Yamaha XSR MTM690 2016 Service Manual Download Page 1

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2016

SERVICE MANUAL

MTM690

MTM690-U

B34-F8197-E0

Summary of Contents for XSR MTM690 2016

Page 1: ...2016 SERVICE MANUAL MTM690 MTM690 U B34 F8197 E0 ...

Page 2: ... MTM690 MTM690 U SERVICE MANUAL 2015 by MBK Industrie First edition November 2015 All rights reserved Any reproduction or unauthorized use without the written permission of MBK Industrie is expressly prohibited ...

Page 3: ...gnificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable TIP Designs and specifications are subject to change without notice EAS30001 IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following notations This is the safety alert symbol ...

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

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

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

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Page 9: ...R UNIT 1 2 IMPORTANT INFORMATION 1 7 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 7 REPLACEMENT PARTS 1 7 GASKETS OIL SEALS AND O RINGS 1 7 LOCK WASHERS PLATES AND COTTER PINS 1 7 BEARINGS AND OIL SEALS 1 8 CIRCLIPS 1 8 RUBBER PARTS 1 8 BASIC SERVICE INFORMATION 1 9 QUICK FASTENERS 1 9 ELECTRICAL SYSTEM 1 10 SPECIAL TOOLS 1 14 ...

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

Page 11: ...before using the bottom and top set but tons For the UK To switch the speedometer and multi function display between kilometers and miles set the multi function display to the odometer mode or a tripmeter mode and then press the bottom set button for three seconds Speedometer The speedometer shows the vehicle s traveling speed Tachometer The tachometer allows the rider to monitor the engine speed ...

Page 12: ... high engine speeds during acceleration Travel at a constant speed Select the transmission gear that is appropri ate for the vehicle speed Transmission gear display This display shows the selected gear The neu tral position is indicated by and by the neutral indicator light Multi function display The multi function display is equipped with the following an odometer two tripmeters a fuel reserve tr...

Page 13: ... F and starts counting the distance traveled from that point In this case push the bottom set button to switch the display between the various tripmeter odometer and fuel consumption modes in the following order TRIP F km L or L 100 km AVE_ _ _ km L or AVE_ _ _ L 100 km _ _ C Air_ _ C Clock _ _ _ _ ODO TRIP 1 TRIP 2 TRIP F For the UK TRIP F km L L 100 km or MPG AVE_ _ _ km L AVE_ _ _ L 100 km or A...

Page 14: ...his display shows the coolant temperature from 40 C to 116 C in 1 C increments If the message HI flashes stop the vehicle then stop the engine and let the it cool TIP When the coolant temperature is below 40 C Lo will be displayed The coolant temperature varies with changes in the weather and engine load Air temperature This display shows the air temperature from 9 C to 99 C in 1 C increments The ...

Page 15: ...ent value one by one or push and hold the button to increase the increment value continuously Brightness control The brightness level of the multi function meter unit panel can be adjusted to suit the rider s pref erence To adjust the brightness 1 Turn the main switch to OFF 2 Push and hold the bottom set button 3 Turn the main switch to ON and continue pushing the bottom set button until the dis ...

Page 16: ... correct installation of all parts 5 Keep all parts away from any source of fire EAS30007 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace ments Use oil and grease recommended by Yamaha for all lubrication jobs Other brands may be similar in function and appearance but inferior in quality EAS30008 GASKETS OIL SEALS AND O RINGS 1 When overhauling the engine replace all gaskets seals ...

Page 17: ... air because this will damage the bearing surfac es EAS30011 CIRCLIPS Before reassembly check all circlips carefully and replace damaged or distorted circlips Al ways replace piston pin clips after one use When installing a circlip 1 make sure the sharp edged corner 2 is positioned opposite the thrust 3 that the circlip receives EAS30012 RUBBER PARTS Check rubber parts for deterioration during in ...

Page 18: ...tener push its pin so that it protrudes from the fastener head then insert the fastener into the part to be secured and push the pin in with a screwdriver Make sure that the pin is flush with the fastener s head Screw type 1 Remove Quick fastener TIP To remove the quick fastener loosen the screw with a screwdriver then pull the fastener out 2 Install Quick fastener TIP To install the quick fastene...

Page 19: ...f a battery lead is difficult to disconnect due to rust on the battery terminal remove the rust us ing hot water NOTICE ECA16760 Be sure to connect the battery leads to the correct battery terminals Reversing the bat tery lead connections could damage the electrical components NOTICE ECA16771 When connecting the battery leads to the battery be sure to connect the positive bat tery lead first then ...

Page 20: ... 5 seconds before turning the main switch back to ON Checking the electrical system TIP Before checking the electrical system make sure that the battery voltage is at least 12 V NOTICE ECA14371 Never insert the tester probes into the cou pler terminal slots Always insert the probes from the opposite end a of the coupler tak ing care not to loosen or damage the leads NOTICE ECA16640 For waterproof ...

Page 21: ...ure to check the type of cou pler lock before disconnecting the coupler NOTICE ECA16790 When disconnecting a connector do not pull the leads Hold both sections of the connec tor securely and then disconnect the con nector 2 Check Lead Coupler Connector Moisture Dry with an air blower Rust stains Connect and disconnect sev eral times 3 Check All connections Loose connection Connect properly TIP If ...

Page 22: ...rminals When checking the wire harness perform steps 1 to 4 As a quick remedy use a contact revitalizer available at most part stores 6 Check Resistance TIP The resistance values shown were obtained at the standard measuring temperature of 20 C 68 F If the measuring temperature is not 20 C 68 F the specified measuring conditions will be shown Pocket tester 90890 03132 Pocket tester 90890 03112 Ana...

Page 23: ...any mistakes TIP For U S A and Canada use part number starting with YM YU or ACC For others use part number starting with 90890 Tool name Tool No Illustration Reference pages Pocket tester 90890 03132 1 13 Pocket tester 90890 03112 Analog pocket tester YU 03112 C 1 13 8 155 8 156 8 157 8 157 8 161 8 162 8 163 8 163 8 164 8 164 8 165 8 165 8 167 8 167 8 168 8 169 8 170 8 170 8 171 Thickness gauge 9...

Page 24: ...t wrench YU A9472 3 19 4 82 Oil filter wrench 90890 01426 Oil filter wrench YU 38411 3 22 Pressure gauge 90890 03153 Pressure gauge YU 03153 3 23 7 14 7 15 Oil pressure adapter H 90890 03139 3 23 Damper rod holder 90890 01460 4 74 4 76 T handle 90890 01326 T handle 3 8 drive 60 cm long YM 01326 4 74 4 76 Tool name Tool No Illustration Reference pages YU 44456 ...

Page 25: ...4136 5 1 Compression gauge 90890 03081 Engine compression tester YU 33223 5 1 Rotor holding tool 90890 01235 Universal magneto and rotor holder YU 01235 5 15 5 19 Yamaha bond No 1215 90890 85505 Three bond No 1215 5 22 5 41 5 66 5 68 Valve spring compressor 90890 04019 Valve spring compressor YM 04019 5 29 5 34 Tool name Tool No Illustration Reference pages YM A9409 7 YM A5142 4 90890 03081 YU 332...

Page 26: ...e installer 4 5 mm YM 04117 5 31 Valve guide reamer ø4 5 90890 04118 Valve guide reamer 4 5 mm YM 04118 5 31 Rotor holding tool 90890 04166 YM 04166 5 39 5 39 5 40 5 40 Flywheel puller 90890 01362 Heavy duty puller YU 33270 B 5 39 Digital circuit tester 90890 03174 Model 88 Multimeter with tachometer YU A1927 5 44 8 166 8 169 Universal clutch holder 90890 04086 Universal clutch holder YM 91042 5 5...

Page 27: ...ng compressor 90890 05158 Piston ring compressor YM 08037 5 79 Radiator cap tester 90890 01325 Mityvac cooling system tester kit YU 24460 A 6 3 Radiator cap tester adapter 90890 01352 Pressure tester adapter YU 33984 6 3 Tool name Tool No Illustration Reference pages YU 01304 YU 24460 A YU 33984 ...

Page 28: ...ctor pressure adapter YU 03210 7 14 Fuel pressure adapter 90890 03176 Fuel pressure adapter YM 03176 7 15 OBD GST Leadwire kit 90890 03249 8 36 Ignition checker 90890 06754 Oppama pet 4000 spark checker YM 34487 8 164 Test harness lean angle sensor 6P 90890 03209 Test harness lean angle sensor 6P YU 03209 8 165 Test harness S pressure sensor 3P 90890 03207 Test harness S pressure sensor 3P YU 0320...

Page 29: ...TORQUES 2 14 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 14 ENGINE TIGHTENING TORQUES 2 15 CHASSIS TIGHTENING TORQUES 2 20 LUBRICATION POINTS AND LUBRICANT TYPES 2 24 ENGINE 2 24 CHASSIS 2 25 LUBRICATION SYSTEM CHART AND DIAGRAMS 2 27 ENGINE OIL LUBRICATION CHART 2 27 LUBRICATION DIAGRAMS 2 29 COOLING SYSTEM DIAGRAMS 2 41 CABLE ROUTING 2 43 ...

Page 30: ...U Dimensions Overall length 2075 mm 81 7 in Overall width 820 mm 32 3 in Overall height 1130 mm 44 5 in Seat height 815 mm 32 1 in Wheelbase 1405 mm 55 3 in Ground clearance 140 mm 5 51 in Minimum turning radius 2700 mm 106 3 in Weight Curb weight 186 kg 410 lb Loading Maximum load 172 kg 379 lb ...

Page 31: ...ecommended brand YAMALUBE SAE viscosity grades 10W 40 Recommended engine oil grade API service SG type or higher JASO standard MA Engine oil quantity Quantity disassembled 3 00 L 3 17 US qt 2 64 Imp qt Without oil filter cartridge replacement 2 30 L 2 43 US qt 2 02 Imp qt With oil filter cartridge replacement 2 60 L 2 75 US qt 2 29 Imp qt Oil pressure 280 0 kPa 5000 r min at 100 C 40 6 psi 5000 r ...

Page 32: ... 08 cm 1 13 1 23 cu in Warpage limit 0 05 mm 0 0020 in Camshaft Drive system Chain drive right Camshaft cap inside diameter 22 000 22 021 mm 0 8661 0 8670 in Camshaft journal diameter 21 959 21 972 mm 0 8645 0 8650 in Camshaft journal to camshaft cap clearance 0 028 0 062 mm 0 0011 0 0024 in Camshaft lobe dimensions Lobe height Intake 35 610 35 710 mm 1 4020 1 4059 in Limit 35 510 mm 1 3980 in Bas...

Page 33: ...4 mm 1 41 in Spring rate K1 intake 26 03 N mm 2 65 kgf mm 148 63 lbf in Spring rate K2 intake 42 21 N mm 4 30 kgf mm 241 02 lbf in Spring rate K1 exhaust 28 90 N mm 2 95 kgf mm 165 02 lbf in Spring rate K2 exhaust 44 19 N mm 4 51 kgf mm 252 32 lbf in Installed compression spring force intake 144 00 166 00 N 14 68 16 93 kgf 32 37 37 32 lbf Installed compression spring force exhaust 149 00 171 00 N ...

Page 34: ...018 0 042 mm 0 0007 0 0017 in Bearing color code 1 Violet Pink 0 White Pink 1 Blue Pink 2 Black Pink 3 Brown Pink Balancer Balancer drive method Gear Balancer shaft runout limit 0 030 mm 0 0012 in Balancer shaft journal to balancer shaft bearing clearance 0 020 0 054 mm 0 0008 0 0021 in Clutch Clutch type Wet multiple disc Clutch release method Outer pull rack and pinion pull Clutch lever free pla...

Page 35: ...l injector Model quantity 297500 2310 2 Throttle body Type quantity EHDW38 1 ID mark 1WS1 10 Throttle position sensor Resistance 2 64 6 16 kΩ Output voltage at idle 0 63 0 73 V Fuel injection sensor Crankshaft position sensor resistance 228 342 Ω Intake air pressure sensor output voltage 3 57 3 71 V at 101 3 kPa 3 57 3 71 V at 1 01 kgf cm 3 57 3 71 V at 14 7 psi Intake air temperature sensor resis...

Page 36: ...ENGINE SPECIFICATIONS 2 7 Throttle grip free play 3 0 5 0 mm 0 12 0 20 in ...

Page 37: ...58V Manufacturer model PIRELLI PHANTOM SPORTSCOMP Wear limit front 1 6 mm 0 06 in Rear tire Type Tubeless Size 180 55 R17M C 73V Manufacturer model PIRELLI PHANTOM SPORTSCOMP Wear limit rear 1 6 mm 0 06 in Tire air pressure measured on cold tires Loading condition 0 173 kg 0 381 lb Front 225 kPa 2 25 kgf cm 33 psi Rear 250 kPa 2 50 kgf cm 36 psi High speed riding Front 225 kPa 2 25 kgf cm 33 psi R...

Page 38: ...Angular bearing Center to lock angle left 35 0 Center to lock angle right 35 0 Front suspension Type Telescopic fork Spring shock absorber type Coil spring oil damper Front fork travel 130 0 mm 5 12 in Fork spring free length 345 4 mm 13 60 in Limit 331 6 mm 13 06 in Fork spring installed length 338 4 mm 13 32 in Collar length 150 0 mm 5 91 in Spring rate K1 8 50 N mm 0 87 kgf mm 48 54 lbf in Spri...

Page 39: ...ing preload Minimum 1 Standard 3 Maximum 9 Drive chain Size manufacturer 525VAZ DAIDO Chain type Sealed type Number of links 108 15 link length limit 239 3 mm 9 42 in Drive chain slack 51 0 56 0 mm 2 01 2 20 in Limit 58 0 mm 2 28 in ...

Page 40: ... 4 4 V AC magneto Charging system AC magneto Standard output 14 0 V 29 3 A at 5000 r min Stator coil resistance 0 128 0 192 Ω W W Rectifier regulator Regulator type Semi conductor short circuit Regulated voltage DC 14 1 14 9 V Rectifier capacity 50 0 A Battery Model YTZ10S Voltage capacity 12 V 8 6 Ah Specific gravity 1 310 Manufacturer GS YUASA Ten hour rate charging current 0 86 A Headlight Bulb...

Page 41: ...g force 6 03 6 52 N 615 665 gf 21 71 23 47 oz Mica undercut depth 0 70 mm 0 03 in Starter relay Amperage 180 0 A Coil resistance 4 18 4 62 Ω Horn Horn type Plane Quantity 1 Maximum amperage 3 0 A Turn signal hazard relay Relay type Full transistor Built in self canceling device No Fuel sender unit Sender unit resistance full 9 0 11 0 Ω Sender unit resistance empty 213 0 219 0 Ω Fuse Main fuse 30 0...

Page 42: ...ELECTRICAL SPECIFICATIONS 2 13 Spare fuse 20 0 A Spare fuse 15 0 A Spare fuse 10 0 A Spare fuse 7 5 A Spare fuse 2 0 A ...

Page 43: ... To avoid warpage tight en multi fastener assemblies in a crisscross pat tern and progressive stages until the specified tightening torque is reached Unless otherwise specified tightening torque specifications re quire clean dry threads Components should be at room temperature A Distance between flats B Outside thread diameter A nut B bolt General tightening torques Nm m kgf ft lbf 10 mm 6 mm 6 0 ...

Page 44: ...Timing chain tensioner cap bolt M6 1 7 Nm 0 7 m kgf 5 1 ft lbf Timing mark accessing bolt M8 1 15 Nm 1 5 m kgf 11 ft lbf Crankshaft end cover M36 1 10 Nm 1 0 m kgf 7 2 ft lbf Cylinder head cover bolt M6 4 10 Nm 1 0 m kgf 7 2 ft lbf Breather plate bolt M5 6 4 0 Nm 0 40 m kgf 2 9 ft lbf Cylinder head bolt M10 6 See TIP Cylinder head bolt M6 2 See TIP Timing chain guide bolt M6 1 10 Nm 1 0 m kgf 7 2 ...

Page 45: ...See TIP l 60 mm 2 36 in Crankcase bolt M6 8 See TIP l 40 mm 1 57 in Oil pressure switch PT1 8 1 15 Nm 1 5 m kgf 11 ft lbf Three bond No 1215 Oil pressure switch lead bolt M4 1 1 8 Nm 0 18 m kgf 1 3 ft lbf Oil pressure switch lead holder bolt M6 1 7 Nm 0 7 m kgf 5 1 ft lbf Blind plate bolt M6 1 10 Nm 1 0 m kgf 7 2 ft lbf Gear position switch bolt M5 2 4 0 Nm 0 40 m kgf 2 9 ft lbf Cylinder plug bolt...

Page 46: ... lbf Oil filter cartridge M20 1 17 Nm 1 7 m kgf 12 ft lbf Oil filter cartridge union bolt M20 1 40 Nm 4 0 m kgf 29 ft lbf Coolant temperature sensor M10 1 16 Nm 1 6 m kgf 12 ft lbf Thermostat cover bolt M6 2 12 Nm 1 2 m kgf 8 7 ft lbf Water pump housing bolt M6 3 10 Nm 1 0 m kgf 7 2 ft lbf Water pump inlet outlet pipe bolt M6 2 10 Nm 1 0 m kgf 7 2 ft lbf Coolant drain bolt M6 1 7 Nm 0 7 m kgf 5 1 ...

Page 47: ... Tighten the crankcase bolts 1 6 to 24 Nm 2 4 m kgf 17 ft lbf 3 Loosen and retighten the crankcase bolts 1 6 to 17 Nm 1 7 m kgf 12 ft lbf in the proper tight ening sequence and then tighten them further to reach the specified angle 60 in the proper tight ening sequence 4 Tighten the crankcase bolts 7 27 7 14 24 Nm 2 4 m kgf 17 ft lbf 15 16 10 Nm 1 0 m kgf 7 2 ft lbf 17 27 10 Nm 1 0 m kgf 7 2 ft lb...

Page 48: ...onnecting rod bolt Tighten the connecting rod bolts to 20 Nm 2 0 m kgf 14 ft lbf and then tighten them further to reach the specified angle 175 185 8 3 2 6 2 6 11 10 5 4 7 8 1 2 13 16 6 3 12 9 20 19 15 21 22 17 18 14 26 27 24 23 25 ...

Page 49: ...olt M5 2 4 0 Nm 0 40 m kgf 2 9 ft lbf Battery terminal bolt M6 2 2 3 Nm 0 23 m kgf 1 7 ft lbf Lean angle sensor bolt M4 2 2 0 Nm 0 20 m kgf 1 4 ft lbf Starter relay bolt M6 2 3 6 Nm 0 36 m kgf 2 6 ft lbf Battery box bolt M6 4 9 Nm 0 9 m kgf 6 5 ft lbf Battery box nut M6 2 4 0 Nm 0 40 m kgf 2 9 ft lbf Tail brake light nut M6 2 3 0 Nm 0 30 m kgf 2 2 ft lbf Rear fender cover bolt M5 5 6 Nm 0 6 m kgf ...

Page 50: ...M10 6 80 Nm 8 0 m kgf 58 ft lbf Rear brake disc bolt M8 5 30 Nm 3 0 m kgf 22 ft lbf Rear wheel sensor rotor bolt M5 3 8 Nm 0 8 m kgf 5 8 ft lbf Rear wheel sensor bolt M6 1 7 Nm 0 7 m kgf 5 1 ft lbf Wheel axle nut M18 1 105 Nm 10 5 m kgf 76 ft lbf Rear brake caliper retaining bolt M12 1 27 Nm 2 7 m kgf 20 ft lbf Rear brake caliper bolt M8 1 22 Nm 2 2 m kgf 16 ft lbf Brake master cylinder reservoir ...

Page 51: ...Nm 0 18 m kgf 1 3 ft lbf Meter assembly bracket bolt M6 2 7 Nm 0 7 m kgf 5 1 ft lbf Front fork damper rod bolt M10 2 30 Nm 3 0 m kgf 22 ft lbf Lower bracket pinch bolt M8 4 23 Nm 2 3 m kgf 17 ft lbf Upper bracket pinch bolt left and right M8 2 26 Nm 2 6 m kgf 19 ft lbf Upper bracket pinch bolt center M10 1 21 Nm 2 1 m kgf 15 ft lbf Front fork cap bolt M38 2 23 Nm 2 3 m kgf 17 ft lbf Front fender b...

Page 52: ...Nm 5 2 m kgf 38 ft lbf Drive sprocket cover bolt M6 3 10 Nm 1 0 m kgf 7 2 ft lbf Drive sprocket nut M22 1 95 Nm 9 5 m kgf 69 ft lbf Stake Shift rod locknut shift arm side M6 1 9 Nm 0 9 m kgf 6 5 ft lbf Shift rod locknut shift pedal side M6 1 9 Nm 0 9 m kgf 6 5 ft lbf Left hand threads Shift arm pinch bolt M6 1 14 Nm 1 4 m kgf 10 ft lbf Shift rod upper joint bolt M6 1 9 Nm 0 9 m kgf 6 5 ft lbf Fuel...

Page 53: ...aft journals Balancer shaft journals Generator rotor bolt thread and washer Balancer shaft buffer plate bolt Oil pump rotors inner and outer Oil pump shaft Oil cooler union bolt Starter clutch idle gear inner surface and end Starter clutch outer assembly Starter clutch gear Primary driven gear end Crankcase cover and clutch pull rod Clutch housing thrust washer Clutch boss nut and conical washer T...

Page 54: ...lay arm spacer Shift pedal pivoting point and metal to metal moving parts Shift rod joint engine side Rear brake pedal pivoting point and metal to metal moving parts Upper bearing and lower bearing Upper bearing cover seal lip and lower bearing dust seal lip Throttle cable housing inner surface and throttle cable Clutch lever pivoting point and clutch cable Sidestand pivoting point and metal to me...

Page 55: ...LUBRICATION POINTS AND LUBRICANT TYPES 2 26 ...

Page 56: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 27 EAS20019 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS30020 ENGINE OIL LUBRICATION CHART 1 2 7 3 4 5 6 8 9 9 10 11 12 13 14 15 ...

Page 57: ...trainer 2 Oil pump 3 Relief valve 4 Oil cooler 5 Oil filter cartridge 6 Main gallery 7 Oil pressure switch 8 Crankshaft 9 Oil nozzle 10 Balancer shaft assembly 11 Timing chain tensioner 12 Intake camshaft 13 Exhaust camshaft 14 Main axle 15 Drive axle ...

Page 58: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 29 EAS30021 LUBRICATION DIAGRAMS Crankcase cylinder and cylinder head right side view 1 2 3 4 5 6 7 8 9 ...

Page 59: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 30 1 Timing chain tensioner 2 Intake camshaft 3 Exhaust camshaft 4 Crankshaft 5 Oil filter cartridge 6 Oil cooler 7 Oil drain bolt 8 Oil strainer 9 Oil pump ...

Page 60: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 31 Crankcase and cylinder left side view 1 2 3 4 5 ...

Page 61: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 32 1 Crankshaft 2 Balancer shaft assembly 3 Connecting rod 4 Oil cooler 5 Oil filter cartridge ...

Page 62: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 33 Oil pump bottom view 2 3 4 5 1 ...

Page 63: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 34 1 Oil pump 2 Oil pressure switch 3 Oil filter cartridge 4 Oil cooler 5 Oil strainer ...

Page 64: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 35 Camshaft top view 2 3 3 1 3 ...

Page 65: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 36 1 Intake camshaft 2 Cylinder head 3 Exhaust camshaft ...

Page 66: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 37 Crankshaft front view 3 4 1 2 1 ...

Page 67: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 38 1 Oil nozzle 2 Piston 3 Crankshaft 4 Main gallery ...

Page 68: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 39 Crankshaft and transmission top view 1 2 4 3 ...

Page 69: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 40 1 Balancer shaft assembly 2 Crankshaft 3 Main axle 4 Drive axle ...

Page 70: ...COOLING SYSTEM DIAGRAMS 2 41 EAS20020 COOLING SYSTEM DIAGRAMS 1 2 3 4 5 6 7 7 8 9 10 6 3 4 5 8 ...

Page 71: ...AMS 2 42 1 Thermostat 2 Oil cooler inlet hose 3 Oil cooler 4 Oil cooler outlet hose 5 Water jacket joint inlet hose 6 Water pump outlet pipe 7 Water pump inlet pipe 8 Radiator outlet hose 9 Water jacket joint 10 Water pump ...

Page 72: ...G 2 43 EAS20021 CABLE ROUTING Handlebar front view I J K L I J L K M 1 2 14 3 10 5 14 11 H G 16 11 17 P 6 7 11 12 Q K L A F 1 2 3 4 5 13 14 15 B 6 7 7 C 8 9 7 10 D E 11 12 K L N O 13 1 14 3 5 14 18 19 5 20 18 22 21 ...

Page 73: ...ide B Fasten the left handlebar switch coupler to the wire harness with tape and then place the coupler in the coupler cover Make sure that the wire harness is positioned to the rear of the coupler C Route the throttle cables through the guide Be sure to route the throttle cable decelerator cable over the throttle cable accelerator cable D Connect the sub wire harness coupler headlight turn signal...

Page 74: ...CABLE ROUTING 2 45 ECU and clutch cable right side view 3 14 11 12 19 20 D B 16 C 11 12 1 2 3 5 4 4 6 7 8 11 12 13 14 15 10 3 9 E F I 13 18 E F G H 12 18 17 A F E ...

Page 75: ...air temperature sensor coupler 15 Brake hose hydraulic unit to left front brake caliper 16 Meter assembly cover 17 Damper 18 Frame 19 Cylinder head breather hose 20 Sub wire harness A Route the clutch cable through the guide as shown in the illustration B Fasten the brake hose hydraulic unit to left front brake caliper and front wheel sensor lead with the holders Refer to CABLE ROUTING Hydraulic u...

Page 76: ...CABLE ROUTING 2 47 Canister right side view E A B C D 1 2 3 4 5 6 7 11 12 B F G H 8 9 10 L M N O 1 11 L M N O 3 6 7 17 J K 13 14 15 16 I 13 14 15 ...

Page 77: ... inside of the O2 sensor lead and then secure the leads by bending the guides around the leads C Do not pinch the O2 sensor lead between the pivot shaft protector and the engine D Fasten the rear brake light switch lead and O2 sensor lead with the holder E To rear brake caliper bracket F Connect the O2 sensor coupler and then insert the projection on the coupler into the hole in the bracket G Make...

Page 78: ...CABLE ROUTING 2 49 Rectifier regulator left side view B A C E F G H I J 1 3 4 5 6 7 10 11 12 13 14 D 8 9 L M Q R S 9 11 T U V 23 24 25 26 27 28 L M 1 13 14 15 16 N O P 17 18 19 20 21 22 2 2 1 L M K ...

Page 79: ... magneto lead F Secure the holder by inserting the projection on the holder into the hole in the radiator fan motor bracket and then fasten the AC magneto lead horn lead and coolant reservoir hose with the holder Make sure that the coolant reservoir hose and leads do not cross between the oil cooler inlet hose and this holder G Fasten the AC magneto lead horn lead and coolant reservoir hose with t...

Page 80: ...CABLE ROUTING 2 51 Canister left side view A B C D 1 2 3 4 5 6 7 8 9 10 11 12 11 12 14 15 1 8 19 20 N O F G F G E 1 16 17 1 H 6 6 7 18 18 F G I J 7 12 13 19 K L M 12 13 ...

Page 81: ...r motor lead to the frame with plastic locking ties Point the end of each plastic locking tie rearward and then cut off the excess end of the tie to 2 mm 0 08 in or less B Make sure that the starter motor lead is not twisted C Fasten the starter motor lead and engine ground lead with the holder Align the white tape on the starter motor lead with the holder D Make sure that there is no twist in the...

Page 82: ...ectrical components tray top view 8 K 24 25 M N D E F G 20 25 26 D E L 1 2 4 5 27 D E F G 18 19 20 25 D E F G 18 19 20 25 D E F G H 20 25 F G I J 25 26 I A B 1 2 3 4 5 6 7 9 10 11 12 13 14 15 16 17 18 19 22 23 24 20 15 21 C ...

Page 83: ...5 Frame 26 Main switch lead 27 Electrical components tray 1 A Insert the projection on the bracket into the hole in the sub wire harness coupler B White paint mark C Insert the projection on the wire harness holder into the hole in the frame D Forward E Rearward F Inward G Outward H Insert the projection on the wire harness holder into the hole in the frame from the bottom of the frame I Route the...

Page 84: ...CABLE ROUTING 2 55 Battery and rear fender top view 1 2 2 3 3 8 9 4 5 6 7 8 8 9 9 10 10 10 12 11 12 13 14 14 14 15 15 16 16 17 17 18 18 19 20 14 11 21 22 E A B C F G I H G F G F D ...

Page 85: ...15 Tail brake light lead 16 Rear fender 17 Lower fender cover 18 Frame 19 Rear turn signal light coupler 20 License plate light coupler 21 Battery 22 Battery box A Route the positive battery lead through the hole in the battery band B Position the Yamaha diagnostic tool lead and coupler above fuse boxes 1 and 2 as shown in the illustration C Connect all of the couplers near fuse box 2 and then ins...

Page 86: ...CABLE ROUTING 2 57 Rear brake hose right side view E I J K L G M 1 1 5 5 4 5 2 2 2 2 2 6 7 E H 1 5 2 A B C F D D D 1 2 3 8 8 5 4 4 4 2 6 7 F ...

Page 87: ...ce the buckle of the plastic locking tie inward with the end pointing downward G Route the brake hoses on top of the frame H Point the end of the plastic locking tie rearward and then cut off the excess end of the tie to 5 mm 0 20 in or less I Fasten the grommets on the rear wheel sensor lead and the brake hose hydraulic unit to rear brake caliper with the holder J Fasten the rear wheel sensor lea...

Page 88: ...CABLE ROUTING 2 59 Front brake hose left and right side view A B C D E D F G H G I 1 1 2 2 2 3 2 3 4 1 ...

Page 89: ... over the hose C Face the catch of the holder forward and then close the holder until three clicks or more are heard D Make sure that the holder contacts the end of the hose protector on the brake hose E Fasten the front wheel sensor lead and brake hose hydraulic unit to left front brake caliper with the holder as shown in the illustration Position the holder 30 50 mm 1 18 1 97 in from the grommet...

Page 90: ...CABLE ROUTING 2 61 Hydraulic unit assembly top and right side view A 1 1 2 2 2 4 3 4 4 3 4 5 5 B C E F H G D E F 3 ...

Page 91: ...ar brake caliper A Make sure that the pipe section of the brake hose rear brake master cylinder to hydraulic unit does not contact the hydraulic unit B Protective sleeve and tape C Tape D Fasten the front wheel sensor lead to the brake hose hydraulic unit to left front brake caliper with the holder Align the edge of the holder with the edge of the tape on the front wheel sensor lead as shown in th...

Page 92: ...CABLE ROUTING 2 63 Fuel tank left side view A B C 1 2 3 4 B ...

Page 93: ... up to the wide portion of the pipe B Align the ends of the hose clamp with the paint mark on the hose Make sure not to install the hose clamp on the raised portion of the hose fitting Make sure that the hose clamp does not contact the bottom of the fuel tank C Face the white paint mark on the fuel tank overflow hose to the right Install the hose up to the wide portion of the pipe ...

Page 94: ...CABLE ROUTING 2 65 Throttle body top right and left side view E F G H I J 6 6 5 8 8 8 D A B C D 1 2 3 4 5 6 7 ...

Page 95: ... making sure that the hose contacts the throttle body assembly D Forward E Face the yellow paint mark on the cylinder head breather hose to the left Install the cylinder head breather hose completely onto the hose fitting F Position the hose clamp 1 4 mm 0 04 0 16 in from the end of the hose Point the ends of the hose clamp to the left G Position the hose clamp 1 4 mm 0 04 0 16 in from the end of ...

Page 96: ...CABLE ROUTING 2 67 Radiator front view A B 1 2 3 4 5 6 ...

Page 97: ... Coolant reservoir hose 4 Radiator inlet hose 5 Coolant reservoir 6 Radiator outlet hose A Connect the end of the coolant reservoir hose that is identified by the white paint mark to the radiator B Point the ends of the hose clamp toward the frame ...

Page 98: ...CABLE ROUTING 2 69 Radiator left side view A B C D I F H G E 1 1 2 6 5 5 3 4 4 4 5 6 7 8 9 10 10 11 12 ...

Page 99: ...lastic locking tie inward with the end pointing downward B Align the white paint mark on the radiator inlet hose with the projection on the thermostat housing Install the radiator inlet hose onto the thermostat housing making sure that the hose contacts the projection on the housing C Point the ends of the hose clamp outward D Install the coolant reservoir hose onto the coolant reservoir cap makin...

Page 100: ...CABLE ROUTING 2 71 Radiator right side view A B C 3 4 2 1 5 7 8 6 ...

Page 101: ...paint marks on the radiator inlet hose and coolant reservoir hose B Point the ends of the hose clamp in the direction shown in the illustration Make sure that the ends of the hose clamp do not contact the coolant reservoir hose C Align the yellow paint mark on the radiator inlet hose with the projection on the radiator pipe Install the radiator inlet hose onto the radiator pipe making sure that th...

Page 102: ...CABLE ROUTING 2 73 ...

Page 103: ... CHECKING THE BRAKE FLUID LEVEL 3 15 CHECKING THE WHEELS 3 16 CHECKING THE TIRES 3 16 CHECKING THE WHEEL BEARINGS 3 17 CHECKING THE SWINGARM OPERATION 3 17 LUBRICATING THE SWINGARM PIVOT 3 17 ADJUSTING THE DRIVE CHAIN SLACK 3 17 LUBRICATING THE DRIVE CHAIN 3 19 CHECKING AND ADJUSTING THE STEERING HEAD 3 19 LUBRICATING THE STEERING HEAD 3 19 CHECKING THE CHASSIS FASTENERS 3 19 LUBRICATING THE BRAKE...

Page 104: ...NG AND LUBRICATING THE CABLES 3 26 CHECKING THE THROTTLE GRIP OPERATION 3 27 CHECKING AND CHARGING THE BATTERY 3 28 CHECKING THE FUSES 3 28 REPLACING THE HEADLIGHT BULB 3 28 ADJUSTING THE HEADLIGHT BEAM 3 29 REPLACING THE LICENSE PLATE LIGHT BULB 3 29 ...

Page 105: ......

Page 106: ...T TIP The annual checks must be performed every year except if a kilometer based maintenance or for the UK a mileage based maintenance is performed instead From 50000 km 30000 mi repeat the maintenance intervals starting from 10000 km 6000 mi Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools data and technical skills NO ITEM CHECK OR MAINTENANCE JOB...

Page 107: ...t all nuts bolts and screws are properly tight ened 15 Brake lever pivot shaft Lubricate with silicone grease 16 Brake pedal pivot shaft Lubricate with lithium soap based grease 17 Clutch lever pivot shaft Lubricate with lithium soap based grease 18 Shift pedal pivot shaft Lubricate with lithium soap based grease 19 Sidestand Check operation Lubricate with lithium soap based grease 20 Sidestand sw...

Page 108: ...uid level Every two years replace the internal components of the brake master cylinders and calipers and change the brake fluid Replace the brake hoses every four years and if cracked or damaged 28 Moving parts and cables Lubricate 29 Throttle grip Check operation Check throttle grip free play and adjust if necessary Lubricate cable and grip housing 30 Lights signals and switches Check operation A...

Page 109: ...fuel tank bracket bolt 4 Install Fuel tank center cover Fuel tank covers Fuel tank top cover Refer to GENERAL CHASSIS 3 on page 4 5 Seat Refer to GENERAL CHASSIS 1 on page 4 1 EAS30620 CHECKING THE SPARK PLUGS The following procedure applies to all of the spark plugs 1 Remove Seat Refer to GENERAL CHASSIS 1 on page 4 1 Fuel tank top cover Fuel tank covers Fuel tank center cover Air scoops Refer to...

Page 110: ...is to be measured or adjusted the piston must be at top dead center TDC on the compression stroke 1 Drain Coolant Refer to CHANGING THE COOLANT on page 3 24 2 Remove Seat Refer to GENERAL CHASSIS 1 on page 4 1 Fuel tank top cover Fuel tank covers Fuel tank center cover Air scoop Refer to GENERAL CHASSIS 3 on page 4 5 Fuel tank Refer to FUEL TANK on page 7 1 Radiator Radiator inlet hose Refer to RA...

Page 111: ...To measure the valve clearances of cylinder 2 turn the crankshaft 270 counterclock wise 6 Remove Camshaft TIP Refer to CHANGING THE COOLANT on page 3 24 When removing the timing chain and cam shafts fasten the timing chain with a wire to re trieve it if it falls into the crankcase 7 Adjust Valve clearance a Remove the valve lifter 1 and the valve pad 2 with a valve lapper 3 Thickness gauge 90890 0...

Page 112: ...the values obtained in steps b and c to determine the required valve pad thickness and the valve pad num ber Example 1 58 mm 0 0622 in 0 05 mm 0 0020 in 1 63 mm 0 0641 in The valve pad number is 163 e Round off the valve pad number according to the following table and then select the suit able valve pad TIP Refer to the following table for the available valve pads Example Valve pad number 163 Roun...

Page 113: ...heck the intake system 02 Clean the ISC idle speed control valve Refer to CLEANING THE ISC IDLE SPEED CONTROL VALVE on page 7 10 a Connect the Yamaha diagnostic tool Use the diagnostic code number 67 Refer to SELF DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE on page 9 5 b Check the ISC idle speed control leaning value EAS30797 SYNCHRONIZING THE THROTTLE BODIES TIP Before synchronizing the throttl...

Page 114: ...rottle body 2 using the air screw 1 TIP Turn the bypass air screw using the carburetor angle driver After each step rev the engine two or three times each time for less than a second and check the synchronization again If a bypass air screw was removed turn the screw in fully and be sure to synchronize the throttle bodies If the throttle body synchronization can not be adjusted using the bypass ai...

Page 115: ...rs Refer to GENERAL CHASSIS 3 on page 4 5 Fuel tank Refer to FUEL TANK on page 7 1 2 Disconnect Intake air pressure sensor hose Refer to THROTTLE BODIES on page 7 7 3 Remove Throttle bodies Refer to THROTTLE BODIES on page 7 7 4 Check Throttle body joints Cracks damage Replace 5 Install Throttle bodies Refer to THROTTLE BODIES on page 7 7 6 Connect Intake air pressure sensor hose Refer to THROTTLE...

Page 116: ...ck Air filter element Damage Replace TIP Replace the air filter element every 40000 km 24000 mi of operation The air filter needs more frequent service if you are riding in unusually wet or dusty areas 5 Install Air filter element Air duct bracket NOTICE ECA14401 Never operate the engine without the air filter element installed Unfiltered air will cause rapid wear of engine parts and may damage th...

Page 117: ...properly Check the brake system Refer to FRONT BRAKE on page 4 29 and REAR BRAKE on page 4 43 TIP Drive on the dry road operate the front and rear brakes separately and check to see if the brakes are operating properly EAS30630 ADJUSTING THE FRONT DISC BRAKE 1 Adjust Brake lever position distance a from the throttle grip to the brake lever TIP While pushing the brake lever forward turn the adjusti...

Page 118: ...sc Replace the brake pads as a set Refer to FRONT BRAKE on page 4 29 EAS30631 ADJUSTING THE REAR DISC BRAKE 1 Adjust Brake pedal position a Loosen the locknut 1 b Turn the adjusting nut 2 in direction a or b until the specified brake pedal position is ob tained WARNING EWA13070 After adjusting the brake pedal position check that the end of the adjusting bolt c is visible through the hole d c Tight...

Page 119: ... 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 EWA16530 Bleed the ABS whenever the system is disassembled a brake hose is loosened disconnected or replaced the brake fluid level is very low brake operation is faulty TIP Be careful not to spill any brake fluid or allow the brake master...

Page 120: ...he operation of the hydraulic unit k After operating the ABS repeat steps e to i and then fill the brake master cylinder res ervoir or brake fluid reservoir to the proper level with the specified brake fluid l Tighten the bleed screw to specification m Fill the brake master cylinder reservoir or brake fluid reservoir to the proper level with the specified brake fluid Refer to CHECKING THE BRAKE FL...

Page 121: ...make any repairs to the wheel TIP After a tire or wheel has been changed or re placed always balance the wheel EAS30640 CHECKING THE TIRES The following procedure applies to both of the tires 1 Check Tire pressure Out of specification Regulate WARNING EWA13181 The tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperature The tire pressure and t...

Page 122: ...eel bearings Refer to CHECKING THE FRONT WHEEL on page 4 14 and CHECKING THE REAR WHEEL on page 4 24 EAS30802 CHECKING THE SWINGARM OPERATION 1 Check Swingarm operation Swingarm not working properly Check the swingarm Refer to SWINGARM on page 4 88 2 Check Swingarm excessive play Refer to SWINGARM on page 4 88 EAS30643 LUBRICATING THE SWINGARM PIVOT 1 Lubricate Bearing Spacer Refer to INSTALLING T...

Page 123: ... can dam age the frame swingarm and other parts To prevent this from occurring keep the drive chain slack within the specified limits 4 Loosen Wheel axle nut 1 5 Adjust Drive chain slack a Loosen both of the drive chain puller locknuts 1 b Turn both of the drive chain puller adjusting nuts 2 in direction a or b until the speci fied drive chain slack is obtained TIP To maintain the proper wheel ali...

Page 124: ... fork Blinding looseness Adjust the steering head 3 Remove Upper bracket Refer to FRONT FORK on page 4 70 4 Adjust Steering head a Loosen the cap nut 1 and then tighten it to specification with a steering nut wrench 2 TIP Set the torque wrench at a right angle to the steering nut wrench Move the steering to the left and right a couple of times to check that it moves smoothly b Loosen the cap nut c...

Page 125: ...k 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 movement Repair Refer to FRONT FORK on page 4 70 EAS30808 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY Re...

Page 126: ... clutch slippage Therefore do not add any chemical additives or use engine oils with a grade of CD or higher and do not use oils labeled ENERGY CONSERVING II Do not allow foreign materials to enter the crankcase 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 set...

Page 127: ...lt along with the gasket 7 Fill Oil pan with the specified amount of the recom mended engine oil 8 Install Engine oil filler cap along with the O ring 9 Start the engine warm it up for several min utes and then turn it off 10 Check Engine for engine oil leaks 11 Check Engine oil level Refer to CHECKING THE ENGINE OIL LEVEL on page 3 21 Oil filter wrench 90890 01426 Oil filter wrench YU 38411 1 3 2...

Page 128: ...engine oil are ex tremely hot 5 Install Oil pressure gauge 1 Adapter 2 6 Measure Engine oil pressure at the following conditions Out of specification Check 7 Install Main gallery bolt O ring TIP Lubricate the O ring 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 a suitable stand Make sure the vehicle...

Page 129: ... outlet hose 3 Oil cooler 4 Oil cooler inlet hose 5 Oil cooler outlet hose 6 Water jacket joint 7 Water jacket joint inlet hose 8 Thermostat cover 9 Thermostat 10 Water pump inlet pipe 11 Water pump outlet pipe 12 Cracks damage Replace Refer to RADIATOR on page 6 1 OIL COOLER on page 6 5 THERMOSTAT on page 6 7 and WATER PUMP on page 6 9 EAS30813 CHANGING THE COOLANT 1 Remove Radiator cap bolt 1 Ra...

Page 130: ...ick fastener Coolant reservoir bolt 9 Fill Cooling system with the specified amount of the recom mended coolant Handling notes for coolant Coolant is potentially harmful and should be handled with special care 1 2 1 4 5 3 1 2 T R Coolant drain bolt 7 Nm 0 7 m kgf 5 1 ft lbf T R Coolant reservoir bolt 5 Nm 0 5 m kgf 3 6 ft lbf Recommended antifreeze High quality ethylene glycol anti freeze containi...

Page 131: ... the engine warm it up for several min utes and then turn it off 14 Check Coolant level Refer to CHECKING THE COOLANT LEV EL on page 3 23 TIP Before checking the coolant level wait a few minutes until the coolant has settled EAS30814 CHECKING THE FRONT BRAKE LIGHT SWITCH Refer to CHECKING THE SWITCHES on page 8 153 EAS30659 ADJUSTING THE REAR BRAKE LIGHT SWITCH TIP The rear brake light switch is o...

Page 132: ...thly and returns properly when released Repeat this check with the handlebar turned all the way to the left and right 3 Check Throttle grip free play a Out of specification Adjust 4 Adjust Throttle grip free play TIP Prior to adjusting the throttle grip free play throt tle body synchronization should be adjusted properly Throttle body side a Loosen the locknut 1 on the accelerator ca ble b Turn th...

Page 133: ...ens unit bolt 1 Headlight lens unit 2 2 Disconnect Headlight coupler 3 3 Remove Headlight bulb cover 4 4 Detach Headlight bulb holder 5 5 Remove Headlight bulb 6 WARNING EWA13320 Since the headlight bulb gets extremely hot keep flammable products and your hands away from the bulb until it has cooled down 6 Install Headlight bulb Secure the new headlight bulb with the head light bulb holder NOTICE ...

Page 134: ...direction a or b 2 Adjust Headlight beam horizontally a Turn the adjusting screw 1 in direction a or b EAS31831 REPLACING THE LICENSE PLATE LIGHT BULB 1 Remove Lower fender cover screws 1 Lower fender cover 2 2 Remove License plate bracket bolts 1 License plate bracket 2 3 Remove License plate nuts 1 License plate light T R Headlight lens unit bolt 4 0 Nm 0 40 m kgf 2 9 ft lbf Direction a Headligh...

Page 135: ...stall License plate light License plate nuts License plate bracket License plate bracket bolts Lower fender cover Lower fender cover screws T R License plate nut 3 8 Nm 0 38 m kgf 2 8 ft lbf License plate bracket bolt 6 Nm 0 6 m kgf 4 3 ft lbf Lower fender cover screw 2 0 Nm 0 20 m kgf 1 4 ft lbf 1 New ...

Page 136: ...PERIODIC MAINTENANCE 3 31 ...

Page 137: ...THE FRONT WHEEL 4 14 DISASSEMBLING THE FRONT WHEEL 4 14 CHECKING THE FRONT WHEEL 4 14 MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR 4 15 ASSEMBLING THE FRONT WHEEL 4 16 ADJUSTING THE FRONT WHEEL STATIC BALANCE 4 16 INSTALLING THE FRONT WHEEL DISC BRAKE 4 17 REAR WHEEL 4 20 REMOVING THE REAR WHEEL DISC BRAKE 4 24 DISASSEMBLING THE REAR WHEEL 4 24 CHECKING THE REAR WHEEL 4 24 CHECKING THE R...

Page 138: ...THE REAR BRAKE CALIPER 4 51 CHECKING THE REAR BRAKE CALIPER 4 51 ASSEMBLING THE REAR BRAKE CALIPER 4 52 INSTALLING THE REAR BRAKE CALIPER 4 52 REMOVING THE REAR BRAKE MASTER CYLINDER 4 53 CHECKING THE REAR BRAKE MASTER CYLINDER 4 53 ASSEMBLING THE REAR BRAKE MASTER CYLINDER 4 54 INSTALLING THE REAR BRAKE MASTER CYLINDER 4 54 ABS ANTI LOCK BRAKE SYSTEM 4 56 REMOVING THE HYDRAULIC UNIT ASSEMBLY 4 58...

Page 139: ...Y ARM 4 86 INSTALLING THE RELAY ARM 4 86 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 4 87 SWINGARM 4 88 REMOVING THE SWINGARM 4 90 CHECKING THE SWINGARM 4 90 CHECKING THE CONNECTING ARM 4 90 INSTALLING THE CONNECTING ARM 4 91 INSTALLING THE SWINGARM 4 91 CHAIN DRIVE 4 93 REMOVING THE DRIVE CHAIN 4 95 REMOVING THE DRIVE SPROCKET 4 95 CHECKING THE DRIVE CHAIN 4 95 CHECKING THE DRIVE SPROCKET 4 97 CH...

Page 140: ... ty Remarks 1 Seat 1 2 Seat bracket 1 3 Yamaha diagnostic tool coupler 1 4 Battery cover 1 5 Negative battery lead 1 Disconnect 6 Positive battery lead 1 Disconnect 7 Battery band 1 8 Battery 1 7 Nm 0 7 m kgf 5 1 ft Ibf T R 4 0 Nm 0 40 m kgf 2 9 ft Ibf T R 2 3 Nm 0 23 m kgf 1 7 ft Ibf T R 1 5 8 6 7 3 4 2 4 ...

Page 141: ...coupler 1 TIP Install the Yamaha diagnostic tool coupler onto the tab a on the battery cover EAS30125 INSTALLING THE SEAT 1 Install Seat 1 TIP Fit the slot a in the seat onto the projection b on the rider seat bracket as shown push the rear of the seat down to lock it in place and then re move the key 1 a a 1 b ...

Page 142: ... turn signal light coupler left 1 Disconnect 7 Front turn signal light left 1 8 Front turn signal light coupler right 1 Disconnect 9 Front turn signal light right 1 10 Headlight lens unit bracket 1 11 Headlight body 1 12 Meter assembly cover 1 4 0 Nm 0 40 m kgf 2 9 ft Ibf T R 4 0 Nm 0 40 m kgf 2 9 ft Ibf T R 4 0 Nm 0 40 m kgf 2 9 ft Ibf T R 4 0 Nm 0 40 m kgf 2 9 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ib...

Page 143: ...MBLY 1 Install Headlight assembly 1 TIP Fit the projections a on the headlight bracket into the grooves b in the headlight assembly T R Headlight assembly bolt M6 16 mm 7 Nm 0 7 m kgf 5 1 ft lbf Headlight assembly bolt M5 12 mm 4 0 Nm 0 40 m kgf 2 9 ft lbf b 1 a ...

Page 144: ...er 1 5 Air scoop left 1 6 Air scoop right 1 7 Outer side cover left 1 8 Inner side cover left 1 9 Outer side cover right 1 10 Inner side cover right 1 4 3 3 4 4 6 1 2 3 4 5 6 8 10 9 7 8 1 5 Nm 0 15 m kgf 1 1 ft Ibf T R 4 0 Nm 0 40 m kgf 2 9 ft Ibf T R 4 0 Nm 0 40 m kgf 2 9 ft Ibf T R 4 0 Nm 0 40 m kgf 2 9 ft Ibf T R 4 0 Nm 0 40 m kgf 2 9 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ...

Page 145: ...o both of the fuel tank covers 1 Install Fuel tank cover 1 TIP Align the holes a in the fuel tank cover with the projections b on the fuel tank center cover and fit the fuel tank cover into the slots c in the fuel tank center cover T R Fuel tank cover bolt 4 0 Nm 0 40 m kgf 2 9 ft lbf a a b c b 1 ...

Page 146: ...at Refer to GENERAL CHASSIS 1 on page 4 1 Fuel tank center cover Outer side cover left In ner side cover left Refer to GENERAL CHASSIS 3 on page 4 5 Fuel tank Refer to FUEL TANK on page 7 1 1 Air duct bracket 1 2 Air duct 1 3 Air filter element 1 1 2 4 3 New 1 6 Nm 0 16 m kgf 1 2 ft Ibf T R 1 6 Nm 0 16 m kgf 1 2 ft Ibf T R ...

Page 147: ...AS31797 INSTALLING THE AIR DUCT 1 Install Air duct 1 TIP Align the tab a on the air duct between the projections b on the air duct bracket Align the projection c on the air duct with the slot d in the seal 2 a 1 b d c 1 1 2 2 ...

Page 148: ...age 4 5 Fuel tank Refer to FUEL TANK on page 7 1 Hydraulic unit assembly Refer to ABS ANTI LOCK BRAKE SYS TEM on page 4 56 1 Stator coil coupler 1 Disconnect 2 Rectifier regulator coupler 1 Disconnect 3 Rectifier regulator 1 4 Turn signal hazard relay 1 5 Headlight relay 1 6 Relay unit 1 7 Fan motor relay 1 4 0 Nm 0 40 m kgf 2 9 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T ...

Page 149: ...an motor coupler 1 12 Crankshaft position sensor coupler 1 13 Electrical components tray 1 1 14 ECU coupler 1 Disconnect 15 ECU Engine Control Unit 1 16 Band 1 17 Sub wire harness coupler 1 18 Electrical components tray 2 1 4 0 Nm 0 40 m kgf 2 9 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 13 12 10 11 8 9 18 17 1...

Page 150: ...a of the coupler in the direction of the arrow shown EAS31129 INSTALLING THE ELECTRICAL COMPONENTS TRAYS 1 Install Electrical components tray 2 1 TIP Tighten the electrical components tray 2 nuts and bolt in the proper tightening sequence as shown 2 Install Intake air pressure sensor 1 TIP Make sure that the intake air pressure sensor contacts the frame T R Electrical components tray 2 nut 7 Nm 0 ...

Page 151: ... Loosen 6 Front wheel axle 1 7 Collar 2 8 Front wheel 1 9 Front brake disc 2 10 Front wheel sensor rotor 1 7 Nm 0 7 m kgf 5 1 ft Ibf T R 18 Nm 1 8 m kgf 13 ft Ibf T R 18 Nm 1 8 m kgf 13 ft Ibf T R 23 Nm 2 3 m kgf 17 ft Ibf T R 40 Nm 4 0 m kgf 29 ft Ibf T R 40 Nm 4 0 m kgf 29 ft Ibf T R 65 Nm 6 5 m kgf 47 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 8 Nm 0 8 m kgf 5 8 ft Ibf T R LT LT LT LT New New New...

Page 152: ...FRONT WHEEL 4 13 Disassembling the front wheel Order Job Parts to remove Q ty Remarks 1 Oil seal 2 2 Wheel bearing 2 3 Spacer 1 New New LS LS New New 1 1 2 2 3 ...

Page 153: ... brake lever when remov ing the brake calipers Be sure not to contact the sensor electrode to any metal part when removing the front wheel sensor from the outer tube 3 Elevate Front wheel TIP Place the vehicle on a suitable stand so that the front wheel is elevated EAS30146 DISASSEMBLING THE FRONT WHEEL 1 Remove Oil seal Wheel bearings a Clean the surface of the front wheel hub b Remove the oil se...

Page 154: ...hock the wheel sensor or the wheel sensor rotor 1 Check Front wheel sensor 1 Cracks bends distortion Replace Iron powder dust Clean 2 Check Front wheel sensor rotor 1 Cracks damage scratches Replace the front wheel sensor rotor Iron powder dust solvent Clean TIP The wheel sensor rotor is installed on the inner side of the wheel hub When cleaning the wheel sensor rotor be careful not to damage the ...

Page 155: ... new wheel bearing right side NOTICE ECA18110 Do not contact the wheel bearing inner race 1 or balls 2 Contact should be made only with the outer race 3 TIP Use a socket 4 that matches the diameter of the wheel bearing outer race b Install the spacer c Install the new wheel bearing left side TIP Place a suitable washer 1 between the socket 2 and the bearing so that both the inner race 3 and outer ...

Page 156: ...he same spot g The spot where all the marks come to rest is the front wheel s heavy spot X 3 Adjust Front wheel static balance a Install a balancing weight 1 onto the rim ex actly opposite the heavy spot X TIP Start with the lightest weight b Turn the front wheel 90 so that the heavy spot is positioned as shown c If the heavy spot does not stay in that posi tion install a heavier weight d Repeat s...

Page 157: ...ta tion 5 Tighten Front wheel axle Front wheel axle pinch bolt NOTICE ECA14140 Before tightening the wheel axle nut push down hard on the handlebar s several times and check if the front fork rebounds smooth ly TIP First tighten the wheel axle then the wheel axle pinch bolt 6 Install Front wheel sensor NOTICE ECA21020 Make sure there are no foreign materials in the front wheel sensor rotor and fro...

Page 158: ...etween the front wheel sensor rotor and front wheel sensor in several places in one rotation of the front wheel Do not turn the front wheel while the thickness gauge is installed This may damage the front wheel sen sor rotor and the front wheel sensor 8 Install Front brake calipers Front reflectors Front brake hose lead holders 1 WARNING EWA13500 Make sure the brake hose is routed properly TIP Ins...

Page 159: ...ocknut 2 Loosen 4 Drive chain adjusting nut 2 Loosen 5 Swingarm end plate left 1 6 Swingarm end plate right 1 7 Wheel axle nut 1 8 Washer 1 9 Rear wheel axle 1 3 4 5 3 4 6 1 8 9 7 S 2 16 Nm 1 6 m kgf 12 ft Ibf T R 16 Nm 1 6 m kgf 12 ft Ibf T R 105 Nm 10 5 m kgf 76 ft lbf T R 22 Nm 2 2 m kgf 16 ft Ibf T R 27 Nm 2 7 m kgf 20 ft Ibf T R LT 7 Nm 0 7 m kgf 5 1 ft Ibf T R ...

Page 160: ...n slack adjusting plate right 1 12 Chain puller 2 13 Rear wheel 1 14 Brake caliper bracket 1 15 Collar left 1 16 Collar right 1 15 16 12 10 12 13 S 14 11 16 Nm 1 6 m kgf 12 ft Ibf T R 16 Nm 1 6 m kgf 12 ft Ibf T R 105 Nm 10 5 m kgf 76 ft lbf T R 22 Nm 2 2 m kgf 16 ft Ibf T R 27 Nm 2 7 m kgf 20 ft Ibf T R LT 7 Nm 0 7 m kgf 5 1 ft Ibf T R ...

Page 161: ...ket assembly 1 3 Rear wheel sprocket 1 4 Rear wheel drive hub 1 5 Rear wheel drive hub damper 6 6 Collar 1 7 Oil seal 1 8 Bearing 1 9 Rear brake disc 1 10 Rear wheel sensor rotor 1 11 Rear wheel 1 LT 5 9 11 5 6 4 3 2 8 7 1 10 3 LS LS LS New New LT 6 30 Nm 3 0 m kgf 22 ft Ibf T R 80 Nm 8 0 m kgf 58 ft Ibf T R 8 Nm 0 8 m kgf 5 8 ft Ibf T R ...

Page 162: ...REAR WHEEL 4 23 Disassembling the rear wheel Order Job Parts to remove Q ty Remarks 1 Oil seal 1 2 Wheel bearing 2 3 Spacer 1 New New 1 3 LS New 2 2 ...

Page 163: ...t to contact the sensor electrode to any metal part when removing the rear wheel sensor from the rear brake caliper bracket 3 Loosen Drive chain puller locknuts 1 Drive chain adjusting nuts 2 4 Remove Wheel axle nut 1 Washer Rear wheel axle 2 Drive chain slack adjusting plates Rear wheel TIP Push the rear wheel forward and remove the drive chain from the rear wheel sprocket EAS30158 DISASSEMBLING ...

Page 164: ...ents with 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 whe...

Page 165: ...ub ject it to shocks If any solvent gets on the wheel sensor ro tor wipe it off immediately Replace the brake disc bolts and wheel sensor rotor bolts with new ones TIP Install the wheel sensor rotor with the stamped mark a facing outward Install the brake disc so that the recessed por tions of the bolt holes b face away from the hub Tighten the brake disc bolts in stages and in a crisscross patter...

Page 166: ... 2 8 Adjust Drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3 17 9 Tighten Wheel axle nut Rear brake caliper retaining bolt Rear brake caliper bolt WARNING EWA13500 Make sure the brake hose is routed properly 10 Install Rear wheel sensor NOTICE ECA21080 Make sure there are no foreign materials in the rear wheel sensor rotor and rear wheel sensor Foreign materials cause damage to...

Page 167: ...ting surface of the rotor deformation caused by an impact during ser vice and caught foreign materials If there is any defective part repair or replace the de fective part TIP Measure the distance between the rear wheel 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 wh...

Page 168: ...of the front brake calipers 1 Brake pad clip 2 2 Brake pad pin 1 3 Brake pad spring 1 4 Brake pad 2 5 Front reflector 1 6 Front brake caliper 1 7 Brake caliper bleed screw 1 Left side only 8 Brake caliper bleed screw 1 Right side only 6 3 2 1 4 7 8 5 New 4 LS 40 Nm 4 0 m kgf 29 ft Ibf T R 5 Nm 0 5 m kgf 3 6 ft Ibf T R 5 Nm 0 5 m kgf 3 6 ft Ibf T R ...

Page 169: ... reservoir cap 1 2 Brake master cylinder reservoir diaphragm hold er 1 3 Brake master cylinder reservoir diaphragm 1 4 Brake lever 1 5 Front brake light switch connector 2 Disconnect 6 Front brake light switch 1 7 Front brake hose union bolt 1 S 1 2 3 4 5 6 7 New 10 Nm 1 0 m kgf 7 2 ft Ibf T R 1 0 Nm 0 10 m kgf 0 72 ft Ibf T R 1 2 Nm 0 12 m kgf 0 87 ft Ibf T R 1 5 Nm 0 15 m kgf 1 1 ft Ibf T R 6 Nm...

Page 170: ...ont brake master cylinder to hy draulic unit 1 10 Front brake master cylinder holder 1 11 Front brake master cylinder assembly 1 S 8 9 10 11 New 10 Nm 1 0 m kgf 7 2 ft Ibf T R 1 0 Nm 0 10 m kgf 0 72 ft Ibf T R 1 2 Nm 0 12 m kgf 0 87 ft Ibf T R 1 5 Nm 0 15 m kgf 1 1 ft Ibf T R 6 Nm 0 6 m kgf 4 3 ft Ibf T R 30 Nm 3 0 m kgf 22 ft Ibf T R ...

Page 171: ...FRONT BRAKE 4 32 Disassembling the front brake master cylinder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder kit 1 2 Brake master cylinder body 1 2 1 New BF BF S ...

Page 172: ...HYDRAULIC BRAKE SYSTEM ABS on page 3 14 1 Front brake hose union bolt 1 2 Brake hose gasket 1 Left side only 3 Brake hose gasket 2 4 Brake hose hydraulic unit to left front brake cal iper 1 Left side only 5 Brake hose left front brake caliper to right front brake caliper 1 6 Front reflector 1 7 Front brake caliper 1 2 7 3 5 6 4 1 New New 30 Nm 3 0 m kgf 22 ft Ibf T R 40 Nm 4 0 m kgf 29 ft Ibf T R ...

Page 173: ...Brake pad clip 2 2 Brake pad pin 1 3 Brake pad spring 1 4 Brake pad 2 5 Brake caliper piston 4 6 Brake caliper piston dust seal 4 7 Brake caliper piston seal 4 8 Brake caliper bleed screw 1 Left side only 9 Brake caliper bleed screw 1 Right side only 7 5 5 5 5 6 2 8 6 7 7 7 6 1 6 3 4 4 S S BF BF New New New New New New New New 9 New LS 5 Nm 0 5 m kgf 3 6 ft Ibf T R ...

Page 174: ... Check Front brake disc Damage galling Replace 3 Measure Brake disc deflection Out of specification Correct the brake disc deflection or replace the brake disc a Place the vehicle on a suitable stand so that the front wheel is elevated b Before measuring the brake disc deflection turn the handlebar to the left or right to ensure that the front wheel is stationary c Remove the brake caliper d Hold ...

Page 175: ... the brake caliper 1 Remove Brake pad clips 1 Brake pad pin 2 Brake pad spring 3 2 Remove Brake pads 1 Front reflector 2 Front brake caliper 3 3 Measure Brake pad wear limit a Out of specification Replace the brake pads as a set 4 Install Brake pads Brake pad spring TIP Always install new brake pads and new brake pad spring as a set a Connect a clear plastic hose 1 tightly to the bleed screw 2 Put...

Page 176: ...g Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS on page 3 14 EAS30724 REMOVING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers TIP Before removing the brake caliper drain the brake fluid from the entire brake system 1 Remove Brake hose union bolt 1 Brake hose gaskets 2 Brake hose hydraulic unit to left front brake caliper 3 Brake ho...

Page 177: ...aliper EAS30173 CHECKING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers 1 Check Brake caliper pistons 1 Rust scratches wear Replace the brake caliper pistons Brake caliper cylinders 2 Scratches wear Replace the brake caliper assembly Brake caliper body 3 Cracks damage Replace the brake caliper assembly Brake fluid delivery passages brake caliper body Obstruc...

Page 178: ...the brake caliper 1 make sure the brake pipe a touches the projection b on the brake caliper There should be 0 5 1 5 mm 0 020 0 059 in of clearance between the brake pipes Left side only 2 Install Brake pads Brake pad spring Brake pad pin Brake pad clips Refer to REPLACING THE FRONT BRAKE PADS on page 4 36 3 Fill Brake master cylinder reservoir with the specified amount of the specified brake flui...

Page 179: ...emove Brake hose union bolt 1 Brake hose gaskets 2 Brake hose front brake master cylinder to hydraulic unit 3 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 Damage scratches wear Replace Brake fluid delivery passages brake master cylinder body Obstruct...

Page 180: ... tighten the union bolt as shown Turn the handlebar to the left and right to make sure the 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 leak...

Page 181: ...um level mark a Add the specified brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 15 6 Check Brake lever operation Soft or spongy feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS on page 3 14 a ...

Page 182: ...er retaining bolt 1 4 Rear brake caliper bolt 1 5 Rear brake caliper 1 6 Brake pad 2 7 Brake pad shim 2 8 Brake pad insulator 2 9 Brake pad spring 1 10 Brake caliper bleed screw 1 S LT S S S 1 2 4 3 5 10 9 8 8 7 6 7 2 5 Nm 0 25 m kgf 1 8 ft Ibf T R 17 Nm 1 7 m kgf 12 ft Ibf T R 22 Nm 2 2 m kgf 16 ft Ibf T R 5 Nm 0 5 m kgf 3 6 ft Ibf T R 27 Nm 2 7 m kgf 20 ft Ibf T R ...

Page 183: ...servoir bolt 1 2 Brake fluid reservoir cap 1 3 Brake fluid reservoir diaphragm holder 1 4 Brake fluid reservoir diaphragm 1 5 Brake fluid reservoir 1 6 Brake fluid reservoir hose 1 7 Rear brake hose union bolt 1 2 1 3 4 6 7 5 LT LS New New 22 Nm 2 2 m kgf 16 ft Ibf T R 5 Nm 0 5 m kgf 3 6 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 30 Nm 3 0 m kgf 22 ft Ibf T R 30 Nm 3 0 m kgf 22 ft Ibf T R 23 Nm 2 3 ...

Page 184: ...connect 11 Footrest assembly right 1 12 Rear brake light switch 1 13 Rear brake master cylinder 1 14 Brake pedal 1 15 Rear brake hose lead holder 1 16 Rear brake hose lead guide 1 8 11 14 15 16 13 12 10 9 LT LS New New 22 Nm 2 2 m kgf 16 ft Ibf T R 5 Nm 0 5 m kgf 3 6 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 30 Nm 3 0 m kgf 22 ft Ibf T R 30 Nm 3 0 m kgf 22 ft Ibf T R 23 Nm 2 3 m kgf 17 ft Ibf T R 4...

Page 185: ...brake master cylinder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder yoke 1 2 Brake master cylinder kit 1 3 Hose joint 1 4 Bushing 1 5 Brake master cylinder body 1 1 2 2 3 4 5 S BF BF New New New 18 Nm 1 8 m kgf 13 ft Ibf T R ...

Page 186: ...AKE SYSTEM ABS on page 3 14 1 Rear brake hose union bolt 1 2 Brake hose gasket 2 3 Brake hose hydraulic unit to rear brake caliper 1 4 Rear brake caliper retaining bolt 1 5 Rear brake caliper bolt 1 6 Rear brake caliper 1 LT LT LT S S 1 2 3 4 5 6 22 Nm 2 2 m kgf 16 ft Ibf T R 27 Nm 2 7 m kgf 20 ft Ibf T R 30 Nm 3 0 m kgf 22 ft Ibf T R New ...

Page 187: ...1 3 Brake pad 2 4 Brake pad shim 2 5 Brake pad insulator 2 6 Brake pad spring 1 7 Brake caliper piston 1 8 Brake caliper piston dust seal 1 9 Brake caliper piston seal 1 10 Brake caliper bleed screw 1 S New S BF S New 10 7 8 9 6 5 4 3 5 4 2 1 5 Nm 0 5 m kgf 3 6 ft Ibf T R 2 5 Nm 0 25 m kgf 1 8 ft Ibf T R 17 Nm 1 7 m kgf 12 ft Ibf T R ...

Page 188: ...age galling Replace 3 Measure Brake disc deflection Out of specification Correct the brake disc deflection or replace the brake disc Refer to CHECKING THE FRONT BRAKE DISCS on page 4 35 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 35 5 Adjust Brake disc deflection Refer t...

Page 189: ...pads and brake pad spring TIP The longer tangs a of the brake pad spring must point in the direction of the brake caliper piston 3 Lubricate Rear brake caliper bolt Rear brake caliper retaining bolt NOTICE ECA18210 Do not allow grease to contact the brake pads Remove any excess grease 4 Install Rear brake caliper Rear brake caliper bolt Rear brake caliper retaining bolt Brake pad retaining bolt Sc...

Page 190: ...piston dust seal 2 Brake caliper piston seal 3 a Blow compressed air into the brake hose joint opening a to force out the piston from the brake caliper WARNING EWA13550 Cover the brake caliper piston with a rag Be careful not to get injured when the pis ton is expelled from the brake caliper Never try to pry out the brake caliper pis ton b Remove the brake caliper piston dust seal and brake calipe...

Page 191: ... internal brake com ponents as they will cause the brake caliper piston dust seal and brake caliper piston seal to swell and distort Whenever a brake 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 gaskets 2 Brake hose hydraulic unit to rear brake cali p...

Page 192: ...E HYDRAULIC BRAKE SYSTEM ABS on page 3 14 6 Check Brake fluid level Below the minimum level mark a Add the specified brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 15 7 Check Brake pedal operation Soft or spongy feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS on page 3 14 EAS30193 REMOVING THE REAR BRAKE MASTER CYLINDER 1 Remove B...

Page 193: ...brake hose lead holder 2 TIP Fit the projection a on the rear brake hose lead guide into the hole b in the swing arm Make sure that the projection c on the rear brake hose lead holder contacts the swingarm 2 Install Brake hose gaskets Brake hose rear brake master cylinder to hy draulic unit Brake hose union bolt Brake fluid reservoir hose WARNING EWA13531 Proper brake hose routing is essential to ...

Page 194: ...servoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock NOTICE ECA13540 Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 4 Bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS on page 3 14 5 Check Brake fluid level Below the minimum level mark a Add the specified brake...

Page 195: ...r to GENERAL CHASSIS 1 on page 4 1 Fuel tank top cover Fuel tank covers Air scoop right Refer to GENERAL CHASSIS 3 on page 4 5 Fuel tank Refer to FUEL TANK on page 7 1 1 ABS ECU coupler 1 Disconnect 2 Brake hose union bolt 4 3 Brake hose gasket 8 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 30 Nm 3 0 m kgf 22 ft Ibf T R 30 Nm 3 0 m kgf 22 ft Ibf T R 30 Nm 3 0 m kgf 22 ft Ibf T R New...

Page 196: ...it to left front brake cal iper 1 Disconnect 6 Brake hose front brake master cylinder to hy draulic unit 1 Disconnect 7 Brake hose rear brake master cylinder to hy draulic unit 1 Disconnect 8 Hydraulic unit assembly 1 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 30 Nm 3 0 m kgf 22 ft Ibf T R 30 Nm 3 0 m kgf 22 ft Ibf T R 30 Nm 3 0 m kgf 22 ft Ibf T R New New New New New 4 8 5 6 7 ...

Page 197: ... torque and bleed the brake system 1 Disconnect ABS ECU coupler 1 TIP While pushing the portion a of the ABS ECU coupler move the lock lever b in the direction of the arrow shown to disconnect the coupler 2 Remove Brake hoses TIP Do not operate the brake lever and brake pedal while removing the brake hoses NOTICE ECA14530 When removing the brake hoses cover the area around the hydraulic unit to ca...

Page 198: ...nt brake master cylinder to hydraulic unit c Temporarily tighten the union bolt for the brake hose rear brake master cylinder to hy draulic unit 1 TIP Make sure that the pipe section b of the brake hose rear brake master cylinder to hydraulic unit does not contact the hydraulic unit d Position the brake hose hydraulic unit to left front brake caliper 3 so that its projection c contacts the brake h...

Page 199: ...fault codes Refer to B 3 DE LETING THE FAULT CODES on page 8 147 9 Perform a trial run Refer to CHECKING THE ABS WARNING LIGHT on page 4 64 EAS31040 HYDRAULIC UNIT OPERATION TESTS The reaction force pulsating action generated in the brake lever and brake pedal when the ABS is activated can be tested when the vehicle is stopped The hydraulic unit operation can be tested using the following two meth...

Page 200: ...brake lever and brake pedal are operated si multaneously and continues for approximately 5 seconds The operation of the hydraulic unit can be con firmed using the indicator On The hydraulic unit is operating Flashing The conditions for operating the hy draulic unit have not been met Off The brake lever and brake pedal are not being operated 9 Check Hydraulic unit operation Click Actuator Check a s...

Page 201: ...e vehicle on a suitable stand 2 Turn the main switch to OFF 3 Remove Seat Seat bracket Battery cover Refer to GENERAL CHASSIS 1 on page 4 1 4 Check Battery voltage Lower than 12 8 V Charge or replace the battery TIP If the battery voltage is lower than 12 8 V charge the battery and then perform ABS reaction force confirmation 5 Removing the protective cap 1 and then connect the Yamaha diagnostic t...

Page 202: ...l it is generated in the brake lever and continues for a few seconds TIP The reaction force pulsating action consists of quick pulses ON and OFF on the tool screen indicate when the brakes are being applied and re leased respectively NOTICE ECA18280 Check that the pulse is felt in the brake le ver brake pedal and again in the brake le ver in this order If the pulse is felt in the brake pedal befor...

Page 203: ...lic unit is normal delete all of the fault codes EAS31041 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 10 km h 6 mph or performing a trial run ...

Page 204: ...t 1 9 Throttle cable housing 1 10 Throttle cable 2 Disconnect LT LS LS LS LS 1 5 7 3 2 4 9 9 10 10 1 8 6 8 10 Nm 1 0 m kgf 7 2 ft Ibf T R 2 0 Nm 0 20 m kgf 1 4 ft Ibf T R 2 0 Nm 0 20 m kgf 1 4 ft Ibf T R 3 8 Nm 0 38 m kgf 2 8 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 17 Nm 1 7 m kgf 12 ft Ibf T R 17 Nm 1 7 m kgf 12 ft Ibf T R 28 Nm 2 8 m kgf 20 ft Ibf T R 32 Nm 3 2 m kgf 23 ft Ibf T R 7 Nm 0 7 m kg...

Page 205: ... Lower handlebar holder 1 LT LS LS LS LS 18 21 20 20 11 12 11 16 13 19 22 14 15 14 17 10 Nm 1 0 m kgf 7 2 ft Ibf T R 2 0 Nm 0 20 m kgf 1 4 ft Ibf T R 2 0 Nm 0 20 m kgf 1 4 ft Ibf T R 3 8 Nm 0 38 m kgf 2 8 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 17 Nm 1 7 m kgf 12 ft Ibf T R 17 Nm 1 7 m kgf 12 ft Ibf T R 28 Nm 2 8 m kgf 20 ft Ibf T R 32 Nm 3 2 m kgf 23 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 11 N...

Page 206: ... level surface WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over 2 Install Lower handlebar holder Handlebar 1 Upper handlebar holders 2 NOTICE ECA18300 First tighten the bolts on the front side of the handlebar holder and then on the rear side TIP The upper handlebar holders should be in stalled with the punch marks a facing for ward Align the punch mark b...

Page 207: ...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 be 1 3 mm 0 04 0 12 in of clear ance a between the handlebar grip and the grip end 5 Install Handlebar switch left 1 TIP Align the projection a on the left handlebar switch with the hole b in the handlebar 6 Install Throt...

Page 208: ... Make sure that the throttle cable holder 1 1 contacts the throttle cable adjusting nut and that the open ends of the holder are pointing rearward Align the throttle cable holder 2 2 with the edge a of the front brake master cylinder 9 Install Front brake master cylinder assembly Refer to INSTALLING THE FRONT BRAKE MASTER CYLINDER on page 4 41 10 Adjust Throttle grip free play Refer to CHECKING TH...

Page 209: ...3 on page 4 5 Fuel tank Refer to FUEL TANK on page 7 1 Front wheel Refer to FRONT WHEEL on page 4 12 1 Front brake hose lead holder 2 2 Front fender 1 3 Front fender bracket 1 4 Front fork cap bolt 1 Loosen 21 Nm 2 1 m kgf 15 ft Ibf T R 23 Nm 2 3 m kgf 17 ft Ibf T R 26 Nm 2 6 m kgf 19 ft Ibf T R 26 Nm 2 6 m kgf 19 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kg...

Page 210: ...upler 2 Disconnect 8 Immobilizer unit coupler 1 Disconnect 9 Upper bracket 1 10 Lower bracket pinch bolt 2 Loosen 11 Front fork leg 1 21 Nm 2 1 m kgf 15 ft Ibf T R 23 Nm 2 3 m kgf 17 ft Ibf T R 26 Nm 2 6 m kgf 19 ft Ibf T R 26 Nm 2 6 m kgf 19 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 9 Nm 0 9 m kgf 6 5 ft Ibf T R 5 9 6 5 8 7 10 10 4 11 ...

Page 211: ...edure applies to both of the front fork legs 1 Protector 1 2 Front fork cap bolt 1 3 O ring 1 4 Spacer 1 5 Spring seat 1 6 Fork spring 1 7 Dust seal 1 8 Oil seal clip 1 9 Front fork damper rod bolt 1 10 Copper washer 1 2 3 4 5 7 1 8 10 9 6 New New New New New New LS New LS LT LT 30 Nm 3 0 m kgf 22 ft Ibf T R ...

Page 212: ... 1 12 Damper rod ring 1 13 Rebound spring 1 14 Inner tube 1 15 Oil seal 1 16 Washer 1 17 Outer tube bushing 1 18 Inner tube bushing 1 19 Oil flow stopper spring 1 20 Oil flow stopper 1 21 Outer tube 1 14 15 16 17 21 18 19 20 12 11 13 New New New New New New LS New LS LT LT 30 Nm 3 0 m kgf 22 ft Ibf T R ...

Page 213: ...NG EWA13640 Before loosening the upper and lower brack et pinch bolts support the front fork leg EAS30207 DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Drain Fork oil TIP Stroke the outer tube several times while drain ing the fork oil 2 Remove Dust seal 1 Oil seal clip 2 with a flathead screwdriver NOTICE ECA14180 Do not scratch the inner tube ...

Page 214: ...mage wear Replace Obstruction Blow out all of the oil passag es with compressed air Oil flow stopper Damage Replace NOTICE ECA14200 The front fork leg has a built in damper ad justing rod and a very sophisticated inter nal construction which are particularly sensitive to foreign material When disassembling and assembling the front fork leg do not allow any foreign ma terial to enter the front fork...

Page 215: ...amper rod to slide slowly down the in ner tube until it protrudes from the bottom of the inner tube Be careful not to damage the inner tube d Install the oil flow stopper and inner tube bushing onto the inner tube 6 2 Lubricate Inner tube s outer surface 3 Install Inner tube in the outer tube 4 Install Copper washer Front fork damper rod bolt 5 Tighten Front fork damper rod bolt 1 TIP While holdin...

Page 216: ...il seal cover the top of the front fork leg with a plastic bag to protect the oil seal during installation 8 Install Oil seal clip 1 TIP Adjust the oil seal clip so that it fits into the outer tube s groove 9 Install Dust seal 1 with the fork seal driver weight 2 Fork seal driver weight 90890 01367 Replacement hammer YM A9409 7 Fork seal driver attachment ø41 90890 01381 Replacement 41 mm YM A5142...

Page 217: ...rease Temporarily tighten the front fork cap bolt Tighten the front fork cap bolt specified torque when installing the front fork with upper brack et 13 Install Protector 1 TIP Align the projection a on the protector with the slot b in the outer tube EAS30210 INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Install Front fork leg Temporarily tighten t...

Page 218: ...fender bracket to the front fork with the arrow mark a on the bracket pointing forward T R Lower bracket pinch bolt 23 Nm 2 3 m kgf 17 ft lbf Upper bracket pinch bolt center 21 Nm 2 1 m kgf 15 ft lbf Upper bracket pinch bolt left and right 26 Nm 2 6 m kgf 19 ft lbf Front fork cap bolt 23 Nm 2 3 m kgf 17 ft lbf T R Front fender bracket bolt 7 Nm 0 7 m kgf 5 1 ft lbf Front fender bolt 9 Nm 0 9 m kgf...

Page 219: ...fer to GENERAL CHASSIS 2 on page 4 3 Handlebar Refer to HANDLEBAR on page 4 65 Front fork legs Refer to FRONT FORK on page 4 70 1 Front brake hose lower holder 1 2 Front brake hose upper holder 1 3 Headlight bracket 1 4 Front brake hose holder bracket 1 4 1 2 3 LS LS LS 1st 52 Nm 5 2 m kgf 38 ft lbf 2nd 18 Nm 1 8 m kgf 13 ft Ibf T R 3 8 Nm 0 38 m kgf 2 8 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R ...

Page 220: ...Job Parts to remove Q ty Remarks 5 Cap nut 1 6 Lower bracket 1 7 Lower bracket cap 1 8 Bearing cover 1 9 Lower bearing dust seal 1 10 Upper bearing 1 11 Lower bearing 1 5 8 10 6 7 9 11 LS LS LS 1st 52 Nm 5 2 m kgf 38 ft lbf 2nd 18 Nm 1 8 m kgf 13 ft Ibf T R 3 8 Nm 0 38 m kgf 2 8 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R ...

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

Page 222: ...er bracket and cap nut 4 Install Front brake hose holder bracket 1 Headlight bracket Front brake hose upper holder 2 Front brake hose lower holder 3 TIP Make sure that the front brake hose holder bracket contacts the projection a on the lower bracket Make sure that the projection b on the front brake hose lower holder fits into the hole in the front brake hose upper holder T R Front brake hose hol...

Page 223: ... shock absorber assembly nut bolt front side 1 1 3 Spacer 1 4 Rear shock absorber assembly nut bolt rear side 1 1 5 Rear shock absorber assembly 1 6 Relay arm rubber cover 1 7 Spacer 1 8 Oil seal 2 9 Bearing 1 7 Nm 0 7 m kgf 5 1 ft Ibf T R 2 4 7 8 8 4 5 2 3 1 6 9 LS LS New New New New New New 44 Nm 4 4 m kgf 32 ft Ibf T R 40 Nm 4 0 m kgf 29 ft Ibf T R 40 Nm 4 0 m kgf 29 ft Ibf T R ...

Page 224: ...olt 1 1 11 Spacer 1 12 Oil seal 2 13 Bearing 1 14 Connecting arm nut bolt relay arm side 1 1 15 Relay arm 1 16 Spacer 1 17 Oil seal 2 18 Bearing 1 7 Nm 0 7 m kgf 5 1 ft Ibf T R 12 12 17 17 10 14 11 15 18 14 10 13 16 LS LS New New New New New New 44 Nm 4 4 m kgf 32 ft Ibf T R 40 Nm 4 0 m kgf 29 ft Ibf T R 40 Nm 4 0 m kgf 29 ft Ibf T R ...

Page 225: ...ber at a point 20 25 mm 0 79 0 98 in from its end as shown WARNING EWA13760 Wear eye protection to prevent eye damage from released gas or metal chips EAS30219 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 1 Stand the vehicle on a level surface WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over TIP Place the vehicle on a suitable stand so that the rear wheel is...

Page 226: ...SORBER ASSEMBLY 1 Install Rear shock absorber assembly 1 TIP Make sure that the label a on the rear shock absorber assembly faces down 2 Tighten Rear shock absorber assembly nut front side Rear shock absorber bolt rear side A Left side B Right side a a 1 2 4 3 A B New 2 New b b a a 1 2 3 New 2 New b b a a 1 2 3 New 2 New b b T R Connecting arm nut relay arm side 40 Nm 4 0 m kgf 29 ft lbf Relay arm...

Page 227: ... to CHAIN DRIVE on page 4 93 1 Pivot shaft protector left 1 2 Pivot shaft protector right 1 3 Sidestand switch coupler 1 Disconnect 4 Sidestand 1 5 Footrest assembly left 1 6 Pivot shaft nut 1 7 Washer 1 8 Pivot shaft 1 4 3 1 2 8 5 7 6 LT LT LT LT LS LS LS LS LS New New New New New 10 Nm 1 0 m kgf 7 2 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 30 Nm 3 0 m kgf 22 ft Ibf ...

Page 228: ...nut bolt frame side 1 1 18 Connecting arm 1 19 Spacer 1 20 Oil seal 2 21 Bearing 2 16 15 14 14 17 19 18 20 20 21 10 13 12 13 9 11 16 12 17 LT LT LT LT LS LS LS LS LS New New New New New 10 Nm 1 0 m kgf 7 2 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 30 Nm 3 0 m kgf 22 ft Ibf T R 52 Nm 5 2 m kgf 38 ft Ibf T R 63 Nm 6 3 m kgf 46 ft Ibf T R 110 Nm 11 m kgf 80 ft lbf T R 45 ...

Page 229: ... up and down If the swingarm vertical movement is not smooth or if there is binding check the pivot shaft collars bearings and dust covers 3 Remove Swingarm EAS30227 CHECKING THE SWINGARM 1 Check Swingarm Bends cracks damage Replace 2 Check Pivot shaft Roll the pivot shaft on a flat surface Bends Replace WARNING EWA13770 Do not attempt to straighten a bent pivot shaft 3 Wash Pivot shaft Dust cover...

Page 230: ... INSTALLING THE SWINGARM 1 Lubricate Collar Pivot shaft Bearings 2 Install Bearings 1 Oil seals 2 to the swingarm TIP Install the oil seals to the swingarm so that they are facing in the directions shown in the illustra tion Recommended lubricant Lithium soap based grease A Left side B Right side Installed depth a 3 5 4 5 mm 0 14 0 18 in Installed depth b 8 0 9 0 mm 0 31 0 35 in T R Connecting arm...

Page 231: ...INGARM 4 92 3 Adjust Drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3 17 A Left side B Right side Drive chain slack 51 0 56 0 mm 2 01 2 20 in A B 1 1 New 2 New 2 New 2 New 2 b c a b d ...

Page 232: ...RM on page 4 88 1 Shift rod locknut shift arm side 1 2 Shift rod locknut shift pedal side 1 Left hand threads 3 Shift rod 1 4 Shift rod joint 1 5 Shift arm 1 6 Drive sprocket cover 1 7 Drive chain guide 1 1 2 3 4 5 6 7 New 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 9 Nm 0 9 m kgf 6 5 ft Ibf T R 14 Nm 1 4 m kgf 10 ft Ibf T R 95 Nm 9 5 m kgf 69 ft Ibf T R 110 Nm 11 m kgf 80 ft lbf...

Page 233: ...t 1 Loosen 9 Drive chain 1 10 Drive sprocket nut 1 11 Washer 1 12 Drive sprocket 1 9 10 11 12 8 New 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 9 Nm 0 9 m kgf 6 5 ft Ibf T R 14 Nm 1 4 m kgf 10 ft Ibf T R 95 Nm 9 5 m kgf 69 ft Ibf T R 110 Nm 11 m kgf 80 ft lbf T R E LS LT LT LT LT ...

Page 234: ...lts 4 d Move the footrest bracket 5 rearward and then remove the drive chain EAS31115 REMOVING THE DRIVE SPROCKET 1 Straighten the drive sprocket nut ribs a 2 Loosen Drive sprocket nut TIP Loosen the drive sprocket nut while pressing the brake pedal EAS30230 CHECKING THE DRIVE CHAIN 1 Measure 15 link section a of the drive chain Out of specification Replace the drive chain a Measure the length b b...

Page 235: ...s Never use high pressure water or air steam gasoline certain sol vents e g benzine or a coarse brush to clean the drive chain High pressure meth ods could force dirt or water into the drive chain s internals and solvents will deterio rate the O rings A coarse brush can also damage the O rings Therefore use only kerosene to clean the drive chain Do not soak the drive chain in kerosene for more tha...

Page 236: ...et 1 Washer 2 Drive sprocket nut 3 TIP While applying the rear brake tighten the drive sprocket nut Install washer with the OUT mark a facing out Stake the drive sprocket nut at cutouts b in the drive axle EAS30234 INSTALLING THE DRIVE CHAIN 1 Install Drive chain 1 TIP Make sure that the drive chain is positioned above the portion a of the footrest bracket 2 2 Tighten Footrest bracket bolts 1 3 Lu...

Page 237: ...ain the correct shift pedal position c Tighten both locknuts TIP The shift rod locknut shift pedal side has left hand threads d Make sure the installed shift rod length is within specification Make sure that the in stalled shift rod length is within specification and that the angle between the shift arm and the shift rod is 90 T R Shift arm pinch bolt 14 Nm 1 4 m kgf 10 ft lbf Installed length a 2...

Page 238: ... 3 17 NOTICE ECA13550 A drive chain that is too tight will overload the engine and other vital parts and one that is too loose can skip and damage the swing arm or cause an accident Therefore keep the drive chain slack within the specified lim its Drive chain slack 51 0 56 0 mm 2 01 2 20 in 90 ...

Page 239: ...MOVING THE CYLINDER HEAD 5 26 CHECKING THE TIMING CHAIN GUIDES 5 26 CHECKING THE CYLINDER HEAD 5 26 INSTALLING THE CYLINDER HEAD 5 27 VALVES AND VALVE SPRINGS 5 28 REMOVING THE VALVES 5 29 CHECKING THE VALVES AND VALVE GUIDES 5 29 CHECKING THE VALVE SEATS 5 31 CHECKING THE VALVE SPRINGS 5 32 CHECKING THE VALVE LIFTERS 5 33 INSTALLING THE VALVES 5 33 GENERATOR AND STARTER CLUTCH 5 36 REMOVING THE G...

Page 240: ...FT SHAFT 5 57 OIL PUMP 5 58 CHECKING THE SPROCKET AND CHAIN 5 60 CHECKING THE OIL PUMP 5 60 CHECKING THE RELIEF VALVE 5 60 ASSEMBLING THE OIL PUMP 5 60 INSTALLING THE OIL PUMP 5 61 OIL PAN 5 62 REMOVING THE OIL PAN 5 63 CHECKING THE OIL STRAINER 5 63 INSTALLING THE OIL PAN 5 63 CRANKCASE 5 64 DISASSEMBLING THE CRANKCASE 5 66 CHECKING THE CRANKCASE 5 66 ASSEMBLING THE CRANKCASE 5 66 INSTALLING THE ...

Page 241: ...ER SHAFT ASSEMBLY 5 83 CHECKING THE CRANKSHAFT 5 85 INSTALLING THE CRANKSHAFT 5 87 INSTALLING THE BALANCER SHAFT ASSEMBLY 5 87 TRANSMISSION 5 88 REMOVING THE TRANSMISSION 5 93 CHECKING THE SHIFT FORKS 5 93 CHECKING THE SHIFT DRUM ASSEMBLY 5 93 CHECKING THE TRANSMISSION 5 94 ASSEMBLING THE MAIN AXLE AND DRIVE AXLE 5 94 INSTALLING THE TRANSMISSION 5 95 ...

Page 242: ...rt accumulat ed in the spark plug wells to prevent it from falling into the cylinders 7 Install Extension 1 Compression gauge 2 8 Measure Compression pressure Out of specification Refer to steps c and d TIP Due to the engine characteristics the compres sion pressure is different for cylinder 1 and cyl inder 2 a Turn the main switch to ON b With the throttle wide open crank the engine until the rea...

Page 243: ...aha diagnostic tool 1 Connect the Yamaha diagnostic tool to the coupler For information about connecting the Yamaha diagnostic tool refer to YAMAHA DIAGNOSTIC TOOL on page 8 36 EAS31133 CHECKING THE CYLINDER HEAD BREATHER HOSE 1 Remove Seat Refer to GENERAL CHASSIS 1 on page 4 1 Fuel tank top cover Fuel tank cover left Fuel tank cover right Fuel tank center cover Refer to GENERAL CHASSIS 3 on page...

Page 244: ...ler 1 Disconnect 2 Muffler assembly 1 3 Exhaust gasket 2 4 Muffler bracket 2 5 Muffler cover 1 6 O2 sensor 1 Remove the O2 sensor only when neces sary 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 20 Nm 2 0 m kgf 14 ft Ibf T R 20 Nm 2 0 m kgf 14 ft Ibf T R 20 Nm 2 0 m kgf 14 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 25 N...

Page 245: ...5 Fuel tank Refer to FUEL TANK on page 7 1 Air duct bracket Refer to GENERAL CHASSIS 4 on page 4 7 Throttle bodies Air filter case Cylinder head breather hose Refer to THROTTLE BODIES on page 7 7 Coolant Drain Refer to CHANGING THE COOLANT on page 3 24 Radiator Coolant reservoir Refer to RADIATOR on page 6 1 Oil cooler outlet hose Oil cooler inlet hose Refer to OIL COOLER on page 6 5 Water pump in...

Page 246: ...ather hose 1 5 Engine ground lead 2 Disconnect 6 Gear position switch coupler 1 Disconnect 7 Starter motor lead 1 Disconnect 8 Coolant temperature sensor coupler 1 Disconnect 9 Stator coil coupler 1 Disconnect 10 Crankshaft position sensor coupler 1 Disconnect 11 Ignition coil coupler 2 Disconnect 12 Oil pressure switch connector 1 Disconnect 1 2 3 4 5 10 9 6 7 8 12 11 10 Nm 1 0 m kgf 7 2 ft Ibf T...

Page 247: ...lt left 2 7 Engine mounting bolt left upper side 1 8 Engine bracket left 1 2 6 7 3 8 1 3 5 4 a 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 25 Nm 2 5 m kgf 18 ft Ibf T R 25 Nm 2 5 m kgf 18 ft Ibf T R 55 Nm 5 5 m kgf 40 ft Ibf T R 55 Nm 5 5 m kgf 40 ft Ibf T R 55 Nm 5 5 m kgf 40 ft Ibf T R 55 Nm 5 5 m kgf 40 ft Ibf T R 75 Nm 7 5 m kgf 54 ft Ibf T R 75 Nm 7 5 m kgf 54 ft Ibf T R 44 Nm...

Page 248: ...g bolt nut rear upper side 1 1 16 Engine 1 17 Plate 1 Install the plate only for frames that have a stamped 1 mark at the location a 9 9 10 11 12 13 14 14 15 15 16 17 a 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 25 Nm 2 5 m kgf 18 ft Ibf T R 25 Nm 2 5 m kgf 18 ft Ibf T R 55 Nm 5 5 m kgf 40 ft Ibf T R 55 Nm 5 5 m kgf 40 ft Ibf T R 55 Nm 5 5 m kgf 40 ft Ibf T R 55 Nm 5 5 m kgf 40 ft...

Page 249: ...rear upper side NOTICE ECA21181 Do not move the rear brake hose joint brack et more than necessary Otherwise the brake hoses could bend and break EAS30251 INSTALLING THE ENGINE 1 Install for models with a stamped 1 mark on the frame Plate 1 TIP Install the plate only for frames that have a stamped 1 mark at the location a Fit the projections b on the plate into the slots c in the frame 2 Install E...

Page 250: ...ke hose joint bracket contacts the projection a on the frame 8 Install Clutch cable guide 1 TIP Make sure that the projection a on the clutch cable guide contacts the frame T R Engine mounting nut rear upper side 55 Nm 5 5 m kgf 40 ft lbf Engine mounting nut rear lower side 55 Nm 5 5 m kgf 40 ft lbf Engine mounting bolt left front side 75 Nm 7 5 m kgf 54 ft lbf T R Engine mounting bolt left upper ...

Page 251: ...ENGINE REMOVAL 5 10 a 1 ...

Page 252: ...on page 4 5 Fuel tank Refer to FUEL TANK on page 7 1 Coolant Drain Refer to CHANGING THE COOLANT on page 3 24 Radiator inlet hose Radiator Refer to RADIATOR on page 6 1 Clutch cable guide Refer to ENGINE REMOVAL on page 5 3 1 Cylinder head breather hose 1 Disconnect 10 Nm 1 0 m kgf 7 2 ft Ibf T R 4 0 Nm 0 40 m kgf 2 9 ft Ibf T R 13 Nm 1 3 m kgf 9 4 ft Ibf T R 13 Nm 1 3 m kgf 9 4 ft Ibf T R New New...

Page 253: ...gnition coil 2 4 Spark plug 2 5 Cylinder head cover 1 6 Cylinder head cover gasket 1 7 Breather plate 1 8 Breather plate gasket 1 9 Timing chain guide upper side 1 10 Nm 1 0 m kgf 7 2 ft Ibf T R 4 0 Nm 0 40 m kgf 2 9 ft Ibf T R 13 Nm 1 3 m kgf 9 4 ft Ibf T R 13 Nm 1 3 m kgf 9 4 ft Ibf T R New New LT S S 7 6 4 3 3 4 4 8 5 2 6 9 ...

Page 254: ...el pin 4 8 Intake camshaft 1 9 Exhaust camshaft 1 10 Intake camshaft sprocket 1 11 Exhaust camshaft sprocket 1 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 15 Nm 1 5 m kgf 11 ft Ibf T R 24 Nm 2 4 m kgf 17 ft Ibf T R 24 Nm 2 4 m kgf 17 ft Ibf T R M M M E E E E ...

Page 255: ...ressor lever pin 2 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 15 Nm 1 5 m kgf 11 ft Ibf T R 24 Nm 2 4 m kgf 17 ft Ibf T R 24 Nm 2 4 m kgf 17 ft Ibf T R M M M E E E E E LS New New New 6 6 13 12 14 14 ...

Page 256: ...nto the timing chain tension er b Remove the timing chain tensioner 4 Remove Intake camshaft cap 1 Exhaust camshaft cap 2 NOTICE ECA13720 To prevent damage to the cylinder head camshafts or camshaft caps loosen the camshaft cap bolts in stages and in a criss cross pattern working from the outside in 5 Remove Intake camshaft 1 Exhaust camshaft 2 TIP To prevent the timing chain from falling into the...

Page 257: ... b Out of specification Replace the camshaft 3 Measure Camshaft runout Out of specification Replace 1 2 2 1 1 Camshaft lobe dimensions Lobe height Intake 35 610 35 710 mm 1 4020 1 4059 in Limit 35 510 mm 1 3980 in Base circle diameter Intake 27 950 28 050 mm 1 1004 1 1043 in Limit 27 850 mm 1 0965 in Lobe height Exhaust 35 710 35 810 mm 1 4059 1 4098 in Limit 35 610 mm 1 4020 in Base circle diamet...

Page 258: ...e with the Plastigauge d Remove the camshaft caps and then mea sure the width of the Plastigauge 1 5 Measure Camshaft journal diameter a Out of specification Replace the camshaft Within specification Replace the cylinder head and camshaft caps as a set EAS30936 CHECKING THE CAMSHAFT SPROCKETS 1 Check Camshaft sprocket More than 1 4 tooth wear a Replace the camshaft sprockets and timing chain as a ...

Page 259: ...the decompressor cams 2 and de compressor lever pins 1 moves smoothly EAS30269 INSTALLING THE CAMSHAFTS 1 Align Mark a on the generator rotor with the slot b in the generator rotor cover a Turn the crankshaft counterclockwise b When piston 1 is at TDC align the TDC mark a on the generator rotor with the slot b in the generator rotor cover 2 Install Intake camshaft sprocket 1 NOTICE ECA19980 Be sur...

Page 260: ...aligned with cam lobe 1 b as shown in the illustration While holding the exhaust camshaft with a suit able tool tighten the exhaust camshaft sprock et bolts Tighten the camshaft sprocket bolts in the tightening sequence as shown 5 Install Timing chain 1 onto the exhaust camshaft sprocket 2 Exhaust camshaft Exhaust camshaft cap NOTICE ECA20930 Lubricate the camshaft cap bolts with the engine oil Th...

Page 261: ... the camshaft to avoid damage or improper valve timing a Install the timing chain onto intake camshaft sprocket and then install the intake camshaft onto the cylinder head TIP Make sure the match mark a on the intake camshaft sprocket is aligned with the cylinder head edge b b Tighten the intake camshaft cap bolts TIP Temporarily tighten the intake camshaft cap bolts and then tighten the bolts to ...

Page 262: ...bolt and gasket and then tighten the timing chain ten sioner cap bolt to specification 8 Turn Crankshaft several turns counterclockwise 9 Check Mark a Make sure the mark a on the generator rotor is aligned with the slot b in the generator ro tor cover Camshaft sprocket match mark Make sure the match marks c on the cam shaft sprockets are aligned with the cylinder head mating surface d Out of align...

Page 263: ...cover gasket 1 to the cylinder head cover cut off the a section Make sure that the projection b on the cylin der head cover gasket is positioned on the ex haust side of the rib c on the cylinder head cover 2 Install Spark plugs Ignition coils 1 TIP Install the ignition coils 1 in the direction shown in the illustration T R Cylinder head cover bolt 10 Nm 1 0 m kgf 7 2 ft lbf Yamaha bond No 1215 908...

Page 264: ...ly Refer to ENGINE REMOVAL on page 5 3 Oil cooler inlet hose Disconnect Refer to OIL COOLER on page 6 5 Radiator Refer to RADIATOR on page 6 1 Cylinder head cover Intake camshaft Exhaust camshaft Refer to CAMSHAFTS on page 5 11 Clutch cover Refer to CLUTCH on page 5 46 Thermostat Refer to THERMOSTAT on page 6 7 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 16 Nm 1 6 m kgf 12 ft Ibf...

Page 265: ...ft 1 6 Engine bracket bolt right 2 7 Engine mounting bolt right upper side 1 8 Engine bracket right 1 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 16 Nm 1 6 m kgf 12 ft Ibf T R 25 Nm 2 5 m kgf 18 ft Ibf T R 25 Nm 2 5 m kgf 18 ft Ibf T R 55 Nm 5 5 m kgf 40 ft Ibf T R 55 Nm 5 5 m kgf 40 ft Ibf T R 75 Nm 7 5 m kgf 54 ft Ibf T R 75 Nm 7 5 m kgf 54 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf...

Page 266: ...der head 1 14 Cylinder head gasket 1 15 Dowel pin 2 16 Timing chain 1 17 Timing chain guide intake side 1 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 16 Nm 1 6 m kgf 12 ft Ibf T R 25 Nm 2 5 m kgf 18 ft Ibf T R 25 Nm 2 5 m kgf 18 ft Ibf T R 55 Nm 5 5 m kgf 40 ft Ibf T R 55 Nm 5 5 m kgf 40 ft Ibf T R 75 Nm 7 5 m kgf 54 ft Ibf T R 75 Nm 7 5 m kgf 54 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft...

Page 267: ...s are fully loosened remove them M6 45 mm 1 2 M10 100 mm 3 8 EAS30278 CHECKING THE TIMING CHAIN GUIDES 1 Check Timing chain guide exhaust side Timing chain guide intake side Damage wear Replace EAS30277 CHECKING THE CYLINDER HEAD 1 Eliminate Combustion chamber carbon deposits with a rounded scraper TIP Do not use a sharp instrument to avoid damag ing or scratching Spark plug bore threads Valve sea...

Page 268: ... bolt M10 6 Cylinder head bolt M6 2 TIP Pass the timing chain through the timing chain cavity Lubricate the cylinder head bolt M10 threads and mating surface with engine oil 2 Tighten Cylinder head bolts 1 6 Cylinder head bolts 7 8 Following the tightening order loosen the bolt one by one and then retighten it to the specific torque TIP Tighten the cylinder head bolts in the tightening sequence as...

Page 269: ...emove Q ty Remarks Cylinder head Refer to CYLINDER HEAD on page 5 23 1 Valve lifter 8 2 Valve pad 8 3 Valve cotter 16 4 Valve spring retainer 8 5 Valve spring 8 6 Exhaust valve 4 7 Intake valve 4 8 Valve stem seal 8 9 Valve spring seat 8 10 Valve guide 8 New New New New E E S S M M M M 2 2 3 3 4 4 5 5 10 10 8 8 9 1 1 9 7 6 ...

Page 270: ... solvent a into the intake and exhaust ports b Check that the valves properly seal TIP There should be no leakage at the valve seat 1 3 Remove Valve cotters TIP Remove the valve cotters by compressing the valve spring with the valve spring compressor 1 and the valve spring compressor attachment 2 4 Remove Valve spring retainer 1 Valve spring 2 Valve 3 Valve stem seal 4 Valve spring seat 5 TIP Iden...

Page 271: ...2 and valve guide remover 1 c After installing the valve guide bore the valve guide with the valve guide reamer 3 to ob tain the proper valve stem to valve guide clearance TIP After replacing the valve guide reface the valve seat Valve stem to valve guide clearance Valve guide inside diameter a Valve stem diameter b Valve stem to valve guide clear ance intake 0 010 0 037 mm 0 0004 0 0015 in Limit ...

Page 272: ...ting 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 the bluein...

Page 273: ... forth be tween your hands e Apply a fine lapping compound to the valve face and repeat the above steps f After every lapping procedure be sure to clean off all of the lapping compound from the valve face and valve seat g Apply blue layout fluid b onto the valve face h Install the valve into the cylinder head i Press the valve through the valve guide and onto the valve seat to make a clear impres ...

Page 274: ...f the valves and related components 1 Deburr Valve stem end with an oil stone 2 Lubricate Valve stem 1 Valve stem end with the recommended lubricant 3 Lubricate Valve stem seal 2 with the recommended lubricant Installed compression spring force intake 144 00 166 00 N 14 68 16 93 kgf 32 37 37 32 lbf Installed compression spring force exhaust 149 00 171 00 N 15 19 17 44 kgf 33 50 38 44 lbf Installed...

Page 275: ...ing compressor attachment 2 6 To secure the valve cotters onto the valve stem lightly tap the valve tip with a soft face hammer NOTICE ECA13800 Hitting the valve tip with excessive force could damage the valve 7 Lubricate Valve lifter with the recommended lubricant 8 Install Valve pad Valve lifter TIP The valve lifter must move smoothly when ro tated with a finger b Smaller pitch M S 2 1 New 3 1 4...

Page 276: ...VALVES AND VALVE SPRINGS 5 35 Each valve lifter and valve pad must be rein stalled in their original position ...

Page 277: ...to CHAIN DRIVE on page 4 93 Coolant reservoir Refer to RADIATOR on page 6 1 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 21 1 Stator coil coupler 1 Disconnect 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R 15 Nm 1 5 m kgf 11 ft Ibf T R 32 Nm 3 2 m kgf 23 ft Ibf T R 70 Nm 7 0 m kgf 51 ft Ibf T R LT LT LT LT ...

Page 278: ...r 1 7 Generator cover gasket 1 8 Bearing 1 9 Dowel pin 2 10 Stator coil lead holder 1 11 Stator coil assembly Stator coil Crankshaft po sition sensor 1 12 Torque limiter 1 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R 15 Nm 1 5 m kgf 11 ft Ibf T R 32 Nm 3 2 m kgf 23 ft Ibf T R 70 Nm 7 0 m kgf 51 ft Ibf T R LT LT LT LT LT...

Page 279: ...ff key 1 17 Starter clutch idle gear shaft 1 18 Starter clutch idle gear 1 19 Starter clutch gear 1 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R 15 Nm 1 5 m kgf 11 ft Ibf T R 32 Nm 3 2 m kgf 23 ft Ibf T R 70 Nm 7 0 m kgf 51 ft Ibf T R LT LT LT LT LT LT LT LT LS LS New New New New E E E E E E 3 8 3 14 15 19 16 18 17 13 ...

Page 280: ...r rotor EAS30868 REMOVING THE STARTER CLUTCH 1 Remove Starter clutch bolts 1 Starter clutch TIP While holding the generator rotor 2 with the ro tor holding tool 3 loosen the starter clutch bolts EAS30869 CHECKING THE STARTER CLUTCH 1 Check Starter clutch rollers Damage wear Replace 2 Check Starter clutch idle gear Starter clutch gear Burrs chips roughness wear Replace the defective part s 3 Check ...

Page 281: ...rd the generator rotor 2 While holding the generator rotor with the rotor holding tool 3 tighten the starter clutch bolts 4 EAS30872 INSTALLING THE GENERATOR 1 Install Woodruff key Generator rotor Washer Generator rotor bolt TIP Clean the tapered portion of the crankshaft and the generator rotor hub When installing the generator rotor make sure the woodruff key is properly seated in the key way of...

Page 282: ... gasket Generator cover TIP Tighten the generator cover bolts in stages and in a crisscross pattern Apply LOCTITE to the threads of only the generator cover bolts 1 shown in the illustra tion 7 Connect Stator coil coupler Crankshaft position sensor coupler TIP To route the stator coil lead refer to CABLE ROUTING on page 2 43 Yamaha bond No 1215 90890 85505 Three bond No 1215 1 3 2 1 1 a T R Genera...

Page 283: ...nk Canister Refer to FUEL TANK on page 7 1 Pivot shaft protectors Refer to SWINGARM on page 4 88 Air duct bracket Refer to GENERAL CHASSIS 4 on page 4 7 Throttle bodies Air filter case Refer to THROTTLE BODIES on page 7 7 1 Gear position switch coupler 1 2 Coupler and hose bracket 1 3 Starter motor lead 1 Disconnect 4 Starter motor 1 5 Canister holder 1 1 2 3 4 5 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 ...

Page 284: ...move Q ty Remarks 1 O ring 1 2 Starter motor front cover 1 3 Starter motor yoke 1 4 Armature assembly 1 5 Gasket 2 6 Brush holder set 1 7 Starter motor rear cover 1 8 Lead guide 1 5 5 2 7 8 6 1 3 4 LS New New New New 5 Nm 0 5 m kgf 3 6 ft Ibf T R 11 Nm 1 1 m kgf 8 0 ft Ibf T R ...

Page 285: ...rmature assembly resistances with the digital circuit tester b If any resistance is out of specification re place the starter motor 4 Measure Brush length a Out of specification Replace the brush holder set 5 Measure Brush spring force Out of specification Replace the brush holder set 6 Check Gear teeth Damage wear Replace the starter motor Mica undercut depth 0 70 mm 0 03 in Digital circuit teste...

Page 286: ... match marks a on the starter motor yoke with the match marks b on the front cover and rear covers EAS30327 INSTALLING THE STARTER MOTOR 1 Install Canister holder 1 Starter motor 2 Canister 3 TIP Pass the starter motor front cover bolts through the slots a in the canister holder to secure it Install the canister holder with the stamped mark 2RC b facing forward 2 Install Coupler and hose holder br...

Page 287: ... OIL on page 3 21 Water pump housing Refer to WATER PUMP on page 6 9 1 Clutch cable 1 Disconnect 2 Clutch cable holder 1 3 Holder O2 sensor lead and oil pressure switch lead 2 4 Clutch cover 1 5 Clutch cover gasket 1 6 Dowel pin 2 1 2 8 4 6 6 5 3 3 LS New New E E LT LT 12 Nm 1 2 m kgf 8 7 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R ...

Page 288: ...remove Q ty Remarks 7 Circlip 1 8 Pull lever 1 9 Pull lever spring 1 10 Circlip 1 11 Pull lever shaft 1 12 Oil seal 1 13 Bearing 1 14 Bearing 1 7 8 9 11 12 14 10 13 8 LS New New E E LT LT 12 Nm 1 2 m kgf 8 7 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R ...

Page 289: ...ressure plate 1 3 Pull rod 1 4 Bearing 1 5 Friction plate 1 2 6 Clutch plate 6 7 Friction plate 2 5 8 Clutch boss nut 1 9 Conical spring washer 1 LT LT E E E LS New E 8 9 5 5 6 6 6 6 6 6 1 6 6 2 3 4 7 7 7 7 7 10 Nm 1 0 m kgf 7 2 ft Ibf T R 8 Nm 0 8 m kgf 5 8 ft Ibf T R 95 Nm 9 5 m kgf 69 ft Ibf T R ...

Page 290: ...ch boss 1 12 Thrust plate 1 13 Spacer 1 14 Bearing 1 15 Clutch housing 1 16 Thrust plate 1 17 Oil pump drive chain 1 18 Oil pump drive chain guide 1 LT LT E E E LS New E 11 10 6 6 17 16 14 13 12 18 15 10 Nm 1 0 m kgf 7 2 ft Ibf T R 8 Nm 0 8 m kgf 5 8 ft Ibf T R 95 Nm 9 5 m kgf 69 ft Ibf T R ...

Page 291: ...tages and in a crisscross pattern 3 Remove Friction plates 1 Clutch plates Friction plates 2 4 Straighten the clutch boss nut rib a 5 Loosen Clutch boss nut 1 TIP While holding the clutch boss 2 with the univer sal clutch holder 3 loosen the clutch boss nut 6 Remove Spacer 1 Bearing 2 Clutch housing 3 a Remove the spacer and bearing b Remove the oil pump drive chain 4 from the oil pump driven spro...

Page 292: ... with a surface plate and thickness gauge 1 Out of specification Replace the clutch plates as a set EAS30351 CHECKING THE CLUTCH SPRINGS The following procedure applies to all of the clutch springs 1 Check Clutch spring Damage Replace the clutch springs as a set 2 Measure Clutch spring free length a Out of specification Replace the clutch springs as a set Friction plate 1 thickness 2 90 3 10 mm 0 ...

Page 293: ...ration EAS30354 CHECKING THE PRESSURE PLATE 1 Check Pressure plate 1 Cracks damage Replace Bearing 2 Damage wear Replace EAS30356 CHECKING THE PRIMARY DRIVE GEAR 1 Check Primary drive gear Damage wear Replace the crankshaft and clutch housing as a set Excessive noise during operation Replace the crankshaft and clutch housing as a set EAS30357 CHECKING THE PRIMARY DRIVEN GEAR 1 Check Primary driven...

Page 294: ...ay from the vehicle While holding the clutch boss 1 with the uni versal clutch holder 3 tighten the clutch boss nut Stake the clutch boss nut at a cutout a in the main axle 3 Install Friction plates 1 1 Friction plates 2 2 TIP First install a friction plate and then alternate between a clutch plate and a friction plate Align a projection on friction plate 1 with the punch mark a on the clutch hous...

Page 295: ...hium soap based grease Install the bearings until they contact the sur faces a and install the oil seal until it contacts the surface b as shown in the illustration 6 Install Pull lever TIP Install the pull lever with the UP mark a fac ing toward upper side When installing the pull lever push the pull le ver and check that the punch mark b on the pull lever aligns with the mark c on the clutch cov...

Page 296: ... Tighten the bolts in stages and in a crisscross pattern 8 Connect Clutch cable 1 TIP Install the clutch cable so that the clutch cable length a is 51 6 62 2mm 2 03 2 45 in as shown in the illustration In addition make sure that the vehicle is positioned upright when measuring the clutch cable length After installing the clutch cable bend the pro jection b on the pull lever 9 Adjust Clutch lever f...

Page 297: ...ousing Refer to CLUTCH on page 5 46 1 Circlip 1 2 Washer 1 3 Shift shaft 1 4 Washer 1 5 Circlip 1 6 Washer 1 7 Stopper lever 1 8 Stopper lever spring 1 9 Collar 1 10 Shift shaft spring 1 11 Shift shaft spring stopper 1 12 Oil seal 1 13 Bearing 1 22 Nm 2 2 m kgf 16 ft Ibf T R E E LS New New New LT E 2 1 12 13 11 3 4 5 6 7 8 9 10 ...

Page 298: ... bearing does not protrude past the line b shown in the illustration Lubricate the oil seal lips with lithium soap based grease 2 Install Shift shaft spring stopper Washer Shift shaft assembly Stopper lever spring TIP Hook the end of the shift shaft spring 2 onto the shift shaft spring stopper 1 Hook the ends of the stopper lever spring 3 onto the stopper lever 4 and the stopper lever spring hook ...

Page 299: ...moving the oil pump Order Job Parts to remove Q ty Remarks Clutch housing Refer to CLUTCH on page 5 46 1 Oil pump assembly 1 2 Holder 1 10 Nm 1 0 m kgf 7 2 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R LT 1 2 ...

Page 300: ... 2 Oil pump rotor assembly 1 3 Oil pump inner rotor 1 4 Oil pump outer rotor 1 5 Pin 1 6 Oil pump driven sprocket 1 7 Circlip 1 Hold down the washer when removing the circlip 8 Washer 1 9 Spring 1 10 Relief valve 1 11 Dowel pin 2 3 8 Nm 0 38 m kgf 2 8 ft Ibf T R New E E E 2 3 4 5 10 11 11 8 1 9 7 6 ...

Page 301: ... defec tive part s 2 Measure Inner rotor to outer rotor tip clearance a Outer rotor to oil pump housing clearance b 3 Check Oil pump operation Rough movement Repeat steps 1 and 2 or replace the defective part s EAS30338 CHECKING THE RELIEF VALVE 1 Check Relief valve 1 Spring 2 Damage wear Replace the oil pump as sembly EAS30342 ASSEMBLING THE OIL PUMP 1 Lubricate Inner rotor Outer rotor with the r...

Page 302: ...e grooves a in the inner rotor 4 Check Oil pump operation Refer to CHECKING THE OIL PUMP on page 5 60 EAS30343 INSTALLING THE OIL PUMP 1 Install Oil pump 1 Oil pump bolts 2 NOTICE ECA20940 After installing the oil pump drive chain and driven sprocket make sure the oil pump turns smoothly Recommended lubricant Engine oil T R Oil pump cover screw 3 8 Nm 0 38 m kgf 2 8 ft lbf T R Oil pump bolt 12 Nm ...

Page 303: ... assembly right Refer to REAR BRAKE on page 4 43 Muffler assembly Refer to ENGINE REMOVAL on page 5 3 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 21 1 Engine oil drain bolt 1 2 Oil pan 1 3 Oil pan gasket 1 4 Oil strainer 1 4 1 3 2 11 10 Nm 1 0 m kgf 7 2 ft Ibf T R 43 Nm 4 3 m kgf 31 ft Ibf T R LT LT New New New 10 Nm 1 0 m kgf 7 2 ft Ibf T R ...

Page 304: ...ver into the slots a in the oil pan to remove the oil pan EAS31069 CHECKING THE OIL STRAINER 1 Check Oil strainer Damage Replace Contaminants Clean with solvent EAS31070 INSTALLING THE OIL PAN 1 Install Oil pan gasket Oil pan TIP Tighten the oil pan bolts in stages and in a criss cross pattern 2 Install Gasket Engine oil drain bolt T R Oil pan bolt 10 Nm 1 0 m kgf 7 2 ft lbf T R Engine oil drain b...

Page 305: ...otor Refer to ELECTRIC STARTER on page 5 42 Clutch housing Refer to CLUTCH on page 5 46 Oil strainer Refer to OIL PAN on page 5 62 2 6 6 3 8 2 E E E E New New New New LT LT LT LT LT LT LS LS LS 24 Nm 2 4 m kgf 17 ft Ibf 17 Nm 1 7 m kgf 12 ft Ibf 1st 2nd Final Specified angle 60 T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft I...

Page 306: ... Main gallery bolt 1 6 Crankcase 1 7 Dowel pin 3 8 Blind plate 1 2 6 6 3 8 2 1 2 3 4 6 7 7 8 5 E E E E New New New New LT LT LT LT LT LT LS LS LS 24 Nm 2 4 m kgf 17 ft Ibf 17 Nm 1 7 m kgf 12 ft Ibf 1st 2nd Final Specified angle 60 T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 15 Nm 1 5 m kgf 11 ft Ibf T R 24 Nm 2 4 m...

Page 307: ...mmer Tap only on reinforced por tions of the crankcase not on the crankcase mating surfaces Work slowly and carefully and make sure the crankcase halves sepa rate evenly EAS30390 CHECKING THE CRANKCASE 1 Thoroughly wash the crankcase halves in a mild solvent 2 Thoroughly clean all the gasket surfaces and crankcase mating surfaces 3 Check Crankcase Cracks damage Replace Oil delivery passages Obstru...

Page 308: ...olts 13 27 threads and mat ing surfaces with engine oil M9 80 mm bolt 6 bolts with washers 1 6 M8 70 mm bolt 6 bolts with new O rings 7 12 M8 65 mm bolt 2 13 14 M6 65 mm bolt 2 15 16 M6 40 mm bolt 8 17 18 21 24 26 27 M6 60 mm bolt 3 19 20 25 7 Tighten Crankcase bolts 1 6 Following the tightening order loosen the bolt one by one and then retighten it to the specific torque WARNING EWA16610 If the b...

Page 309: ... 2 2 Apply Sealant onto the oil pressure switch threads TIP Apply Three bond No 1215 to the threads a of the oil pressure switch However do not ap ply Three bond No 1215 to the portion b of the oil pressure switch Install the oil pressure switch lead so that it is routed within the range shown in the illustra tion T R Crankcase bolts 7 14 24 Nm 2 4 m kgf 17 ft lbf Crankcase bolts 15 27 10 Nm 1 0 m...

Page 310: ...CRANKCASE 5 69 a 1 2 2 b 45 10 1 ...

Page 311: ... The following procedure applies to all of the connecting rods and pistons Refer to CRANKCASE on page 5 64 1 Connecting rod cap 1 2 Big end lower bearing 1 3 Big end upper bearing 1 4 Piston pin clip 2 5 Piston pin 1 6 Piston 1 7 Connecting rod 1 2 1 3 4 4 6 7 5 1st 20 Nm 2 0 m kgf 14 ft Ibf 2nd Specified angle 180 T R New New New New E E E E E M M ...

Page 312: ...TONS 5 71 Removing the connecting rods and pistons Order Job Parts to remove Q ty Remarks 8 Top ring 1 9 2nd ring 1 10 Oil ring 1 9 10 8 1st 20 Nm 2 0 m kgf 14 ft Ibf 2nd Specified angle 180 T R New New New New E E E E E M M ...

Page 313: ...pin out TIP For reference during installation put identifica tion marks on the piston crown Before removing the piston pin deburr the pis ton pin clip groove and the piston pin bore ar ea If both areas are debarred and the piston pin is still difficult to remove remove it with the piston pin puller set 5 3 Remove Top ring 2nd ring Oil ring TIP When removing a piston ring open the end gap with your...

Page 314: ...e piston and piston rings as a set TIP Before measuring the piston ring side clearance eliminate any carbon deposits from the piston ring grooves and piston rings Bore 80 000 80 010 mm 3 1496 3 1500 in Taper limit 0 050 mm 0 0020 in Out of round limit 0 050 mm 0 0020 in C maximum of D1 D2 D3 D4 D5 D6 Taper front to back maximum difference be tween D1 D3 D5 Taper side to side maximum difference be ...

Page 315: ...Blue discoloration grooves Replace the piston pin and then check the lubrication sys tem 2 Measure Piston pin outside diameter a Out of specification Replace the piston pin 3 Measure Piston pin bore inside diameter b Out of specification Replace the piston Piston ring Top ring End gap installed 0 15 0 25 mm 0 0059 0 0098 in Limit 0 50 mm 0 0197 in 2nd ring End gap installed 0 30 0 45 mm 0 0118 0 0...

Page 316: ...ng into the connecting rod cap TIP Align the projections a on the big end bearings with the notches b in the connecting rod and connecting rod cap c Put a piece of Plastigauge 1 on the crank shaft pin d Assemble the connecting rod halves NOTICE ECA18390 Tighten the connecting rod bolts using the plastic region tightening angle method Al ways install new bolts TIP Clean the connecting rod bolts and...

Page 317: ...easurement has been completed Make sure that the projection a on the con necting rod cap faces the same direction as the Y mark b on the connecting rod Make sure the Y marks b on the connecting rods face towards the left side of the crank shaft g Tighten the connecting rod bolts with a torque wrench h Put a mark 1 on the corner of the connecting rod bolt 2 and the connecting rod cap 3 i Tighten th...

Page 318: ...rings P1 P2 TIP The numbers A stamped into the crankshaft web and the numbers B on the connecting rods are used to determine the replacement big end bearings sizes P1 P2 refer to the bearings shown in the crankshaft illustration For example if the connecting rod P1 and the crankshaft web P1 numbers are 5 and 2 respectively then the bearing size for P1 is EAS30751 INSTALLING THE CONNECTING ROD AND ...

Page 319: ...lybdenum disulfide oil c After installing the big end bearing assemble the connecting rod and connecting rod cap without installing them onto the crankshaft d Tighten the connecting rod bolt while check ing that the sections shown a and b are flush with each other by touching the surface TIP To install the big end bearing care should be taken not to install it at an angle and the position should n...

Page 320: ...onnecting rod assemblies 1 into the cylinder and onto the crankshaft pin Connecting rod caps onto the connecting rod TIP While compressing the piston ring with piston ring compressor 2 install the connecting rod assembly into the cylinder with the other hand Make sure the Y marks a on the connecting rods face towards the left side of the crank shaft Make sure that the projection b on the con necti...

Page 321: ...do not loosen the bolt and then re tighten it Instead replace the bolt with a new one and perform the procedure again NOTICE ECA20890 Do not use a torque wrench to tighten the bolt to the specified angle d After the installation check that the section shown a is flush with each other by touching the surface WARNING EWA17120 If the connecting rod and cap are not flush with each other remove the con...

Page 322: ...CONNECTING RODS AND PISTONS 5 81 a ...

Page 323: ...ankcase Refer to CRANKCASE on page 5 64 Connecting rod Refer to CONNECTING RODS AND PIS TONS on page 5 70 1 Balancer shaft assembly 1 2 Balancer shaft journal lower bearing 3 3 Balancer shaft journal upper bearing 3 4 Crankshaft assembly 1 5 Crankshaft journal lower bearing 3 6 Crankshaft journal upper bearing 3 1 2 3 3 3 2 4 6 6 6 5 5 5 2 E E E E E E E E E ...

Page 324: ...aft assembly Cracks damage wear Replace the balanc er shaft assembly and journal bearings Dirt Clean Bearings Damage wear Replace 4 Measure Balancer shaft journal to balancer shaft jour nal bearing clearance Out of specification Replace the balancer shaft journal bearings NOTICE ECA18400 Do not interchange the balancer shaft jour nal bearings To obtain the correct balancer shaft journal to balance...

Page 325: ...RANKCASE on page 5 64 f Remove the crankcase and the balancer shaft journal lower bearings g Measure the compressed Plastigauge width e on each balancer shaft journal If the balancer shaft journal to balancer shaft journal bearing clearance is out of specification select replacement balancer shaft journal bearings 5 Select Balancer shaft journal bearings J1 J3 TIP The numbers A stamped into the cr...

Page 326: ...nal bearings NOTICE ECA13920 Do not interchange the crankshaft journal bearings To obtain the correct crankshaft journal to crankshaft journal bearing clear ance and prevent engine damage the crank shaft journal bearings must be installed in their original positions a Clean the crankshaft journal bearings crank shaft journals and bearing portions of the cyl inder and crankcase b Install the cranks...

Page 327: ...idth g on each crankshaft journal If the crankshaft journal to crankshaft jour nal bearing clearance is out of specification select replacement crankshaft journal bear ings 5 Select Crankshaft journal bearings J1 J3 TIP The numbers A stamped into the crankcase and the numbers B stamped into the crank shaft web are used to determine the replace ment crankshaft journal bearing sizes J1 J3 refer to t...

Page 328: ...nstall Balancer shaft journal upper bearings into the upper crankcase Balancer shaft journal lower bearings into the lower crankcase TIP Align the projections a on the balancer shaft journal bearings 1 with the notches b in the crankcase Be sure to install each balancer shaft journal bearing in its original place 2 Install Balancer shaft 1 TIP Align the punch mark a in the balancer drive gear with...

Page 329: ...ks Crankcase Refer to CRANKCASE on page 5 64 1 Drive axle assembly 1 2 Shift drum retainer 1 3 Shift fork guide bar 2 4 Shift fork L 1 5 Shift fork R 1 6 Shift drum assembly 1 7 Shift fork C 1 8 Bearing retainer 1 9 Main axle assembly 1 LT LT E LT E E E E E 1 2 3 3 6 4 5 7 9 8 10 Nm 1 0 m kgf 7 2 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R ...

Page 330: ...remove Q ty Remarks 1 2nd pinion gear 1 2 Toothed lock washer 1 3 Toothed lock washer retainer 1 4 6th pinion gear 1 5 Collar 1 6 Washer 1 7 Circlip 1 8 3rd pinion gear 1 9 Circlip 1 10 Washer 1 11 5th pinion gear 1 12 Collar 1 M M M M M M M New New 8 10 11 12 9 7 6 5 4 3 1 2 ...

Page 331: ...TRANSMISSION 5 90 Disassembling the main axle assembly Order Job Parts to remove Q ty Remarks 13 Main axle 1 M M M M M M M New New 13 ...

Page 332: ...Q ty Remarks 1 1st wheel gear 1 2 Collar 1 3 5th wheel gear 1 4 Circlip 1 5 Washer 1 6 3rd wheel gear 1 7 Collar 1 8 Toothed lock washer 1 9 Toothed lock washer retainer 1 10 4th wheel gear 1 11 Collar 1 12 Washer 1 10 11 12 1 2 3 4 5 6 7 8 9 LS M M M M M M M M M New New New New New ...

Page 333: ...Job Parts to remove Q ty Remarks 13 Circlip 1 14 6th wheel gear 1 15 Circlip 1 16 Washer 1 17 Collar 1 18 2nd wheel gear 1 19 Oil seal 1 20 Circlip 1 21 Bearing 1 22 Collar 1 23 Drive axle 1 13 14 15 16 17 18 20 19 21 22 23 LS M M M M M M M M M New New New New New ...

Page 334: ...KING THE SHIFT FORKS The following procedure applies to all of the shift forks 1 Check Shift fork cam follower 1 Shift fork pawl 2 Bends damage scoring wear Replace the shift fork 2 Check Shift fork guide bar Roll the shift fork guide bar on a flat surface Bends Replace WARNING EWA12840 Do not attempt to straighten a bent shift fork guide bar 3 Check Shift fork movement along the shift fork guide ...

Page 335: ...r s 4 Check Transmission gear engagement each pinion gear to its respective wheel gear Incorrect Reassemble the transmission axle assemblies 5 Check Transmission gear movement Rough movement Replace the defective part s 6 Check Circlips Bends damage looseness Replace EAS30435 ASSEMBLING THE MAIN AXLE AND DRIVE AXLE 1 Install Toothed washer 1 Circlip 2 TIP Be sure the circlip sharp edged corner a i...

Page 336: ...s the cylinder 2 Install Shift fork C Shift drum assembly Shift fork guide bar TIP The embossed marks on the shift forks should face towards the right side of the engine Install shift fork C into the groove in the 3rd pinion gear on the main axle 3 Install Shift fork L 1 Shift fork R 2 Shift fork guide bar Shift drum retainer Drive axle assembly 3 TIP Install shift fork L into the groove in the 6t...

Page 337: ...TRANSMISSION 5 96 4 Check Transmission Rough movement Repair TIP Oil each gear shaft and bearing thoroughly 3 2 1 c b a ...

Page 338: ...TRANSMISSION 5 97 ...

Page 339: ... THE RADIATOR 6 4 OIL COOLER 6 5 CHECKING THE OIL COOLER 6 6 CHECKING THE WATER JACKET JOINT 6 6 INSTALLING THE OIL COOLER 6 6 THERMOSTAT 6 7 CHECKING THE THERMOSTAT 6 8 INSTALLING THE THERMOSTAT 6 8 WATER PUMP 6 9 DISASSEMBLING THE WATER PUMP 6 11 CHECKING THE WATER PUMP 6 11 ASSEMBLING THE WATER PUMP 6 11 INSTALLING THE CLUTCH COVER 6 13 ...

Page 340: ...ant reservoir hose 1 3 Coolant reservoir cap 1 4 Coolant reservoir cover 1 5 Coolant reservoir 1 6 Radiator side cover left 1 7 Radiator side cover bracket bolt left 1 1 0 Nm 0 10 m kgf 0 72 ft Ibf T R 2 0 Nm 0 20 m kgf 1 4 ft Ibf T R 5 Nm 0 5 m kgf 3 6 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 8 Nm 0 8 m kgf 5 8 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf ...

Page 341: ...adiator fan motor coupler 1 Disconnect 13 Radiator outlet hose 1 14 Radiator inlet hose 1 15 Radiator 1 16 Radiator fan 1 1 0 Nm 0 10 m kgf 0 72 ft Ibf T R 2 0 Nm 0 20 m kgf 1 4 ft Ibf T R 5 Nm 0 5 m kgf 3 6 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 8 Nm 0 8 m kgf 5 8 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 10 11 12 16 9 15 13 14 8 ...

Page 342: ... 29 EAS31796 INSTALLING THE RADIATOR SIDE COVER BRACKETS AND RADIATOR SIDE COVERS The following procedure applies to both of the radiator side cover brackets and radiator side covers 1 Install Radiator side cover bracket bolt 1 Radiator side cover 2 TIP Install the radiator side cover bracket so that the end with round hole a is pointing upward and the end with the oval hole b is pointing downward...

Page 343: ... in the illustration 2 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 24 3 Check Cooling system Leaks Repair or replace any faulty part 4 Measure Radiator cap opening pressure Below the specified pressure Replace the radiator cap Refer to CHECKING THE RADIATOR on page 6 3 2 d c a 1 20 ...

Page 344: ...age 3 21 Coolant reservoir Refer to RADIATOR on page 6 1 1 Oil filter cartridge 1 2 Water jacket joint 1 3 Water jacket joint inlet hose 1 4 Oil cooler inlet hose 1 5 Oil cooler outlet hose 1 6 Oil filter cartridge union bolt 1 7 Oil cooler 1 8 Gasket 1 LS New New E E LS 10 Nm 1 0 m kgf 7 2 ft Ibf T R 2 0 Nm 0 20 m kgf 1 4 ft Ibf T R 40 Nm 4 0 m kgf 29 ft Ibf T R 17 Nm 1 7 m kgf 12 ft Ibf T R 3 2 ...

Page 345: ...ling the oil cooler apply engine oil lightly to the oil filter cartridge union bolt Align the projection a on the oil cooler with the slot b in the crankcase 3 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 24 Crankcase with the specified amount of the recom mended engine oil Refer to CHANGING THE ENGINE OIL on page 3 21 4 Check Co...

Page 346: ... 1 on page 4 1 Fuel tank center cover Refer to GENERAL CHASSIS 3 on page 4 5 Fuel tank Canister Refer to FUEL TANK on page 7 1 1 Coolant temperature sensor coupler 1 Disconnect 2 Coolant temperature sensor 1 3 Radiator inlet hose 1 Disconnect 4 Thermostat cover 1 5 Thermostat 1 New 2 0 Nm 0 20 m kgf 1 4 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R 16 Nm 1 6 m kgf 12 ft Ibf T R 3 4 2 1 5 ...

Page 347: ...ulty thermostat could cause serious overheating or overcooling 2 Check Thermostat cover Cracks damage Replace EAS30939 INSTALLING THE THERMOSTAT 1 Install Thermostat TIP Install the thermostat with its breather valve a facing inward 2 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 24 3 Check Cooling system Leaks Repair or replace a...

Page 348: ...1 Clutch cable 1 Disconnect 2 Water pump outlet hose 1 Disconnect 3 Oil cooler outlet hose 1 Disconnect 4 Radiator outlet hose 1 Disconnect 5 Water pump inlet pipe 1 LT LT LS LS LS New New New New New New New E LS LT 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R...

Page 349: ... cover 1 9 Impeller shaft 1 10 Water pump seal assembly 1 11 Oil seal 1 12 Bearing 1 LT LT LS LS LS New New New New New New New E LS LT 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R 10 12 11 6 8 10 7 9 ...

Page 350: ...eller shaft Cracks damage wear Replace 2 Check Bearing Rough movement Replace 3 Check Water pump outlet pipe Water pump inlet pipe Cracks damage wear Replace EAS30448 ASSEMBLING THE WATER PUMP 1 Install Oil seal 1 Bearing into the clutch cover 2 TIP Install the oil seal with a socket 3 that matches its outside diameter 2 Install Mechanical seal housing side 1 into the clutch cover 2 NOTICE ECA2033...

Page 351: ...contacts the mechanical seal housing side is dirty clean it 5 Install Impeller shaft 1 Circlip 2 TIP Be sure the circlip sharp edged corner a is positioned opposite side to the bearing After installation check that the impeller shaft rotates smoothly Mechanical seal installer 90890 04132 Water pump seal installer YM 33221 A Middle driven shaft bearing driv er 90890 04058 Middle drive bearing insta...

Page 352: ...e clutch cover make sure that the alignment mark d on the clutch cover is aligned with the punch mark e on the pull le ver 6 2 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 24 3 Check Cooling system Leaks Repair or replace the faulty part 4 Measure Radiator cap opening pressure Below the specified pressure Replace the radiator cap...

Page 353: ... THROTTLE BODIES 7 7 CHECKING THE INJECTORS BEFORE REMOVING 7 10 REMOVING THE INJECTORS 7 10 CHECKING THE INJECTORS 7 10 CHECKING THE THROTTLE BODIES 7 10 CLEANING THE ISC IDLE SPEED CONTROL VALVE 7 10 CHECKING THE THROTTLE BODY JOINTS 7 12 ADJUSTING THE THROTTLE POSITION SENSOR 7 13 INSTALLING THE FUEL INJECTORS 7 13 CHECKING THE INJECTOR PRESSURE 7 14 CHECKING THE FUEL PRESSURE 7 14 INSTALLING T...

Page 354: ...3 on page 4 5 1 Intake air temperature sensor coupler 1 Disconnect 2 Fuel tank overflow hose 1 Disconnect 3 Fuel tank breather hose 1 Disconnect 4 Fuel pump coupler 1 Disconnect 5 Fuel hose 1 1 2 4 3 5 4 New 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 3 8 Nm 0 38 m kgf 2 8 ft Ibf T R 4 0 Nm 0 40 m kgf 2 9 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 30 N...

Page 355: ... air temperature sensor 1 10 Fuel pump 1 11 Front fuel tank bracket 1 12 Rear fuel tank bracket 1 8 4 New 7 6 8 12 9 10 11 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 3 8 Nm 0 38 m kgf 2 8 ft Ibf T R 4 0 Nm 0 40 m kgf 2 9 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 30 Nm 3 0 m kgf 22 ft Ibf T R ...

Page 356: ... center cover Refer to GENERAL CHASSIS 3 on page 4 5 Fuel tank Refer to FUEL TANK on page 7 1 1 Fuel tank overflow hose 1 2 Fuel tank breather hose fuel tank to canister 1 3 Canister purge hose hose joint to canister 1 4 Canister breather hose 1 5 Canister holder 1 Refer to ELECTRIC STARTER on page 5 42 6 Canister 1 1 2 3 5 6 4 ...

Page 357: ...IP Do not set the fuel tank down on the installation surface of the fuel pump Be sure to lean the fuel tank against a wall or the like EAS30451 REMOVING THE FUEL PUMP 1 Remove Fuel pump NOTICE ECA14721 Do not drop the fuel pump or give it a strong shock Do not touch the base section of the fuel sender EAS30454 CHECKING THE FUEL PUMP BODY 1 Check Fuel pump body Obstruction Clean Cracks damage Repla...

Page 358: ...ars Front fuel tank bracket 1 TIP Make sure that the arrow mark a on the front fuel tank bracket points toward the hole b in the fuel tank 2 Install Grommets Collars Rear fuel tank bracket 1 TIP Make sure that the arrow mark a on the rear fuel tank bracket points toward the punch mark b on the fuel tank EAS30457 INSTALLING THE FUEL TANK 1 Tighten Front fuel tank bracket bolt temporarily 1 a New FW...

Page 359: ...nstall the fuel hose securely onto the fuel rail and fuel pump until a distinct click is heard To install the fuel hose slide the fuel hose con nector cover 1 on each end of the hose in the direction of the arrow shown 3 Connect Fuel pump coupler Fuel tank breather hose Fuel tank overflow hose Intake air temperature sensor 4 Tighten Rear fuel tank bracket bolts 5 Tighten Front fuel tank bracket bo...

Page 360: ...n page 7 1 Air duct bracket Refer to GENERAL CHASSIS 4 on page 4 7 Pivot shaft protector left right Refer to SWINGARM on page 4 88 1 Cylinder head breather hose 1 2 Throttle position sensor coupler 1 Disconnect 3 Canister purge hose 3 4 Hose joint 1 5 Injector coupler 2 Disconnect 3 0 Nm 0 30 m kgf 2 2 ft Ibf T R 3 0 Nm 0 30 m kgf 2 2 ft Ibf T R 4 5 Nm 0 45 m kgf 3 3 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ...

Page 361: ...ttle cable accelerator cable 1 Disconnect 10 Throttle body joint clamp screw 4 Loosen 11 Air filter case bolt 2 12 Air filter case joint clamp screw 2 Loosen 13 Throttle bodies 1 14 Throttle body joint 2 15 Air filter case 1 3 0 Nm 0 30 m kgf 2 2 ft Ibf T R 3 0 Nm 0 30 m kgf 2 2 ft Ibf T R 4 5 Nm 0 45 m kgf 3 3 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R 12 Nm 1 2 m kgf...

Page 362: ...Remarks 1 ISC Idle Speed Control valve plate 1 2 ISC Idle Speed Control valve 1 3 Spring 1 4 Throttle position sensor 1 5 Fuel rail 1 6 Fuel injector 2 New New New New New 3 5 Nm 0 35 m kgf 2 5 ft Ibf T R 3 5 Nm 0 35 m kgf 2 5 ft Ibf T R 5 Nm 0 5 m kgf 3 6 ft Ibf T R 6 6 3 1 2 5 4 ...

Page 363: ...ce 2 Check Injector resistance Refer to CHECKING THE FUEL INJEC TORS on page 8 171 EAS30479 CHECKING THE THROTTLE BODIES TIP Before checking the throttle bodies check the following items Valve clearance Spark plugs Air filter element Throttle body joints Fuel hose Exhaust system Cylinder head breather hose Vacuum hoses WARNING EWA17850 If the throttle bodies are subjected to strong shocks or dropp...

Page 364: ...ed solvent to the portions of the throttle valve shafts be tween the throttle bodies e Remove the carbon deposits from the inside of each throttle body in a downward direction from the air filter case side of the throttle body to the engine side NOTICE ECA18470 Do not use a tool such as a wire brush to remove the carbon deposits otherwise the inside of the throttle bodies may be dam aged Do not al...

Page 365: ...r enters the throttle bodies thoroughly wipe it off TIP Clean the area a of the ISC valve and the ISC valve installation hole b in the throttle bodies 3 Install O ring ISC Idle Speed Control valve ISC Idle Speed Control valve plate TIP Align the slot a in the ISC valve plate with the projection b on the ISC valve Resetting the ISC idle speed control learn ing values 1 Install Throttle bodies 2 Res...

Page 366: ...nostic tool screen g After adjusting the throttle position sensor an gle tighten the throttle position sensor bolts 2 EAS31124 INSTALLING THE FUEL INJECTORS NOTICE ECA20000 Always use new O rings When checking the injectors do not allow any foreign material to enter or adhere to the injectors fuel rail or O rings Be careful not to twist or pinch the O rings when installing the injectors If an inje...

Page 367: ...t one minute Pressure drops Check the pressure gauge and adapter Check the seals and O rings and then rein stall Replace the fuel injectors EAS30482 CHECKING THE FUEL PRESSURE 1 Remove Seat Refer to GENERAL CHASSIS 1 on page 4 1 Fuel tank center cover Refer to GENERAL CHASSIS 3 on page 4 5 2 Check Fuel pressure a Remove the rear fuel tank bracket bolts 1 and holdup the fuel tank NOTICE ECA20070 Wh...

Page 368: ...1 Install Air filter case joint clamps 1 TIP Align the projection a on the air filter case joint with the slot b in the air filter case joint clamp Face the screw head c of the air filter case joint clamp outward Pressure gauge 90890 03153 Pressure gauge YU 03153 Fuel pressure adapter 90890 03176 Fuel pressure adapter YM 03176 Fuel line pressure at idling 300 390 kPa 3 0 3 9 kgf cm 43 5 56 6 psi R...

Page 369: ...1 CIRCUIT DIAGRAM 8 21 TROUBLESHOOTING 8 23 COOLING SYSTEM 8 29 CIRCUIT DIAGRAM 8 29 TROUBLESHOOTING 8 31 FUEL INJECTION SYSTEM 8 33 CIRCUIT DIAGRAM 8 33 ECU SELF DIAGNOSTIC FUNCTION 8 35 TROUBLESHOOTING METHOD 8 35 YAMAHA DIAGNOSTIC TOOL 8 36 TROUBLESHOOTING DETAILS FAULT CODE 8 38 TROUBLESHOOTING DETAILS EVENT CODE 8 99 FUEL PUMP SYSTEM 8 101 CIRCUIT DIAGRAM 8 101 TROUBLESHOOTING 8 103 IMMOBILIZ...

Page 370: ...MPONENTS 8 149 CHECKING THE SWITCHES 8 153 CHECKING THE BULBS AND BULB SOCKETS 8 156 CHECKING THE FUSES 8 157 REPLACING THE ECU engine control unit 8 158 CHECKING AND CHARGING THE BATTERY 8 158 CHECKING THE RELAYS 8 161 CHECKING THE TURN SIGNAL HAZARD RELAY 8 162 CHECKING THE RELAY UNIT DIODE 8 163 CHECKING THE IGNITION COILS 8 164 CHECKING THE IGNITION SPARK GAP 8 164 CHECKING THE CRANKSHAFT POSI...

Page 371: ......

Page 372: ...L W L R R R R R R R Lg R W G B R G Y L Dg Dg B B Y Y G G L R L R Ch Ch B Dg B Ch L R G Y B B B B B B B B L R L L R Br L R W Br L Br R Br R B W R G Y L G B R W W W W B R B R R L W R W B Br Y B B Y L R R W L W R B R L W L L W L Y R W L G B R B Y Sb W Sb L G B B B B B Gy B Gy B L L B L P W L B B W L B R W Gy G B L P B B L W B L B B B L Br W B B L G W L R L B Y L B L P W B R W L Y B R R B B Y G B L W ...

Page 373: ... Joint coupler 26 Sidestand switch 27 Crankshaft position sensor 30 Ignition coil 1 31 Ignition coil 2 32 Spark plug 36 ECU Engine Control Unit 40 Lean angle sensor 61 Gear position switch 62 Handlebar switch right 65 Start engine stop switch A Wire harness C Sub wire harness gear position switch coolant temperature sensor fuel injector ...

Page 374: ...n gine continues to run under the following conditions The transmission is in gear the neutral circuit of the gear position switch is open and the sidestand is up the sidestand switch circuit is closed The transmission is in neutral the neutral circuit of the gear position switch is closed and the side stand is down the sidestand switch circuit is open 10 11 9 1 4 5 7 2 6 3 8 1 Battery 2 Main fuse...

Page 375: ...NG AND CHARGING THE BATTERY on page 8 158 Clean the battery terminals Recharge or replace the battery 3 Check the spark plugs Refer to CHECKING THE SPARK PLUGS on page 3 4 Re gap or replace the spark plug s 4 Check the ignition spark gap Refer to CHECKING THE IGNI TION SPARK GAP on page 8 164 Ignition system is OK 5 Check the ignition coils Refer to CHECKING THE IGNI TION COILS on page 8 164 Repla...

Page 376: ...ch 10 Check the sidestand switch Refer to CHECKING THE SWITCHES on page 8 153 Replace the sidestand switch 11 Check the relay unit diode Refer to CHECKING THE RELAY UNIT DIODE on page 8 163 Replace the relay unit 12 Check the lean angle sensor Refer to CHECKING THE LEAN ANGLE SENSOR on page 8 165 Replace the lean angle sensor 13 Check the entire ignition system wiring Refer to CIRCUIT DIAGRAM on p...

Page 377: ...IGNITION SYSTEM 8 6 ...

Page 378: ... L W L W L W L R R R R R R R Lg R W G B R G Y L Dg Dg B B Y Y G G L R L R Ch Ch B Dg B Ch L R G Y B B B B B B B B L R L L R Br L R W Br L Br R Br R B W R G Y L G B R W W W W B R B R R L W R W B Br Y B B Y L R R W L W R B R L W L L W L Y R W L G B R B Y Sb W Sb L G B B B B B Gy B Gy B L L B L P W L B B W L B R W Gy G B L P B B L W B L B B B L Br W B B L G W L R L B Y L B L P W B R W L Y B R R B B Y...

Page 379: ... 20 Starter motor 22 Relay unit 23 Starting circuit cut off relay 25 Joint coupler 26 Sidestand switch 61 Gear position switch 62 Handlebar switch right 65 Start engine stop switch 67 Handlebar switch left 68 Clutch switch A Wire harness C Sub wire harness gear position switch coolant temperature sensor fuel injector ...

Page 380: ...tor from operating when neither of these condi tions has been met In this instance the starting circuit cut off relay is open so current cannot reach the starter motor When at least one of the above conditions has been met the starting circuit cut off relay is closed and the engine can be cranked up by pressing the side of the start engine stop switch 12 1 11 4 6 6 6 6 a b 8 6 9 7 5 2 3 10 10 a WH...

Page 381: ...TTERY on page 8 158 Clean the battery terminals Recharge or replace the battery 3 Check the starter motor operation Refer to CHECKING THE START ER MOTOR OPERATION on page 8 166 Starter motor is OK Perform the electric starting system troubleshooting starting with step 5 4 Check the starter motor Refer to CHECKING THE START ER MOTOR on page 5 44 Repair or replace the starter motor 5 Check the relay...

Page 382: ...he sidestand switch Refer to CHECKING THE SWITCHES on page 8 153 Replace the sidestand switch 11 Check the clutch switch Refer to CHECKING THE SWITCHES on page 8 153 Replace the clutch switch 12 Check the start engine stop switch Refer to CHECKING THE SWITCHES on page 8 153 The start engine stop switch is faulty Replace the right handlebar switch 13 Check the entire starting system wiring Refer to...

Page 383: ...ELECTRIC STARTING SYSTEM 8 12 ...

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

Page 385: ...CHARGING SYSTEM 8 14 13 AC magneto 14 Rectifier regulator 15 Battery 16 Engine ground 18 Main fuse ...

Page 386: ...fer to CHECKING AND CHARGING THE BATTERY on page 8 158 Clean the battery terminals Recharge or replace the battery 3 Check the stator coil Refer to CHECKING THE STATOR COIL on page 8 166 Replace the stator coil assembly 4 Check the rectifier regulator Refer to CHECKING THE RECTI FIER REGULATOR on page 8 166 Replace the rectifier regulator 5 Check the entire charging system wiring Refer to CIRCUIT ...

Page 387: ...CHARGING SYSTEM 8 16 ...

Page 388: ... L W L R R R R R R R Lg R W G B R G Y L Dg Dg B B Y Y G G L R L R Ch Ch B Dg B Ch L R G Y B B B B B B B B L R L L R Br L R W Br L Br R Br R B W R G Y L G B R W W W W B R B R R L W R W B Br Y B B Y L R R W L W R B R L W L L W L Y R W L G B R B Y Sb W Sb L G B B B B B Gy B Gy B L L B L P W L B B W L B R W Gy G B L P B B L W B L B B B L Br W B B L G W L R L B Y L B L P W B R W L Y B R R B B Y G B L W...

Page 389: ...use 25 Joint coupler 36 ECU Engine Control Unit 48 Meter assembly 51 Meter light 57 High beam indicator light 67 Handlebar switch left 69 Dimmer switch 70 Pass switch 76 Headlight assembly 77 Auxiliary light 78 Headlight 80 License plate light 81 Tail brake light 84 Headlight relay A Wire harness E Sub wire harness headlight turn signal light auxiliary light ...

Page 390: ...ling system head light fuel injection system and main Refer to CHECKING THE FUS ES on page 8 157 Replace the fuse s 3 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 158 Clean the battery terminals Recharge or replace the battery 4 Check the main switch Refer to CHECKING THE SWITCHES on page 8 153 Replace the main switch immobilizer unit 5 Check the dimmer switch Refer to CH...

Page 391: ...ck the entire lighting system wiring Refer to CIRCUIT DIAGRAM on page 8 17 Properly connect or replace the wiring har ness Replace the ECU meter assembly or tail brake light Refer to REPLACING THE ECU engine control unit on page 8 158 ...

Page 392: ... L B L B L B L B L R W R W R W Y Y L R L R L R L W L W L W L W L R R R R R R R Lg R W G B R G Y L Dg Dg B B Y Y G G L R L R Ch Ch B Dg B Ch L R G Y B B B B B B B B L R L L R Br L R W Br L Br R Br R B W R G Y L G B R W W W W B R B R R L W R W B Br Y B B Y L R R W L W R B R L W L L W L Y R W L G B R B Y Sb W Sb L G B B B B B Gy B Gy B L L B L P W L B B W L B R W Gy G B L P B B L W B L B B B L Br W B...

Page 393: ...ndicator light 52 Tachometer 53 Multi function meter 54 Oil pressure warning light 56 Coolant temperature warning light 58 Turn signal indicator light 60 Horn 61 Gear position switch 62 Handlebar switch right 63 Front brake light switch 64 Hazard switch 66 Turn signal hazard relay 67 Handlebar switch left 71 Turn signal switch 72 Horn switch 73 Rear turn signal light right 74 Rear turn signal ligh...

Page 394: ...tion signaling system fuel in jection system backup and main Refer to CHECKING THE FUS ES on page 8 157 Replace the fuse s 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 158 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 153 Replace the main switch immobilizer unit 4 Check the entire signaling s...

Page 395: ...he rear brake light switch 3 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 8 21 Properly connect or replace the wiring har ness Replace the tail brake light 1 Check the turn signal light bulbs and sockets Refer to CHECKING THE BULBS AND BULB SOCKETS on page 8 156 Replace the turn signal light bulb socket or both 2 Check the turn signal switch Refer to CHECKING THE SWITC...

Page 396: ...r position switch 2 Check the relay unit diode Refer to CHECKING THE RELAY UNIT DIODE on page 8 163 Replace the relay unit 3 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 8 21 Properly connect or replace the wiring har ness Replace the meter assembly 1 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 8 21 Properly connect or replace the wiring h...

Page 397: ... viscosity oil seal oil filter or oil pump Replace the oil pressure switch 1 Check the fuel sender Refer to CHECKING THE FUEL SENDER on page 8 167 Replace the fuel pump assembly 2 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 8 21 Properly connect or replace the wiring har ness Replace the meter assembly 1 Check the coolant temperature sen sor Refer to CHECKING THE COOL...

Page 398: ... ECU coupler and meter assembly coupler blue black blue black blue red blue red 1 Check the rear wheel sensor Refer to MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR on page 4 25 Replace the rear wheel sensor 2 Check the entire rear wheel sensor wiring Refer to TIP Properly connect or replace the wiring har ness Replace the ECU ABS ECU or meter assembly Refer to REPLACING THE ECU engine con...

Page 399: ...SIGNALING SYSTEM 8 28 ...

Page 400: ...L W L R R R R R R R Lg R W G B R G Y L Dg Dg B B Y Y G G L R L R Ch Ch B Dg B Ch L R G Y B B B B B B B B L R L L R Br L R W Br L Br R Br R B W R G Y L G B R W W W W B R B R R L W R W B Br Y B B Y L R R W L W R B R L W L L W L Y R W L G B R B Y Sb W Sb L G B B B B B Gy B Gy B L L B L P W L B B W L B R W Gy G B L P B B L W B L B B B L Br W B B L G W L R L B Y L B L P W B R W L Y B R R B B Y G B L W ...

Page 401: ...Radiator fan motor fuse 15 Battery 16 Engine ground 18 Main fuse 25 Joint coupler 36 ECU Engine Control Unit 38 Coolant temperature sensor 82 Radiator fan motor 83 Radiator fan motor relay A Wire harness C Sub wire harness gear position switch coolant temperature sensor fuel injector ...

Page 402: ...er to CHECKING AND CHARGING THE BATTERY on page 8 158 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 153 Replace the main switch immobilizer unit 4 Check the radiator fan motor Refer to CHECKING THE RADIA TOR FAN MOTOR on page 8 168 Replace the radiator fan motor 5 Check the radiator fan motor relay Refer to CHECKING THE...

Page 403: ... 8 32 NG OK 7 Check the entire cooling system wiring Refer to CIRCUIT DIAGRAM on page 8 29 Properly connect or replace the wiring har ness Replace the ECU Refer to REPLAC ING THE ECU engine control unit on page 8 158 ...

Page 404: ... W L W L W L R R R R R R R Lg R W G B R G Y L Dg Dg B B Y Y G G L R L R Ch Ch B Dg B Ch L R G Y B B B B B B B B L R L L R Br L R W Br L Br R Br R B W R G Y L G B R W W W W B R B R R L W R W B Br Y B B Y L R R W L W R B R L W L L W L Y R W L G B R B Y Sb W Sb L G B B B B B Gy B Gy B L L B L P W L B B W L B R W Gy G B L P B B L W B L B B B L Br W B B L G W L R L B Y L B L P W B R W L Y B R R B B Y G...

Page 405: ...SC Idle Speed Control unit 36 ECU Engine Control Unit 37 Intake air temperature sensor 38 Coolant temperature sensor 39 Intake air pressure sensor 40 Lean angle sensor 42 Rear wheel sensor 43 ABS ECU electronic control unit 44 Yamaha diagnostic tool coupler 46 Fuel pump 48 Meter assembly 53 Multi function meter 55 Engine trouble warning light 61 Gear position switch 62 Handlebar switch right 65 St...

Page 406: ...es the specified values that are programmed for each sensor in order to provide the engine with alternate operating instructions that enable the engine to continue operating or stop operating depending on the conditions EAS30506 TROUBLESHOOTING METHOD The engine operation is not normal and the engine trouble warning light comes on 1 Check Fault code number a Check the fault code numbers that have ...

Page 407: ...tions and for maintenance to display on the computer The displayed information includes the sen sor output data and information recorded in the ECU Functions of the Yamaha diagnostic tool 01 Throttle position sensor signal throttle angle 30 Cylinder 1 ignition coil 31 Cylinder 2 ignition coil 36 Fuel injector 1 37 Fuel injector 2 Yamaha diagnostic tool 90890 03250 OBD GST Leadwire kit 90890 03249 ...

Page 408: ...diagnostic tool Malfunction mode The results of the fault diagnosis are displayed as shown in the following screen shot TIP The screen display may vary depending on the version of the Yamaha diagnostic tool that you are us ing Reprogram ECU If necessary the ECU is rewritten using ECU rewrite data provided by Yamaha Ignition timing adjustment etc cannot be changed from the vehicle s original state ...

Page 409: ...ing to the reinstatement method Fault code No Fault code number displayed on the Yamaha diagnostic tool when the engine failed to work normally Diagnostic code No Diagnostic code number to be used when the diagnostic mode is operated Refer to SELF DIAGNOS TIC FUNCTION AND DIAGNOSTIC CODE TABLE on page 9 5 Parts connected to the ECU The following parts are connected to the ECU When checking for a p...

Page 410: ... to drive vehicle Diagnostic code No Tool display Procedure Item Probable cause of malfunc tion and check Maintenance job Confirmation of service com pletion 1 Connection of O2 sensor cou pler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the coupler securely or re place ...

Page 411: ...tween main switch and igni tion fuse brown blue brown blue Between ignition fuse and joint coupler red white red white Turn the main switch to ON and then check the condition of the fault code using the mal function mode of the Yamaha di agnostic tool Condition is Recovered Go to item 6 and finish the service Condition is Detected Start the engine and then check the condition of the fault code Con...

Page 412: ... SYSTEM 8 41 6 Delete the fault code and check that the engine trouble warning light goes off Confirm that the fault code has a condition of Recovered us ing the Yamaha diagnostic tool and then delete the fault code ...

Page 413: ...the condition of the fault code using the mal function mode of the Yamaha di agnostic tool Condition is Recovered Go to item 7 and finish the service Condition is Detected Go to item 2 2 Connection of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the coupler s...

Page 414: ...ke air pressure sensor coupler and ECU coupler pink white pink white If there is no continuity replace the wire harness 3 6 For P0108 Open circuit Between intake air pressure sensor coupler and ECU coupler black blue black blue If there is no continuity replace the wire harness B L P W L B L P W L L R L B Y L B L P W R W L Y B R R B B Y G B L W Y G Br W W G P L R G G W W Y R L R B P B B W Y B B Gy...

Page 415: ...r pressure sensor Check for looseness or pinch ing Improperly installed sensor Reinstall or replace the sensor Turn the main switch to ON and then check the condition of the fault code using the mal function mode of the Yamaha di agnostic tool Condition is Recovered Go to item 7 and finish the service Condition is Detected Go to item 5 L R L B Y L B L P W R W L Y B R R B B Y G B L W Y G Br W W G P...

Page 416: ...e changes The value does not change when engine is cranking Check the intake air pressure sensor Replace if defective Refer to CHECKING THE IN TAKE AIR PRESSURE SEN SOR on page 8 169 Crank the engine and then check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item 7 and finish the service Condition is Detected Go to item 6 6 ...

Page 417: ...or re place the wire harness Turn the main switch to ON and then check the condition of the fault code using the mal function mode of the Yamaha di agnostic tool Condition is Recovered Go to item 7 and finish the service Condition is Detected Go to item 2 2 Connection of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and lo...

Page 418: ...Open circuit Between intake air temperature sensor coupler and ECU coupler brown white brown white If there is no continuity replace the wire harness 3 5 For P0113 Open circuit Between intake air temperature sensor coupler and ECU coupler black blue black blue If there is no continuity replace the wire harness Br W B L Br W B L 5V 1 2 3 4 B L Br W B L Br W L R L B Y L B L P W R W L Y B R R B B Y G...

Page 419: ...ive intake air tempera ture sensor Execute the diagnostic mode Code No 05 When engine is cold Displayed temperature is close to the ambient temperature The displayed temperature is not close to the ambient tem perature Check the intake air temperature sensor Replace if defective Refer to CHECKING THE IN TAKE AIR PRESSURE SEN SOR on page 8 169 Turn the main switch to ON and then check the condition...

Page 420: ... SYSTEM 8 49 7 Delete the fault code and check that the engine trouble warning light goes off Confirm that the fault code has a condition of Recovered us ing the Yamaha diagnostic tool and then delete the fault code ...

Page 421: ...ly connected Con nect the coupler securely or re place the wire harness Turn the main switch to ON and then check the condition of the fault code using the mal function mode of the Yamaha di agnostic tool Condition is Recovered Go to item 7 and finish the service Condition is Detected Go to item 2 2 Connection of ECU coupler Check the locking condition of the coupler Disconnect the coupler and che...

Page 422: ...Open circuit Between coolant temperature sensor coupler and ECU coupler green white green white If there is no continuity replace the wire harness 3 5 For P0118 Open circuit Between coolant temperature sensor coupler and ECU coupler black blue black blue If there is no continuity replace the wire harness G W B L G W B L 5V 1 2 3 4 B L G W B L G W L R L B Y L B L P W R W L Y B R R B B Y G B L W Y G...

Page 423: ...ctive coolant temperature sensor Execute the diagnostic mode Code No 06 When engine is cold Displayed temperature is close to the ambient temperature The displayed temperature is not close to the ambient tem perature Check the coolant temperature sensor Replace if defective Refer to CHECKING THE COOLANT TEMPERATURE SENSOR on page 8 168 Turn the main switch to ON and then check the condition of the...

Page 424: ... SYSTEM 8 53 7 Delete the fault code and check that the engine trouble warning light goes off Confirm that the fault code has a condition of Recovered us ing the Yamaha diagnostic tool and then delete the fault code ...

Page 425: ...rely or re place the wire harness Turn the main switch to ON and then check the condition of the fault code using the mal function mode of the Yamaha di agnostic tool Condition is Recovered Go to item 8 and finish the service Condition is Detected Go to item 2 2 Connection of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals a...

Page 426: ...and ECU coupler blue blue If there is no continuity replace the wire harness 3 4 For P0122 Open circuit Between throttle position sensor coupler and ECU coupler white white If there is no continuity replace the wire harness W B L L W B L L 5V 1 2 3 4 5 L W B L L R L B Y L B L P W R W L Y B R R B B Y G B L W Y G Br W W G P L R G G W W Y R L R B P B B W Y B B Gy G Br L G Y O Gy R Gy W L L R L B Y L ...

Page 427: ... ECU on page 8 38 3 8 For P0122 P0123 Short circuit Between throttle position sensor output terminal white a of ECU coupler and any other ECU cou pler terminal b If there is continuity replace the wire harness A MTM690 B MTM690 U L W B L L R L B Y L B L P W R W L Y B R R B B Y G B L W Y G Br W W G P L R G G W W Y R L R B P B B W Y B B Gy G Br L G Y O Gy R Gy W L L W B L L R L B Y L B L P W R W L Y...

Page 428: ...of the Yamaha di agnostic tool Condition is Recovered Go to item 8 and finish the service Condition is Detected Go to item 6 6 Defective throttle position sen sor Check throttle position sensor signal Execute the diagnostic mode Code No 01 When the throttle valves are ful ly closed A value of 11 21 is indicated When throttle valves are fully open A value of 96 106 is indicated Turn the main switch...

Page 429: ... service Condition is Detected Go to item 3 3 Connection of wire harness ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the coupler securely or re place the wire harness Turn the main switch to ON and then check the condition of the fault code using the mal fun...

Page 430: ... Refer to REPLACING THE ECU engine control unit on page 8 158 7 Delete the fault code and check that the engine trouble warning light goes off Confirm that the fault code has a condition of Recovered us ing the Yamaha diagnostic tool and then delete the fault code ...

Page 431: ...e if out of specification Refer to CHECKING THE FUEL INJECTORS on page 8 171 Execute the diagnostic mode Code No 36 Operating sound Go to item 7 No operating sound Go to item 3 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 Improperly connected Con nect the coupler securely ...

Page 432: ... unit on page 8 158 7 Delete the fault code and check that the engine trouble warning light goes off Start the engine and let it idle for approximately 5 seconds Confirm that the fault code has a condition of Recovered us ing the malfunction mode of the Yamaha diagnostic tool and then delete the fault code ...

Page 433: ... out of specification Refer to CHECKING THE FUEL INJECTORS on page 8 171 Execute the diagnostic mode Code No 37 Operating sound Go to item 7 No operating sound Go to item 3 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 Improperly connected Con nect the coupler securely or r...

Page 434: ... unit on page 8 158 7 Delete the fault code and check that the engine trouble warning light goes off Start the engine and let it idle for approximately 5 seconds Confirm that the fault code has a condition of Recovered us ing the malfunction mode of the Yamaha diagnostic tool and then delete the fault code ...

Page 435: ...nect the coupler securely or re place the wire harness Crank the engine and then check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item 7 and finish the service Condition is Detected Go to item 3 3 Wire harness continuity Open or short circuit Replace the wire harness Between crankshaft position sensor coupler and ECU cou pl...

Page 436: ... malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item 7 and finish the service Condition is Detected Go to item 6 6 Malfunction in ECU Replace the ECU Refer to REPLACING THE ECU engine control unit on page 8 158 Service is finished 7 Delete the fault code and check that the engine trouble warning light goes off Confirm that the fault code has a condition of Recovered us...

Page 437: ... Detected Go to item 2 2 Connection of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the coupler securely or re place the wire harness Start the engine and let it idle for approximately 5 seconds Check the condition of the fault code using the malfunction mode...

Page 438: ...sing the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item 7 and finish the service Condition is Detected Go to item 6 6 Malfunction in ECU Execute the diagnostic mode Code No 30 No spark Replace the ECU Refer to REPLACING THE ECU engine control unit on page 8 158 Service is finished 7 Delete the fault code and check that the engine trouble warning light goes off Con...

Page 439: ...etected Go to item 2 2 Connection of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the coupler securely or re place the wire harness Start the engine and let it idle for approximately 5 seconds Check the condition of the fault code using the malfunction mode o...

Page 440: ...sing the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item 7 and finish the service Condition is Detected Go to item 6 6 Malfunction in ECU Execute the diagnostic mode Code No 31 No spark Replace the ECU Refer to REPLACING THE ECU engine control unit on page 8 158 Service is finished 7 Delete the fault code and check that the engine trouble warning light goes off Con...

Page 441: ...lever re leased OFF Incorrect indication Go to item B 2 for the gear position switch When the transmission is in gear with the clutch lever squeezed and the sidestand re tracted ON Incorrect indication Go to item C 2 for the clutch switch A 2 Connection of rear wheel sen sor coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and lo...

Page 442: ...ic mode Code No 07 Rotate the rear wheel by hand and check that the indicated val ue increases Value increases Go to item A 8 Value does not increase Go to item A 6 A 6 Malfunction in ECU Replace the ECU Refer to REPLACING THE ECU engine control unit on page 8 158 Execute the diagnostic mode Code No 07 Rotate the rear wheel by hand and check that the indicated val ue increases Value increases Go t...

Page 443: ...ed OFF Incorrect indication Go to item B 2 When the transmission is in gear with the clutch lever squeezed and the sidestand is retracted ON Incorrect indication Go to item C 2 for the clutch switch B 2 Connection of gear position switch coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly...

Page 444: ... transmission is in neutral ON When the transmission is in gear with the clutch lever re leased OFF Correct indication Go to item B 9 Incorrect indication Go to item B 6 B 6 Defective gear position switch Check the gear position switch Replace if defective Refer to CHECKING THE GEAR POSITION SWITCH on page 8 170 Execute the diagnostic mode Code No 21 When the transmission is in neutral ON When the...

Page 445: ... rotate the rear wheel by hand Start the engine and input the vehicle speed signals by operat ing the vehicle at 20 to 30 km h 12 to 19 mph Confirm that the fault code has a condition of Recovered us ing the malfunction mode of the Yamaha diagnostic tool and then delete the fault code Delete this fault code even if it has a condition of Detected ...

Page 446: ...nction Execute the diagnostic mode Code No 07 Rotate the rear wheel by hand and check that the indicated val ue increases Value does not increase Go to item A 2 for the rear wheel sensor Execute the diagnostic mode Code No 21 When the transmission is in neutral ON When the transmission is in gear with the clutch lever re leased OFF Incorrect indication Go to item B 2 for the gear position switch W...

Page 447: ...ransmission in gear and when the sidestand is retracted ON Correct indication Go to item C 8 Incorrect indication Go to item C 5 C 5 Wire harness continuity Open or short circuit Replace the wire harness Between clutch switch coupler and left handlebar switch cou pler black red black red black yellow black yellow Between left handlebar switch coupler and joint coupler black red black red black yel...

Page 448: ...e warning light goes off Turn the main switch to ON and then rotate the rear wheel by hand Start the engine and input the vehicle speed signals by operat ing the vehicle at 20 to 30 km h 12 to 19 mph Confirm that the fault code has a condition of Recovered us ing the malfunction mode of the Yamaha diagnostic tool and then delete the fault code Delete this fault code even if it has a condition of D...

Page 449: ...fully opens the valve This operation takes approximately 6 seconds ISC operating sound is heard Go to item A 2 Check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item A 6 and finish the ser vice Condition is Detected Go to item A 2 A 2 Incorrect rear wheel sensor sig nal Check the rear wheel sensor Execute the diagnostic mode...

Page 450: ...nostic tool Condition is Recovered Go to item A 6 and finish the ser vice Condition is Detected Go to item A 5 A 5 Malfunction in ECU Replace the ECU Refer to REPLACING THE ECU engine control unit on page 8 158 Service is finished A 6 Delete the fault code and check that the engine trouble warning light goes off Confirm that the fault code has a condition of Recovered us ing the Yamaha diagnostic ...

Page 451: ...ISC idle speed control unit coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the coupler securely or re place the wire harness Execute the diagnostic mode Code No 54 ISC operating sound is heard Go to item B 8 ISC operating sound is not heard Go to item B 3 B 3 Conne...

Page 452: ...lve is not moving correct ly Replace the ISC valve Execute the diagnostic mode Code No 54 ISC operating sound is heard Go to item B 8 ISC operating sound is not heard Go to item B 7 B 7 Malfunction in ECU Replace the ECU Refer to REPLACING THE ECU engine control unit on page 8 158 Service is finished B 8 Delete the fault code and check that the engine trouble warning light goes off Start the engin...

Page 453: ...and then check the condition of the fault code using the mal function mode of the Yamaha di agnostic tool Condition is Recovered Go to item 6 and finish the service Condition is Detected Go to item 3 3 Wire harness continuity Open or short circuit Properly connect or replace the wire har ness Between ISC idle speed con trol unit coupler and sub wire harness coupler red green red green pink blue pi...

Page 454: ... SYSTEM 8 83 6 Delete the fault code and check that the engine trouble warning light goes off Confirm that the fault code has a condition of Recovered us ing the Yamaha diagnostic tool and then delete the fault code ...

Page 455: ...tion mode of the Yamaha diagnostic tool Condition is Recovered Go to item 2 and finish the service Condition is Detected Re peat item 1 2 Delete the fault code and check that the engine trouble warning light goes off Confirm that the fault code has a condition of Recovered us ing the Yamaha diagnostic tool and then delete the fault code Fault code No P0601 Item Faulty ECU memory When this malfunct...

Page 456: ... 2 01 is indicated in diagnostic mode code No 60 EEPROM data error for adjustment of CO concentration of cylinder 1 Change the CO concentration of cylinder 1 and rewrite in EE PROM Refer to ADJUSTING THE EX HAUST GAS VOLUME on page 5 2 After this adjustment is made turn the main switch to OFF Set the main switch to ON and then check the condition of the fault code using the mal function mode of th...

Page 457: ...ch to ON and then check the condition of the fault code using the mal function mode of the Yamaha di agnostic tool Condition is Recovered Go to item 6 and finish the service Condition is Detected Re peat item 1 If the same number is indicated go to item 5 5 Malfunction in ECU Replace the ECU Refer to REPLACING THE ECU engine control unit on page 8 158 Service is finished 6 Delete the fault code an...

Page 458: ...irmation of service com pletion 1 Connection of relay unit coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the coupler securely or re place the wire harness Start the engine and let it idle for approximately 5 seconds Check the condition of the fault code using the ...

Page 459: ... mode Code No 50 No operating sound Replace the relay unit Start the engine and let it idle for approximately 5 seconds Check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item 7 and finish the service Condition is Detected Go to item 5 5 Defective relay unit Execute the diagnostic mode Code No 09 Fuel system voltage is below ...

Page 460: ...mproperly connected Con nect the coupler securely or re place the wire harness Turn the main switch to ON and then extend and retract the sidestand Check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item 7 and finish the service Condition is Detected Go to item 3 3 Connection of relay unit coupler Check the locking condition ...

Page 461: ... the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item 7 and finish the service Condition is Detected Go to item 6 6 Malfunction in ECU Replace the ECU Refer to REPLACING THE ECU engine control unit on page 8 158 Service is finished 7 Delete the fault code and check that the engine trouble warning light goes off Confirm that the fault code has a ...

Page 462: ...locking condition of the pins Improperly connected Con nect the coupler securely or re place the wire harness Turn the main switch to ON and then check the condition of the fault code using the mal function mode of the Yamaha di agnostic tool Condition is Recovered Go to item 7 and finish the service Condition is Detected Go to item 3 3 Check the backup fuse Blown fuse Replace the fuse or wire har...

Page 463: ...white red white Turn the main switch to ON and then check the condition of the fault code using the mal function mode of the Yamaha di agnostic tool Condition is Recovered Go to item 7 and finish the service Condition is Detected Go to item 6 6 Malfunction in ECU Replace the ECU Service is finished 7 Delete the fault code and check that the engine trouble warning light goes off Confirm that the fa...

Page 464: ...OFF and then back to ON Check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item 6 and finish the service Condition is Detected Go to item 2 2 Connection of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly conn...

Page 465: ...rt circuit Between lean angle sensor coupler and ground yellow green ground If there is continuity replace the wire harness 3 4 For P1605 Open circuit Between lean angle sensor coupler and ECU coupler blue blue If there is no continuity replace the wire harness Y G B L L Y G B L L 5V 5V 1 2 3 4 5 B L L Y G G G G B L L Y G G G G L R L B Y L B L P W R W L Y B R R B B Y G B L W Y G Br W W G P L R G G...

Page 466: ...ensor output terminal yellow green a of ECU coupler and any other ECU coupler terminal b If there is continuity replace the wire harness A MTM690 B MTM690 U B L L Y G G G G L R L B Y L B L P W R W L Y B R R B B Y G B L W Y G Br W W G P L R G G W W Y R L R B P B B W Y B B Gy G Br L G Y O Gy R Gy W L B L L Y G G G G L R L B Y L B L P W R W L Y B R R B B Y G B L W Y G Br W W G P L R G G W W Y R L R B...

Page 467: ...he Yamaha diagnostic tool Condition is Recovered Go to item 6 and finish the service Condition is Detected Go to item 5 5 Malfunction in ECU Replace the ECU Refer to REPLACING THE ECU engine control unit on page 8 158 Service is finished 6 Delete the fault code and check that the engine trouble warning light goes off Confirm that the fault code has a condition of Recovered us ing the Yamaha diagno...

Page 468: ... Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the coupler securely or re place the wire harness Start the engine and let it idle for approximately 10 seconds Check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recov...

Page 469: ...e 7 14 Start the engine and let it idle for approximately 10 seconds Check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recovered Go to item 8 and finish the service Condition is Detected Go to item 6 Also delete this fault code which has a condition of De tected 6 Defective O2 sensor Check the O2 sensor Replace if defective Refer to ENGINE ...

Page 470: ... broken terminals and locking condition of the pins Improperly connected Con nect the coupler securely or re place the wire harness Turn the main switch to ON and then check the condition of the fault code using the mal function mode of the Yamaha di agnostic tool Condition is Recovered Go to item 6 and finish the service Condition is Detected Go to item 3 3 Wire harness continuity Open or short c...

Page 471: ... Service is finished Engine trouble warning light comes on Go to item 2 2 Installed condition of lean angle sensor Check the installed direction and condition of the sensor Turn the main switch to ON then to OFF and then back to ON Engine trouble warning light does not come on Service is finished Engine trouble warning light comes on Go to item 3 3 Defective lean angle sensor Execute the diagnosti...

Page 472: ...W L W L R R R R R R R Lg R W G B R G Y L Dg Dg B B Y Y G G L R L R Ch Ch B Dg B Ch L R G Y B B B B B B B B L R L L R Br L R W Br L Br R Br R B W R G Y L G B R W W W W B R B R R L W R W B Br Y B B Y L R R W L W R B R L W L L W L Y R W L G B R B Y Sb W Sb L G B B B B B Gy B Gy B L L B L P W L B B W L B R W Gy G B L P B B L W B L B B B L Br W B B L G W L R L B Y L B L P W B R W L Y B R R B B Y G B L ...

Page 473: ...tch 7 Ignition fuse 10 Fuel injection system fuse 15 Battery 16 Engine ground 18 Main fuse 22 Relay unit 24 Fuel pump relay 25 Joint coupler 36 ECU Engine Control Unit 46 Fuel pump 62 Handlebar switch right 65 Start engine stop switch ...

Page 474: ...ery Refer to CHECKING AND CHARGING THE BATTERY on page 8 158 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 153 Replace the main switch immobilizer unit 4 Check the start engine stop switch Refer to CHECKING THE SWITCHES on page 8 153 The start engine stop switch is faulty Replace the right handlebar switch 5 Check the r...

Page 475: ...8 104 NG OK 7 Check the entire fuel pump system wiring Refer to CIRCUIT DIAGRAM on page 8 101 Properly connect or replace the wiring har ness Replace the ECU Refer to REPLAC ING THE ECU engine control unit on page 8 158 ...

Page 476: ...L W L W L R R R R R R R Lg R W G B R G Y L Dg Dg B B Y Y G G L R L R Ch Ch B Dg B Ch L R G Y B B B B B B B B L R L L R Br L R W Br L Br R Br R B W R G Y L G B R W W W W B R B R R L W R W B Br Y B B Y L R R W L W R B R L W L L W L Y R W L G B R B Y Sb W Sb L G B B B B B Gy B Gy B L L B L P W L B B W L B R W Gy G B L P B B L W B L B B B L Br W B B L G W L R L B Y L B L P W B R W L Y B R R B B Y G B ...

Page 477: ...Ignition fuse 10 Fuel injection system fuse 11 Backup fuse 15 Battery 16 Engine ground 17 Immobilizer unit 18 Main fuse 25 Joint coupler 36 ECU Engine Control Unit 48 Meter assembly 49 Immobilizer system indicator light 53 Multi function meter ...

Page 478: ...ering key is lost regis tering new codes in the standard keys is impossible The standard keys can still be used to start the vehicle However if code re registering is required e g if a new standard key is made or all keys are lost the entire immobilizer system must be replaced Therefore it is highly rec ommended to use either standard key for driving and to keep the code re registering key in a sa...

Page 479: ...the ignition key to OFF 30 seconds later the indicator light will start flashing continuously in the standby flashing mode pattern for up to 24 hours After that time the indicator light will stop flashing but the immobilizer system is still enabled Standby mode Parts to be replaced Key registration re quirement Main switch immobi lizer unit Standard key ECU Accessory lock and key Main switch Immob...

Page 480: ...emory when the key registration mode is activated When the key registration mode is activated the immobilizer system indicator light flashes rapidly 4 While the indicator light is flashing turn the main switch to OFF remove the key and within 5 sec onds insert the second standard key to be registered into the main switch TIP If the immobilizer system indicator light stops flashing 5 seconds after ...

Page 481: ...m the memory thus disabling the lost standard key To re register refer to Standard key registration Standard key code voiding method a Main switch ON b Main switch OFF c LED on d LED off e Less than 5 0 s f Code re registering key g Remaining standard key h Registration mode A If the immobilizer system indicator light stops flashing 5 seconds after the first standard key is registered the second s...

Page 482: ...e s 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 158 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 153 Replace the main switch immobilizer unit 4 Check the entire immobilizer sys tem wiring Refer to CIRCUIT DIAGRAM on page 8 105 Properly connect or replace the wiring har ness Check the condit...

Page 483: ... dard key 53 IMMOBILIZER UNIT Codes cannot be transmitted between the ECU and the im mobilizer unit Noise interference or dis connected lead cable 1 Interference due to ra dio wave noise 2 Disconnected commu nication harness 3 Immobilizer unit mal function 4 ECU malfunction 1 Check the wire harness and con nector 2 Replace the main switch immobiliz er unit 3 Replace the ECU Refer to REPLAC ING THE...

Page 484: ... for 0 5 second and off for 0 5 second Example fault code 52 56 ECU Unidentified code is received Noise interference or dis connected lead cable 1 Check the wire harness and con nector 2 Replace the main switch immobiliz er unit 3 Replace the ECU Refer to REPLAC ING THE ECU en gine control unit on page 8 158 Fault code Part Symptom Cause Action a Light on b Light off ...

Page 485: ...IMMOBILIZER SYSTEM 8 114 ...

Page 486: ...L W L W L W L W L R R R R R R R Lg R W G B R G Y L Dg Dg B B Y Y G G L R L R Ch Ch B Dg B Ch L R G Y B B B B B B B B L R L L R Br L R W Br L Br R Br R B W R G Y L G B R W W W W B R B R R L W R W B Br Y B B Y L R R W L W R B R L W L L W L Y R W L G B R B Y Sb W Sb L G B B B B B Gy B Gy B L L B L P W L B B W L B R W Gy G B L P B B L W B L B B B L Br W B B L G W L R L B Y L B L P W B R W L Y B R R B ...

Page 487: ...ry 16 Engine ground 18 Main fuse 21 Rear brake light switch 25 Joint coupler 36 ECU Engine Control Unit 41 Front wheel sensor 42 Rear wheel sensor 43 ABS ECU electronic control unit 44 Yamaha diagnostic tool coupler 48 Meter assembly 53 Multi function meter 59 ABS warning light 62 Handlebar switch right 63 Front brake light switch 81 Tail brake light A Wire harness B Positive battery sub wire harn...

Page 488: ...KE SYSTEM 8 117 EAS30990 ABS COUPLER LOCATION CHART 2 5 3 1 4 W B Gy W Gy W B W L R L B R W B G R G W L R L B Sb W Y Dg Ch G R Gy O W R Y W P W R W R G G B B W Gy W B B W Y W G G R Y G G B L Br W B L R L B B B G R W R L ...

Page 489: ...ABS ANTI LOCK BRAKE SYSTEM 8 118 1 ABS ECU coupler 2 Rear wheel sensor coupler 3 Yamaha diagnostic tool coupler 4 Meter assembly coupler 5 Front wheel sensor coupler ...

Page 490: ...a diagnostic tool For information about using the Yamaha diagnostic tool refer to B 2 DIAG NOSIS USING THE FAULT CODES on page 8 124 For troubleshooting items other than the following items follow the normal service method WARNING EWA16710 When maintenance or checks have been performed on components related to the ABS be sure to perform a final check before delivering the vehicle to the customer T...

Page 491: ...ubjecting them to shocks or pulling on them with too much force since the ABS components are precisely adjusted The ABS ECU and hydraulic unit are united assemblies and cannot be disassembled The malfunction history is stored in the memory of the ABS ECU Delete the fault codes when the ser vice is finished This is because the past fault codes will be displayed again if another malfunction occurs E...

Page 492: ...s Were all of the final checks completed normally Finished Yes No A Turn the main switch to ON and check the ABS warning light Fails to come on Comes on The ABS control unit fuse is blown The ABS ECU coupler is disconnected The wire harness is defective The hydraulic unit assembly is defective The connection with the Yamaha diagnostic tool is defective The wire harness is defective Cannot communic...

Page 493: ... WARNING EWA16710 When maintenance or checks have been performed on components related to the ABS be sure to perform a final check before delivering the vehicle to the customer TIP To final check refer to C 1 FINAL CHECK on page 8 147 ...

Page 494: ...n page 8 153 If there is no continuity replace the main switch immobilizer unit 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 158 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 on page 8 157 If the main fuse is blown replace the f...

Page 495: ...place the hydraulic unit assembly EAS31136 A 5 ABS ECU AND FI ECU FAIL TO COMMUNICATE Cannot connect due to a tool error 1 Yamaha diagnostic tool Check that the Yamaha diagnostic tool is properly connected 2 Wire harness Open circuit in the wire harness between the ABS ECU coupler and the Yamaha diagnostic tool cou pler Check for continuity between blue red terminal of the ABS ECU coupler and blue...

Page 496: ... B 3 TIP Check the inspection points after terminating the connection with the Yamaha diagnostic tool and turn ing the main switch off Operation of the Yamaha diagnostic tool Fault diagnosis mode The results of the fault diagnosis are displayed as shown in the following screen shot TIP The screen display may vary depending on the version of the Yamaha diagnostic tool that you are us ing 1 1 2 3 4 ...

Page 497: ...tallation of the front wheel Defective sensor rotor or incorrect installation of the rotor Defective front wheel sen sor or incorrect installation of the sensor 12 Rear wheel sensor intermit tent pulses or no pulses Rear wheel sensor signal is not received properly Puls es are not received or are re ceived intermittently while the vehicle is traveling Foreign material adhered around the rear wheel...

Page 498: ... or short circuit in the wire harness between the rear wheel sensor and the hydraulic unit assembly Defective rear wheel sen sor or hydraulic unit as sembly 17 45 Front wheel sensor missing pulses Front wheel sensor signal is not received properly Miss ing pulses are detected in the signal while the vehicle is traveling Foreign material adhered around the front wheel sen sor Incorrect installation...

Page 499: ...r supply circuit Short circuit is detected in the solenoid power supply circuit in the hydraulic unit assembly Defective hydraulic unit as sembly 33 Hydraulic unit assembly ab normal ABS motor power supply Power is not supplied to the motor circuit in the hydraulic unit assembly Blown ABS motor fuse Defective coupler between the battery and the hydrau lic unit assembly Open or short circuit in the...

Page 500: ...or signal is not received properly Miss ing pulses are detected in the signal while the vehicle is traveling Foreign material adhered around the rear wheel sen sor Incorrect installation of the rear wheel Defective sensor rotor or incorrect installation of the rotor Defective rear wheel sen sor or incorrect installation of the sensor 51 52 Vehicle system power sup ply voltage of ABS ECU power supp...

Page 501: ...raulic unit as sembly 56 Hydraulic unit assembly ab normal internal power sup ply Abnormality is detected in the power supply circuit in the hydraulic unit assembly Defective hydraulic unit as sembly 63 Front wheel sensor power supply voltage of power supply is low Power voltage supplied from the ABS ECU to the front wheel sensor is too low Short circuit in the wire har ness between the front whee...

Page 502: ...llation of the sensor Check the wheel sensor for damage and the installed condition of the sensor Repair or replace the wheel sensor if necessary Refer to MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR on page 4 15 Fault code No 12 Item Rear wheel sensor intermittent pulses or no pulses Symptom Rear wheel sensor signal is not received properly Pulses are not re ceived or are received inter...

Page 503: ...heck the surface of the sensor rotor and wheel sensor for foreign material such as metal particles Clean the sensor rotor and wheel sensor if necessary 2 Incorrect installation of the front wheel Check the components for looseness distortion and bends Refer to CHECKING THE FRONT WHEEL on page 4 14 3 Defective sensor rotor or incorrect instal lation of the rotor Check the surface of the sensor roto...

Page 504: ...heck the surface of the sensor rotor and wheel sensor for foreign material such as metal particles Clean the sensor rotor and wheel sensor if necessary 2 Incorrect installation of the rear wheel Check the components for looseness distortion and bends Refer to CHECKING THE REAR WHEEL on page 4 24 3 Defective sensor rotor or incorrect instal lation of the rotor Check the surface of the sensor rotor ...

Page 505: ...nal 2 and the black terminal 5 If there is no continuity the wire harness is defective Replace the wire harness Check that there is no short circuit between the white terminal 1 and the black terminal 2 and between the white terminal 4 and the black terminal 5 If there is short circuit the wire harness is defective Replace the wire harness Check that there is no short circuit between the black ter...

Page 506: ...nal 2 and the black terminal 5 If there is no continuity the wire harness is defective Replace the wire harness Check that there is no short circuit between the white terminal 1 and the black terminal 2 and between the white terminal 4 and the black terminal 5 If there is short circuit the wire harness is defective Replace the wire harness Check that there is no short circuit between the black ter...

Page 507: ...round the front wheel sensor Check the surface of the sensor rotor and wheel sensor for foreign material such as metal particles Clean the sensor rotor and wheel sensor if necessary 2 Incorrect installation of the front wheel Check the components for looseness distortion and bends Refer to CHECKING THE FRONT WHEEL on page 4 14 3 Defective sensor rotor or incorrect instal lation of the rotor Check ...

Page 508: ... if necessary 2 Incorrect installation of the rear wheel Check the components for looseness distortion and bends Refer to CHECKING THE REAR WHEEL on page 4 24 3 Defective sensor rotor or incorrect instal lation of the rotor Check the surface of the sensor rotor for damage Replace the sensor rotor if there is visible damage Refer to MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR on page 4 25...

Page 509: ...ow yellow Between ABS ECU coupler and joint coupler yellow yellow Between joint coupler and rear brake light switch cou pler yellow yellow 4 Defective hydraulic unit assembly If the above items were performed and no malfunctions were found replace the hydraulic unit assembly Refer to ABS ANTI LOCK BRAKE SYSTEM on page 4 56 Fault code No 31 Item Hydraulic unit assembly abnormal ABS solenoid power s...

Page 510: ...er to CHECKING THE FUSES on page 8 157 2 Defective coupler between the battery and the hydraulic unit assembly Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the cou pler securely See TIP 3 Open or short circuit in the wire harness between the battery and the hydraulic unit assembly Replace if there i...

Page 511: ...eness distortion and bends Refer to CHECKING THE FRONT WHEEL on page 4 14 2 Incorrect rotation of the front wheel Check that there is no brake disc drag on the front wheel and make sure that it rotates smoothly Refer to CHECKING THE FRONT WHEEL on page 4 14 and CHECKING THE FRONT BRAKE DISCS on page 4 35 3 Front brake dragging Check that the brake fluid pressure is correctly transmit ted to the br...

Page 512: ...ective hydraulic unit assembly If the above items were performed and no malfunctions were found replace the hydraulic unit assembly Refer to ABS ANTI LOCK BRAKE SYSTEM on page 4 56 Fault code No 43 Item Front wheel sensor missing pulses Symptom Front wheel sensor signal is not received properly Missing pulses are detected in the signal while the vehicle is traveling Order Item components and proba...

Page 513: ... WHEEL SENSOR AND SENSOR ROTOR on page 4 25 4 Defective rear wheel sensor or incorrect installation of the sensor Check the wheel sensor for damage and the installed condition of the sensor Repair or replace the wheel sensor if necessary Refer to MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR on page 4 25 Fault code No 51 52 Item Vehicle system power supply voltage of ABS ECU power supply i...

Page 514: ...attery Refer to CHECKING AND CHARGING THE BATTERY on page 8 158 2 Defective coupler between the battery and the hydraulic unit assembly Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the cou pler securely See TIP 3 Open or short circuit in the wire harness between the battery and the hydraulic unit as...

Page 515: ...ere is an open or short circuit Between ABS ECU coupler and ABS motor fuse red blue red blue Between ABS ECU coupler and ABS solenoid fuse red white red white 4 Defective charging system Check the charging system Refer to CHARGING SYSTEM on page 8 13 5 Defective hydraulic unit assembly If the above items were performed and no malfunctions were found replace the hydraulic unit assembly Refer to ABS...

Page 516: ...o short circuit between the black terminal 3 and the white terminal 1 If there is a short circuit the wire harness is defective Replace the wire harness 4 ABS ECU 5 Front wheel sensor 2 Defective front wheel sensor Check that there is no short circuit between the gray terminal 1 and the white terminal 2 If there is a short circuit the wheel sensor is defective Repair or replace the wheel sensor 3 ...

Page 517: ...o short circuit between the black terminal 3 and the white terminal 1 If there is a short circuit the wire harness is defective Replace the wire harness 4 ABS ECU 5 Rear wheel sensor 2 Defective rear wheel sensor Check that there is no short circuit between the gray terminal 1 and the white terminal 2 If there is a short circuit the wheel sensor is defective Repair or replace the wheel sensor 3 AB...

Page 518: ... wheel sensors for proper installation Refer to INSTALLING THE FRONT WHEEL DISC BRAKE on page 4 17 and INSTALLING THE REAR WHEEL REAR BRAKE DISC on page 4 26 3 Perform brake line routing confirmation Refer to HYDRAULIC UNIT OPERATION TESTS on page 4 60 If it does not have reaction force properly the brake hose is not properly routed or connected 4 Delete the fault codes Refer to B 3 DELETING THE F...

Page 519: ...ABS ANTI LOCK BRAKE SYSTEM 8 148 ...

Page 520: ...ELECTRICAL COMPONENTS 8 149 EAS20089 ELECTRICAL COMPONENTS 1 2 3 4 5 5 6 7 8 9 11 12 13 14 10 15 16 17 18 ...

Page 521: ...ch switch 4 Rectifier regulator 5 Ignition coil 6 Battery 7 Fuse box 1 8 Fuse box 2 9 Main fuse 10 Starter relay 11 Rear brake light switch 12 Sidestand switch 13 O2 sensor 14 Gear position switch 15 Oil pressure switch 16 Horn 17 Radiator fan motor 18 ECU Engine Control Unit ...

Page 522: ...ELECTRICAL COMPONENTS 8 151 1 3 4 5 7 8 12 13 14 15 6 2 11 9 9 10 ...

Page 523: ...ntake air pressure sensor 4 Fuel pump 5 Lean angle sensor 6 Rear wheel sensor 7 Coolant temperature sensor 8 Crankshaft position sensor 9 Fuel injector 10 Throttle position sensor 11 Front wheel sensor 12 Radiator fan motor relay 13 Headlight relay 14 Relay unit 15 Turn signal hazard relay ...

Page 524: ...549 CHECKING THE SWITCHES Dg Br W L B B Y B R Ch G B W Y Br R W L W B B L B L Br W R B Dg Ch Br Y B B 11 10 9 8 7 6 5 4 3 2 1 Y L B G L B Y Br W Ch Dg Br B W B R B Y Br R ON OFF P R W Br L Br R B L W R B R W Ch Dg Br W R W Br L B L B L ...

Page 525: ...TS 8 154 1 Start engine stop switch 2 Hazard switch 3 Front brake light switch 4 Rear brake light switch 5 Sidestand switch 6 Main switch 7 Clutch switch 8 Horn switch 9 Turn signal switch 10 Pass switch 11 Dimmer switch ...

Page 526: ... 1 range When checking for continuity switch back and forth between the switch positions a few times The switches and their terminal connections are illustrated as in the following example of the main switch The switch positions a are shown in the far left column and the switch lead colors b are shown in the top row The continuity i e a closed circuit between switch terminals at a given switch pos...

Page 527: ...wing procedure applies to all of the bulbs 1 Remove Bulb WARNING EWA13320 Since the headlight bulb gets extremely hot keep flammable products and your hands away from the bulb until it has cooled down NOTICE ECA14381 Be sure to hold the socket firmly when re moving the bulb Never pull the lead other wise it may be pulled out of the terminal in the coupler Avoid touching the glass part of a headlig...

Page 528: ...et the pocket tester selector to Ω 1 b If the pocket tester indicates replace the fuse 3 Replace Blown fuse a Set the main switch to OFF b Install a new fuse of the correct amperage rating c Set on the switches to verify if the electrical circuit is operational d If the fuse immediately blows again check the electrical circuit WARNING EWA13310 Never use a fuse with an amperage rating other than th...

Page 529: ...5 minutes and get immediate medical attention INTERNAL Drink large quantities of water or milk fol lowed with milk of magnesia beaten egg or vegetable oil Get immediate medical atten tion NOTICE ECA13661 This is a VRLA Valve Regulated Lead Acid battery Never remove the sealing caps be cause the balance between cells will not be maintained and battery performance will deteriorate Charging time char...

Page 530: ... battery lead from the battery terminal To reduce the chance of sparks do not plug in the battery charger until the battery charger leads are connected to the battery Before removing the battery charger lead clips from the battery terminals be sure to turn off the battery charger Make sure the battery charger lead clips are in full contact with the battery terminal and that they are not shorted A ...

Page 531: ... a lapse of 5 hours If there is any change in the amperage readjust the voltage to obtain the standard charging current g Measure the battery open circuit voltage after leaving the battery unused for more than 30 minutes Charging method using a constant volt age charger a Measure the open circuit voltage prior to charging TIP Voltage should be measured 30 minutes after the engine is stopped b Conn...

Page 532: ...the relay from the wire harness 2 Connect the pocket tester Ω 1 and battery 12 V to the relay terminal as shown Check the relay operation Out of specification Replace Starter relay Relay unit starting circuit cut off relay Relay unit fuel pump relay Recommended lubricant Dielectric grease Pocket tester 90890 03112 Analog pocket tester YU 03112 C 1 2 1 Positive battery terminal 2 Negative battery t...

Page 533: ...of specification Replace a Connect the pocket tester DC 20 V to the turn signal hazard relay terminal as shown 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 1 Positive battery terminal 2 Negative ba...

Page 534: ...ester 90890 03112 Analog pocket tester YU 03112 C Continuity Positive tester probe Sky blue 1 Negative tester probe Black yellow 2 No continuity Positive tester probe Black yellow 2 Negative tester probe Sky blue 1 Continuity Positive tester probe Sky blue 1 Negative tester probe Blue red 3 No continuity Positive tester probe Blue red 3 Negative tester probe Sky blue 1 Continuity Positive tester p...

Page 535: ...SPARK GAP 1 Check Ignition spark gap Out of specification Perform the ignition system troubleshooting starting with step 5 Refer to TROUBLESHOOTING on page 8 4 TIP If the ignition spark gap is within specification the ignition system circuit is operating normally a Remove the ignition coil from the spark plug b Connect the ignition checker 1 as shown Primary coil resistance 1 19 1 61 Ω Pocket test...

Page 536: ...ENSOR 1 Remove Lean angle sensor from the battery box 2 Check Lean angle sensor output voltage Out of specification Replace a Connect the test harness lean angle sensor 6P 1 to the lean angle sensor and wire harness as shown b Connect the pocket tester DC 20 V to the test harness lean angle sensor 6P 2 Ignition coil Crankshaft position sensor resis tance 228 342 Ω Pocket tester 90890 03112 Analog ...

Page 537: ...duce sparks therefore make sure no flammable gas or fluid is in the vicinity b Check the starter motor operation EAS30566 CHECKING THE STATOR COIL 1 Disconnect Stator coil coupler from the wire harness 2 Check Stator coil resistance Out of specification Replace the stator coil a Connect the digital circuit tester to the stator coil coupler as shown b Measure the stator coil resistance EAS30680 CHE...

Page 538: ...G LIGHT This model is equipped with a self diagnosis de vice for the fuel level detection circuit 1 Check Frame 1 Fuel meter 2 Fuel level warning light 3 Turn the main switch to ON Warning light comes on for a few seconds then goes off Warning light is OK Warning light does not come on Replace the meter assembly Fuel level segments frame and fuel level warning light flashes repeatedly Replace the ...

Page 539: ...eplace it 2 Check Coolant temperature sensor resistance Out of specification Replace a Connect the pocket tester Ω 1 k to the coolant temperature sensor as shown b Immerse the coolant temperature sensor 1 in a container filled with coolant 2 TIP Make sure the coolant temperature sensor ter minals do not get wet c Place a thermometer 3 in the coolant d Heat the coolant or let it cool down to the sp...

Page 540: ...0593 CHECKING THE INTAKE AIR PRESSURE SENSOR 1 Check Intake air pressure sensor output voltage Out of specification Replace a Connect the test harness S pressure sensor 3P 1 to the intake air pressure sensor and wire harness as shown NOTICE ECA20920 Pay attention to the installing direction of the test harness S pressure sensor 3P cou pler b Connect the digital circuit tester DCV to the test harne...

Page 541: ... container filled with water 2 TIP Make sure that the intake air temperature sensor terminals do not get wet c Place a thermometer 3 in the water d Slowly heat the water then let it cool down to the specified temperature e Measure the intake air temperature sensor resistance 3 Install Intake air temperature sensor EAS31088 CHECKING THE GEAR POSITION SWITCH 1 Remove Drive sprocket cover Refer to CH...

Page 542: ... tester probe Pink 2 Negative tester probe Switch terminal b 2nd position Continuity Positive tester probe White 3 Negative tester probe Switch terminal c 3rd position Continuity Positive tester probe Gray 4 Negative tester probe Switch terminal d 4th position Continuity Positive tester probe Orange 5 Negative tester probe Switch terminal e 5th position Continuity Positive tester probe White red 6...

Page 543: ...9 2 OVERCOOLING 9 3 POOR BRAKING PERFORMANCE 9 3 FAULTY FRONT FORK LEGS 9 3 UNSTABLE HANDLING 9 3 FAULTY LIGHTING OR SIGNALING SYSTEM 9 4 TROUBLESHOOTING AT THE ABS WARNING LIGHT 9 4 SELF DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE 9 5 SELF DIAGNOSTIC FUNCTION TABLE FOR FUEL INJECTION SYSTEM 9 5 SELF DIAGNOSTIC FUNCTION TABLE FOR IMMOBILIZER SYSTEM 9 11 DIAGNOSTIC CODE SENSOR OPERATION TABLE 9 1...

Page 544: ...mp Faulty fuel pump Faulty relay unit fuel pump relay 3 Throttle body ies Deteriorated or contaminated fuel Sucked in air Electrical system 1 Battery Discharged battery Faulty battery 2 Fuse s Blown damaged or incorrect fuse Improperly installed fuse 3 Spark plug s Incorrect spark plug gap Incorrect spark plug heat range Fouled spark plug Worn or damaged electrode Worn or damaged insulator 4 Ignit...

Page 545: ...n a shift drum groove Seized shift fork Bent shift fork guide bar Transmission Seized transmission gear Foreign object between transmission gears Improperly assembled transmission EAS30605 JUMPS OUT OF GEAR Shift shaft Incorrect shift pedal position Improperly returned stopper lever Shift forks Worn shift fork Shift drum Incorrect axial play Worn shift drum groove Transmission Worn gear dog EAS308...

Page 546: ... brake caliper seal Loose union bolt Damaged brake hose Oil or grease on the brake disc Oil or grease on the brake pad Incorrect brake fluid level EAS30610 FAULTY FRONT FORK LEGS Leaking oil Bent damaged or rusty inner tube Cracked or damaged outer tube Improperly installed oil seal Damaged oil seal lip Incorrect oil level high Loose damper rod assembly bolt Damaged damper rod assembly bolt copper...

Page 547: ...fe expired Tail brake light does not come on Faulty brake light switch Too many electrical accessories Incorrect connection Faulty tail brake light assembly Turn signal does not come on Faulty turn signal switch Faulty turn signal hazard relay Burnt out turn signal bulb Incorrect connection Damaged or faulty wire harness Improperly grounded circuit Faulty battery Blown damaged or incorrect fuse Tu...

Page 548: ...es not oper ate O2 feedback is not carried out P0107 P0108 P0107 Intake air pressure sensor ground short circuit detected P0108 Intake air pressure sensor open or power short circuit detected P0107 Low voltage of the intake air pres sure sensor circuit 0 2 V or less P0108 High voltage of the intake air pres sure sensor circuit 4 8 V or more Defective coupler between intake air pressure sensor and ...

Page 549: ...k is not carried out ISC learning is not carried out P0117 P0118 P0117 Coolant tem perature sensor ground short circuit detected P0118 Coolant tem perature sensor open or power short circuit detected P0117 Low voltage of the coolant tem perature sensor circuit 0 2 V or less P0118 High voltage of the coolant tem perature sensor circuit 4 8 V or more Defective coupler between coolant temperature sen...

Page 550: ...ottle open ing Output is restricted ISC feedback is not carried out ISC learning is not carried out P0132 O2 sensor short cir cuit detected power short circuit P0132 High voltage of the O2 sensor cir cuit 4 8 V or more Improperly installed O2 sensor Defective coupler between O2 sensor and ECU Open or short cir cuit in wire harness between O2 sensor and ECU Incorrect fuel pres sure Defective O2 sen...

Page 551: ...t ISC feedback is not carried out ISC learning is not carried out P0500 Rear wheel sensor no normal signals are received from the rear wheel sen sor Gear position switch open or short circuit is detected Clutch switch open or short circuit is de tected Open or short cir cuit in wire harness between rear wheel sensor and ECU Open or short cir cuit in wire harness between ABS unit and ECU Open or sh...

Page 552: ...Defective coupler between ISC unit and ECU Open or short cir cuit in wire harness between ISC unit and ECU Defective ISC step ping motor Malfunction in ECU Engine is difficult to start Engine idling speed is unstable Engine idling speed is high Power is not supplied to the ISC unit ISC learning is not carried out P0560 Charging voltage is abnormal Battery overcharg ing defective rectifi er regulat...

Page 553: ...ifficult to start Engine idling speed is unstable OBD memory value is not correct CO adjustment value for the faulty cylinder 0 default value ISC learning values Default values OBD memory value is initialized P0657 Fuel system voltage incorrect voltage sup plied to the fuel injec tor and fuel pump Open or short cir cuit in wire harness between relay unit and ECU Open circuit in wire harness betwee...

Page 554: ...e sen sor circuit 4 8 V or more Open or short cir cuit in wire harness between lean angle sensor and ECU Defective lean an gle sensor Malfunction in ECU Engine cannot be started Engine cannot be started P2195 O2 sensor open cir cuit detected Signal voltage is 0 25 0 53 V Improperly installed O2 sensor Defective coupler between O2 sensor and ECU Open or short cir cuit in wire harness between O2 sen...

Page 555: ...ature closer to air temperature When engine is hot Displays current coolant temperature Compare the actually mea sured coolant temperature with the tool display value 07 Rear wheel vehicle speed pulses Rear wheel speed pulse 0 999 Check that the number in creases when the rear wheel is rotated The number is cu mulative and does not reset each time the wheel is stopped 08 Lean angle sensor Lean ang...

Page 556: ... defective the display al ternates every two seconds to show all the detected cylinder numbers When all cylinder numbers are shown the display re peats the same process 11 Data error for ISC idle speed control learning val ues 12 O2 feedback learning value 13 OBD memory value 67 ISC idle speed control learning condition display ISC idle speed control learning data erasure 00 ISC idle speed control...

Page 557: ...listen ing for the operating sound 37 Fuel injector 2 Actuates fuel injector 2 five times at one second inter vals The check indicator on the Yamaha diagnostic tool screen come on each time the fuel injector is actuated Disconnect the fuel pump coupler Check that fuel injector 2 is actuated five times by listen ing for the operating sound 50 Relay unit Actuates the relay unit five times at one sec...

Page 558: ...ns the valve This operation is performed 3 times and takes approxi mately 6 seconds each time The check indicator on the Yamaha diagnostic tool screen come on during the operation Check that the ISC unit is ac tuated three times by listen ing for the operating sound Diagnostic code No Item Actuation Procedure ...

Page 559: ...ber P0122 and P0123 Perform the checks and maintenance jobs for fault code number P0122 and P0123 195 Sidestand switch Brief abnormality de tected in black red in put lead of ECU Same as for fault code number P1601 Perform the checks and maintenance jobs for fault code number P1601 196 Coolant temperature sensor Brief abnormality de tected in coolant tem perature sensor Same as for fault code numb...

Page 560: ...rst Event code number 241 may be indicated even if the system is normal 242 ISC idle speed con trol Correction value re mains at upper limit Correction value re mains at upper limit while the engine is idling Low engine idling speed Clogged throttle body Improperly adjusted throttle cable Improperly adjusted clutch cable Defective fuel injec tion system Dirty or worn spark plug Defective battery D...

Page 561: ...ault code first Event code number 244 may be indicated even if the system is normal 245 Engine stall Engine stall detected Empty fuel tank Improperly adjusted throttle cable Improperly adjusted clutch cable Defective fuel injec tion system Dirty or worn spark plug Defective battery Defective ECU If a fault code is indi cated perform the checks and mainte nance jobs for the fault code first Event c...

Page 562: ...ight 60 Horn 61 Gear position switch 62 Handlebar switch right 63 Front brake light switch 64 Hazard switch 65 Start engine stop switch 66 Turn signal hazard relay 67 Handlebar switch left 68 Clutch switch 69 Dimmer switch 70 Pass switch 71 Turn signal switch 72 Horn switch 73 Rear turn signal light right 74 Rear turn signal light left 75 Front turn signal light right 76 Headlight assembly 77 Auxi...

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Page 565: ...R W R W Y Y L R L R L R L W L W L W L W L R R R R R R R Lg R W G B R G Y L Dg Dg B B Y Y G G L R L R Ch Ch B Dg B Ch L R G Y B B B B B B B B L R L L R Br L R W Br L Br R Br R B W R G Y L G B R W W W W B R B R R L W R W B Br Y B B Y L R R W L W R B R L W L L W L Y R W L G B R B Y Sb W Sb L G B B B B B Gy B Gy B L L B L P W L B B W L B R W Gy G B L P B B L W B L B B B L Br W B B L G W L R L B Y L B ...

Page 566: ...D C B D A A B A D D D D D D A E B B B B B B L B B B B B B B B Gy Gy B B B B B B B B B Gy Gy B B B O O B B Gy B B B B B B Gy Gy Gy Gy 1 2 3 6 5 4 7 8 9 17 13 14 15 16 18 19 20 21 22 23 24 25 25 26 25 25 27 39 40 28 29 37 38 30 31 32 32 33 34 35 44 25 25 45 46 47 48 49 50 51 51 52 53 54 55 56 57 58 61 60 62 63 64 65 68 70 71 72 73 74 66 81 82 84 85 83 36 67 69 10 11 12 42 43 41 59 75 79 76 77 78 80 ...

Page 567: ... R W R W R W Y Y L R L R L R L W L W L W L W L R R R R R R R Lg R W G B R G Y L Dg Dg B B Y Y G G L R L R Ch Ch B Dg B Ch L R G Y B B B B B B B B L R L L R Br L R W Br L Br R Br R B W R G Y L G B R W W W W B R B R R L W R W B Br Y B B Y L R R W L W R B R L W L L W L Y R W L G B R B Y Sb W Sb L G B B B B B Gy B Gy B L L B L P W L B B W L B R W Gy G B L P B B L W B L B B B L Br W B B L G W L R L B Y...

Page 568: ... C A D C B D A A B A D D D D D D A E B B B B B B L B B B B B B B B Gy Gy B B B B B B B B B Gy Gy B B B O O B B Gy B B B B B B Gy Gy Gy Gy 1 2 3 6 5 4 7 8 9 17 13 14 15 16 18 19 20 21 22 23 24 25 25 26 25 25 27 39 40 28 29 37 38 30 31 32 32 33 34 35 44 25 25 45 46 47 48 49 50 51 51 52 53 54 55 56 57 58 61 60 62 63 64 65 68 70 71 72 73 74 66 81 82 84 85 83 36 67 69 10 11 12 42 43 41 59 75 79 76 77 7...

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