Lg W...

Page 663: ...AS33323 TROUBLESHOOTING Item Hydraulic unit assembly short circuit in ABS motor power supply circuit Procedure 1 Defective hydraulic unit assembly Replace the hydraulic unit assembly Refer to ABS Anti lock Brake System on page 4 67 ...

Page 664: ...NG THE FRONT WHEEL on page 4 24 and CHECKING THE FRONT BRAKE DISCS on page 4 43 3 Front brake dragging Check that the brake fluid pressure is correctly transmitted to the brake caliper when the brake lever is operated and that the pressure decreases when the lever is released Refer to CHECKING THE FRONT BRAKE DISCS on page 4 43 4 Defective hydraulic unit assembly Replace the hydraulic unit assembl...

Page 665: ...to CHECKING THE REAR WHEEL on page 4 33 and CHECKING THE REAR BRAKE DISC on page 4 58 3 Rear brake dragging Check that the brake fluid pressure is correctly transmitted to the brake caliper when the brake lever is operated and that the pressure decreases when the lever is released Refer to CHECKING THE REAR BRAKE DISC on page 4 58 4 Defective hydraulic unit assembly Replace the hydraulic unit asse...

Page 666: ...e of the sensor rotor for damage Refer to MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR on page 4 26 4 Defective front wheel sensor or incorrect installation of the sensor Check the wheel sensor for damage and the installed condition of the sensor Refer to MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR on page 4 26 Is check result OK YES Go to step 2 NO Clean the sensor rotor and ...

Page 667: ...e of the sensor rotor for damage Refer to MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR on page 4 34 4 Defective rear wheel sensor or incorrect installation of the sensor Check the wheel sensor for damage and the installed condition of the sensor Refer to MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR on page 4 34 Is check result OK YES Go to step 2 NO Clean the sensor rotor and whe...

Page 668: ...y Recharge or replace the battery and check again Refer to CHECKING AND CHARGING THE BATTERY on page 8 94 2 Disconnected battery terminal Check the connection 3 Defective charging system Check the charging system Refer to CHARGING SYSTEM on page 8 17 Is check result OK YES Go to step 3 NO Replace or reconnect the terminal Is check result OK YES Replace the hydraulic unit assembly ABS ECU NO Confir...

Page 669: ...e disconnecting or connecting a coupler 3 Wire harness continuity Disconnect the ABS ECU fuse and ABS ECU coupler Open circuit check Short circuit check TIP Disconnect the ABS ECU related connectors before checking Refer to PARTS CONNECTED TO THE ABS ECU on page 9 4 Ground short circuit check A Is check result OK YES Go to step 3 NO If there is a malfunction repair it and connect the coupler secur...

Page 670: ...white any other coupler terminal Is resistance YES Go to step 4 NO Replace the wire harness Is check result OK YES Replace the hydraulic unit assembly ABS ECU NO Confirm the cause of the problem and repair it and check again B W G G R W Y W B B W R W B G B L Lg W Lg L Br W Lg Lg G Y R L B W G G R W Y W B B W R W B G B L Lg W Lg L Br W Lg Lg G Y R L 2 2 A B ...

Page 671: ... before disconnecting or connecting a coupler 3 Wire harness continuity Disconnect the ABS ECU fuse ABS motor fuse and ABS ECU coupler Open circuit check Short circuit check TIP Disconnect the ABS ECU related connectors before checking Refer to PARTS CONNECTED TO THE ABS ECU on page 9 4 Is check result OK YES Go to step 3 NO If there is a malfunction repair it and connect the coupler securely Betw...

Page 672: ...on page 9 26 Between ABS ECU coupler 3 and ground brown white ground red blue ground ABS ECU coupler 3 brown white any other coupler terminal red blue any other coupler terminal Is resistance YES Go to step 4 NO Replace the wire harness Is check result OK YES Go to step 5 NO Confirm the cause of the problem and repair it and check again B W G G R W Y W B B W R W B G B L Lg W Lg L Br W Lg Lg G Y R ...

Page 673: ...S20700 55_ABS EAS33328 TROUBLESHOOTING Item Hydraulic unit assembly defective ABS ECU Procedure 1 Defective hydraulic unit assembly Replace the hydraulic unit assembly Refer to ABS Anti lock Brake System on page 4 67 ...

Page 674: ... 56_ABS EAS33329 TROUBLESHOOTING Item Hydraulic unit assembly abnormal internal power supply Procedure 1 Defective hydraulic unit assembly Replace the hydraulic unit assembly Refer to ABS Anti lock Brake System on page 4 67 ...

Page 675: ...t check A Lines short circuit check B Between front wheel sensor coupler 1 and ground white ground black ground Front wheel sensor coupler 1 white any other coupler terminal black any other coupler terminal ABS ECU coupler 2 white any other coupler terminal black any other coupler terminal Is resistance YES Go to step 2 NO Replace the wire harness Between front wheel sensor 1 and ground white grou...

Page 676: ... 63_ABS 3 Defective hydraulic unit assembly Replace the hydraulic unit assembly Refer to ABS Anti lock Brake System on page 9 26 Is resistance YES Go to step 3 NO Replace the wire harness W Gy W Gy A A B 1 1 ...

Page 677: ... A Lines short circuit check B Between rear wheel sensor coupler 1 and ground white ground black ground Rear wheel sensor coupler 1 white any other coupler terminal black any other coupler terminal ABS ECU coupler 2 white any other coupler terminal black any other coupler terminal Is resistance YES Go to step 2 NO Replace the wire harness Between rear wheel sensor coupler 1 and ground white ground...

Page 678: ... 64_ABS 3 Defective hydraulic unit assembly Replace the hydraulic unit assembly Refer to ABS Anti lock Brake System on page 9 26 Is resistance YES Go to step 3 NO Replace the wire harness W Gy W Gy A A B 1 1 ...

Page 679: ...amper and suspen sion warning light 54 ABS warning light 55 High beam indicator light 56 Multi function display 57 ECU Engine Control Unit 58 Ignition coil 59 Spark plug 60 Grip warmer connector 61 Grip warmer left OPTION 62 Grip warmer right OPTION 63 Coolant temperature sensor 64 Intake air temperature sensor 65 Intake air pressure sensor 66 Lean angle sensor 67 O2 sensor 68 Injector 1 69 Inject...

Page 680: ...icator light left 63 Turn signal indicator light right 64 Cruise control system indicator light 65 Cruise control setting indicator light 66 Steering damper and suspen sion warning light 67 ABS warning light 68 High beam indicator light 69 Multi function display 70 ECU Engine Control Unit 71 Ignition coil 72 Spark plug 73 Grip warmer connector 74 Grip warmer left 75 Grip warmer right 76 Coolant te...

Page 681: ... L Green Blue G R Green Red G W Green White G Y Green Yellow Gy G Gray Green Gy W Gray White L B Blue Black L G Blue Green L R Blue Red L W Blue White L Y Blue Yellow Lg B Light green Black Lg L Light green Blue Lg W Light green White O L Orange Blue O W Orange White P B Pink Black P W Pink White R B Red Black R G Red Green R L Red Blue R W Red White R Y Red Yellow V W Violet White W G White Green...

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Page 685: ... B L B L R L R V W V W W L W G W R W L Br Y Br Y Y B R Y W R W G R L R L O L O L L L P Lg L Lg L Lg W Lg W Lg W Lg W Lg W Lg W Lg L Lg L Lg W Lg W Lg L Lg L Lg L Lg L Lg W Lg W Lg W Lg W L G L G L G L G R G R G R G B W B W L L L B B B B B B B B B B B B B B B B B R L R R R B Br L Br B Br B Br L Br L Br L Br L Br L R G Br R Br R Br R R G B B B B B B W B W O O Ch Ch Gy W Gy W V V Gy Gy L Y L Y R G B ...

Page 686: ...20 14 22 25 31 33 32 27 28 29 30 41 42 43 58 10 59 60 61 62 63 57 45 44 46 48 47 49 50 51 52 53 54 68 10 10 71 72 73 74 75 10 77 10 80 79 78 76 69 70 64 65 66 10 67 23 26 24 11 10 12 13 9 N HI FREE PASS N L PUSH PUSH FREE UP R DOWN LO PUSH FREE ON OFF RUN OFF OFF ON B B B B B B B B B B B B B B B Gy Gy B B L B B B Gy Gy B B B B B R B B B B B A A A C C B C A A A B B B B B B C 55 56 B B B B B B Gy B ...

Page 687: ...R Y V Y L Gy Y B R Y Ch Y L B B Dg Y B W W W B L Y L Y R B R B R B R B R B R B R B R W R W R W R W Dg Br G Dg L L Br B Br B Br Y B R R W W W B B B B L L L L B G Y Y Y B Y B B B W W R R R R Y B Y B W Y W Y L L L G Y G Y L Y L Y R R B L B L W W Gy G Gy G Y R Y R L B L B L R L R V W V W W L W L Br Y Br Y Y R B R Y W R W R W G W G G B G B Br Y Br Y P B P B B W B W R L R L O L O L L L P P Lg L Lg L Lg ...

Page 688: ...0 41 43 42 44 45 46 47 48 49 51 50 53 52 71 10 72 73 74 75 76 70 56 55 57 59 58 60 61 62 63 64 65 66 67 81 10 10 84 85 86 87 88 10 90 10 93 92 91 89 82 83 77 78 79 10 80 54 23 26 24 11 10 12 13 9 RES N HI SET FREE PASS N FREE L PUSH PUSH PUSH FREE UP R FREE DOWN LO PUSH FREE ON ON OFF OFF ON OFF RUN OFF OFF ON B B B B B B B B B B B B B B B B B B B B Gy Gy B B L B B B B Gy Gy B B B B B R B B B B B ...

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