Yamaha XSR900 2022 Service Manual Download Page 249

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VALVES AND VALVE SPRINGS

EAS30283

REMOVING THE VALVES

The following procedure applies to all of the
valves and related components.

TIP

Before removing the internal parts of the cylinder
head (e.g., valves, valve springs, valve seats),
make sure the valves properly seal.

1. Remove:

• Valve lifter
• Valve pad

TIP

Make a note of the position of each valve lifter
and valve pad so that they can be reinstalled in
their original place.

2. Check:

• Valve sealing

Leakage at the valve seat

→

Check the valve

face, valve seat, and valve seat width.
Refer to “CHECKING THE VALVE SEATS”
on page 5-34.

a. Pour a clean solvent “a” into the intake and

exhaust ports.

b. Check that the valves properly seal.

TIP

There should be no leakage at the valve seat “1”.

3. Remove:

• Valve cotter

TIP

Remove the valve cotters by compressing the
valve spring with the valve spring compressor
“1” and the valve spring compressor attachment
“2”.

4. Remove:

• Valve spring retainer
• Valve spring
• Valve
• Valve stem seal
• Valve spring seat

TIP

Identify the position of each part very carefully so
that it can be reinstalled in its original place.

EAS30284

CHECKING THE VALVES AND VALVE
GUIDES

The following procedure applies to all of the
valves and valve guides.
1. Measure:

• Valve-stem-to-valve-guide clearance

Out of specification

→

Replace the valve

guide.

G088958

Valve spring compressor

90890-04200

Valve spring compressor

YM-04019

Valve spring compressor attach-
ment (ø2

)

90890-04179

Valve spring compressor adapter
(ø2

)

YM-04179

• Valve-stem-to-valve-guide clearance =

Valve guide inside diameter “a” -
Valve stem diameter “b”

Valve-stem-to-valve-guide clear-
ance limit (intake)

0.080 mm (0.00

2 in)

Valve-stem-to-valve-guide clear-
ance limit (exhaust)

0.100 mm (0.00

9 in)

G088959

Summary of Contents for XSR900 2022

Page 1: ...2022 SERVICE MANUAL XSR 900 BEA 28197 E0 MTM890 ...

Page 2: ......

Page 3: ...and will appear in future editions of this manual where applicable TIP If the contents of the manual are revised the last digit of the manual number will be increased by one Designs and specifications are subject to change without notice EAS30001 IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following notations EAS20002 This is the safety al...

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

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

Page 6: ......

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

Page 8: ......

Page 9: ...1 GENERAL INFORMATION IDENTIFICATION 1 1 VEHICLE IDENTIFICATION NUMBER 1 1 MODEL LABEL 1 1 FEATURES 1 2 GLOSSARY 1 2 DISPLAY 1 2 BASIC SERVICE INFORMATION 1 11 ELECTRICAL SYSTEM 1 11 SPECIAL TOOLS 1 12 ...

Page 10: ...CLE 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 1 1 ...

Page 11: ... the operator and increase the risk of an accident Speedometer The speedometer shows the vehicle s traveling speed TIP The display can be switched between kilometers and miles Tachometer The tachometer shows the engine speed as measured by the rotational velocity of the crank shaft in revolutions per minute r min NOTICE ECA19660 Do not operate the engine in the tachometer red zone Vehicle informat...

Page 12: ...E mode the vehicle information dis play is replaced by the lap information TRIP1 TRIP2 F TRIP F AVE FUEL CON and TRIP TIME items can be individually reset Odometer The odometer shows the total distance traveled by the vehicle TIP ODO will lock at 999999 and cannot be reset Fuel reserve tripmeter When the fuel tank reserve level has been reached F TRIP appears automatically and be gins recording di...

Page 13: ... lower will be displayed if the detected tempera ture is higher Coolant temperature The coolant temperature is displayed from 40 C 104 F to 124 C 255 F in 1 C 1 F incre ments TIP If the vehicle coolant temperature is below 40 C 104 F the coolant temperature display will read Lo If the vehicle coolant temperature is above 124 C 255 F the coolant temperature display will read Hi Fuel Meter The fuel ...

Page 14: ... TIP When TCS MODE has been set to OFF the traction control system SCS and LIF sys tems are all turned off together The TCS MODE OFF and TCS MODE M settings can only be selected while the vehicle is stopped Clock The clock uses a 12 hour time system Quick shifter indicator QS When able to shift the respective QS or turns green When unable to shift QS is white If the quick shifter function is turne...

Page 15: ...eplaced by the auxiliary system warning and coolant temperature warning indi cators when they are activated Error mode warning Err When an internal error occurs e g communica tion with a system controller has been cut off the error mode warning will appear as follows Err and indicator light indicates an ECU error Err only indicates an ABS ECU error TIP Depending on the nature of the error the disp...

Page 16: ...switch the lap time mode and tachometer color mode ON OFF When the lap time mode is selected the twin ve hicle information displays on the main screen will display a lap timer and a lap counter To exit the lap time mode the turn lap timer OFF in the display setting module To change the tachometer to color mode select ON Manual TCS Setting This module allows you to customize the TCS MODE M which is...

Page 17: ...vel 1 provides the least amount of sys tem intervention and setting 3 most strongly re duces the rate of wheel lift OFF turns LIF off Vehicle Setting The vehicle setting module allows you to adjust setting for the BC and quick shifter BC The brake control system has two settings BC1 and BC2 Select BC1 when only standard ABS is desired Select BC2 to have the brake control system further regulate br...

Page 18: ...between engine oil changes use the OIL item and for two other items of your choice use INTERVAL 1 and INTERVAL 2 To reset a maintenance trip meter select it and then press and hold the wheel switch TIP Maintenance item names cannot be changed Unit This module allows you to switch the display be tween metric and imperial measurement units When using kilometers the fuel consumption units can be chan...

Page 19: ...o confirm and highlight the minutes After confirming the minutes you will be re turned to the top MENU screen All Reset This module resets all settings items except the odometer and clock to their default or factory presets Select YES to reset all items After selecting YES all items will be reset and the screen will automatically return to the top MENU screen km h Clock 00 10 NO YES km h All Reset...

Page 20: ...nto the washer where con tacting the IMU grommet When installing the IMU use only a genuine bolt and washer and tighten the bolt to the specified torque Pay attention not to expose the IMU to strong shocks such as striking or drop ping it Do not place any foreign objects in and around the battery box Do not obstruct breather opening a of the IMU Do not clean the breather opening and do not blow it...

Page 21: ... list provided below to avoid any mistakes TIP For U S A and Canada use part number starting with YM YU or ACC For others use part number starting with 90890 Tool name Tool No Illustration Reference pages Yamaha diagnostic tool USB 90890 03267 3 4 3 11 4 57 4 58 7 12 9 3 9 41 9 41 Yamaha diagnostic tool A I 90890 03264 3 4 3 11 4 57 4 58 7 12 9 3 9 41 9 41 Thickness gauge 90890 03268 Feeler gauge ...

Page 22: ...mm 90890 04176 YU 04176 3 26 Oil pressure gauge set 90890 03120 3 26 Fork spring compressor 90890 01441 Fork spring compressor YM 01441 4 69 4 74 Rod holder 90890 01434 Damper rod holder double ended YM 01434 4 69 4 74 Damper rod holder ø27 90890 01582 Damper rod holder YM 01582 4 70 4 71 Fork seal driver 90890 01442 Adjustable fork seal driver 36 46 mm YM 01442 4 72 4 72 4 73 Tool name Tool No Il...

Page 23: ...4 Ring nut wrench 90890 01268 Spanner wrench YU 01268 4 79 Drive chain cut rivet tool 90890 01550 Drive chain cut rivet tool YM 01550 4 89 4 91 Compression gauge 90890 03081 Engine compression tester YU 33223 5 7 Compression gauge extension 122mm 90890 04136 Compression gauge extension 122mm YM 04136 5 7 Tool name Tool No Illustration Reference pages YM A8703 90890 01578 YM A8703 90890 03081 YU 33...

Page 24: ... 5 32 5 36 Valve spring compressor attachment ø23 90890 04179 Valve spring compressor adapter ø23 YM 04179 5 32 5 36 Valve guide remover ø4 5 90890 04116 Valve guide remover 4 5 mm YM 04116 5 33 Valve guide installer ø4 5 90890 04117 Valve guide installer 4 5 mm YM 04117 5 33 Valve guide reamer ø4 5 90890 04118 Valve guide reamer 4 5 mm YM 04118 5 33 Sheave holder 90890 01903 Primary clutch holder...

Page 25: ...hometer YU A1927 5 44 8 40 8 42 8 43 8 44 8 44 8 45 8 46 8 46 8 47 8 48 8 49 8 49 8 50 8 50 8 50 Clutch holder 90890 04199 Universal clutch holder YM 91042 5 50 5 54 Piston pin puller set 90890 01304 Piston pin puller YU 01304 5 71 Connecting rod big end bearing installer 90890 04193 Connecting rod big end bearing installer YM 04193 5 73 5 76 Tool name Tool No Illustration Reference pages YU 01304...

Page 26: ...ester adapter YU 33984 6 5 6 5 Mechanical seal installer 90890 04078 Water pump seal installer YM 33221 A 6 14 Middle driven shaft bearing driver 90890 04058 Middle drive bearing installer 40 50 mm YM 04058 6 14 Pressure gauge 90890 03153 Pressure gauge YU 03153 7 11 7 12 Fuel injector pressure adapter 90890 03210 Fuel injector pressure adapter YU 03210 7 11 Tool name Tool No Illustration Referenc...

Page 27: ...8 SPECIAL TOOLS Fuel pressure adapter 90890 03176 Fuel pressure adapter YM 03176 7 12 Ignition checker 90890 06754 Oppama pet 4000 spark checker YM 34487 8 45 Tool name Tool No Illustration Reference pages ...

Page 28: ...1 19 SPECIAL TOOLS ...

Page 29: ...S GENERAL SPECIFICATIONS 2 1 ENGINE SPECIFICATIONS 2 2 CHASSIS SPECIFICATIONS 2 6 ELECTRICAL SPECIFICATIONS 2 9 TIGHTENING TORQUES 2 11 ENGINE TIGHTENING TORQUES 2 11 CHASSIS TIGHTENING TORQUES 2 11 CABLE ROUTING 2 13 ...

Page 30: ...ions Overall length 2155 mm 84 8 in Overall width 860 mm 33 9 in Overall height 1155 mm 45 5 in Wheelbase 1495 mm 58 9 in Ground clearance 140 mm 5 51 in Minimum turning radius 3 5 m 11 48 ft Weight Curb weight 193 kg 425 lb Loading Maximum load 221 kg 487 lb Riding capacity 2 person ...

Page 31: ...ommended engine oil grade API service SG type or higher JASO standard MA Lubrication system Wet sump Engine oil quantity Oil change 2 80 L 2 96 US qt 2 46 Imp qt With oil filter removal 3 20 L 3 38 US qt 2 82 Imp qt Quantity disassembled 3 50 L 3 70 US qt 3 08 Imp qt Oil filter Oil filter type Cartridge Oil pump Oil pressure 200 0 kPa 5000 r min 2 00 kgf cm 5000 r min 29 0 psi 5000 r min Cooling s...

Page 32: ... clearance cold Intake 0 11 0 20 mm 0 0043 0 0079 in Exhaust 0 28 0 32 mm 0 0110 0 0126 in Valve dimensions Valve seat contact width limit intake 1 6 mm 0 06 in Valve seat contact width limit exhaust 1 8 mm 0 07 in Valve stem diameter limit intake 4 445 mm 0 1750 in Valve stem diameter limit exhaust 4 430 mm 0 1744 in Valve guide inside diameter intake 4 500 4 512 mm 0 1772 0 1776 in Valve guide i...

Page 33: ...earance 0 027 0 051 mm 0 0011 0 0020 in Bearing color code Code 1 Blue Code 2 Black Code 3 Brown Code 4 Green Crankshaft Runout limit 0 030 mm 0 0012 in Journal oil clearance 0 013 0 037 mm 0 0005 0 0015 in Bearing color code Code 0 White Code 1 Blue Code 2 Black Code 3 Brown Code 4 Green Balancer Balancer shaft runout limit 0 030 mm 0 0012 in Bearing color code Code 1 Blue Code 2 Black Code 3 Bro...

Page 34: ...mary reduction ratio 1 681 79 47 1st 2 571 36 14 2nd 1 947 37 19 3rd 1 619 34 21 4th 1 381 29 21 5th 1 190 25 21 6th 1 037 28 27 Secondary reduction ratio 2 813 45 16 Main axle runout limit 0 08 mm 0 0032 in Drive axle runout limit 0 08 mm 0 0032 in Shifting mechanism Installed shift rod length 236 0 238 0 mm 9 29 9 37 in Air filter Air filter element Oil coated paper element Fuel injector Resista...

Page 35: ...urer model BRIDGESTONE BATTLAX HYPERSPORT S22F Rear tire Type Tubeless Size 180 55ZR17M C 73W Manufacturer model BRIDGESTONE BATTLAX HYPERSPORT S22R Tire air pressure measured on cold tires 1 person Front 250 kPa 2 50 kgf cm 36 psi Rear 290 kPa 2 90 kgf cm 42 psi 2 persons Front 250 kPa 2 50 kgf cm 36 psi Rear 290 kPa 2 90 kgf cm 42 psi Front brake Brake disc thickness limit 4 0 mm 0 16 in Brake d...

Page 36: ...nsion Oil 01 Quantity left 466 0 cm 15 76 US oz 16 44 Imp oz Quantity right 470 0 cm 15 89 US oz 16 58 Imp oz Level left 107 mm 4 2 in Level right 107 mm 4 2 in Spring preload Adjustment value Soft 19 0 mm 0 75 in Adjustment value STD 14 0 mm 0 55 in Adjustment value Hard 4 0 mm 0 16 in Rebound damping Unit for adjustment Click Adjustment value from the start position Soft 11 Adjustment value from...

Page 37: ...r adjustment Turn Adjustment value from the start position Soft 2 1 2 Adjustment value from the start position STD 1 Adjustment value from the start position Hard 0 Drive chain Size 525 Chain type Sealed type Number of links 118 Drive chain slack Maintenance Stand 45 0 50 0 mm 1 77 1 97 in Drive chain slack Sidestand 45 0 50 0 mm 1 77 1 97 in Drive chain slack limit 55 0 mm 2 17 in 15 link length ...

Page 38: ...4 7 V Battery Model YTZ10S Voltage capacity 12 V 8 6 Ah 10 HR Bulb wattage Headlight LED Brake tail light LED Front turn signal light LED Rear turn signal light LED Auxiliary light LED License plate light 5 0 W Meter lighting LED Indicator light Neutral indicator light LED Stability control indicator light LED Engine oil and Coolant warning light LED High beam indicator light LED Turn signal indic...

Page 39: ... air pressure sensor output voltage 3 59 3 67 V at 101 3 kPa 3 59 3 67 V at 1 01 kgf cm 3 59 3 67 V at 14 7 psi Coolant temperature sensor resistance 2513 2777 Ω at 20 C 2513 2777 Ω at 68 F Coolant temperature sensor resistance 210 221 Ω at 100 C 210 221 Ω at 212 F Fuse s Main fuse 50 0 A Headlight fuse 7 5 A Brake light fuse 2 0 A Signaling system fuse 7 5 A Ignition fuse 10 0 A Radiator fan moto...

Page 40: ... 1 10 N m 1 0 kgf m 7 4 lb ft Engine oil drain bolt M14 1 43 N m 4 3 kgf m 32 lb ft Item Thread size Q ty Tightening torque Remarks Front wheel axle M18 1 72 N m 7 2 kgf m 53 lb ft Front wheel axle pinch bolt M8 1 23 N m 2 3 kgf m 17 lb ft Rear wheel sprocket nut M10 5 80 N m 8 0 kgf m 59 lb ft Rear wheel axle nut M24 1 105 N m 10 5 kgf m 77 lb ft Rear brake caliper bolt front M12 1 27 N m 2 7 kgf...

Page 41: ...G TORQUES TIP Lower ring nut 1 Tighten the ring nut to approximately 52 N m 5 2 kgf m 38 lb ft with a torque wrench then loosen the lower ring nut completely 2 Tighten the lower ring nut to 14 N m 1 4 kgf m 10 lb ft ...

Page 42: ...2 13 CABLE ROUTING EAS20021 CABLE ROUTING Handlebar front view 2 L L K 13 14 15 M 3 C F 4 A 5 3 20 S 19 R 18 Q 16 N 17 O 21 T 2 1 11 10 7 6 9 8 22 22 13 G 14 J 4 I 3 3 2 H 12 D 4 P 2 U 13 E 14 5 B 5 6 V ...

Page 43: ...etween the coupler holder and coupler cover Route the horn lead to the forward of the clutch switch lead J Route the front brake light switch lead between the coupler holder and coupler cover K Fasten the front brake light switch lead and handlebar switch lead right with a rubber band Face the buckle of the rubber band upward with the end pointing forward Fasten the straight portion of the handleb...

Page 44: ...2 15 CABLE ROUTING Handlebar side view 6 7 8 10 9 8 7 1 2 3 6 5 4 A 5 C 9 10 11 12 2 1 3 D B ...

Page 45: ...9 Upper bracket 10 Headlight bracket 2 11 Coupler cover 12 Coupler holder A Insert the clamp of the handlebar switch lead left into the hole in the connector cover B Insert the clamp of the handlebar switch lead left into the hole in the headlight bracket 2 C Route the clutch cable to the rearward of the handlebar switch lead left D Route the brake hose to the inside of the upper bracket ...

Page 46: ...2 17 CABLE ROUTING Main switch left side view A 5 4 2 B 4 3 2 1 C 2 D 2 5 5 ...

Page 47: ...rness 3 Front wheel sensor lead 4 Bracket 5 Frame A Insert the clamp into the hole of the bracket B Insert the clamp into the rib of the frame C Insert the clamp with touched the protrusion on the frame D Insert the clamp between the protrusions on the frame ...

Page 48: ... CABLE ROUTING Frame and engine right side view 13 E G H M G 12 2 1 4 3 6 5 11 14 F 12 11 8 16 7 18 I 15 11 12 17 18 8 Q 7 A 16 9 10 D 10 Q 22 23 3 5 2 25 24 C B P H G 8 J 8 K 19 L G 14 19 21 N O 20 U 18 T ...

Page 49: ...the clamp The opening of the clamp should face the right G Right side of the vehicle H Forward of the vehicle I Insert the clamp into the hole of the battery box The opening of the clamp should face the right J Route the sub wire harness oil pressure switch to the inside of the damper K Route the sub wire harness oil pressure switch through the guide in the front side panel right L Route the front...

Page 50: ...2 21 CABLE ROUTING Frame 1 front left side view 7 8 9 11 I 12 I 3 7 5 G 4 H 2 F 7 R 3 10 3 7 6 I 9 N 22 20 M 21 19 K L 18 J 15 16 17 13 14 23 24 24 25 27 Q 28 P 18 O 23 26 9 6 A 5 4 2 1 1 3 C D B 2 E ...

Page 51: ... tie downward and cut off the excess C Left outside of the vehicle D Lower side of the vehicle E Route the O2 sensor lead to the inside of the radiator outlet hose F Place the O2 sensor lead inside the vehicle on the damper G Insert the O2 sensor coupler into the groove of front side panel left H Insert the projection on the front turn signal light coupler left into the hole in the front side pane...

Page 52: ...2 23 CABLE ROUTING Frame 2 rear left side view 2 G F A 1 B 10 11 12 10 13 5 13 E 14 10 D 17 K I 15 16 5 10 J 11 1 7 8 9 3 4 5 7 H 11 H 8 H 8 H 11 H 7 H 8 C 7 6 7 8 13 13 13 ...

Page 53: ...or on the left side of the starter motor lead C Face the paint mark on the fuel tank drain hose outward Align the holder with the paint mark on the fuel tank drain hose D Route the shift sensor lead to the front of the shift sensor E Point the open ends of the clamp to the right F Left side of the vehicle G Forward of the vehicle H Arrange the sidestand switch lead canister breather hose and fuel ...

Page 54: ...2 25 CABLE ROUTING Frame 3 rear left side view 9 9 H 12 11 10 8 6 5 7 4 6 8 E 6 M 4 M L 16 7 K 4 C 3 B 2 A 1 3 15 8 9 J 14 6 4 13 2 D H G F ...

Page 55: ...fuel tank drain hose and canister breather hose D Left side of the vehicle E Route the stator coil lead to the front of the vehicle and fix the gray tape part with a plas tic locking tie F Fix the plastic locking tie is located 20 30 mm 0 79 1 18 in away from the plastic lock ing tie 7 Face the locking part of the plastic locking tie forward Face the end of the plastic locking tie rightward and do...

Page 56: ...2 27 CABLE ROUTING Top view 1 1 28 21 29 23 9 A 10 11 12 13 B 15 16 C 17 18 D 19 E 20 F 21 G 27 28 12 J 26 25 24 I 23 H 22 14 7 6 8 5 4 3 2 29 O P 23 N Q 33 30 L 31 M 32 28 K ...

Page 57: ...ose to the left side of the wire harness to throttle servo motor and wire harness to coolant tempera ture sensor Route the fuel tank breather hose to the right side of the wire harness to stator coil wire harness to shift sensor wire harness to sidestand switch D Route the rear wheel sensor lead over the wire harness E Insert the rear wheel sensor coupler into the hole of the battery box F Insert ...

Page 58: ...2 29 CABLE ROUTING Top view 2 5 D 3 C 1 B 4 6 8 9 7 10 10 14 16 20 19 I 20 H 7 12 11 20 10 17 21 L 15 M 22 13 E 15 F 8 J A 19 K 15 17 18 19 G 20 21 9 10 2 ...

Page 59: ...osi tion sensor coupler on the right side of the vehicle C Route the rear brake light switch lead on the rear side of the wire harness to rectifier reg ulator D Route the rear wheel sensor lead on the rear side of the wire harness to rectifier regula tor E Insert the starter relay until it stops the rib stopper on the battery box F Pass the starter motor lead under the bracket G Route the wire har...

Page 60: ...2 31 CABLE ROUTING Top view 3 12 J 13 16 17 15 18 21 L 17 O 23 N 22 M 4 R 14 K 6 D 7 8 E 9 F 5 C B I H G 19 3 A 20 2 3 16 4 2 2 1 11 J 10 J 12 Q 24 P 13 P 25 2 10 Q 11 Q 2 ...

Page 61: ... rear turn signal light wire harness to tail brake light lead and wire har ness to YDT G Align with the white tape of the license plate light lead and route the license plate light lead through the guide of the battery box H Align with the black tape of the tail brake light lead and route the tail brake light lead through the guide of the battery box Pass the license plate light lead to the rearwa...

Page 62: ...2 33 CABLE ROUTING Front brake hose right side view 2 1 2 1 7 7 E F 6 5 2 4 3 8 1 6 6 2 7 10 D 5 E G 6 F 1 11 B C 2 1 8 9 A 5 ...

Page 63: ...trusion 17 mm 0 67 in on the brake hose joint with an appropriate tool tighten the brake hose union bolts to the specified torque B Fit the metal fitting for the front brake hose to the recess of the brake hose joint C Install the brake hose between the stoppers on the brake hose joint D Insert the grommet of the front wheel sensor lead E Make sure the clamp is engaged by 2 or more notches Engage ...

Page 64: ...2 35 CABLE ROUTING Front brake hose left side view 1 2 4 3 A 3 7 C 5 B 6 H 3 2 8 3 F F G G E E I D 2 8 3 J ...

Page 65: ... mark facing outward C Install the holder with contacted the front fork leg D Route the front wheel sensor lead on the front side of the brake hose and clamp the white tape portion The opening of the clamp should face the front Make sure the clamp is engaged by 3 or more notches E 45 F Left side of the vehicle G Front side of the vehicle H Insert the grommet of the front wheel sensor lead I Route ...

Page 66: ...2 37 CABLE ROUTING Rear brake hose right side view 5 F 6 6 5 6 1 3 2 H I 5 L 9 E O Q P P 5 R 6 T O P 5 N 7 S D J M 6 5 8 2 K 3 G 1 3 4 5 6 2 P B A C ...

Page 67: ...er G Route the rear wheel sensor lead and rear brake hose hydraulic unit to rear brake cali per through the guide H Fasten the grommet on the rear wheel sensor lead with the bracket I Align the gray tape on the rear brake light switch lead and then fasten the rear brake light switch lead and rear brake hose rear brake master cylinder to hydraulic unit with the clamp J 70 mm 2 76 in K Route the rea...

Page 68: ...2 39 CABLE ROUTING ABS ECU Electronic Control Unit top and left side view 7 8 4 A B 1 2 3 4 5 C D 5 8 E 9 7 6 ...

Page 69: ... Brake hose joint 4 Hydraulic unit brake pipe rear brake master cylinder to hydraulic unit 5 Hydraulic unit brake pipe hydraulic unit to front brake calipers 6 Battery box 7 Hydraulic unit brake pipe hydraulic unit to rear brake caliper 8 Hydraulic unit brake pipe rear brake master cylinder to hydraulic unit 9 Bracket A 79 B 89 C 77 D 78 E Forward ...

Page 70: ...2 41 CABLE ROUTING Air filter case and throttle bodies left side view 1 2 2 E B C Q P F O L L D A L G H I F K J 3 1 M N C ...

Page 71: ...hose until it reaches the rounded end of the pipe Install the cylinder head breather hose with the white paint mark facing the right Install the clip with its end facing the right F White paint mark G 123 H 105 I 10 J Install the canister purge hose completely onto the purge cut valve solenoid K Point the ends of the hose clamp upward L Face the bolt head to the position as shown in the illustrati...

Page 72: ...2 43 CABLE ROUTING Fuel tank left side view 1 2 3 4 5 6 A 1 7 C 4 5 B 4 D E 8 3 9 4 H 5 G 5 F ...

Page 73: ...ll the hose clip on the raised por tion of the hose fitting D Face the tip of the clip backward from the central axis of the fuel tank breather hose E Face the tip of the hose clip forward from the central axis of the fuel tank drain hose F Install the fuel tank drain hose on the projec tion side of the fuel tank G Align the hose clip with the paint mark on the fuel tank breather hose and install ...

Page 74: ...2 45 CABLE ROUTING Canister H D F F E 7 7 8 G D 2 A 1 B 3 4 B C D I 5 6 D 1 ...

Page 75: ...el tank breather hose fuel tank to canister upward B Install the clip with its end facing the down C Face the yellow paint mark on the canister purge hose purge cut valve solenoid to can ister upward D Insert each hose until it stops each part E Install the clip with its end facing the top F Face the blue paint mark on the canister purge hose purge cut valve solenoid to can ister upward G Install ...

Page 76: ...2 47 CABLE ROUTING Radiator front side view S G H T Q V C B A P D E F 4 O L K N M K J I S U S 1 6 5 1 1 1 2 3 7 8 R R U ...

Page 77: ... the coolant reservoir hose up to the section where the radiator pipe increases in diameter I Insert the radiator outlet hose up to the sec tion where the radiator pipe increases in diameter J Install the radiator outlet hose with its white paint mark facing outward K Install the hose clamp with the screw head facing the inward L Install the hose clamp screw to face it top side M Insert the radiat...

Page 78: ...2 49 CABLE ROUTING Radiator right side view H G F D C E 3 4 2 B A 1 ...

Page 79: ...ator fan cover B Route the radiator fan motor lead through the notch of the radiator fan cover C Insert the radiator hose cylinder head to radiator until it contacts the cylinder head D 0 2 mm 0 0 08 in E Point the end of clamp rearward F Hose clamp fixed position details G Make sure not to install the hose clamp on the raised portion of the hose fitting H 3 mm 0 12 in or more I Hose plug in secti...

Page 80: ...2 51 CABLE ROUTING Water pump left side view 3 4 2 A C D B F 1 E ...

Page 81: ...Align the white paint mark on the water pump inlet hose with the rib on the water pump and insert until the hose stops B Hose clamp fixed position details C 3 mm 0 12 in or more D 0 1 mm 0 0 04 in E Hose plug in section F Make sure not to install the hose clamp on the raised portion of the hose fitting ...

Page 82: ...2 53 CABLE ROUTING Oil cooler and thermostat front side view F F G A G 3 4 7 A E 2 C D B A 5 I H K L J K P O N 1 M M 6 ...

Page 83: ... its end the screw head facing the down F Fit the clip at a position more than 1 mm 0 04 in from the end of the hose and do not ride on the spool G Face the yellow paint mark on the hoses for ward insert them up to the step where the thick part of pipe H Install the hose clamp with its end facing the right I Align the white paint mark on the oil cooler inlet hose with the rib on the water jacket j...

Page 84: ...2 55 CABLE ROUTING ...

Page 85: ...D LEVEL 3 13 ADJUSTING THE FRONT DISC BRAKE 3 14 CHECKING THE FRONT BRAKE PADS 3 14 ADJUSTING THE REAR DISC BRAKE 3 14 CHECKING THE REAR BRAKE PADS 3 15 CHECKING THE FRONT BRAKE HOSE 3 15 CHECKING THE REAR BRAKE HOSE 3 15 BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS 3 15 CHECKING THE WHEELS 3 16 CHECKING THE TIRES 3 17 CHECKING THE WHEEL BEARINGS 3 18 CHECKING THE SWINGARM OPERATION 3 18 LUBRICATING TH...

Page 86: ...26 CHECKING THE COOLANT LEVEL 3 27 CHECKING THE COOLING SYSTEM 3 28 CHANGING THE COOLANT 3 28 CHECKING THE FRONT BRAKE LIGHT SWITCH 3 30 ADJUSTING THE REAR BRAKE LIGHT SWITCH 3 30 CHECKING AND LUBRICATING THE CABLES 3 30 CHECKING THE THROTTLE GRIP 3 31 CHECKING AND CHARGING THE BATTERY 3 31 CHECKING THE FUSES 3 31 ADJUSTING THE HEADLIGHT BEAM 3 31 ...

Page 87: ...RAL MAINTENANCE AND LUBRICATION CHART No ITEM CHECK OR MAINTENANCE JOB ODOMETER READING ANNUAL CHECK 1000 km 600 mi 10000 km 6000 mi 20000 km 12000 mi 30000 km 18000 mi 40000 km 24000 mi 1 Fuel line Check fuel hoses for cracks or damage Replace if necessary 2 Spark plugs Check condition Adjust gap and clean Replace 3 Valve clearance Check and adjust Every 40000 km 24000 mi 4 Fuel injection Check e...

Page 88: ...re 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 molybdenum disulfide grease 20 Sidestand switch Check operation and re...

Page 89: ...correct the brake fluid 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 Lubricate the throttle grip housing tube guides 30 Lights signals and switches Check operation Adjust headlight bea...

Page 90: ...Use the Dynamic inspection function of the YDT version 3 0 and after to perform the dynam ic inspection For information about using the YDT refer to the operation manual that is includ ed with the tool 5 Install Rider seat Refer to GENERAL CHASSIS 1 on page 4 1 EAS30619 CHECKING THE FUEL LINE The following procedure applies to all of the fuel drain and breather hoses 1 Remove Rider seat Side cover...

Page 91: ...2 Abnormal color Replace the spark plug Normal color is medium to light tan 5 Clean Spark plug with a spark plug cleaner or wire brush 6 Measure Spark plug gap a with a wire thickness gauge Out of specification Regap 7 Install Spark plug Ignition coil TIP Before installing the spark plug clean the spark plug and gasket surface 8 Install Air filter case Refer to GENERAL CHASSIS 5 on page 4 11 Fuel ...

Page 92: ...erclockwise b When piston 1 is at TDC on the compres sion stroke align the TDC mark a on the generator rotor with the generator rotor cov er mark b TIP TDC on the compression stroke can be found when the camshaft lobes are turned away from each other c Measure the valve clearance with a thick ness gauge TIP If the valve clearance is incorrect record the measured reading Measure the valve clearance...

Page 93: ...5 mm 0 010 in 0 20 mm 0 008 in 0 05 mm 0 002 in c Check the thickness of the current valve pad TIP The thickness a of each valve pad is marked in hundredths of millimeters on the side that touch es the valve lifter Example If the valve pad is marked 158 the pad thickness is 1 58 mm 0 062 in d Calculate the sum of the values obtained in steps b and c to determine the required valve pad thickness an...

Page 94: ...NG THE ENGINE IDLING SPEED TIP Prior to checking the engine idling speed the throttle body synchronization should be adjusted properly the air filter element should be clean and the engine should have adequate compres sion 1 Start the engine and let it warm up for several minutes 2 Check Engine idling speed Out of specification Go to next step 3 Check ISC idle speed control learning value 00 or 01...

Page 95: ...body that has the bypass air screw 1 with a white paint mark as the standard adjust the other throttle bodies by turning its bypass air screw in or out NOTICE ECA21300 Do not turn the bypass air screw white paint mark of the throttle body that is the stan dard Otherwise the engine may run roughly at idle and the throttle bodies may not oper ate properly TIP Turn the bypass air screw using the carb...

Page 96: ...ODIES on page 7 6 EAS30623 CHECKING THE CYLINDER HEAD BREATHER HOSE 1 Remove Rider seat Side cover Refer to GENERAL CHASSIS 1 on page 4 1 Fuel tank cover Refer to GENERAL CHASSIS 4 on page 4 10 Fuel tank Refer to FUEL TANK on page 7 1 Air filter case Refer to GENERAL CHASSIS 5 on page 4 11 2 Check Cylinder head breather hose 1 Cracks damage Replace Loose connection Connect properly NOTICE ECA14920...

Page 97: ... cover Rider seat Refer to GENERAL CHASSIS 1 on page 4 1 EAS33546 CHECKING THE PURGE CUT VALVE SOLENOID Refer to CHECKING THE PURGE CUT VALVE SOLENOID on page 7 5 EAS30799 ADJUSTING THE EXHAUST GAS VOLUME TIP Be sure to set the CO density level to standard and then adjust the exhaust gas volume To adjust the exhaust gas volume use the CO adjustment mode of the YDT For more infor mation refer to th...

Page 98: ...NG THE ECU Engine Control Unit on page 8 41 NOTICE ECA20710 Never operate the engine without the air filter element installed Unfiltered air will cause rapid wear of engine parts and may damage the engine Operating the engine without the air filter element will also affect throttle body synchronization leading to poor engine per formance and possible overheating TIP When installing the air filter ...

Page 99: ...ance stand Make sure the vehicle is upright 2 Check Brake fluid level Below the minimum level mark Add the specified brake fluid to the proper level WARNING EWA13090 Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may...

Page 100: ... is no brake drag EAS30633 CHECKING THE FRONT BRAKE PADS The following procedure applies to all of the brake pads 1 Operate the brake 2 Check Front brake pad Wear indicators 1 almost touch the brake disc Replace the brake pads as a set Refer to FRONT BRAKE on page 4 27 EAS30631 ADJUSTING THE REAR DISC BRAKE 1 Adjust Brake pedal position a Loosen the locknut 1 b Turn the adjusting bolt 2 until the ...

Page 101: ... the vehicle upright and apply the rear brake several times 4 Check Brake hose Brake fluid leakage Replace the damaged hose Refer to REAR BRAKE on page 4 40 EAS30893 BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS WARNING EWA14000 Always bleed the brake system when the brake related parts are removed NOTICE ECA22640 Bleed the brake system in the following or der 1st step Front brake master cylinder 2nd st...

Page 102: ...RATION TESTS on page 4 56 NOTICE ECA17061 Make sure that the main switch is turned to OFF before checking the operation of the hydraulic unit k After operating the ABS repeat steps e to i and then fill the brake fluid reservoir to the proper level with the specified brake flu id l Tighten the bleed screw to specification m Fill the brake fluid reservoir to the proper level with the specified brake...

Page 103: ... by the same manufacturer and of the same design No guarantee con cerning handling characteristics can be giv en if a tire combination other than one approved by Yamaha is used on this vehicle WARNING EWA13210 New tires have a relatively low grip on the road surface until they have been slightly worn Therefore approximately 100 km should be traveled at normal speed before any high speed riding is ...

Page 104: ...is too loose can skip and damage the swing arm or cause an accident Therefore keep the drive chain slack within the specified lim its 1 Shift the transmission into the neutral posi tion 2 Check Drive chain slack Out of specification Adjust TIP Measure the distance a between the rib end on the drive chain guide 1 and the center point of the drive chain 2 The center point b of the drive chain is ap ...

Page 105: ... with small rubber O rings between each side plate Steam clean ing high pressure washing certain solvents and the use of a coarse brush can damage these O rings Therefore use only kerosene to clean the drive chain Wipe the drive chain dry and thoroughly lubricate it with engine oil or chain lubricant that is suitable for O ring chains Do not use any other lubricants on the drive chain since they m...

Page 106: ...nger tighten the upper ring nut then align the slots of both ring nuts If necessary hold the lower ring nut and tighten the upper ring nut until their slots are aligned h Install the lock washer 1 TIP Make sure the lock washer tabs a sit correctly in the ring nut slots b 5 Install Upper bracket Refer to STEERING HEAD on page 4 77 EAS30646 LUBRICATING THE STEERING HEAD 1 Lubricate Upper bearing Low...

Page 107: ...eplace 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 66 EAS30806 ADJUSTING THE FRONT FORK LEGS The following procedure applies to both of th...

Page 108: ...t would be advisable to check the number of clicks of each damping force adjusting mechanism and to modify the specifications as necessary When turning the damping force adjusting bolt in direction a the 0 click position and the 1 click position may be the same Compression damping left side only NOTICE ECA13590 Never go beyond the maximum or minimum adjustment positions 1 Adjust Compression dampin...

Page 109: ... is no danger of it falling over Spring preload NOTICE ECA13590 Never go beyond the maximum or minimum adjustment positions 1 Remove Side cover Refer to GENERAL CHASSIS 1 on page 4 1 2 Adjust Spring preload a Adjust the spring preload with the special wrench 1 and extension bar 2 included in the owner s tool kit b Turn the adjusting ring 3 in direction a or b c Align the desired position on the ad...

Page 110: ... 4 82 EAS30656 CHECKING THE ENGINE OIL LEVEL 1 Stand the vehicle on a level surface TIP Place the vehicle on a maintenance stand Make sure the vehicle is upright 2 Start the engine warm it up for several min utes and then turn it off 3 Check Engine oil level The engine oil level should be between the minimum level mark a and maximum level mark b Below the minimum level mark Add the recommended eng...

Page 111: ...e warm it up for several min utes and then turn it off 2 Place a container under the engine oil drain bolt 3 Remove Engine oil filler cap 1 Engine oil drain bolt 2 Gasket 3 4 Drain Engine oil completely from the crankcase 5 If the oil filter cartridge is also to be replaced perform the following procedure a Remove the oil filter cartridge 1 with an oil filter wrench 2 b Lubricate the O ring of the...

Page 112: ... is cold the engine oil will have a higher viscosity causing the engine oil pressure to increase Therefore be sure to measure the engine oil pressure after warming up the engine 3 Remove Oil pressure switch joint bolt 1 Oil pressure switch joint with the oil pressure switch 2 WARNING EWA12980 The engine muffler and engine oil are ex tremely hot 4 Install Oil pressure gauge joint 18 mm 1 Oil pressu...

Page 113: ...evel should be between the maximum level mark a and minimum level mark b Below the minimum level mark Add the recommended coolant to the proper level NOTICE ECA21281 Adding water instead of coolant dilutes the antifreeze concentration of the coolant If water is used instead of coolant check and if necessary correct the antifreeze concentration of the coolant Use only distilled water However if dis...

Page 114: ...age 4 8 Radiator cap 1 WARNING EWA13030 A hot radiator is under pressure Therefore do not remove the radiator cap when the en gine is hot Scalding hot fluid and steam may be blown out which could cause serious in jury When the engine has cooled open the radiator cap as follows Place a thick rag or a towel over the radiator cap and slowly turn the radiator cap counter clockwise toward the detent to...

Page 115: ...ediate medical attention NOTICE ECA21291 Adding water instead of coolant dilutes the antifreeze concentration of the coolant If water is used instead of coolant check and if necessary correct the antifreeze concentration of the coolant Use only distilled water However if dis tilled water is not available soft water may be used If coolant comes into contact with painted surfaces immediately wash th...

Page 116: ...ffect starts 1 Check Rear brake light operation timing Incorrect Adjust 2 Remove Footrest plate Refer to REAR BRAKE on page 4 40 3 Adjust Rear brake light operation timing a Hold the main body 1 of the rear brake light switch so that it does not rotate and turn the adjusting nut 2 until the rear brake light comes on at the proper time EAS30660 CHECKING AND LUBRICATING THE CABLES The following proc...

Page 117: ...the way to the left and right EAS30816 CHECKING AND CHARGING THE BATTERY Refer to CHECKING AND CHARGING THE BATTERY on page 8 41 EAS30662 CHECKING THE FUSES Refer to CHECKING THE FUSES on page 8 40 EAS30664 ADJUSTING THE HEADLIGHT BEAM 1 Adjust Headlight beam vertically TIP To adjust the headlight beam vertically turn the adjusting screw a Turn the adjusting screw 1 2 Adjust Headlight beam horizon...

Page 118: ...3 32 PERIODIC MAINTENANCE ...

Page 119: ...CHECKING THE FRONT WHEEL 4 14 ASSEMBLING THE FRONT WHEEL 4 15 MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR 4 16 ADJUSTING THE FRONT WHEEL STATIC BALANCE 4 16 INSTALLING THE FRONT WHEEL FRONT BRAKE DISCS 4 17 REAR WHEEL 4 19 REMOVING THE REAR WHEEL 4 22 DISASSEMBLING THE REAR WHEEL 4 22 CHECKING THE REAR WHEEL 4 22 CHECKING THE REAR WHEEL DRIVE HUB 4 22 CHECKING AND REPLACING THE REAR WHE...

Page 120: ...CALIPER 4 48 CHECKING THE REAR BRAKE CALIPER 4 48 ASSEMBLING THE REAR BRAKE CALIPER 4 49 INSTALLING THE REAR BRAKE CALIPER 4 49 REMOVING THE REAR BRAKE MASTER CYLINDER 4 50 CHECKING THE REAR BRAKE MASTER CYLINDER 4 50 ASSEMBLING THE REAR BRAKE MASTER CYLINDER 4 50 INSTALLING THE REAR BRAKE MASTER CYLINDER 4 50 ABS ANTI LOCK BRAKE SYSTEM 4 52 REMOVING THE HYDRAULIC UNIT ASSEMBLY 4 54 CHECKING THE H...

Page 121: ...CK ABSORBER ASSEMBLY 4 82 CHECKING THE CONNECTING ARM AND RELAY ARM 4 82 INSTALLING THE RELAY ARM 4 83 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 4 83 SWINGARM 4 84 REMOVING THE SWINGARM 4 86 CHECKING THE SWINGARM 4 86 INSTALLING THE SWINGARM 4 87 CHAIN DRIVE 4 88 REMOVING THE DRIVE CHAIN 4 89 CHECKING THE DRIVE CHAIN 4 89 CHECKING THE DRIVE SPROCKET 4 90 CHECKING THE REAR WHEEL SPROCKET 4 90 CHE...

Page 122: ...1 EAS20026 GENERAL CHASSIS 1 Removing the seat and side covers Order Job Parts to remove Q ty Remarks 1 Rider seat 1 2 Side cover left 1 3 Side cover grille left 1 4 Side cover right 1 5 Side cover grille right 1 4 1 5 2 3 ...

Page 123: ...isconnect 6 Positive battery lead 1 Disconnect 7 Battery 1 8 Passenger footrest 1 9 IMU coupler 1 Disconnect 10 IMU Inertial Measurement Unit 1 11 Rectifier regulator coupler 1 Disconnect 12 Rectifier regulator 1 1 6 5 4 9 10 8 4 4 4 4 4 4 4 7 11 12 2 3 17 N m 1 7 kgf m 13 lb ft T R 9 N m 0 9 kgf m 6 6 lb ft T R 7 N m 0 7 kgf m 5 2 lb ft T R 7 N m 0 7 kgf m 5 2 lb ft T R 2 0 N m 0 20 kgf m 1 5 lb ...

Page 124: ... 1 2 Tail brake light coupler 1 Disconnect 3 Tail brake light 1 4 Tail brake light bracket 1 5 Bracket 1 6 Rear turn signal light coupler License plate light coupler 2 1 Disconnect 7 Mudguard assembly 1 8 Lower fender cover 1 1 2 3 8 7 6 2 4 4 2 2 4 5 10 N m 1 0 kgf m 7 4 lb ft T R 7 N m 0 7 kgf m 5 2 lb ft T R 7 N m 0 7 kgf m 5 2 lb ft T R 6 N m 0 6 kgf m 4 4 lb ft T R ...

Page 125: ...he washer where con tacting the IMU grommet When installing the IMU use only a genuine bolt and washer and tighten the bolt to the specified torque Pay attention not to expose the IMU to strong shocks such as striking or drop ping it Do not place any foreign objects in and around the battery box Do not obstruct breather opening a of the IMU Do not clean the breather opening and do not blow it with...

Page 126: ...tion a on the side cover into the grommet b Insert the slit c of the side cover into the grom met d EAS30125 INSTALLING THE SEAT 1 Install Seat a Insert the projections 1 into the seat hold ers 2 as shown b Push the rear of the seat down to lock it in place TIP Make sure that the seat is properly secured be fore riding S S 1 4 4 4 4 4 4 2 a b 1 d c 2 2 2 2 1 ...

Page 127: ...eadlight bracket 1 left 1 2 Headlight bracket 1 right 1 3 Headlight control unit coupler 1 Disconnect 4 Headlight assembly 1 5 Meter assembly coupler 1 Disconnect 6 Meter assembly 1 7 Meter bracket 1 3 5 1 6 4 2 7 4 4 4 10 N m 1 0 kgf m 7 4 lb ft T R 7 N m 0 7 kgf m 5 2 lb ft T R 7 N m 0 7 kgf m 5 2 lb ft T R 1 8 N m 0 18 kgf m 1 3 lb ft T R ...

Page 128: ...rder Job Parts to remove Q ty Remarks 1 Coupler cover 1 2 Harness clamp Coupler clamp 4 1 Disconnect 3 Coupler holder 1 4 Headlight bracket 2 1 1 3 2 4 4 4 1 2 2 2 2 7 N m 0 7 kgf m 5 2 lb ft T R 7 N m 0 7 kgf m 5 2 lb ft T R 1 5 N m 0 15 kgf m 1 1 lb ft T R ...

Page 129: ...4 O2 sensor coupler 1 Disconnect 5 Front turn signal light left 1 6 Front side panel left 1 7 Front turn signal light coupler right 1 Disconnect 8 Sub wire harness coupler Oil pressure switch 1 Disconnect 9 Front turn signal light right 1 10 Front side panel right 1 1 3 6 5 2 10 7 9 8 4 LT LT LT LT LT 3 8 N m 0 38 kgf m 2 8 lb ft T R 3 8 N m 0 38 kgf m 2 8 lb ft T R 7 N m 0 7 kgf m 5 2 lb ft T R 7...

Page 130: ... cover 1 a Remove the radiator cover bolts b Remove the radiator cover EAS32348 INSTALLING THE RADIATOR COVER The following procedure applies to both of the radiator cover 1 Install Radiator cover 1 Radiator cover bolt TIP Insert projections a on the radiator cover into slots b Radiator cover bolt 3 8 N m 0 38 kgf m 2 8 lb ft 1 T R 1 a b ...

Page 131: ...NERAL CHASSIS 4 Removing the fuel tank cover Order Job Parts to remove Q ty Remarks 1 Fuel tank cover 1 2 Fuel tank cover grille 2 2 1 2 2 5 N m 0 25 kgf m 1 8 lb ft T R 2 5 N m 0 25 kgf m 1 8 lb ft T R 2 5 N m 0 25 kgf m 1 8 lb ft T R ...

Page 132: ...ler 3 Disconnect 2 ECU Engine Control Unit 1 3 Intake air temperature sensor 1 Disconnect 4 Air filter case cover 1 5 Air filter element 1 6 Air filter case joint clamp screw 3 Loosen 7 Cylinder head breather hose 1 Disconnect 8 Air filter case 1 3 7 1 6 5 2 10 4 4 4 4 8 New 7 N m 0 7 kgf m 5 2 lb ft T R 1 6 N m 0 16 kgf m 1 2 lb ft T R 2 8 N m 0 28 kgf m 2 1 lb ft T R ...

Page 133: ...3 Front wheel sensor 1 4 Wheel axle pinch bolt 1 Loosen 5 Wheel axle 1 6 Front wheel 1 7 Collar 2 8 Front brake disc 2 LT New LT New 7 7 8 8 4 3 1 2 5 2 6 1 72 N m 7 2 kgf m 53 lb ft T R 35 N m 3 5 kgf m 26 lb ft T R 35 N m 3 5 kgf m 26 lb ft T R 7 N m 0 7 kgf m 5 2 lb ft T R 23 N m 2 3 kgf m 17 lb ft T R 18 N m 1 8 kgf m 13 lb ft T R 18 N m 1 8 kgf m 13 lb ft T R ...

Page 134: ...FRONT WHEEL Disassembling the front wheel Order Job Parts to remove Q ty Remarks 1 Front wheel sensor rotor 1 2 Oil seal 2 3 Wheel bearing 2 4 Spacer 1 LT New New New 2 3 2 1 3 4 5 8 N m 0 8 kgf m 5 9 lb ft ...

Page 135: ...lace the vehicle on a maintenance stand so that the front wheel is elevated 4 Loosen Wheel axle pinch bolt 5 Remove Wheel axle Front wheel EAS31149 DISASSEMBLING THE FRONT WHEEL NOTICE ECA21340 Do not drop the wheel sensor rotor or sub ject it to shocks If any solvent gets on the wheel sensor ro tor wipe it off immediately 1 Remove Oil seal Wheel bearing a Clean the surface of the front wheel hub ...

Page 136: ...ll the spacer c Install the new wheel bearing right side TIP Place a suitable washer 1 between the socket 2 and the bearing so that both the inner race 3 and outer race 4 are pressed at the same time and then press the bearing until the inner race makes contact with the spacer 5 d Install the new oil seals 2 Install Front wheel sensor rotor NOTICE ECA17200 Replace the wheel sensor rotor bolts with...

Page 137: ...r rotor runout Out of specification Clean the installation surface of the wheel sensor rotor and correct the wheel sensor rotor runout or replace the wheel sensor rotor a Hold the dial gauge at a right angle against the wheel sensor rotor surface b Measure the wheel sensor rotor runout c If the runout is above specification remove the sensor rotor from the wheel rotate it by two or three bolt hole...

Page 138: ... in the front wheel sensor rotor and front wheel sensor Foreign materials cause damage to the front wheel sensor rotor and front wheel sensor TIP When installing the front wheel sensor check the wheel sensor lead for twists 7 Measure Distance a between the wheel sensor rotor 1 and wheel sensor 2 Out of specification Check the wheel bear ing for looseness and the front wheel sensor and sensor rotor...

Page 139: ...o 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 caliper WARNING EWA13500 Make sure the brake hose is routed properly Thickness gauge 90890 03268 Feeler gauge set YU 26900 9 Front brake caliper bolt 35 N m 3 5 kgf m 26 lb ft 1 1 2 2 a G088903 T R ...

Page 140: ...r wheel sensor 1 2 Locknut 2 Loosen 3 Adjusting bolt 2 Loosen 4 Wheel axle nut 1 5 Washer 1 6 Wheel axle 1 7 Adjusting block left 1 8 Adjusting block right 1 9 Rear wheel 1 10 Brake caliper bracket assembly 1 LS 4 5 8 1 10 9 7 6 2 3 3 2 7 N m 0 7 kgf m 5 2 lb ft T R 16 N m 1 6 kgf m 12 lb ft T R 16 N m 1 6 kgf m 12 lb ft T R 105 N m 10 5 kgf m 77 lb ft T R ...

Page 141: ...brake disc 1 3 Bracket 1 4 Rear wheel sprocket 1 5 Collar 1 6 Collar 1 7 Oil seal 1 8 Bearing 1 9 Rear wheel drive hub 1 10 Collar 1 11 Oil seal 1 12 Rear wheel drive hub damper 5 13 Rear wheel 1 LT LT New LS LS LS 1 12 11 10 9 4 3 8 7 5 6 2 5 5 5 New New New 13 30 N m 3 0 kgf m 22 lb ft 80 N m 8 0 kgf m 59 lb ft 8 N m 0 8 kgf m 5 9 lb ft ...

Page 142: ...4 21 REAR WHEEL Disassembling the rear wheel Order Job Parts to remove Q ty Remarks 1 Oil seal 1 2 Wheel bearing 1 3 Spacer 1 4 Wheel bearing 1 New 1 2 3 4 ...

Page 143: ...et assembly 3 Loosen Locknut Adjusting bolt 4 Remove Wheel axle nut Washer Wheel axle Rear wheel Brake caliper bracket assembly NOTICE ECA27280 Be sure to remove the rear wheel sensor be fore removing the brake caliper bracket as sembly otherwise the sensor could be damaged TIP Push the rear wheel forward and remove the drive chain from the rear wheel sprocket EAS31154 DISASSEMBLING THE REAR WHEEL...

Page 144: ...40 Do not drop the wheel sensor rotor or sub ject it to shocks If any solvent gets on the wheel sensor ro tor wipe it off immediately 1 Install Wheel bearing Oil seal a Install the new wheel bearing right side NOTICE ECA18110 Do not contact the wheel bearing inner race 1 or balls 2 Contact should be made only with the outer race 3 TIP Use a socket 4 that matches the diameter of the wheel bearing o...

Page 145: ...L STATIC BALANCE TIP After replacing the tire wheel or both the rear wheel static balance should be adjusted Adjust the rear wheel static balance with the brake disc and rear wheel drive hub installed 1 Adjust Rear wheel static balance Refer to ADJUSTING THE FRONT WHEEL STATIC BALANCE on page 4 16 EAS31157 INSTALLING THE REAR WHEEL REAR BRAKE DISC 1 Install Rear brake disc NOTICE ECA19150 Replace ...

Page 146: ... wheel sensor rotor and rear wheel sensor Foreign materials cause damage to the rear wheel sensor rotor and rear wheel sensor TIP When installing the rear wheel sensor check the rear wheel sensor lead for twists A Left side B Right side Drive chain slack Maintenance Stand 45 0 50 0 mm 1 77 1 97 in Drive chain slack Sidestand 45 0 50 0 mm 1 77 1 97 in Drive chain slack limit 55 0 mm 2 17 in Rear wh...

Page 147: ...d 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 wheel sen sor rotor and the rear wheel sensor...

Page 148: ...ove Q ty Remarks The following procedure applies to both of the front brake calipers 1 Brake pad clip 2 2 Brake pad pin 1 3 Brake pad spring 1 4 Brake pad 2 5 Reflector bracket 1 6 Front brake caliper 1 7 Bleed screw 1 1 2 3 4 5 7 6 5 N m 0 5 kgf m 3 7 lb ft T R 35 N m 3 5 kgf m 26 lb ft T R ...

Page 149: ...YSTEM ABS on page 3 15 1 Brake fluid reservoir cap stopper 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 bracket 1 7 Brake fluid reservoir hose 1 6 7 5 4 1 3 2 New S S S 6 N m 0 6 kgf m 4 4 lb ft T R 1 2 N m 0 12 kgf m 0 88 lb ft T R 1 2 N m 0 12 kgf m 0 88 lb ft T R 2 5 N m 0 25 kgf ...

Page 150: ...marks 8 Brake hose union bolt 1 9 Brake hose 1 10 Brake hose gasket 2 11 Front brake light switch 1 12 Front brake master cylinder holder 1 13 Brake lever 1 14 Front brake master cylinder 1 9 11 12 13 14 14 New 10 8 S S S 6 N m 0 6 kgf m 4 4 lb ft T R 1 2 N m 0 12 kgf m 0 88 lb ft T R 1 2 N m 0 12 kgf m 0 88 lb ft T R 2 5 N m 0 25 kgf m 1 8 lb ft T R 17 N m 1 7 kgf m 13 lb ft T R 1 0 N m 0 10 kgf ...

Page 151: ...sassembling the front brake master cylinder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder kit 1 2 Bleed screw 1 3 Cap 1 4 Brake master cylinder body 1 6 N m 0 6 kgf m 4 4 lb ft T R 4 1 3 2 S New BF BF New ...

Page 152: ...he front brake calipers Brake fluid Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS on page 3 15 1 Brake hose union bolt 1 2 Brake hose gasket 3 3 Brake hose 2 4 Reflector bracket 1 5 Reflector 1 6 Front brake caliper 1 3 1 2 5 6 4 New 30 N m 3 0 kgf m 22 lb ft T R 35 N m 3 5 kgf m 26 lb ft T R 3 8 N m 0 38 kgf m 2 8 lb ft T R ...

Page 153: ...lies to both of the front brake calipers 1 Brake pad clip 2 2 Brake pad pin 1 3 Brake pad spring 1 4 Brake pad 2 5 Brake caliper piston 4 6 Brake caliper piston dust seal 4 7 Brake caliper piston seal 4 8 Bleed screw 1 FWD FWD BF BF S S 3 8 4 7 5 6 7 6 6 7 5 6 7 2 1 5 N m 0 5 kgf m 3 7 lb ft New New New New New New New New ...

Page 154: ...dure applies to both brake discs 1 Check Front brake disc Damage galling Replace 2 Measure Brake disc runout Out of specification Replace a Place the vehicle on a maintenance stand so that the front wheel is elevated b Remove the brake caliper c Hold the dial gauge at a right angle against the brake disc surface d Measure the runout 1 5 mm 0 06 in below the edge of the brake disc 3 Measure Brake d...

Page 155: ... the bleed screw and push the brake caliper pistons into the brake caliper with your finger c Tighten the bleed screw d Install the brake pads and brake pad spring TIP The arrow mark a on the brake pad spring must point in the direction of disc rotation 6 Install Brake pad pin Brake pad clip Front brake caliper 7 Check Brake fluid level Below the minimum level mark Add the specified brake fluid to...

Page 156: ...m the brake caliper WARNING EWA17060 Never try to pry out the brake caliper pis tons Do not loosen the bolts 4 c Remove the brake caliper piston dust seals and brake caliper piston seals d Repeat the previous steps to force out the right side pistons from the brake caliper EAS30173 CHECKING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers 1 Check Brake caliper...

Page 157: ...asket Brake hose 2 Brake hose union bolt 3 WARNING EWA13531 Proper brake hose routing is essential to in sure safe vehicle operation NOTICE ECA21410 When installing the brake hose onto the brake caliper 1 make sure the brake pipe a touches the projection b on the brake caliper Install the brake pipe c so that it is aligned with the brake pipe a 2 Remove Front brake caliper 3 Install Brake pad Brak...

Page 158: ... CYLINDER TIP Before removing the front brake master cylinder drain the brake fluid from the entire brake sys tem 1 Remove Brake hose union bolt Brake hose gasket Brake hose TIP To collect any remaining brake fluid place a container under the master cylinder and the end of the brake hose EAS30725 CHECKING THE FRONT BRAKE MASTER CYLINDER 1 Check Brake master cylinder Damage scratches wear Replace B...

Page 159: ...es leads Correct if necessary 3 Fill Brake master cylinder reservoir with the specified amount of the specified brake fluid WARNING EWA13540 Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chem...

Page 160: ...imum level mark Add the specified brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 13 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 15 ...

Page 161: ...etaining bolt 1 3 Rear brake caliper 1 4 Brake pad 2 5 Brake pad shim 2 6 Brake pad insulator 2 7 Brake pad spring 1 8 Bleed screw 1 9 Brake caliper bracket assembly 1 LT S S S S 22 N m 2 2 kgf m 16 lb ft T R 17 N m 1 7 kgf m 13 lb ft T R 2 5 N m 0 25 kgf m 1 8 lb ft T R 7 8 3 1 2 6 6 5 4 5 5 N m 0 5 kgf m 3 7 lb ft T R 27 N m 2 7 kgf m 20 lb ft T R 9 ...

Page 162: ...oir cap 1 3 Brake fluid reservoir diaphragm holder 1 4 Brake fluid reservoir diaphragm 1 5 Brake fluid reservoir 1 6 Footrest plate 1 7 Brake hose union bolt 1 8 Brake hose gasket 2 9 Brake hose 1 5 6 8 1 9 7 4 3 2 New New LS LT 30 N m 3 0 kgf m 22 lb ft T R 3 8 N m 0 38 kgf m 2 8 lb ft T R 21 N m 2 1 kgf m 15 lb ft T R 30 N m 3 0 kgf m 22 lb ft T R 28 N m 2 8 kgf m 21 lb ft T R 23 N m 2 3 kgf m 1...

Page 163: ...ket 1 13 Rear brake light switch coupler 1 Disconnect 14 Rear brake light switch 1 15 Brake pedal 1 16 Footrest assembly 1 13 New 10 New 11 12 14 15 16 LS LT 30 N m 3 0 kgf m 22 lb ft T R 3 8 N m 0 38 kgf m 2 8 lb ft T R 21 N m 2 1 kgf m 15 lb ft T R 30 N m 3 0 kgf m 22 lb ft T R 28 N m 2 8 kgf m 21 lb ft T R 23 N m 2 3 kgf m 17 lb ft T R 7 N m 0 7 kgf m 5 2 lb ft T R 5 N m 0 5 kgf m 3 7 lb ft T R...

Page 164: ...he rear brake master cylinder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder yoke 1 2 Brake master cylinder kit 1 3 Hose joint 1 4 Bushing 1 5 Brake master cylinder body 1 S BF BF New New New 18 N m 1 8 kgf m 13 lb ft ...

Page 165: ... Remarks Brake fluid Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS on page 3 15 1 Brake hose union bolt 1 2 Brake hose gasket 2 3 Brake hose 1 4 Rear brake caliper 1 LT S S New 1 3 4 2 30 N m 3 0 kgf m 22 lb ft 22 N m 2 2 kgf m 16 lb ft T R 27 N m 2 7 kgf m 20 lb ft T R ...

Page 166: ... 1 2 Brake pad retaining bolt 1 3 Brake pad 2 4 Brake pad shim 2 5 Brake pad insulator 2 6 Brake pad spring 1 7 Brake caliper piston 1 8 Brake caliper piston dust seal 1 9 Brake caliper piston seal 1 10 Bleed screw 1 S S S BF 2 5 N m 0 25 kgf m 1 8 lb ft 5 N m 0 5 kgf m 3 7 lb ft 17 N m 1 7 kgf m 13 lb ft ...

Page 167: ...l brake com ponents Use only clean or new brake fluid for clean ing brake components Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately Avoid brake fluid coming into contact with the eyes as it can cause serious injury FIRST AID FOR BRAKE FLUID ENTERING THE EYES Flush with water for 15 minutes and get im mediate medical attention E...

Page 168: ...r b Loosen the bleed screw and push the brake caliper piston into the brake caliper with your finger c Tighten the bleed screw d Install the brake pad insulators and brake pad shims onto each brake pads TIP Apply silicone grease between the brake pad in sulator and brake pad shim NOTICE ECA14150 Do not allow grease to contact the brake pads Remove any excess grease e Install the brake pads and bra...

Page 169: ...g 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 caliper piston seal EAS30188 CHECKING THE REAR BRAKE CALIPER 1 Check Brake caliper piston Rust scratches wear Replace the brake caliper piston Brake caliper cylinder Scratches wear Replace the brake caliper assembly...

Page 170: ...Proper brake hose routing is essential to in sure safe vehicle operation NOTICE ECA19080 When installing the brake hose onto the brake caliper 1 make sure the brake pipe a passes between the projections b on the brake caliper TIP Apply Three Bond No 1521 onto the mating sur faces of the brake caliper bracket and brake cal iper bracket retainer 2 Remove Rear brake caliper 3 Install Brake pad insula...

Page 171: ...page 3 15 EAS30193 REMOVING THE REAR BRAKE MASTER CYLINDER 1 Remove Brake hose union bolt Brake hose gasket Brake hose TIP To collect any remaining brake fluid place a container under the master cylinder and the end of the brake hose EAS30194 CHECKING THE REAR BRAKE MASTER CYLINDER 1 Check Brake master cylinder Damage scratches wear Replace Brake fluid delivery passages brake master cylinder body ...

Page 172: ...l reaction leading to poor brake performance When refilling be careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock NOTICE ECA13540 Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 3 Bleed Brake system Refer to BLEEDING THE HYDRA...

Page 173: ...d Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS on page 3 15 1 Brake hose union bolt 2 2 Gasket 4 3 Brake hose hydraulic unit to front brake cali pers 1 Disconnect 4 Brake hose front brake master cylinder to hydraulic unit 1 Disconnect 13 1 2 New 2 New 3 4 30 N m 3 0 kgf m 22 lb ft T R 7 N m 0 7 kgf m 5 2 lb ft T R 6 N m 0 6 kgf m 4 4 lb ft T R 7 N m 0 7 kgf m 5 2 lb ft T R 7 N m 0 7 kgf ...

Page 174: ... brake pipe hydraulic unit to rear brake caliper 1 Disconnect 11 Hydraulic unit brake pipe hydraulic unit to front brake calipers 1 12 Hydraulic unit brake pipe front brake master cylinder to hydraulic unit 1 13 Hydraulic unit assembly 1 13 10 7 12 13 8 9 6 5 New 11 New 30 N m 3 0 kgf m 22 lb ft T R 7 N m 0 7 kgf m 5 2 lb ft T R 6 N m 0 6 kgf m 4 4 lb ft T R 7 N m 0 7 kgf m 5 2 lb ft T R 7 N m 0 7...

Page 175: ...leed the brake system 1 Disconnect ABS ECU coupler 1 TIP While pushing the portion a of the ABS ECU coupler pull the lock lever 2 up to release the lock 2 Remove Brake hose TIP Do not operate the brake lever and brake pedal while removing the brake hoses Do not bend the brake pipe when loosening the brake pipe flare nuts NOTICE ECA19800 When removing the brake hoses and brake pipes cover the area ...

Page 176: ... the specified torque in this or der 2 Remove Rubber plugs or bolt M10 1 0 3 Install Hydraulic unit brake pipe 4 Tighten Hydraulic unit brake pipe flare nut NOTICE ECA19820 If the brake pipe flare nut does not turn easi ly replace the hydraulic unit assembly brake pipes and related parts as a set TIP Do not bend the brake pipe when tightening the brake pipe flare nuts 5 Install Gasket Brake hose u...

Page 177: ...TC Refer to SELF DIAGNOS TIC FUNCTION AND DIAGNOSTIC CODE TABLE on page 9 43 11 Perform a trial run Refer to CHECKING THE ABS WARNING LIGHT on page 4 59 EAS30930 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 follo...

Page 178: ...or Check a single pulse will be generated in the brake lever 1 brake pedal 2 and again in the brake lever 1 in this or der TIP ON and OFF on the tool screen indicate when the brakes are being applied and released respectively NOTICE ECA17371 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 before it is ...

Page 179: ...ctuator Check and then operate the brake lever 1 and brake pedal 2 simulta neously TIP The hydraulic unit operates 1 second after the 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 ...

Page 180: ...nd again in the brake le ver in this order If the pulse is felt in the brake pedal before it is felt in the brake lever check that the brake hoses and brake pipes are connected correctly to the hydraulic unit assembly If the pulse is hardly felt in either the brake lever or brake pedal check that the brake hoses and brake pipes are connected cor rectly to the hydraulic unit assembly 12 Turn the ma...

Page 181: ...embly 1 5 Handlebar switch right 1 6 Throttle grip 1 7 Rearview mirror bolt left 1 8 Rearview mirror left 1 13 1 5 3 4 2 6 7 8 LS LS LS 38 N m 3 8 kgf m 28 lb ft T R 17 N m 1 7 kgf m 13 lb ft T R 38 N m 3 8 kgf m 28 lb ft T R 40 N m 4 0 kgf m 30 lb ft T R 11 N m 1 1 kgf m 8 1 lb ft T R 16 N m 1 6 kgf m 12 lb ft T R 3 5 N m 0 35 kgf m 2 6 lb ft T R 2 0 N m 0 20 kgf m 1 5 lb ft T R 22 N m 2 2 kgf m ...

Page 182: ...lebar holder 2 15 Handlebar 1 16 Lower handlebar holder 2 17 Collar 2 13 14 16 13 11 12 15 9 10 LS LS LS 17 38 N m 3 8 kgf m 28 lb ft T R 17 N m 1 7 kgf m 13 lb ft T R 38 N m 3 8 kgf m 28 lb ft T R 40 N m 4 0 kgf m 30 lb ft T R 11 N m 1 1 kgf m 8 1 lb ft T R 16 N m 1 6 kgf m 12 lb ft T R 3 5 N m 0 35 kgf m 2 6 lb ft T R T R 22 N m 2 2 kgf m 16 lb ft T R T R 2 0 N m 0 20 kgf m 1 5 lb ft 1 8 N m 0 1...

Page 183: ...er and then on the rear side TIP Align the punch mark a on the handlebar with the left side upper surface of the lower handle bar holder left 3 The upper handlebar holders should be in stalled with the punch marks b facing for ward e Tighten the lower handlebar holder nuts EAS30203 REMOVING THE HANDLEBAR 1 Stand the vehicle on a level surface WARNING EWA13120 Securely support the vehicle so that t...

Page 184: ...ers should be in stalled with the punch marks b facing for ward 3 Tighten Lower handlebar holder nut 4 Install Handlebar switch right Throttle grip Rearview mirror right a Fit the slot a in the throttle grip 1 into the projection b in the handlebar switch right front side 2 and the throttle grip onto the handlebar 3 b Make sure that the throttle grip 1 turns smoothly c Install the handlebar switch...

Page 185: ...er with the punch mark a on the handlebar 7 Install Handlebar grip Rearview mirror left a Apply a thin coat of rubber adhesive onto the end of the handlebar left b Slide the handlebar grip over the end of the handlebar left 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 4 6 mm 0 ...

Page 186: ...ar switch holder Handlebar switch screw left TIP Align the projection a on the handlebar switch left with the hole b in the handlebar 9 Adjust Clutch lever free play Refer to ADJUSTING THE CLUTCH LEVER FREE PLAY on page 3 12 Handlebar switch holder screw 3 5 N m 0 35 kgf m 2 6 lb ft Handlebar switch screw handle bar switch left 2 0 N m 0 20 kgf m 1 5 lb ft Clutch lever free play 10 0 15 0 mm 0 39 ...

Page 187: ... front fork legs Front wheel Refer to FRONT WHEEL on page 4 12 1 Front fender 1 2 Upper bracket pinch bolt 1 Loosen 3 Cap bolt 1 Loosen 4 Lower bracket pinch bolt 2 Loosen 5 Front fork leg 1 5 4 3 2 1 10 N m 1 0 kgf m 7 4 lb ft T R 23 N m 2 3 kgf m 17 lb ft T R 23 N m 2 3 kgf m 17 lb ft T R 26 N m 2 6 kgf m 19 lb ft T R 10 N m 1 0 kgf m 7 4 lb ft T R ...

Page 188: ... Cap bolt 1 2 O ring 1 3 Washer 1 4 Spacer 1 5 Fork spring 1 6 Locknut 1 7 Dust seal 1 8 Oil seal clip 1 9 Outer tube 1 10 Oil seal 1 11 Washer 1 12 Outer tube bushing 1 13 Inner tube bushing 1 LT LS LS 9 12 1 2 6 3 4 5 11 10 8 7 New New New New New New New New 13 23 N m 2 3 kgf m 17 lb ft T R 15 N m 1 5 kgf m 11 lb ft T R 23 N m 2 3 kgf m 17 lb ft T R ...

Page 189: ...marks 14 Wheel axle pinch bolt 1 Right side only 15 Damper rod assembly bolt 1 16 Copper washer 1 17 Damper rod assembly 1 18 Inner tube 1 LT LS LS 15 17 16 New New New New New New 18 New New 14 23 N m 2 3 kgf m 17 lb ft T R 15 N m 1 5 kgf m 11 lb ft T R 23 N m 2 3 kgf m 17 lb ft T R ...

Page 190: ...racket pinch bolt 1 Cap bolt 2 Lower bracket pinch bolt 3 WARNING EWA13640 Before loosening the upper and lower brack et pinch bolts support the front fork leg 4 Remove Front fork leg EAS30207 DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Remove Cap bolt 1 from the damper rod assembly Washer 2 Spacer 3 Locknut 4 a Press down on the spacer with t...

Page 191: ...st be replaced 5 Remove Damper rod assembly bolt Damper rod assembly TIP While holding the damper rod with the damper rod holder 1 loosen the damper rod assembly bolt EAS30208 CHECKING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Check Inner tube Outer tube Bends damage scratches Replace WARNING EWA13650 Do not attempt to straighten a bent inner tube as this...

Page 192: ...h the specified amount of the fork oil If both front fork legs are not filled with the specified amount of the fork oil it may cause poor handling and a loss of stability TIP When assembling the front fork leg be sure to replace the following parts Inner tube bushing Outer tube bushing Oil seal Oil seal clip Dust seal Copper washer O ring Before assembling the front fork leg make sure all of the c...

Page 193: ...f the front fork leg with a plastic bag to protect the oil seal during installation 5 Install Outer tube to the inner tube 6 Install Outer tube bushing 1 Washer 2 with the fork seal driver 3 7 Install Oil seal 1 with the fork seal driver 2 8 Install Oil seal clip 1 TIP Adjust the oil seal clip so that it fits into the outer tube s groove Recommended oil Yamaha Suspension Oil 01 New New New New New...

Page 194: ...e damper rod slowly be cause the fork oil may spurt out 13 Before measuring the fork oil level wait ten minutes until the oil has settled and the air bubbles have dispersed TIP Be sure to bleed the front fork leg of any residual air 14 Measure Front fork leg oil level a from the top of the outer tube with the outer tube fully compressed and without the fork spring Out of specification Correct Fork...

Page 195: ...on the spacer with the fork spring compressor 1 h Pull up the rod puller and install the rod holder 2 between the locknut 3 and the washer 4 TIP Use the side of the rod holder that is marked B i Remove the rod puller and rod puller at tachment j Position the locknut 3 as distance b Level left 107 mm 4 2 in Level right 107 mm 4 2 in a G088930 New G088931 Rod puller 90890 01437 Universal damping rod...

Page 196: ... FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Install Front fork leg Temporarily tighten the upper and lower bracket pinch bolts WARNING EWA13680 Make sure the brake hoses are routed prop erly TIP When installing the front fork set the outer tube with the specified length a from the top of the outer tube to the top of the lower bracket 2 Tighten Lower bracket pi...

Page 197: ...P Make sure the brake hoses clutch cable and handlebar switch leads are routed properly Refer to CABLE ROUTING on page 2 13 4 Adjust Spring preload Rebound damping Compression damping Refer to ADJUSTING THE FRONT FORK LEGS on page 3 21 2 3 1 ...

Page 198: ...r to HANDLEBAR on page 4 60 Front fork legs Refer to FRONT FORK on page 4 66 1 Front brake hose bracket 1 2 Headlight bracket 1 3 Horn bracket 1 4 Lower bracket cap 1 5 Cap 1 6 Steering stem nut 1 7 Upper bracket 1 8 Lock washer 1 9 Upper ring nut 1 10 Rubber washer 1 11 Lower ring nut 1 6 FWD 7 6 5 1 2 3 8 9 10 11 4 FWD 6 LS LS LS LT 110 N m 11 kgf m 81 lb ft T R 15 N m 1 5 kgf m 11 lb ft T R 1st...

Page 199: ...ecification Order Job Parts to remove Q ty Remarks 12 Lower bracket 1 13 Bearing cover 1 14 Upper bearing 1 15 Lower bearing dust seal 1 16 Lower bearing 1 FWD 12 15 16 14 13 FWD LS LS LS LT 110 N m 11 kgf m 81 lb ft T R T R 1st 2nd 52 N m 5 2 kgf m 38 lb ft 14 N m 1 4 kgf m 10 lb ft 15 N m 1 5 kgf m 11 lb ft ...

Page 200: ...mage pitting Replace the bearings and bearing races as a set 3 Replace Bearing Bearing race a Remove the bearing races from the steer ing 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 cou...

Page 201: ...nut TIP Temporarily tighten the steering stem nut 4 Install Front fork leg Refer to FRONT FORK on page 4 66 TIP Temporarily tighten the upper and lower bracket pinch bolts 5 Tighten Steering stem nut 6 Tighten Lower bracket pinch bolt Upper bracket pinch bolt Recommended lubricant Lithium soap based grease Steering stem nut 110 N m 11 kgf m 81 lb ft Lower bracket pinch bolt 23 N m 2 3 kgf m 17 lb ...

Page 202: ...ck absorber assembly 1 5 Relay arm nut Bolt 1 1 6 Connecting arm upper nut Bolt 1 1 7 Relay arm 2 8 Connecting arm lower nut Bolt 1 1 9 Connecting arm 1 10 Collar Oil seal Bearing 1 2 1 11 Collar Oil seal Bearing 1 2 1 12 Collar Oil seal Bearing 1 2 1 13 Collar Oil seal Bearing 1 2 1 14 Collar 1 8 8 6 5 5 6 2 2 3 3 10 10 4 7 7 13 9 13 11 12 New 11 14 1 LS LS New New New New New New LS LS LS 44 N m...

Page 203: ...ressure drill a 2 3 mm 0 08 0 12 in hole through the rear shock absorber 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 ove...

Page 204: ...er bolt Rear shock absorber assembly lower nut TIP Install the rear shock absorber assembly upper bolt and rear shock absorber assembly lower bolt from the left When installing the rear shock absorber as sembly lift up the swingarm 2 Tighten Rear shock absorber assembly upper nut Rear shock absorber assembly lower nut Recommended lubricant Lithium soap based grease Installed depth a 4 mm 0 16 in I...

Page 205: ... 40 Rear wheel Refer to REAR WHEEL on page 4 19 Relay arm nut Bolt Refer to REAR SHOCK ABSORBER ASSEMBLY on page 4 81 1 Pivot shaft nut 1 2 Washer 1 3 Pivot shaft 1 4 Swingarm 1 5 Rear fender 1 6 Drive chain guide 1 1 2 3 4 5 6 7 N m 0 7 kgf m 5 2 lb ft T R 7 N m 0 7 kgf m 5 2 lb ft T R 115 N m 11 5 kgf m 85 lb ft T R LS LS LS LS LS New New ...

Page 206: ... remove Q ty Remarks 7 Cable holder 1 8 Dust cover 2 9 Collar 1 10 Bearing 2 11 Collar 1 12 Oil seal 2 13 Bearing 1 7 8 9 10 10 11 12 12 13 8 7 N m 0 7 kgf m 5 2 lb ft T R 7 N m 0 7 kgf m 5 2 lb ft T R 115 N m 11 5 kgf m 85 lb ft T R LS LS LS LS LS New New ...

Page 207: ...he swingarm vertical movement B by moving the swingarm up and down If the swingarm vertical movement is not smooth or if there is binding check the pivot shaft collar 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 straig...

Page 208: ...allow grease to contact the pivot shaft nut threads 5 Install Rear wheel Refer to REAR WHEEL on page 4 19 6 Adjust Drive chain slack Refer to DRIVE CHAIN SLACK on page 3 18 Recommended lubricant Lithium soap based grease Installed depth a 0 1 0 mm 0 0 039 in Installed depth b 4 mm 0 157 in Installed depth c 0 2 1 0 mm 0 008 0 039 in A Left side B Right side New New 1 1 2 1 N 2 A B a a b c c A B Ne...

Page 209: ... joint 2 7 Shift pedal 1 8 Drive sprocket cover 1 9 Drive chain guide 1 10 Drive chain 1 11 Drive sprocket nut 1 12 Washer 1 13 Drive sprocket 1 LT LT LT LT LT LS LS New 11 12 10 13 5 6 7 8 9 1 2 2 2 4 3 6 28 N m 2 8 kgf m 21 lb ft T R 10 N m 1 0 kgf m 7 4 lb ft T R 7 N m 0 7 kgf m 5 2 lb ft T R 7 N m 0 7 kgf m 5 2 lb ft T R 8 N m 0 8 kgf m 5 9 lb ft T R 160 N m 16 kgf m 118 lb ft T R 14 N m 1 4 k...

Page 210: ...ce the drive chain a Measure the length a between the inner sides of the pins and the length b between the outer sides of the pins on a 15 link sec tion of the drive chain as shown in the illus tration b Calculate the 15 link section length c of the 15 link section of the drive chain using the following formula Drive chain 15 link section length c length a between pin inner sides length b between ...

Page 211: ... to clean the drive chain Do not soak the drive chain in kerosene for more than ten minutes otherwise the O rings can be damaged 4 Check O ring 1 Damage Replace the drive chain Drive chain roller 2 Damage wear Replace the drive chain Drive chain side plate 3 Damage wear cracks Replace the drive chain 5 Lubricate Drive chain EAS30231 CHECKING THE DRIVE SPROCKET 1 Check Drive sprocket More than 1 4 ...

Page 212: ...ecting pin 2 is 5 7 6 0 mm 0 22 0 24 in c After riveting make sure the space c which is inside of the connecting link 3 and inside of the connecting plate 1 is 14 35 14 55 mm 0 565 0 573 in 2 Lubricate Drive chain 3 Install Drive sprocket Washer 1 Drive sprocket nut 2 TIP Thoroughly clean all the drive sprocket nut seat and threads of drive axle While applying the rear brake tighten the drive spro...

Page 213: ...THE SHIFT PEDAL on page 4 93 7 Adjust Drive chain slack Refer to DRIVE CHAIN SLACK on page 3 18 NOTICE ECA13550 A drive chain that is too tight will overload the engine and other vital parts and one that is too loose can skip and damage the swing arm or cause an accident Therefore keep the drive chain slack within the specified lim its Shift arm bolt 14 N m 1 4 kgf m 10 lb ft Shift rod joint bolt ...

Page 214: ...ength a Loosen both locknuts 1 b Turn the shift rod 2 until the specified in stalled shift rod length is obtained c Tighten both locknuts TIP Be sure to place the shift rod joints in parallel The allowable twist of the shift rod joints is 5 d Make sure the installed shift rod length is within specification Installed shift rod length 236 0 238 0 mm 9 29 9 37 in Shift rod locknut 7 N m 0 7 kgf m 5 2...

Page 215: ... 5 27 REMOVING THE CYLINDER HEAD 5 28 CHECKING THE TIMING CHAIN GUIDE EXHAUST SIDE 5 28 CHECKING THE CYLINDER HEAD 5 28 INSTALLING THE CYLINDER HEAD 5 29 VALVES AND VALVE SPRINGS 5 30 REMOVING THE VALVES 5 32 CHECKING THE VALVES AND VALVE GUIDES 5 32 CHECKING THE VALVE SEATS 5 34 CHECKING THE VALVE SPRINGS 5 35 CHECKING THE VALVE LIFTERS 5 35 INSTALLING THE VALVES 5 35 GENERATOR AND STARTER CLUTCH...

Page 216: ...P 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 OIL PRESSURE SWITCH 5...

Page 217: ...FT 5 82 CHECKING THE BALANCER SHAFT 5 84 INSTALLING THE CRANKSHAFT 5 86 INSTALLING THE BALANCER ASSEMBLY 5 86 TRANSMISSION 5 87 REMOVING THE TRANSMISSION 5 92 CHECKING THE SHIFT FORKS 5 92 CHECKING THE SHIFT DRUM ASSEMBLY 5 93 CHECKING THE TRANSMISSION 5 93 ASSEMBLING THE MAIN AXLE AND DRIVE AXLE 5 94 INSTALLING THE TRANSMISSION 5 95 ...

Page 218: ...CHART 16 15 13 12 12 12 11 7 6 5 8 9 10 8 8 4 1 2 3 14 1 Oil strainer 2 Oil pump 3 Relief valve 4 Oil cooler 5 Oil filter cartridge 6 Main gallery 7 Oil pressure switch 8 Mission shower 9 Main axle 10 Drive axle 11 Crankshaft 12 Oil nozzle 13 Balancer shaft 14 Timing chain tensioner 15 Intake camshaft 16 Exhaust camshaft ...

Page 219: ...5 2 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS32363 LUBRICATION DIAGRAMS 1 2 3 5 4 1 Oil filter cartridge union bolt 2 Oil filter cartridge 3 Oil delivery pipe 4 Drive axle 5 Main axle ...

Page 220: ...HART AND DIAGRAMS 10 7 4 5 6 7 9 8 2 1 3 1 Timing chain tensioner 2 Intake camshaft 3 Exhaust camshaft 4 Balancer shaft 5 Crankshaft 6 Oil cooler 7 Oil strainer 8 Oil drain bolt 9 Oil pump driven sprocket 10 Oil delivery pipe ...

Page 221: ...5 4 LUBRICATION SYSTEM CHART AND DIAGRAMS 4 5 2 3 1 1 Oil cooler 2 Oil filter cartridge 3 Oil pressure switch 4 Oil strainer 5 Oil pump ...

Page 222: ...5 5 LUBRICATION SYSTEM CHART AND DIAGRAMS 2 3 1 4 5 6 1 Balancer shaft 2 Crankshaft 3 Oil delivery pipe 4 Main axle 5 Drive axle 6 Oil gallery bolt ...

Page 223: ...RT AND DIAGRAMS 1 2 3 4 5 6 7 8 1 Cylinder head 2 Intake camshaft 3 Exhaust camshaft 4 Oil passage to the cylinder head 5 Oil passage to the clutch chamber 6 Oil return passage from the cylinder head 7 Crankshaft 8 Main gallery ...

Page 224: ... 16 NOTICE ECA13340 Before removing the spark plugs use com pressed air to blow away any dirt accumulat ed in the spark plug wells to prevent it from falling into the cylinders 4 Install Compression gauge 1 Extension 2 5 Measure Compression pressure Out of specification Refer to steps c and d a Set the main switch to ON b With the throttle wide open crank the en gine until the reading on the compr...

Page 225: ...k plug 7 Install Ignition coil Refer to CAMSHAFTS on page 5 16 Air filter case Refer to GENERAL CHASSIS 5 on page 4 11 Fuel tank Refer to FUEL TANK on page 7 1 Fuel tank cover Refer to GENERAL CHASSIS 4 on page 4 10 Side cover Refer to GENERAL CHASSIS 1 on page 4 1 Rider seat Refer to GENERAL CHASSIS 1 on page 4 1 Compression pressure with oil applied into the cylinder Reading Diagnosis Higher tha...

Page 226: ...o remove Q ty Remarks Radiator bracket Refer to RADIATOR on page 6 3 1 O2 sensor coupler 1 Disconnect 2 Muffler assembly 1 3 Exhaust gasket 3 4 O2 sensor 1 Remove the O2 sensor only when neces sary 3 1 4 2 6 New 20 N m 2 0 kgf m 15 lb ft 20 N m 2 0 kgf m 15 lb ft 20 N m 2 0 kgf m 15 lb ft 25 N m 2 5 kgf m 18 lb ft ...

Page 227: ...l tank cover Refer to GENERAL CHASSIS 4 on page 4 10 Fuel tank Refer to FUEL TANK on page 7 1 Air filter case Refer to GENERAL CHASSIS 5 on page 4 11 Canister Refer to FUEL TANK on page 7 1 Throttle bodies Refer to THROTTLE BODIES on page 7 6 Front side panel Refer to GENERAL CHASSIS 3 on page 4 8 Radiator Refer to RADIATOR on page 6 3 7 N m 0 7 kgf m 5 2 lb ft T R 7 N m 0 7 kgf m 5 2 lb ft T R ...

Page 228: ...or lead 1 Disconnect 3 Purge cut valve solenoid coupler 1 Disconnect 4 Ignition coil coupler 3 Disconnect 5 Coolant temperature sensor coupler 1 Disconnect 6 Neutral switch coupler 1 Disconnect 7 Gear position sensor coupler 1 Disconnect 8 Crankshaft position sensor coupler 1 Disconnect 9 Stator coil coupler 1 Disconnect 10 Oil pressure switch connector 1 Disconnect 7 N m 0 7 kgf m 5 2 lb ft T R 7...

Page 229: ...ine mounting bolt left front lower side 1 9 Engine mounting nut lower 1 10 Muffler bracket bolt 1 11 Muffler bracket 1 12 Sidestand switch coupler 1 Disconnect 13 Muffler bracket bolt 1 14 Muffler bracket 1 15 Pivot shaft nut 1 Loosen 1 2 3 9 10 5 6 7 11 4 1 8 15 13 12 14 2 LT LT LT LT LT LS 25 N m 2 5 kgf m 18 lb ft 25 N m 2 5 kgf m 18 lb ft 45 N m 4 5 kgf m 33 lb ft 60 N m 6 0 kgf m 44 lb ft 60 ...

Page 230: ...ing bolt rear upper side 1 19 Engine 1 20 Engine mounting adjust bolt 2 LT LT LT LT LT 20 20 19 16 18 17 25 N m 2 5 kgf m 18 lb ft 25 N m 2 5 kgf m 18 lb ft 45 N m 4 5 kgf m 33 lb ft 60 N m 6 0 kgf m 44 lb ft 60 N m 6 0 kgf m 44 lb ft 45 N m 4 5 kgf m 33 lb ft 55 N m 5 5 kgf m 41 lb ft 7 N m 0 7 kgf m 5 2 lb ft 55 N m 5 5 kgf m 41 lb ft LS 115 N m 11 5 kgf m 85 lb ft ...

Page 231: ...ngine mounting bolt right front lower side 10 temporarily tighten 7 Tighten Engine mounting adjust bolt lower 1 TIP Tighten the engine mounting adjust bolt to specification with the pivot shaft wrench and pivot shaft wrench adapter Make sure that the flange on the engine mounting adjust bolt contacts the engine 8 Install Muffler bracket 11 Muffler bracket bolt 12 temporarily tighten 9 Tighten Engi...

Page 232: ... upper side 21 temporarily tighten 16 Tighten Engine bracket bolt left 17 Engine mounting bolt left front upper side 18 Engine bracket bolt right 20 Engine mounting bolt right front upper side 21 Engine mounting bolt left front lower side 60 N m 6 0 kgf m 44 lb ft Engine mounting bolt right front lower side 60 N m 6 0 kgf m 44 lb ft Pivot shaft nut 115 N m 11 5 kgf m 85 lb ft Engine mounting adjus...

Page 233: ...over Refer to GENERAL CHASSIS 1 on page 4 1 Fuel tank cover Refer to GENERAL CHASSIS 4 on page 4 10 Fuel tank Refer to FUEL TANK on page 7 1 Air filter case Refer to GENERAL CHASSIS 5 on page 4 11 Front side panel Refer to GENERAL CHASSIS 3 on page 4 8 Radiator Refer to RADIATOR on page 6 3 13 N m 1 3 kgf m 9 6 lb ft T R 10 N m 1 0 kgf m 7 4 lb ft T R 10 N m 1 0 kgf m 7 4 lb ft T R ...

Page 234: ...move Q ty Remarks 1 Ignition coil coupler 3 Disconnect 2 Ignition coil 3 3 Spark plug 3 4 Cylinder head cover 1 5 Cylinder head cover gasket 1 6 Timing chain guide top side 1 1 2 2 2 3 3 3 4 6 5 New 13 N m 1 3 kgf m 9 6 lb ft T R 10 N m 1 0 kgf m 7 4 lb ft T R 10 N m 1 0 kgf m 7 4 lb ft T R ...

Page 235: ...er gasket 1 4 Timing chain tensioner 1 5 Timing chain tensioner gasket 1 6 Intake camshaft cap 1 7 Exhaust camshaft cap 1 8 Camshaft cap 1 9 Dowel pin 6 10 Intake camshaft 1 11 Exhaust camshaft 1 E 1 2 3 4 7 7 8 8 4 4 9 9 9 9 11 10 New 5 New 10 N m 1 0 kgf m 7 4 lb ft T R 10 N m 1 0 kgf m 7 4 lb ft T R 12 N m 1 2 kgf m 8 9 lb ft T R 10 N m 1 0 kgf m 7 4 lb ft T R 10 N m 1 0 kgf m 7 4 lb ft T R 24 ...

Page 236: ...t sprocket 1 14 Timing chain bolt 1 15 Dowel pin 1 16 Timing chain guide intake side 1 17 Timing chain 1 E 14 7 8 4 4 15 16 17 New New 10 N m 1 0 kgf m 7 4 lb ft T R 10 N m 1 0 kgf m 7 4 lb ft T R 12 N m 1 2 kgf m 8 9 lb ft T R 10 N m 1 0 kgf m 7 4 lb ft T R 10 N m 1 0 kgf m 7 4 lb ft T R M 13 12 24 N m 2 4 kgf m 18 lb ft T R ...

Page 237: ...s are turned away from each other 3 Remove Timing chain tensioner 1 Timing chain tensioner gasket 4 Remove Camshaft cap Intake camshaft cap Exhaust camshaft cap 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...

Page 238: ...el pins and camshaft caps Refer to INSTALLING THE CAMSHAFTS on page 5 23 TIP Do not turn the camshaft when measuring the camshaft journal to camshaft cap clearance with the Plastigauge d Remove the camshaft caps and then mea sure the width of the Plastigauge 1 5 Measure Camshaft journal diameter a Out of specification Replace the camshaft Within specification Replace the cylinder head and the cams...

Page 239: ...acks damage rough movement Re place a Using the valve spring compressor 1 push and insert timing chain tensioner rod 2 into the timing chain tensioner housing TIP Push the timing chain tensioner rod in direction a and turn the timing chain tensioner body 3 in direction b until the circlip fits into the groove b Lock the timing chain tensioner rod by set ting the circlip 4 to groove 5 while push in...

Page 240: ...ounterclockwise b When piston 1 is at BTDC125 align the mark a on the generator rotor with the generator rotor cover mark b 3 Install Intake camshaft sprocket 1 Exhaust camshaft sprocket 2 TIP Install the camshaft projection a at the posi tion shown in the illustration Tighten the camshaft sprocket bolt with the camshaft wrench 3 4 Install Exhaust camshaft 1 Intake camshaft 2 TIP Make sure the pun...

Page 241: ...caps and camshafts will result Do not turn the crankshaft when installing the camshaft to avoid damage or improper valve timing 7 Tighten Camshaft cap bolt 1 TIP Tighten the camshaft cap bolts in stage and in a crisscross pattern working from the inner caps out NOTICE ECA17430 Lubricate the camshaft cap bolts with the engine oil The camshaft cap bolts must be tightened evenly or damage to the cyli...

Page 242: ...imes to release the timing chain tensioner rod 10 Turn Crankshaft several turns counterclockwise 11 Confirm the timing chain tension properly 12 Check Mark a Make sure the mark a on the generator rotor is aligned with the generator rotor cover mark b Camshaft punch mark c Make sure the camshaft punch mark c on the camshaft is aligned with the camshaft cap alignment mark d Out of alignment Adjust R...

Page 243: ...er head cover and cyl inder head cover gasket After installing the cylinder head cover gasket 1 to the cylinder head cover cut off the a section 16 Install Spark plug Ignition coil 1 TIP Install the ignition coils 1 in the direction shown in the illustration Cylinder head cover bolt 10 N m 1 0 kgf m 7 4 lb ft 1 2 New T R 1 a New Spark plug 13 N m 1 3 kgf m 9 6 lb ft T R 1 ...

Page 244: ...Intake camshaft Refer to CAMSHAFTS on page 5 16 Exhaust camshaft Refer to CAMSHAFTS on page 5 16 Timing chain Refer to CAMSHAFTS on page 5 16 1 Coolant temperature sensor 1 2 Cylinder head 1 3 Cylinder head gasket 1 4 Dowel pin 2 5 Timing chain guide exhaust side 1 1 2 3 4 5 8 E 4 New New 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft 1st 3rd 2nd 15 N m 1 5 kgf m 11 lb ft Specified angle 12...

Page 245: ...t use a sharp instrument to avoid damag ing or scratching Spark plug bore threads Valve seats 2 Check Cylinder head Damage scratches Replace Cylinder head water jacket Mineral deposits rust Eliminate 3 Measure Cylinder head warpage Out of specification Resurface the cylinder head a Place a straightedge 1 and a thickness gauge 2 across the cylinder head b Measure the warpage c If the limit is excee...

Page 246: ...inder head bolt 9 12 Following the tightening order loosen the bolt one by one and then retighten it to the specified torque and the specified angle TIP Tighten the cylinder head bolts 1 8 in the tightening sequence as shown and torque them in 3 stages 4 Install Exhaust camshaft Intake camshaft Refer to INSTALLING THE CAMSHAFTS on page 5 23 Cylinder head bolt 1 8 1st 20 N m 2 0 kgf m 15 lb ft 2nd ...

Page 247: ...lve lifter 6 2 Intake valve pad 6 3 Intake valve cotter 12 4 Intake valve spring retainer 6 5 Intake valve spring 6 6 Intake valve 6 7 Intake valve stem seal 6 8 Intake valve spring seat 6 9 Intake valve guide 6 10 Exhaust valve lifter 6 11 Exhaust valve pad 6 12 Exhaust valve cotter 12 13 Exhaust valve spring retainer 6 14 Exhaust valve spring 6 New M M E M M E 14 13 12 11 10 6 9 M 8 7 5 4 3 1 2 ...

Page 248: ... SPRINGS Removing the valves and valve springs Order Job Parts to remove Q ty Remarks 15 Exhaust valve 6 16 Exhaust valve stem seal 6 17 Exhaust valve spring seat 6 18 Exhaust valve guide 6 New 15 16 17 M M E M M E 18 M New ...

Page 249: ...P Remove the valve cotters by compressing the valve spring with the valve spring compressor 1 and the valve spring compressor attachment 2 4 Remove Valve spring retainer Valve spring Valve Valve stem seal Valve spring seat TIP Identify the position of each part very carefully so that it can be reinstalled in its original place EAS30284 CHECKING THE VALVES AND VALVE GUIDES The following procedure a...

Page 250: ...lve stem to valve guide clearance TIP After replacing the valve guide reface the valve seat 3 Eliminate Carbon deposits from the valve face and valve seat 4 Check Valve face Pitting wear Grind the valve face Valve stem end Mushroom shape or diameter larger than the body of the valve stem Replace the valve Valve guide position 13 3 13 7 mm 0 52 0 54 in G088960 G088961 G088962 a Valve guide position...

Page 251: ...head c Press the valve through the valve guide and onto the valve seat to make a clear impres sion d Measure the valve seat contact width TIP Where the valve seat and valve face contacted one another the blue layout fluid will have been removed 4 Lap Valve face Valve seat TIP After replacing the cylinder head or replacing the valve and valve guide the valve seat and valve face should be lapped a A...

Page 252: ... the valve seat to make a clear impres sion j Measure the valve seat contact width c again If the valve seat width is out of spec ification reface and lap the valve seat EAS30286 CHECKING THE VALVE SPRINGS The following procedure applies to all of the valve springs 1 Measure Valve spring free length a Out of specification Replace the valve spring EAS30287 CHECKING THE VALVE LIFTERS The following p...

Page 253: ...stem lightly tap the valve tip with a soft face hammer NOTICE ECA13800 Hitting the valve tip with excessive force could damage the valve 6 Lubricate Valve pad with the recommended lubricant Valve lifter with the recommended lubricant 7 Install Valve pad Valve lifter TIP The valve lifter must move smoothly when ro tated with a finger Each valve lifter and valve pad must be rein stalled in its origi...

Page 254: ... FUEL TANK on page 7 1 Water pump Refer to WATER PUMP on page 6 11 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 25 1 Stator coil coupler 1 Disconnect 2 Crankshaft position sensor coupler 1 Disconnect 3 Holder fuel tank overflow hose 3 4 Bracket 1 5 Generator cover 1 6 Generator cover gasket 1 1 2 3 3 6 6 4 3 5 New New New New New LT LT LT LT E E E LT E E 10 N m 1 0 kgf m 7 4 lb ft T...

Page 255: ...rter clutch 1 12 Starter clutch gear 1 13 Woodruff key 1 14 Starter clutch idle gear shaft 1 15 Starter clutch idle gear 1 16 Crankshaft end cover 1 17 Timing mark accessing bolt 1 18 Water pump outlet pipe 1 New 3 3 6 18 11 12 8 9 17 16 7 7 13 15 14 10 New New New New LT LT LT LT E E E LT E E 10 N m 1 0 kgf m 7 4 lb ft T R 10 N m 1 0 kgf m 7 4 lb ft T R 11 N m 1 1 kgf m 8 1 lb ft T R 12 N m 1 2 k...

Page 256: ...he flywheel puller is centered over the generator rotor EAS30868 REMOVING THE STARTER CLUTCH 1 Remove Starter clutch bolt Starter clutch TIP While holding the generator rotor 1 with the sheave holder 2 loosen the starter clutch bolts EAS30869 CHECKING THE STARTER CLUTCH 1 Check Starter clutch roller Damage wear Replace 2 Check Starter clutch idle gear Starter clutch gear Burrs chips roughness wear...

Page 257: ...holding the generator rotor with the sheave holder 3 tighten the starter clutch bolts EAS30872 INSTALLING THE GENERATOR 1 Install Woodruff key Generator rotor Washer Generator rotor bolt TIP Clean the tapered portion of the crankshaft and the generator rotor hub When installing the generator rotor make sure the woodruff key is properly seated in the key way of the crankshaft Lubricate the washer w...

Page 258: ...ver bolts in stages and in a crisscross pattern 5 Connect Stator coil coupler Crankshaft position sensor coupler TIP To route the stator coil lead refer to CABLE ROUTING on page 2 13 Yamaha bond No 1215 90890 85505 Three bond No 1215 Generator cover bolt 1 12 N m 1 2 kgf m 8 9 lb ft LOCTITE Generator cover bolt 2 12 N m 1 2 kgf m 8 9 lb ft 1 2 3 G088980 New T R 1 2 2 2 ...

Page 259: ...b Parts to remove Q ty Remarks Purge cut valve solenoid Refer to FUEL TANK on page 7 1 Throttle bodies Refer to THROTTLE BODIES on page 7 6 1 Starter motor lead 1 Disconnect 2 Starter motor 1 3 Canister holder 1 1 3 2 LS New 7 N m 0 7 kgf m 5 2 lb ft T R 12 N m 1 2 kgf m 8 9 lb ft T R ...

Page 260: ... Parts to remove Q ty Remarks 1 O ring 1 2 Starter motor front cover 1 3 Starter motor yoke 1 4 Armature assembly 1 5 Gasket 2 6 Brush holder set 1 7 Starter motor rear cover 1 1 2 5 4 6 3 7 5 11 N m 1 1 kgf m 8 1 lb ft 5 N m 0 5 kgf m 3 7 lb ft New New New New New ...

Page 261: ...t tester and check the continuity b If there is no continuity replace the starter motor 4 Measure Brush length a Out of specification Replace the brush holder set 5 Check Gear teeth Damage wear Replace the starter motor assembly 6 Check Bearing Oil seal Damage wear Replace the starter motor assembly EAS30326 ASSEMBLING THE STARTER MOTOR 1 Install Brush holder set Insulator 1 TIP Install the insula...

Page 262: ...th the match marks b on the front and rear cover EAS30327 INSTALLING THE STARTER MOTOR 1 Install Canister holder Starter motor Starter motor bolt TIP Tighten the starter motor bolts in the tightening sequence as shown 2 Connect Starter motor lead Starter motor bolt 12 N m 1 2 kgf m 8 9 lb ft Starter motor lead nut 7 N m 0 7 kgf m 5 2 lb ft 1 2 3 a b b T R 1 2 T R ...

Page 263: ...ING THE ENGINE OIL on page 3 25 1 Clutch cable 1 Disconnect 2 Cover 1 3 Clutch cover 1 4 Clutch cover gasket 1 5 Dowel pin 2 6 Oil filler cap 1 2 6 8 3 4 5 5 1 LS New New 12 N m 1 2 kgf m 8 9 lb ft T R 12 N m 1 2 kgf m 8 9 lb ft T R 12 N m 1 2 kgf m 8 9 lb ft T R 7 N m 0 7 kgf m 5 2 lb ft T R 1 5 N m 0 15 kgf m 1 1 lb ft T R ...

Page 264: ...oving the pull lever shaft Order Job Parts to remove Q ty Remarks 1 Circlip 1 2 Pull lever 1 3 Pull lever spring 1 4 Circlip 1 5 Pull lever shaft 1 6 Oil seal 1 7 Bearing 1 8 Bearing 1 5 1 2 3 6 7 8 4 E LS New New New ...

Page 265: ...ion plate 2 3 Inside diameter 126 mm 4 96 in 7 Clutch plate 1 1 Inside diameter 116 mm 4 57 in 8 Clutch plate 2 7 Inside diameter 105 mm 4 13 in 9 Friction plate 1 6 Inside diameter 119 mm 4 69 in 10 Clutch damper spring 1 11 Clutch damper spring seat 1 12 Clutch boss nut 1 13 Conical spring washer 1 14 Washer 1 1 2 3 6 6 9 7 8 E 4 5 10 11 12 13 14 E E 10 11 E New 10 N m 1 0 kgf m 7 4 lb ft 125 N ...

Page 266: ...remove Q ty Remarks 15 Clutch boss 1 16 Thrust plate 1 17 Clutch housing 1 18 Oil pump drive chain 1 19 Bearing 1 20 Spacer 1 21 Thrust plate 1 22 Thrust plate 1 E 16 17 18 19 20 21 22 E E 15 New E 125 N m 12 5 kgf m 92 lb ft 10 N m 1 0 kgf m 7 4 lb ft ...

Page 267: ...5 58 3 Remove Clutch spring bolt 1 Pressure plate 1 2 Clutch spring Pressure plate 2 3 Pull rod 4 4 Remove Friction plate 2 1 5 Remove Clutch plate 1 1 Clutch plate 2 Friction plate 1 Clutch damper spring Clutch damper spring seat 6 Straighten the clutch boss nut rib a 7 Loosen Clutch boss nut 1 TIP While holding the clutch boss 2 with the univer sal clutch holder 3 loosen the clutch boss nut 1 2 ...

Page 268: ...ate 1 2 Damage Replace the clutch plates as a set 2 Measure Clutch plate 1 2 thickness with a surface plate and thickness gauge Out of specification Replace the clutch plates as a set 3 Measure Assembly width a of the friction plates and clutch plates Out of specification Adjust Friction plate 1 thickness 2 92 3 08 mm 0 115 0 121 in Wear limit 2 82 mm 0 111 in Friction plate 2 thickness 2 92 3 08 ...

Page 269: ... replace the clutch plate 2 2 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 Out of specification Replace the clutch springs as a set EAS30352 CHECKING THE CLUTCH HOUSING 1 Check Clutch housing dogs Damage pitting wear Deburr the clutch housing dog...

Page 270: ...t 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 gear Damage wear Replace the clutch housing and crankshaft as a set Excessive noise during operation Replace the clutch housing and crankshaft as a set EAS30358 CHECKING THE PULL LEVER SHAFT AND PULL ROD 1 Check Pull leve...

Page 271: ...ffset from the other friction plates 2 making sure to align a projection on the friction plate with the punch mark a on the clutch housing 4 Install Pull rod Pressure plate 2 Clutch spring Pressure plate 1 Clutch spring bolt 1 Oil pump driven sprocket 2 TIP Tighten the clutch spring bolts in stages and in a crisscross pattern Apply lithium soap based grease onto the pull rod Position the pull rod ...

Page 272: ...Make sure that the pull rod teeth and pull lever shaft pinion gear are engaged 7 Connect Clutch cable 1 TIP For the clutch cable 1 turn the nut 2 in fully and then adjust the length a by using the nut 3 so that the cable length is 47 1 54 8 mm 1 85 2 16 in Measure the length while keeping the measur ing surface b parallel After installing the clutch cable bend the pro jection c on the pull lever 8...

Page 273: ... page 5 46 Shift arm Refer to CHAIN DRIVE on page 4 88 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 11 8 3 12 1 2 13 10 9 7 6 4 5 E E New New New LT LT LT E E LS 22 N m 2 2 kgf m 16 lb ft T R ...

Page 274: ...tall Shift shaft spring stopper 1 Shift shaft assembly Stopper lever spring 2 TIP Hook the end of the shift shaft spring 3 onto the shift shaft spring stopper 1 Hook the ends of the stopper lever spring 2 onto the stopper lever 4 and the crankcase boss 5 Mesh the stopper lever with the shift drum seg ment assembly 2 Install Bearing Oil seal Washer 1 Circlip 2 TIP Lubricate the oil seal lips with l...

Page 275: ... pump Order Job Parts to remove Q ty Remarks Clutch cover Refer to CLUTCH on page 5 46 1 Oil pump driven sprocket 1 2 Oil pump assembly 1 2 1 L TL T LT LT LT 15 N m 1 5 kgf m 11 lb ft T R 10 N m 1 0 kgf m 7 4 lb ft T R 10 N m 1 0 kgf m 7 4 lb ft T R ...

Page 276: ...rder Job Parts to remove Q ty Remarks 1 Oil pump cover 1 2 Oil pump shaft 1 3 Pin 1 4 Oil pump inner rotor 1 5 Oil pump outer rotor 1 6 Washer 1 7 Spring 1 8 Relief valve 1 9 Dowel pin 2 2 5 4 9 8 7 6 9 3 1 E E 3 8 N m 0 38 kgf m 2 8 lb ft T R ...

Page 277: ...mp cover Oil pump shaft Oil pump inner rotor Oil pump outer rotor Cracks damage wear Replace the oil pump assembly 2 Check Oil pump operation Rough movement Replace the oil pump assembly 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 Oil pump shaft 2 Install Outer rot...

Page 278: ...TICE ECA20940 After installing the oil pump drive chain and driven sprocket make sure the oil pump turns smoothly TIP 1RC mark of the oil pump driven sprocket is in stalled at oil pump side Install the oil pump drive chain onto the oil pump driven sprocket Oil pump bolt 10 N m 1 0 kgf m 7 4 lb ft LOCTITE Oil pump driven sprocket bolt 15 N m 1 5 kgf m 11 lb ft LOCTITE T R T R 1 2 2 3 ...

Page 279: ...ly Refer to ENGINE REMOVAL on page 5 9 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 25 1 Oil pan 1 2 Oil pan gasket 1 3 Oil strainer 1 2 1 15 3 New New New LT LT LT LT 43 N m 4 3 kgf m 32 lb ft T R 13 N m 1 3 kgf m 9 6 lb ft T R 10 N m 1 0 kgf m 7 4 lb ft T R 10 N m 1 0 kgf m 7 4 lb ft T R ...

Page 280: ...d remove them 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 Oil pan bolt 13 N m 1 3 kgf m 9 6 lb ft LOCTITE Engine oil drain bolt 43 N m 4 3 kgf m 32 lb ft New T R New T ...

Page 281: ... CLUTCH on page 5 37 Starter motor 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 2 4 2 12 E E LS E LT LT LT New New LS New New E E E E LT LT L T LT LS New 1st 25 N m 2 5 kgf m 18 lb ft 16 N m 1 6 kgf m 12 lb ft 2nd Specified angle 60 T R 22 N m 2 2 kgf m 16 lb ft T R 1 8 N m 0 18 kgf m 1 3 lb ft T R 10 N m 1 0 kgf ...

Page 282: ...in 3 9 7 6 5 9 9 4 3 8 2 6 2 4 2 12 2 1 E E LS E LT LT LT New New LS New New New E E E E LT LT L T LT LS 1st 25 N m 2 5 kgf m 18 lb ft 16 N m 1 6 kgf m 12 lb ft 2nd Specified angle 60 T R 22 N m 2 2 kgf m 16 lb ft T R 1 8 N m 0 18 kgf m 1 3 lb ft T R 10 N m 1 0 kgf m 7 4 lb ft T R 13 N m 1 3 kgf m 9 6 lb ft T R 12 N m 1 2 kgf m 8 9 lb ft T R 17 N m 1 7 kgf m 13 lb ft T R 70 N m 7 0 kgf m 52 lb ft ...

Page 283: ...e lower crankcase TIP Identify the position of each part very carefully so that it can be reinstalled in its original place EAS30390 CHECKING THE CRANKCASE 1 Thoroughly wash the crankcase halves in a mild solvent 2 Thoroughly clean all the gasket surfaces and crankcase mating surfaces 3 Check Crankcase Cracks damage Replace Oil delivery passages Obstruction Blow out with compressed air EAS30397 AS...

Page 284: ...n bolt 18 M6 65 mm 2 56 in bolt 15 16 M6 65 mm 2 56 in bolt 26 M6 50 mm 1 97 in bolt 17 19 21 23 25 27 31 M6 40 mm 1 57 in bolt 22 7 Tighten Crankcase bolt 1 8 Following the tightening order loosen the bolt one by one and then retighten it to the specified torque and the specified angle WARNING EWA16610 If the bolt is tightened more than the speci fied angle do not loosen the bolt and then re tigh...

Page 285: ... Bond No 1215B 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 Crankcase bolts 9 12 22 N m 2 2 kgf m 16 lb ft Crankcase bolts 13 14 24 N m 2 4 kgf m 18 lb ft Crankcase bolts 15 31 10 N m 1 0 kgf m 7 4 lb ft 8 1 2 3 4 5 6 7 8 T R 23 9 10 12 11 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 Oi...

Page 286: ...pickup tool with a magnet magnetized screwdrivers etc away from the gear position sensor 1 Install O ring Gear position sensor 1 TIP Lubricate the O ring with lithium soap based grease Fit the end a of the shift drum assembly into the opening b in the gear position sensor 1 Gear position sensor bolt 4 0 N m 0 40 kgf m 3 0 lb ft LOCTITE New T R a b 1 ...

Page 287: ... ty Remarks Lower crankcase Refer to CRANKCASE on page 5 64 1 Connecting rod cap 3 2 Big end lower bearing 3 3 Piston pin clip 6 4 Piston pin 3 5 Piston 3 6 Connecting rod 3 7 Big end upper bearing 3 8 Top ring 3 9 2nd ring 3 10 Oil ring 3 E 1 2 3 4 6 7 8 9 10 M M E E 3 E 5 New New New 1st 2nd 20 N m 2 0 kgf m 15 lb ft Specified angle 180 ...

Page 288: ...ton pin deburr the pis ton pin clip groove and the piston pin bore ar ea If both areas are deburred and the piston pin is still difficult to remove remove it with the piston pin puller set 3 3 Remove Top ring 2nd ring Oil ring TIP When removing a piston ring open the end gap with your fingers and lift the other side of the ring over the piston crown EAS30747 CHECKING THE CYLINDER AND PISTON 1 Chec...

Page 289: ... grooves and piston rings 2 Install Piston ring into the cylinder TIP Use the piston crown to level the piston ring near bottom of cylinder where cylinder wear is low est 3 Measure Piston ring end gap Out of specification Replace the piston ring TIP The oil ring expander spacer s end gap cannot be measured If the oil ring rail s gap is exces sive replace all three piston rings Piston Diameter 77 9...

Page 290: ...nd bearings must be installed in their origi nal positions a Clean the big end bearings crankshaft pins and the inside of the connecting rods halves b Install the big end upper bearing into the connecting rod and the big end lower bear ing into the connecting rod cap with the connecting rod big end metal installer 1 TIP From the 3 types choose the connecting rod big end metal installer 1 that fits...

Page 291: ...rod and connecting rod cap without installing them onto the crankshaft TIP Install by carrying out the following procedures in order to assemble in the most suitable condition e Tighten the connecting rod bolt while checking that the sections shown 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...

Page 292: ...ecified angle 180 WARNING EWA16610 If the bolt is tightened more than the speci fied angle do not loosen the bolt and then re tighten it Instead replace the bolt with a new one and perform the procedure again NOTICE ECA20890 Do not use a torque wrench to tighten the bolt to the specified angle j After the installation check that the section shown a is flush with each other by touch ing the surface...

Page 293: ... Be sure to reinstall each big end bearing in its original place From the 3 types choose the connecting rod big end metal installer 1 that fits exactly and install it to the connecting rod and connecting rod cap as shown in the illustration Align the projections a on the big end bear ings with the notches b in the connecting rods and connecting rod caps Push the big end bearing 2 down and install ...

Page 294: ...big end bearing assem ble the connecting rod and connecting rod cap without installing them onto the crank shaft d Tighten the connecting rod bolt while checking 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 not be out of alignment e Loosen the connectin...

Page 295: ...sure that the Y mark a on the connect ing rod faces left when the punch mark b on the piston is pointing up as shown Make sure that the clip ends c are positioned away from the cutout d in the piston as shown in the illustration Reinstall each piston into its original cylinder 5 Lubricate Piston Piston ring Cylinder with the recommended lubricant 6 Offset Piston ring end gap New Recommended lubric...

Page 296: ... the connecting rods face towards the left side of the crank shaft Make sure that the projection b on the con necting rod cap faces the same direction as the Y mark a on the connecting rod Apply Molybdenum disulfide oil to the bolt threads and seats 10 Tighten Connecting rod bolt TIP Tighten the connecting rod bolts using the fol lowing procedure a Tighten the connecting rod bolts with a torque wr...

Page 297: ...ure 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 touch ing the surface WARNING EWA17120 If the connecting rod and cap are not flush with each other remove the connecting rod bolts and big end bearing and restart from step 1 In this case make sure to replace the connect...

Page 298: ...r crankcase Refer to CRANKCASE on page 5 64 Connecting rod Refer to REMOVING THE CONNECTING RODS AND PISTONS on page 5 71 1 Balancer shaft 1 2 Balancer shaft journal lower bearing 2 3 Balancer shaft journal upper bearing 2 4 Crankshaft 1 5 Crankshaft journal lower bearing 4 6 Crankshaft journal upper bearing 4 7 Oil nozzle 3 7 7 5 1 2 3 4 6 E 2 3 E New New E E ...

Page 299: ...Crankshaft journal to crankshaft journal bearing clearance Out of specification Replace the crank shaft journal bearings NOTICE ECA13920 Do not interchange the crankshaft journal bearings To obtain the correct crankshaft journal to crankshaft journal bearing clear ance and prevent engine damage the crank shaft journal bearings must be installed in their original positions a Clean the crankshaft jo...

Page 300: ...each crankshaft journal If the crankshaft journal to crankshaft jour nal bearing clearance is out of specifica tion select replacement crankshaft journal bearings 4 Select Crankshaft journal bearing J1 J4 TIP The numbers A stamped into the crankshaft web and the numbers B stamped into the lower crankcase are used to determine the re placement crankshaft journal bearing sizes J1 J4 refer to the bea...

Page 301: ... and bearing por tions of the crankcase b Place the upper crankcase upside down on a bench c Install the balancer shaft journal upper bearings 1 and the balancer shaft into the upper crankcase TIP Align the projections a on the balancer shaft journal upper bearings with the notches b in the upper crankcase d Put a piece of Plastigauge 1 on each balancer shaft journal TIP Do not put the Plastigauge...

Page 302: ...r shaft journal bearings 4 Select Balancer shaft journal bearing J1 J2 TIP The numbers A stamped into the balancer shaft web and the numbers B stamped into the lower crankcase are used to determine the replacement balancer shaft journal bearing siz es J1 J2 refer to the bearings shown in the bal ancer shaft and lower crankcase illustration For example if the crankcase J1 and bal ancer shaft web J1...

Page 303: ... journal bear ings in its original place EAS31172 INSTALLING THE BALANCER ASSEMBLY 1 Install Balancer shaft journal upper bearing into the upper crankcase Balancer shaft journal lower bearing into the lower crankcase TIP Align the projections a on the balancer shaft journal bearings 1 with the notches b in the crankcases Be sure to install each balancer shaft journal bearing in its original place ...

Page 304: ...xle assembly 1 2 Oil seal 1 3 Bearing 1 4 Circlip 1 5 Washer 1 6 Shift drum retainer 2 7 Shift fork guide bar 2 1 8 Spring 4 9 Shift fork L 1 10 Shift fork R 1 11 Shift fork guide bar 1 1 12 Shift drum assembly 1 13 Shift fork C 1 1 4 2 3 9 10 13 5 8 12 8 8 6 7 8 11 6 New New New E E E LT LT E LT LT E E E LT 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft 12 N m 1 2 kgf m 8 9 lb ft 0 5 N m 0...

Page 305: ...marks 14 Main axle assembly 1 15 Oil delivery pipe 1 16 O ring 1 17 Oil nozzle 1 18 Bearing cover plate 1 19 Bearing 1 19 14 15 16 17 New New New 18 E E E LT LT E LT LT E E E LT 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft 12 N m 1 2 kgf m 8 9 lb ft 0 5 N m 0 05 kgf m 0 37 lb ft 14 N m 1 4 kgf m 10 lb ft ...

Page 306: ...on gear 1 2 Toothed lock washer 1 3 Toothed lock washer retainer 1 4 6th pinion gear 1 5 Collar 1 6 Washer 1 7 Circlip 1 8 3rd pinion gear 1 9 Circlip 1 10 Washer 1 11 5th pinion gear 1 12 Collar 1 13 Bearing housing 1 14 Bearing 1 15 Main axle 1 9 10 12 15 13 14 7 8 6 5 4 3 2 1 11 E M M M M M M M New New ...

Page 307: ...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 13 Circlip 1 14 6th wheel gear 1 15 Circlip 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 M M M E M M M M M M New New New New ...

Page 308: ...embling the drive axle assembly Order Job Parts to remove Q ty Remarks 16 Washer 1 17 2nd wheel gear 1 18 Collar 1 19 Collar 1 20 Bearing 1 21 Circlip 1 22 Drive axle 1 19 M M M E 20 21 22 M M M M M 18 17 16 M New New New New ...

Page 309: ...il the main axle assembly comes free from the upper crankcase 3 Remove Oil delivery pipe 1 Oil nozzle 2 Bearing cover plate 3 Bearing 4 EAS30431 CHECKING THE SHIFT FORKS The following procedure applies to all of the shift forks 1 Check Shift fork cam follower 1 Shift fork pawl 2 Bends damage scoring wear Replace the shift fork 2 Check Shift fork guide bar 1 Shift fork guide bar 2 Roll the shift fo...

Page 310: ...rive axle runout with a centering device and dial gauge 1 Out of specification Replace the drive axle 3 Check Transmission gear Blue discoloration pitting wear Replace the defective gear s Transmission gear dogs Cracks damage rounded edges Replace the defective gear s 4 Check Transmission gear engagement each pinion gear to its respective wheel gear Incorrect Reassemble the transmission axle assem...

Page 311: ... is in the center of the gap between the circlip ends e as shown 2 Install Toothed lock washer retainer 1 Toothed lock washer 2 TIP With the toothed lock washer retainer in the groove a in the axle align the projection on the retainer with an axle spline and then install the toothed lock washer Be sure to align the projection on the toothed lock washer that is between the alignment marks b with th...

Page 312: ... of the engine and be in the following sequence R C L Carefully position the shift forks so that they are installed correctly into the transmission gears Install shift fork C into the groove a in the 3rd pinion gear on the main axle 4 Install Shift fork R 1 Shift fork L 2 Spring Shift fork guide bar 2 Shift drum retainer 3 Bearing 4 Circlip 5 Oil seal Drive axle assembly 6 Bearing cover plate scre...

Page 313: ...side Install the shift drum retainer with its OUT mark c facing outward Make sure that the projection d on the drive axle assembly is inserted into the slot in the crankcase Make sure that the drive axle bearing circlips 5 is inserted into the grooves e in the upper crankcase 5 Check Transmission Rough movement Repair TIP Oil each gear shaft and bearing thoroughly d 2 5 6 1 4 a b e 5 e New New c c...

Page 314: ...5 97 TRANSMISSION ...

Page 315: ...ALLING THE RADIATOR 6 5 OIL COOLER 6 7 CHECKING THE OIL COOLER 6 8 INSTALLING THE OIL COOLER 6 8 THERMOSTAT 6 9 CHECKING THE THERMOSTAT 6 10 INSTALLING THE THERMOSTAT ASSEMBLY 6 10 WATER PUMP 6 11 DISASSEMBLING THE WATER PUMP 6 13 CHECKING THE WATER PUMP 6 13 ASSEMBLING THE WATER PUMP 6 13 ...

Page 316: ...6 1 COOLING SYSTEM DIAGRAMS EAS20299 COOLING SYSTEM DIAGRAMS 3 2 1 1 1 Water pump 2 Thermostat 3 Radiator ...

Page 317: ...6 2 COOLING SYSTEM DIAGRAMS 1 2 3 4 5 1 Water jacket joint 2 Thermostat 3 Water pump 4 Oil cooler 5 Coolant reservoir ...

Page 318: ...nt reservoir cover 1 3 Coolant reservoir 1 4 Coolant reservoir cap 1 5 Coolant reservoir breather hose 1 6 Radiator cap 1 7 Radiator fan motor coupler 1 Disconnect 8 Radiator hose cylinder head to radiator 1 Disconnect 9 Radiator inlet hose 1 Disconnect 10 Radiator outlet hose 1 Disconnect 2 3 4 1 6 5 10 7 9 8 LT LT 9 N m 0 9 kgf m 6 6 lb ft 0 5 N m 0 05 kgf m 0 37 lb ft 2 0 N m 0 20 kgf m 1 5 lb ...

Page 319: ...diator 1 12 Radiator fan cover 1 13 Radiator fan 1 14 Radiator bracket 1 14 11 13 12 LT LT 9 N m 0 9 kgf m 6 6 lb ft 0 5 N m 0 05 kgf m 0 37 lb ft 2 0 N m 0 20 kgf m 1 5 lb ft 10 N m 1 0 kgf m 7 4 lb ft 8 N m 0 8 kgf m 5 9 lb ft 7 N m 0 7 kgf m 5 2 lb ft 10 N m 1 0 kgf m 7 4 lb ft ...

Page 320: ... Check Radiator fan Damage Replace Malfunction Check and repair Refer to COOLING SYSTEM on page 8 29 EAS30440 INSTALLING THE RADIATOR 1 Install All removed parts 2 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 28 3 Check Cooling system Leaks Repair or replace any faulty part a Attach the radiator cap tester 1 and radia tor cap tes...

Page 321: ...e that coolant is filled up to the up per level beforehand 4 Check Pressure value No stay for 5 to 10 seconds at the test pres sure value Repair Radiator Radiator hose connections Coolant leaks Repair or replace Radiator hose Bulges Replace WARNING EWA19090 When the radiator cap tester is removed coolant will spout therefore cover it with a cloth beforehand Cooling system leak test pres sure 137 3...

Page 322: ... 6 3 Coolant Drain Refer to CHANGING THE COOLANT on page 3 28 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 25 1 Radiator inlet hose 1 2 Oil cooler inlet hose 1 3 Oil cooler outlet hose 1 4 Oil cooler 1 5 Water jacket joint 1 4 3 1 5 2 LS LT LT LT New New LT LT LS 2 0 N m 0 20 kgf m 1 5 lb ft T R 10 N m 1 0 kgf m 7 4 lb ft T R ...

Page 323: ...sed grease to the O ring Make sure the O ring is positioned properly 3 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 28 Crankcase with the specified amount of the recom mended engine oil Refer to CHANGING THE ENGINE OIL on page 3 25 4 Check Cooling system Leaks Repair or replace any faulty part Refer to INSTALLING THE RADIATOR on ...

Page 324: ...ING THE COOLANT on page 3 28 Radiator Refer to RADIATOR on page 6 3 Muffler assembly Refer to ENGINE REMOVAL on page 5 9 1 Oil cooler outlet hose 1 2 Radiator outlet hose 1 3 Water pump inlet hose 1 4 Thermostat cover 1 5 Thermostat 1 6 Thermostat housing 1 LS 10 N m 1 0 kgf m 7 4 lb ft T R 1 6 3 2 5 4 2 0 N m 0 20 kgf m 1 5 lb ft T R ...

Page 325: ...e place it A faulty thermostat could cause serious overheating or overcooling 2 Check Thermostat cover Thermostat housing Cracks damage Replace EAS30445 INSTALLING THE THERMOSTAT ASSEMBLY 1 Install Thermostat 2 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 28 3 Check Cooling system Leaks Repair or replace any faulty part Refer to ...

Page 326: ... water pump Order Job Parts to remove Q ty Remarks Coolant Drain Refer to CHANGING THE COOLANT on page 3 28 1 Water pump inlet hose 1 Disconnect 2 Water pump assembly 1 1 2 LS New New LS 12 N m 1 2 kgf m 8 9 lb ft T R 2 0 N m 0 20 kgf m 1 5 lb ft T R ...

Page 327: ...er Job Parts to remove Q ty Remarks 1 Water pump housing cover 1 2 O ring 1 3 Circlip 1 4 Water pump driven gear 1 5 Pin 1 6 Washer 1 7 Impeller shaft 1 8 Mechanical seal 1 9 Bearing 1 10 Oil seal 1 E E 1 2 3 4 5 6 7 8 9 10 10 N m 1 0 kgf m 7 4 lb ft ...

Page 328: ...Cracks damage wear Replace Water pump housing Cracks damage wear Replace the water pump assembly 2 Check Bearing Rough movement Replace 3 Check Water pump inlet hose Cracks damage wear Replace EAS30448 ASSEMBLING THE WATER PUMP 1 Install Oil seal 1 Bearing 2 into the water pump housing 3 TIP Install the oil seal with a socket that matches its outside diameter 2 Install Mechanical seal housing side...

Page 329: ...ler side apply tap water or coolant onto its outer surface If the top of the mechanical seal is dirty clean it Mechanical seal installer 90890 04078 Water pump seal installer YM 33221 A Middle driven shaft bearing driv er 90890 04058 Middle drive bearing installer 40 50 mm YM 04058 2 Water pump housing 3 Mechanical seal installer 4 Middle driven shaft bearing driver A Push down 1 New G089035 ...

Page 330: ...6 15 WATER PUMP ...

Page 331: ...UEL TANK 7 5 THROTTLE BODIES 7 6 CHECKING THE INJECTORS BEFORE REMOVING 7 8 REMOVING THE FUEL HOSE FUEL RAIL SIDE 7 8 REMOVING THE INJECTORS 7 8 CHECKING THE INJECTORS 7 8 CHECKING AND CLEANING THE THROTTLE BODIES 7 9 REPLACING THE THROTTLE BODIES 7 10 INSTALLING THE INJECTORS 7 10 CHECKING THE INJECTOR PRESSURE 7 11 CHECKING THE FUEL PRESSURE 7 11 INSTALLING THE FUEL HOSE FUEL RAIL SIDE 7 12 ADJU...

Page 332: ...nk breather hose 1 Disconnect 4 Fuel tank drain hose 1 Disconnect 5 Fuel tank bracket left 1 6 Fuel tank bracket right 1 7 Fuel tank 1 8 Fitting plate left 1 9 Fitting plate right 1 10 Fuel pump bracket 1 New New 4 4 4 9 6 7 3 2 1 8 5 10 2 2 3 2 2 2 2 7 N m 0 7 kgf m 5 2 lb ft T R 7 N m 0 7 kgf m 5 2 lb ft T R 11 N m 1 11 kgf m 8 1 lb ft T R 7 N m 0 7 kgf m 5 2 lb ft T R 7 N m 0 7 kgf m 5 2 lb ft ...

Page 333: ...ank damper 1 16 Damper 2 17 Plug 2 New New 4 4 13 16 17 17 16 12 15 14 11 2 2 3 2 2 2 2 7 N m 0 7 kgf m 5 2 lb ft T R 7 N m 0 7 kgf m 5 2 lb ft T R 2 8 N m 0 28 kgf m 2 1 lb ft T R 11 N m 1 11 kgf m 8 1 lb ft T R 7 N m 0 7 kgf m 5 2 lb ft T R 7 N m 0 7 kgf m 5 2 lb ft T R 6 N m 0 6 kgf m 4 4 lb ft T R 7 N m 0 7 kgf m 5 2 lb ft T R 4 0 N m 0 40 kgf m 3 0 lb ft T R ...

Page 334: ...ge 7 1 1 Fuel tank breather hose fuel tank to canister 1 2 Canister purge hose purge cut valve solenoid to canister 1 3 Canister breather hose 1 4 Canister 1 5 Purge cut valve solenoid coupler 1 Disconnect 6 Canister purge hose purge cut valve solenoid to hose joint 1 7 Purge cut valve solenoid 1 3 4 1 7 2 5 6 ...

Page 335: ... hose connector cover 1 in direction b slide the fuel hose connector cover in direction c and then remove the hose from the fuel pump Before removing the hose place a few rags in the area under where it will be removed It is prohibited to wear the cotton work gloves or equivalent coverings 4 Remove Fuel tank TIP Do not set the fuel tank down so that the instal lation surface of the fuel pump is di...

Page 336: ...projection a toward the fuel tank slot b Align the projection a on the fuel pump with the slot in the fuel pump bracket Tighten the fuel pump bolts in the proper tight ening sequence as shown EAS30457 INSTALLING THE FUEL TANK 1 Connect Fuel hose fuel tank side NOTICE ECA17500 When installing the fuel hose make sure that it is securely connected and that the fuel hose connector cover on the fuel ho...

Page 337: ... pressure sensor 2 coupler 1 Disconnect 4 Injector coupler 3 Disconnect 5 Throttle servo motor coupler 1 Disconnect 6 Throttle position sensor coupler 1 Disconnect 7 Canister purge hose purge cut valve solenoid to hose joint 1 Disconnect 8 Throttle body joint clamp screw 3 Loosen 9 Throttle body assembly 1 10 Throttle body joint 1 11 Throttle body joint 1 LT 10 11 1 8 9 6 2 3 7 4 5 3 3 N m 0 30 kg...

Page 338: ...ressure sensor 2 1 4 Intake air pressure sensor 1 1 5 Throttle position sensor 1 6 Negative pressure hose 6 7 Hose joint 2 8 Canister purge hose 4 9 Hose joint 2 8 6 6 6 7 9 9 8 7 8 6 6 5 3 2 2 2 4 6 New New New New New New 1 3 5 N m 0 35 kgf m 2 6 lb ft T R 3 5 N m 0 35 kgf m 2 6 lb ft T R 3 5 N m 0 35 kgf m 2 6 lb ft T R ...

Page 339: ...gs in the area under where it will be removed It is prohibited to wear the cotton work gloves or equivalent coverings EAS30476 REMOVING THE INJECTORS WARNING EWA17330 Check the injectors in a well ventilated area free of combustible materials Make sure that there is no smoking or use of electric tools in the vicinity of the injectors Be careful when disconnecting the fuel hose Any remaining pressu...

Page 340: ...ution Do not apply cleaning solvent directly to any plastic parts sensors or seals Be careful not to remove the white paint mark that identifies the standard throttle body Do not turn the bypass air screws a oth erwise the throttle body synchronization will be affected a Place the throttle bodies on a flat surface with the air filter case side facing up b Install the caps 895 14169 00 onto the hos...

Page 341: ...ication Replace the throttle bodies Refer to SYNCHRONIZING THE THROT TLE BODIES on page 3 8 EAS31160 REPLACING THE THROTTLE BODIES 1 Remove the throttle bodies from the vehicle 2 Install a new throttle bodies to the vehicle 3 Reset ISC idle speed control learning values Use the diagnostic code number 67 Refer to DIAGNOSTIC CODE SENSOR OPERATION TABLE on page 9 77 A F control learning value Use the...

Page 342: ... g Check that the specified air pressure is held at least one minute Pressure drops Check the pressure gauge and adapter Check the seals and O rings and then rein stall Out of specification Replace the fuel in jectors EAS30482 CHECKING THE FUEL PRESSURE 1 Check Fuel pressure a Remove the rider seat side cover and fuel tank cover Refer to GENERAL CHASSIS 1 on page 4 1 Refer to GENERAL CHASSIS 4 on ...

Page 343: ...ubject the throttle position sensor to strong shocks If the throttle position sensor is dropped replace it 1 Check Throttle position sensor Refer to DIAGNOSTIC CODE SENSOR OPERATION TABLE on page 9 77 2 Adjust Throttle position sensor angle TIP Before adjusting the throttle position sensor the throttle bodies must be removed a Temporary tighten the throttle position sen sor screws 1 b Check that t...

Page 344: ...Adjust the position of the throttle position sensor angle so that 11 21 can appear in the YDT screen g After adjusting the throttle position sensor angle tighten the throttle position sensor screws Throttle position sensor screw 3 5 N m 0 35 kgf m 2 6 lb ft T R 1 1 ...

Page 345: ... 8 23 COOLING SYSTEM 8 29 CIRCUIT DIAGRAM 8 29 TROUBLESHOOTING 8 31 FUEL PUMP SYSTEM 8 33 CIRCUIT DIAGRAM 8 33 TROUBLESHOOTING 8 35 ELECTRICAL COMPONENTS 8 37 CHECKING THE SWITCHES 8 39 CHECKING THE FUSES 8 40 REPLACING THE ECU Engine Control Unit 8 41 CHECKING AND CHARGING THE BATTERY 8 41 CHECKING THE RELAYS 8 42 CHECKING THE RELAY UNIT DIODE 8 43 CHECKING THE IGNITION COILS 8 44 CHECKING THE IG...

Page 346: ...DIATOR FAN MOTOR 8 47 CHECKING THE COOLANT TEMPERATURE SENSOR 8 47 CHECKING THE THROTTLE SERVO MOTOR 8 48 CHECKING THE INTAKE AIR TEMPERATURE SENSOR 8 49 CHECKING THE FUEL INJECTORS 8 49 CHECKING THE PURGE CUT VALVE SOLENOID 8 50 CHECKING THE WHEEL SWITCH 8 50 ...

Page 347: ......

Page 348: ...B R W R R W R W R R R W R R R W R R R R B B B B B B B B W B B B B B B W B B B B R R W R W R W R W B B B W B W B W B B B B B L B L B Y B L W L W W L Y L L Y B Y B B Y W L W W L W Br L R Gy B B Gy 46 64 51 50 52 51 53 51 49 5 ON OFF 23 24 35 36 START OFF RUN R L R L L W W B W G B W R W B R 31 33 38 B B B 39 4 3 3 11 12 9 Br L R B L B L L W L B B Y B W L B Y B L W W W W L W B Y B L Y L L B Sb L W R L...

Page 349: ...ery 24 Engine ground 31 Handlebar switch right 33 Stop run start switch 35 Relay unit 36 Starting circuit cut off relay 38 Neutral switch 39 Sidestand switch 46 Crankshaft position sensor 49 ECU Engine Control Unit 50 Ignition coil 1 51 Spark plug 52 Ignition coil 2 53 Ignition coil 3 64 IMU Inertial Measurement Unit ...

Page 350: ...h is open However the engine continues to run un der the following conditions The transmission is in gear the neutral switch is open and the sidestand is up the sidestand switch circuit is closed The transmission is in neutral the neutral switch is closed and the sidestand is down the sidestand switch circuit is open 10 11 9 1 4 5 7 2 6 3 8 1 Battery 2 Main fuse 3 Main switch 4 Ignition fuse 5 Sto...

Page 351: ...battery terminals Recharge or replace the battery OK 3 Check the spark plugs Refer to CHECKING THE SPARK PLUGS on page 3 5 NG Re gap or replace the spark plugs OK 4 Check the ignition spark gap Refer to CHECKING THE IGNI TION SPARK GAP on page 8 44 OK Ignition system is OK NG 5 Check the ignition coils Refer to CHECKING THE IGNI TION COILS on page 8 44 NG Replace the ignition coils OK 6 Check the ...

Page 352: ...K 10 Check the sidestand switch Refer to CHECKING THE SWITCHES on page 8 39 NG Replace the sidestand switch OK 11 Check the relay unit diode Refer to CHECKING THE RELAY UNIT DIODE on page 8 43 NG Replace the relay unit OK 12 Check the entire ignition system s wiring Refer to CIRCUIT DIAGRAM on page 8 1 NG Properly connect or repair the ignition sys tem s wiring OK Replace the ECU Refer to REPLACIN...

Page 353: ...8 6 IGNITION SYSTEM ...

Page 354: ... R R W Dgy Y B B Y Y W L Y B Br W R Y R W B Y B Y R R R R B B B B B B B B W B B B B B B W B B B B R R W R W R W R W B B B W B W B W B B B B B L B L B Y B L W L W W L Y L L Y B Y B B Y W L W W L W Br L R 64 49 5 ON OFF 25 26 23 24 OFF ON Y B Y W Gy L Y B Y 28 35 36 START OFF RUN R R L Y G W G R L L W W B W G B W R W B R W R Y G Y B B W G W B Y R 31 33 38 B B B 39 4 3 9 3 11 12 Br L R L W L B Y B W ...

Page 355: ...se 2 12 Ignition fuse 23 Battery 24 Engine ground 25 Starter relay 26 Starter motor 28 Clutch switch 31 Handlebar switch right 33 Stop run start switch 35 Relay unit 36 Starting circuit cut off relay 38 Neutral switch 39 Sidestand switch 49 ECU Engine Control Unit 64 IMU Inertial Measurement Unit ...

Page 356: ...perating 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 started by pressing the side of the stop run start switch 12 1 11 4 6 6 6 6 a b 8 6 9 7 5 2 3 10 10 a WHEN THE TRANSMISS...

Page 357: ... the battery OK 3 Check the starter motor operation Refer to CHECKING THE START ER MOTOR OPERATION on page 8 45 OK Starter motor is OK Perform the electric starting system troubleshooting starting with step 5 NG 4 Check the starter motor Refer to CHECKING THE START ER MOTOR on page 5 44 NG Repair or replace the starter motor OK 5 Check the relay unit starting circuit cut off relay Refer to CHECKIN...

Page 358: ... SWITCHES on page 8 39 NG Replace the sidestand switch OK 11 Check the clutch switch Refer to CHECKING THE SWITCHES on page 8 39 NG Replace the clutch switch OK 12 Check the stop run start switch Refer to CHECKING THE SWITCHES on page 8 39 NG Replace the handlebar switch right OK 13 Check the entire starting system s wiring Refer to CIRCUIT DIAGRAM on page 8 7 NG Properly connect or repair the sta...

Page 359: ...8 12 ELECTRIC STARTING SYSTEM ...

Page 360: ...8 13 CHARGING SYSTEM EAS20074 CHARGING SYSTEM EAS30496 CIRCUIT DIAGRAM W W W Dgy W B W W R R R R R B B B B B B B B W B 23 24 2 4 3 1 W W W R R R R R B B B R R B B W W W R ...

Page 361: ...8 14 CHARGING SYSTEM 1 AC magneto 2 Rectifier regulator 3 Fuse box 4 Main fuse 23 Battery 24 Engine ground ...

Page 362: ...G AND CHARGING THE BATTERY on page 8 41 NG Clean the battery terminals Recharge or replace the battery OK 3 Check the stator coil Refer to CHECKING THE STA TOR COIL on page 8 46 NG Replace the stator coil assembly OK 4 Check the rectifier regulator Refer to CHECKING THE RECTI FIER REGULATOR on page 8 46 NG Replace the rectifier regulator OK 5 Check the entire charging system s wiring Refer to CIRC...

Page 363: ...8 16 CHARGING SYSTEM ...

Page 364: ...G W G W Lg B L W L Y B R R R R B B B B B B B B W B B B B B B W B B B B B B B W B W B W B B B B B Y B Y B Y B Y Y Y B B B W B L W L W W L B L B Y B Br L R R Y B Y L R Y B B 49 5 ON OFF 23 24 83 81 68 73 69 PUSH FREE UP N DOWN L R N HI PASS LO OFF ON RES SET FREE PUSH FREE OFF ON B W Gy Br L L B L R Gy Br L G L W Y W L L B W G W R G B Y W O W Y Y B 97 100 G R B Gy 94 L Y L B B 93 4 3 9 3 10 13 3 20 ...

Page 365: ...use 23 Battery 24 Engine ground 49 ECU Engine Control Unit 68 Meter assembly 69 Multi function meter 73 Auxiliary system warning light 81 Meter light 83 High beam indicator light 89 Headlight control unit 90 Headlight low 91 Headlight high 92 Auxiliary light 93 Tail brake light 94 License plate light 97 Handlebar switch left 100 Dimmer pass switch ...

Page 366: ...k the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 41 NG Clean the battery terminals Recharge or replace the battery OK 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 39 NG Replace the main switch immobilizer unit OK 4 Check the dimmer switch Refer to CHECKING THE SWITCHES on page 8 39 NG The dimmer switch is faulty Replace the handlebar switch left OK 5 Check the...

Page 367: ...8 20 LIGHTING SYSTEM Replace the ECU meter assembly headlight assembly tail brake light or license plate light Refer to REPLACING THE ECU En gine Control Unit on page 8 41 ...

Page 368: ...B B B W B B B B B B W B B B B B B B W B W B W B B B B B L B L B Y B L W L W W B B B W B B B B B Br L R 42 47 W R R B W B 66 61 49 5 ON OFF 23 24 A 96 Ch B Ch 87 Ch B Ch B 88Ch B Ch 86 84 78 77 75 70 68 72 69 Ch B B B Ch 85 PUSH FREE UP N DOWN L R N HI PASS LO OFF ON RES SET FREE PUSH FREE OFF ON B W Gy Br L L B L R B Br L Gy Br L G L W Y W L L B W G W R G B Y W O W Y Y B 97 101 104 105 106 L Y L B...

Page 369: ...trol Unit 61 Hydraulic unit assembly ABS ECU 63 Rear wheel sensor 66 Shift sensor 68 Meter assembly 69 Multi function meter 70 Neutral indicator light 72 Oil pressure and coolant temperature warn ing light 75 Fuel level warning light 77 Left turn signal indicator light 78 Right turn signal indicator light 84 Oil pressure switch 85 Rear turn signal light left 86 Rear turn signal light right 87 Fron...

Page 370: ...up backup 2 and brake light Refer to CHECKING THE FUS ES on page 8 40 NG Replace the fuse s OK 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 41 NG Clean the battery terminals Recharge or replace the battery OK 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 39 NG Replace the main switch immobilizer unit OK 4 Check the entire signaling sys tem s wiring Re...

Page 371: ...brake light switch Refer to CHECKING THE SWITCHES on page 8 39 NG Replace the front brake light switch OK 2 Check the rear brake light switch Refer to CHECKING THE SWITCHES on page 8 39 NG Replace the rear brake light switch OK 3 Check the entire signaling sys tem s wiring Refer to CIRCUIT DIAGRAM on page 8 21 NG Properly connect or repair the signaling system s wiring OK This circuit is OK The tu...

Page 372: ...ing sys tem s wiring Refer to CIRCUIT DIAGRAM on page 8 21 NG Properly connect or repair the signaling system s wiring OK Replace the meter assembly The oil pressure and coolant temperature warning light fails to come on or the oil pressure warn ing icon flashes when the main switch is set to ON 1 Check the entire signaling sys tem s wiring Refer to CIRCUIT DIAGRAM on page 8 21 NG Properly connect...

Page 373: ...el sender Refer to CHECKING THE FUEL SENDER on page 8 46 NG Replace the fuel pump assembly OK 2 Check the entire signaling sys tem s wiring Refer to CIRCUIT DIAGRAM on page 8 21 NG Properly connect or repair the signaling system s wiring OK Replace the meter assembly The oil pressure and coolant temperature warning light fails to come on 1 Check the coolant temperature sensor Refer to CHECKING THE...

Page 374: ...g other than OFF OK 4 Are you operating while the QS icon is lit NG Operate while the QS icon is lit OK 5 Is the transmission gear display normal NG Repair the gear position sensor OK 6 Check the connection of the cou pler between the gear position sen sor and the ECU NG Connect the gear position sensor coupler OK 7 Are the clutch and neutral switches normal NG Repair the switch if it is not norma...

Page 375: ...hite blue black blue black OK Replace the ECU Refer to REPLACING THE ECU En gine Control Unit on page 8 41 The speedometer fails to operate 1 Check the rear wheel sensor Refer to MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR on page 4 24 NG Replace the rear wheel sensor OK 2 Check the entire wheel sensor wir ing Refer to TIP NG Properly connect or repair the wheel sen sor wiring OK Replace...

Page 376: ...Br Y L G W R Y R W Y Br B L Y B B W B B Gy L L V P P W Lg L O W Y L L B B L B L Br W Gy G G L Br L B Y L W W Y W G G W G W Lg B L W L Y B R W R R W R W R R R W R R R W R R R R B B B B B W B B B B B B B W B W B W B B B B B B R B Br L R 47 49 5 ON OFF 23 24 4 3 6 9 3 12 3 21 95 L B L B Br L R G Y B L B B L B R R R R R B B R R R R W Br L G Y R B R R R R R G R R Br L R R R Br L Br L B B B R B R R B B ...

Page 377: ...se box 4 Main fuse 5 Main switch 6 Radiator fan motor relay 9 Backup fuse 2 12 Ignition fuse 21 Radiator fan motor fuse 23 Battery 24 Engine ground 47 Coolant temperature sensor 49 ECU Engine Control Unit 95 Radiator fan motor ...

Page 378: ...the main switch Refer to CHECKING THE SWITCHES on page 8 39 NG Replace the main switch immobilizer unit OK 4 Check the radiator fan motor Refer to CHECKING THE RADIA TOR FAN MOTOR on page 8 47 NG Replace the radiator fan motor s OK 5 Check the radiator fan motor relay Refer to CHECKING THE RE LAYS on page 8 42 NG Replace the radiator fan motor relay OK 6 Check the coolant temperature sensor Refer ...

Page 379: ...8 32 COOLING SYSTEM Replace the ECU Refer to REPLACING THE ECU En gine Control Unit on page 8 41 ...

Page 380: ... W Y L L B B L B L Br W Gy G G L Br L B Y L W W Y W G G W G W Lg B L W L Y B R W R R W R W R R R W R R R W R L G W B B B R R R R B B B B B B B B W B R L R L R L R L R L R R R W R W R W R W B B B W B W B W B B B B B Br L R 49 5 ON OFF 23 24 35 37 START OFF RUN R R L Y G W G R L L W W B W G B W R W B R 31 33 40 4 3 9 3 12 7 Br L R R L L W R Br R R W R W B R R R R R B B B R R W R W Br L R R R R G R B...

Page 381: ...Main fuse 5 Main switch 7 Fuel injection system fuse 9 Backup fuse 2 12 Ignition fuse 23 Battery 24 Engine ground 31 Handlebar switch right 33 Stop run start switch 35 Relay unit 37 Fuel pump relay 40 Fuel pump 49 ECU Engine Control Unit ...

Page 382: ...rge or replace the battery OK 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 39 NG Replace the main switch immobilizer unit OK 4 Check the stop run start switch Refer to CHECKING THE SWITCHES on page 8 39 NG Replace the handlebar switch right OK 5 Check the relay unit fuel pump re lay Refer to CHECKING THE RE LAYS on page 8 42 NG Replace the relay unit OK 6 Check the fuel pump Re...

Page 383: ...8 36 FUEL PUMP SYSTEM Replace the ECU Refer to REPLACING THE ECU En gine Control Unit on page 8 41 ...

Page 384: ...Unit 2 Fuel pump 3 Relay unit 4 Radiator fan motor relay 5 Fuse box 6 Brake light relay 7 Starter relay 8 Gear position sensor 9 Shift sensor 10 Sidestand switch 11 AC magneto 12 Crankshaft position sensor 13 O2 sensor 14 Purge cut valve solenoid 15 Front wheel sensor 16 Horn 17 Intake air temperature sensor 18 Clutch switch ...

Page 385: ...essure sensor 1 5 Throttle position sensor 6 Injector 7 Accelerator position sensor 8 Front brake light switch 9 Main switch Immobilizer unit 10 Ignition coil 11 Radiator fan motor 12 Coolant temperature sensor 13 Starter motor 14 Oil pressure switch 15 Neutral switch 16 Rear brake light switch 17 Rear wheel sensor 18 Rectifier regulator 19 IMU Inertial Measurement Unit 20 Battery ...

Page 386: ... L Br L G B B W R Y B Y Y W L L R W Y START OFF RUN OFF ON OFF ON OFF ON Y B Y W L Y B Y G W Y B G Y Y W B L R Br L Br L G L W Y W L L B W G W R G B Y W O W Y Y B Br G B Y OFF ON SET FREE RES HI LO PASS PUSH FREE ON OFF FREE PUSH UP N DOWN OFF ON R N L Br L R 1 12 2 3 5 4 6 7 8 9 10 11 13 14 15 1 Cruise control power switch 2 Cruise control setting switch 3 Dimmer pass switch 4 Horn switch 5 Mode ...

Page 387: ... the fuse immediately blows again check the electrical circuit WARNING EWA13310 Never use a fuse with an amperage rating other than that specified Improvising or us ing a fuse with the wrong amperage rating may cause extensive damage to the electri cal system cause the lighting and ignition systems to malfunction and could possibly cause a fire Digital circuit tester CD732 90890 03243 Model 88 Mul...

Page 388: ...ed EAS30552 CHECKING AND CHARGING THE BATTERY TIP Refer to CHECKING AND CHARGING THE BATTERY in BASIC INFORMATION sepa rate volume 1 Remove Rider seat Side cover left and right Bracket Refer to GENERAL CHASSIS 1 on page 4 1 2 Disconnect Battery lead from the battery terminals NOTICE ECA13700 First disconnect the negative battery lead and then the positive battery lead 3 Remove Battery Refer to GEN...

Page 389: ... unit fuel pump relay Digital circuit tester CD732 90890 03243 Model 88 Multimeter with ta chometer YU A1927 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Relay operation Continuity between 3 and 4 L W R W 1 2 3 4 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity betwee...

Page 390: ...2 90890 03243 Model 88 Multimeter with ta chometer YU A1927 R G Y R B R L R Y Lg B B No continuity Positive tester probe sky blue 1 Negative tester probe black 2 Continuity Positive tester probe black 2 Negative tester probe sky blue 1 No continuity Positive tester probe sky blue 1 Negative tester probe blue 3 Continuity Positive tester probe blue 3 Negative tester probe sky blue 1 No continuity P...

Page 391: ...n coil as shown b Measure the secondary coil resistance EAS30556 CHECKING THE IGNITION 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 Pr...

Page 392: ...R MOTOR OPERATION 1 Check Starter motor operation Does not operate Perform the electric starting system troubleshooting starting with step 4 Refer to TROUBLESHOOTING on page 8 10 a Connect the positive battery terminal 1 and starter motor lead 2 with a jumper lead 3 WARNING EWA13810 A wire that is used as a jumper lead must have at least the same capacity of the bat tery lead otherwise the jumper ...

Page 393: ...d let it run at approxi mately 5000 r min c Measure the battery charging voltage EAS30569 CHECKING THE HORN 1 Check Horn sound Faulty sound Replace EAS30573 CHECKING THE FUEL SENDER 1 Disconnect Fuel pump coupler from the fuel pump 2 Remove Fuel tank 3 Remove Fuel pump from the fuel tank Stator coil resistance 0 152 0 228 Ω Digital circuit tester CD732 90890 03243 Model 88 Multimeter with ta chome...

Page 394: ...ce the fuel pump assembly EAS30577 CHECKING THE RADIATOR FAN MOTOR 1 Check Radiator fan motor Faulty rough movement Replace a Disconnect the radiator fan motor coupler from the wire harness b Connect the battery DC 12 V as shown c Measure the radiator fan motor movement EAS30578 CHECKING THE COOLANT TEMPERATURE SENSOR 1 Remove Coolant temperature sensor Refer to CYLINDER HEAD on page 5 27 WARNING ...

Page 395: ...ilter case Refer to GENERAL CHASSIS 5 on page 4 11 2 Check Throttle valve operation Throttle valves do not fully close Replace the throttle bodies a Connect two C size batteries to the throttle servo motor terminals 1 as shown NOTICE ECA17660 Do not use a 12 V battery to operate the throt tle servo motor TIP Do not use old batteries to operate the throttle servo motor Coolant temperature sensor re...

Page 396: ... e Measure the intake air temperature sensor resistance 3 Install Intake air temperature sensor EAS30681 CHECKING THE FUEL INJECTORS The following procedure applies to all of the fuel injectors 1 Remove Fuel injector Refer to THROTTLE BODIES on page 7 6 2 Check Fuel injector resistance Out of specification Replace the fuel injec tor a Disconnect the fuel injector coupler from the fuel injector b C...

Page 397: ... shown e When turning the wheel switch in direction a check that the output voltage is within the specified values f When turning the wheel switch in direction b check that the output voltage is within the specified values Solenoid resistance 22 26 Ω Digital circuit tester CD732 90890 03243 Model 88 Multimeter with ta chometer YU A1927 Positive tester probe Purge cut valve solenoid terminal 1 Nega...

Page 398: ...8 51 ELECTRICAL COMPONENTS ...

Page 399: ...L 9 15 B THE MIL DOES NOT COME ON BUT THE ENGINE OPERATION IS NOT NORMAL 9 15 IMMOBILIZER SYSTEM 9 16 CIRCUIT DIAGRAM 9 16 SYSTEM OUTLINE 9 18 PART REPLACEMENT AND KEY CODE REGISTRATION REQUIREMENTS 9 19 TROUBLESHOOTING 9 22 HOW TO CHECK DTC 9 23 CRUISE CONTROL SYSTEM 9 24 CIRCUIT DIAGRAM 9 24 CRUISE CONTROL CIRCUIT OPERATION 9 26 BASIC INSTRUCTIONS FOR TROUBLESHOOTING 9 27 BASIC PROCESS FOR TROUB...

Page 400: ...LFUNCTION ARE CURRENTLY DETECTED 9 40 B 2 DIAGNOSIS USING THE DTC 9 41 B 3 DELETING THE DTC 9 41 C 1 FINAL CHECK 9 41 SELF DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE 9 43 DTC TABLE 9 43 SELF DIAGNOSTIC FUNCTION TABLE FOR FUEL INJECTION SYSTEM 9 51 SELF DIAGNOSTIC FUNCTION TABLE FOR IMMOBILIZER SYSTEM 9 71 SELF DIAGNOSTIC FUNCTION TABLE FOR ABS Anti lock Brake System 9 72 COMMUNICATION ERROR WIT...

Page 401: ...12 P0112 P0113 9 115 TROUBLESHOOTING 9 115 P0115 9 119 TROUBLESHOOTING 9 119 P0116 9 120 TROUBLESHOOTING 9 120 P0117 P0118 9 123 TROUBLESHOOTING 9 123 P0122 P0123 P0222 P0223 9 127 TROUBLESHOOTING 9 127 P0132 9 132 TROUBLESHOOTING 9 132 P0133 9 136 OUTLINE 9 136 FAIL SAFE SYSTEM 9 137 TROUBLESHOOTING 9 137 P0134 9 138 TROUBLESHOOTING 9 138 P0201 9 140 TROUBLESHOOTING 9 140 ...

Page 402: ...ROUBLESHOOTING 9 153 P0351 9 157 TROUBLESHOOTING 9 157 P0352 9 161 TROUBLESHOOTING 9 161 P0353 9 165 TROUBLESHOOTING 9 165 P0458 9 169 TROUBLESHOOTING 9 169 P0480 9 173 TROUBLESHOOTING 9 173 P0500 P1500 9 176 TROUBLESHOOTING 9 176 P0560 P0563 9 188 TROUBLESHOOTING 9 188 P0564 9 189 TROUBLESHOOTING 9 189 P056C 9 195 TROUBLESHOOTING 9 195 P0601 9 202 TROUBLESHOOTING 9 202 ...

Page 403: ... 214 TROUBLESHOOTING 9 214 P0915 9 216 TROUBLESHOOTING 9 216 P0916 P0917 9 218 TROUBLESHOOTING 9 218 P1004 9 222 TROUBLESHOOTING 9 222 P1600 9 224 TROUBLESHOOTING 9 224 P1601 9 228 TROUBLESHOOTING 9 228 P1602 9 232 TROUBLESHOOTING 9 232 P1606 P1607 9 236 TROUBLESHOOTING 9 236 P1608 9 240 TROUBLESHOOTING 9 240 P1609 9 242 TROUBLESHOOTING 9 242 ...

Page 404: ...LESHOOTING 9 260 U0155 or Err 9 263 TROUBLESHOOTING 9 263 51_IMMOBILIZER 9 267 TROUBLESHOOTING 9 267 52_IMMOBILIZER 9 268 TROUBLESHOOTING 9 268 53_IMMOBILIZER 9 269 TROUBLESHOOTING 9 269 54_IMMOBILIZER 9 272 TROUBLESHOOTING 9 272 55_IMMOBILIZER 9 273 TROUBLESHOOTING 9 273 56_IMMOBILIZER 9 274 TROUBLESHOOTING 9 274 11_ABS 9 277 TROUBLESHOOTING 9 277 12_ABS 9 278 TROUBLESHOOTING 9 278 ...

Page 405: ...BS 9 285 TROUBLESHOOTING 9 285 31_ABS 9 286 TROUBLESHOOTING 9 286 33_ABS 9 288 TROUBLESHOOTING 9 288 34_ABS 9 290 TROUBLESHOOTING 9 290 41_ABS 9 291 TROUBLESHOOTING 9 291 42_ABS 9 292 TROUBLESHOOTING 9 292 43 45_ABS 9 293 TROUBLESHOOTING 9 293 44 46_ABS 9 294 TROUBLESHOOTING 9 294 51_ABS 9 295 TROUBLESHOOTING 9 295 53_ABS 9 296 TROUBLESHOOTING 9 296 ...

Page 406: ...BS 9 299 TROUBLESHOOTING 9 299 57_ABS 9 300 TROUBLESHOOTING 9 300 62_ABS 9 304 TROUBLESHOOTING 9 304 68_ABS 9 305 TROUBLESHOOTING 9 305 89_ABS 9 306 TROUBLESHOOTING 9 306 90_ABS 9 309 TROUBLESHOOTING 9 309 91_ABS 9 312 TROUBLESHOOTING 9 312 ...

Page 407: ...C is a code that is saved within a control unit s memory when the control unit detects an abnormal condition If the abnormal condition continues a malfunction may be determined Driving cycle Driving cycle is the duration from the main switch being turned on OBD re quirements are met and until the main switch is turned off FFD Freeze frame data FFD is the data of all signal sensors saved at the mom...

Page 408: ...ng light coming on without malfunction Reprogramming of the ECU software Using the electrical accessory which may affect the ECU Using the incorrect specification of spark plug and injector Using the third party accessories such as suspension and exhaust system Change of specifications of drive chain sprocket wheel and tire Removing or modifying the O2 sensor the exhaust system part catalyst etc P...

Page 409: ...he YDT refer to the operation manual that is included with the tool TIP Yamaha diagnostic tool A I 90890 03264 includes YDT sub harness 6P 90890 03266 If you already have Yamaha diagnostic tool A I 90890 03262 YDT sub harness 6P 90890 03266 is separately required A GST can also be used to identify malfunctions Connecting the YDT Remove the protective cap and then connect the YDT to the coupler 1 Y...

Page 410: ...DTC is sometimes stored In this case question the customer about the conditions when the problem occurred and do the troubleshooting Refer to P0300 P0301 P0302 P0303 on page 9 149 Crankshaft position sensor Fuel pump Injector 1 O2 sensor Injector 2 Hydraulic unit assembly ABS ECU Injector 3 Throttle servo motor Clutch switch Relay unit Ignition coil 1 Starter relay Ignition coil 2 Purge cut valve ...

Page 411: ...ion coil 2 45 Ignition coil 3 12 Sidestand switch 26 Tail brake light 10 Brake light relay 18 Rear brake light switch 17 Front brake light switch 16 Clutch switch 22 Rectifier regulator 7 Starting circuit cut off relay 13 Neutral switch 19 Cruise control power switch 20 Cruise control setting switch SET 21 Cruise control setting switch RES 16 Clutch switch 17 Front brake light switch 18 Rear brake...

Page 412: ...osition sensor 35 Throttle position sensor 46 Grip warmer left OPTION 47 Grip warmer right OPTION 48 Purge cut valve solenoid 50 Dimmer switch 51 Pass switch 53 Meter assembly 54 CAN communication circuit 19 49 Radiator fan motor 52 Headlight control unit 37 Hydraulic unit assembly ABS ECU ...

Page 413: ...egulator 23 Fuel pump 24 Starter motor 25 Neutral indicator light 26 Tail brake light 27 Crankshaft position sensor 28 Intake air pressure sensor 2 29 Intake air pressure sensor 1 30 Coolant temperature sensor 31 Intake air temperature sensor 32 Shift sensor 33 Gear position sensor 34 O2 sensor 35 Throttle position sensor 36 Accelerator position sensor 37 Hydraulic unit assembly ABS ECU 38 Injecto...

Page 414: ...ttle servo motor Lg R 11 12 13 14 Injector 3 L B 15 Injector 2 G B 16 Injector 1 R B 17 Ground B 18 Electronic throttle valve fuse R L 19 Radiator fan motor relay G Y 20 21 22 23 24 25 Ground B 26 Backup fuse 2 R G 27 Purge cut valve so lenoid Y R 28 Dimmer pass switch Headlight control unit Y B 29 Fuel pump relay L W 30 31 32 Fuel pump relay Fuel pump R L 33 Ground B W 34 Ground B W 35 Accelerato...

Page 415: ...r position sen sor L 74 75 76 Crankshaft position sensor Gy No Connected parts Wireharness color 77 CAN communica tion circuit L W 78 79 80 Starting circuit cut off relay Clutch switch B Y 81 82 Cruise control set ting switch RES Br L 83 Cruise control set ting switch SET G L 84 O2 sensor Gy G 85 86 Intake air tempera ture sensor Br W 87 88 Crankshaft position sensor Intake air pressure sensor 1 I...

Page 416: ...STEM DIAGRAM 102 Coolant tempera ture sensor G W 103 Gear position sen sor G W 104 105 Hydraulic unit as sembly ABS ECU W G 106 107 Hydraulic unit as sembly ABS ECU W Y 108 No Connected parts Wireharness color ...

Page 417: ...9 11 SYSTEM DIAGRAM ...

Page 418: ... G Y R B R B Dgy W B W W R W W W Dgy Y B B Y Y W L Y Br L R 42 43 44 B B W L B B B L W 45 Gy B B Gy 46 47 48 64 65 W R R B W B 66 67 51 50 52 51 53 51 54 55 56 59 61 60 49 5 ON OFF 23 24 76 68 69 35 36 37 START OFF RUN R R L Y G W G R L L W W B W G B W R W B R W R Y G Y B B W G W B Y R 31 33 34 38 B B B 39 40 4 3 7 9 8 3 11 12 14 3 20 21 B W 62 W B 63 W B 25 6 95 L B L B 2 1 W W W OFF ON Y B Y W G...

Page 419: ...ay 38 Neutral switch 39 Sidestand switch 40 Fuel pump 42 Gear position sensor 43 Intake air pressure sensor 1 44 Intake air pressure sensor 2 45 O2 sensor 46 Crankshaft position sensor 47 Coolant temperature sensor 48 Intake air temperature sensor 49 ECU Engine Control Unit 50 Ignition coil 1 51 Spark plug 52 Ignition coil 2 53 Ignition coil 3 54 Injector 1 55 Injector 2 56 Injector 3 59 Throttle ...

Page 420: ...he MIL come on Does the MIL LED work properly B Perform the checking with the diagnostic mode Temporary failure Check the MIL LED The MIL goes off after 2 seconds Still on flash A Check the DTC Delete the DTC Are DTCs displayed on the screen after performs the problem verification Do the troubleshooting according to the DTCs of malfunction Check the DTCs of malfunction are not displayed on the scr...

Page 421: ... IS NOT NORMAL 1 Monitor the operation of these sensors and actuators by using the YDT in the diagnostic mode Refer to DIAGNOSTIC CODE SENSOR OPERATION TABLE on page 9 77 and DIAGNOSTIC CODE ACTUATOR OPERATION TABLE on page 9 82 If a malfunction is detected in the sensors or actuators repair or replace all faulty parts If no malfunction is detected in the sensors and actuators check and repair the...

Page 422: ...Y B B W B B Gy L L V P P W Lg L O W Y L L B B L B L Br W Gy G G L Br L B Y L W W Y W G G W G W Lg B L W L Y B R W R R W R W R R R W R R R W R R R R B B B B B W B B B B B B B W B W B W B B B B B L W L W W B B B W B L B Y B L B Br L R 67 49 5 ON OFF 23 24 68 71 69 R W B R W Lg R G Y L 27 4 3 9 3 12 3 20 11 Br L R B L W Y B B L B B B B B L L W L B L B L W B B Y B W L W L W W B R Y L R G Lg B R R R R ...

Page 423: ... Main switch 9 Backup fuse 2 11 Ignition fuse 2 12 Ignition fuse 20 Backup fuse 23 Battery 24 Engine ground 27 Immobilizer unit 49 ECU Engine Control Unit 67 YDT coupler 68 Meter assembly 69 Multi function meter 71 Immobilizer system indicator light ...

Page 424: ...during production therefore re registering at purchase is not neces sary NOTICE ECA14971 DO NOT LOSE THE CODE RE REGISTERING KEY If the code re registering 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 immobili...

Page 425: ...ng key TIP Check that the immobilizer system indicator light comes on for one second then goes off When the im mobilizer system indicator light goes off the code re registering key has been registered 2 Check that the engine can be started 3 Register the standard key following the instructions in the section below Parts to be replaced Key registration requirement Main switch immobilizer unit Stand...

Page 426: ...tering key turn the main switch to ON then OFF and then remove the key within 5 seconds 3 Insert the first standard key to be registered into the main switch then turn the key to ON within 5 seconds to activate the key registration mode TIP The existing standard key code is erased from the memory when the key registration mode is activated When the key registration mode is activated the immobilize...

Page 427: ...Main switch OFF c LED on d LED off e Less than 5 0 s f Code re registering key g First standard key h Second standard key i Registration mode A Registration of the second standard key is complete B Immobilizer system indicator light stops flash ing when the registration of the second stan dard key is complete a Main switch ON b Main switch OFF c LED on d LED off e Less than 5 0 s f Code re registe...

Page 428: ... CHECKING AND CHARGING THE BATTERY on page 8 41 NG Clean the battery terminals Recharge or replace the battery OK 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 39 NG Replace the main switch immobilizer unit OK 4 Check the entire immobilizer sys tem wiring Refer to CIRCUIT DIAGRAM on page 9 16 NG Properly connect or repair the immobilizer system wiring OK Check the condition of t...

Page 429: ...e meter display and the immobilizer sys tem indicator light flashes at the same time The pattern of flashing also shows the DTC Immobilizer system indicator light DTC indication Digit of 10 Cycles of 1 sec ON and 1 5 sec OFF Digit of 1 Cycles of 0 5 sec ON and 0 5 sec OFF Example DTC 52 a Light on b Light off ...

Page 430: ...W B W B B B B B L B L B Y B L W L W W B B B W B L Y L L Y B Y B B Y B B B B Br L R 42 W R R B W B 66 67 49 5 ON OFF 23 24 96 80 79 76 68 69 PUSH FREE UP N DOWN L R N HI PASS LO OFF ON RES SET FREE PUSH FREE OFF ON B W Gy Br L Gy Br L G L W Y W L L B W G W R G B Y W O W Y Y B 97 99 98 OFF ON Y B Y W Gy L Y B Y 28 OFF ON B G W Y B G Y Y W 29 ON OFF Br G B Y B Br G B Y 30 START OFF RUN R R L Y G W G ...

Page 431: ...brake light switch 30 Rear brake light switch 31 Handlebar switch right 34 Accelerator position sensor 42 Gear position sensor 49 ECU Engine Control Unit 66 Shift sensor 67 YDT coupler 68 Meter assembly 69 Multi function meter 76 MIL Malfunction indicator light 79 Cruise control system indicator light 80 Cruise control setting indicator light 96 Brake light relay 97 Handlebar switch left 98 Cruise...

Page 432: ...y 17 Multi function meter 16 ECU Engine Control Unit 18 Cruise control system indicator light 19 Cruise control setting indicator light 1 Battery 2 Main fuse 3 Main switch 4 Ignition fuse 2 5 Signaling system fuse 6 Brake light fuse 7 Ignition fuse 8 Cruise control fuse 9 Cruise control power switch 10 Cruise control setting switch 11 Clutch switch 12 Front brake light switch 13 Rear brake light s...

Page 433: ... check the DTC of malfunction is not displayed TIP If another DTC is displayed repeat steps 1 to 3 until no DTC is displayed Turning the main switch to OFF will not erase the malfunction history 4 Do the final check WARNING EWA17420 Perform the troubleshooting A B C in order Be sure to follow the order since a wrong diagnosis could result if the steps are followed in a different order or omitted U...

Page 434: ...ntrol system to the customer Finished Is there automatic deactivation history for the cruise control system Check the malfunction history using the malfunction mode of the YDT Is there any malfunction history Diagnosis using the DTC Yes Yes OK The cruise control power switch is defective The cruise control fuse is blown The ECU is defective Delete the DTC Final check Return to A Return to A When t...

Page 435: ...DT B 1 Malfunction history is not displayed on the YDT B 3 EAS32882 B 3 MALFUNCTION HISTORY IS NOT DISPLAYED Use the YDT to check whether automatic deactivation history for the cruise control system exists 1 There is automatic deactivation history for the cruise control system Explain the conditions for automatically deactivating the cruise control system to the customer For information about the ...

Page 436: ... going uphill the actual traveling speed may become lower than the set cruising speed If this occurs accelerate to the desired traveling speed using the throttle When going downhill the actual traveling speed may become higher than the set cruising speed If this occurs the setting switch cannot be used to adjust the set cruising speed To reduce the traveling speed apply the brakes When the brakes ...

Page 437: ...9 31 CRUISE CONTROL SYSTEM ...

Page 438: ... W B G Y Y B Lg B Lg L Dgy Y B B Y Y W L Y R R R R B B B B B B B B W B B B B B B W B B B B B B B W B W B W B B B B B L B L B Y B L W L W W B B B W B B B B B Br L R 64 67 61 49 5 ON OFF 23 24 96 82 76 68 69 L Y L B B 93 OFF ON Y B Y W Gy L Y B Y 28 OFF ON B G W Y B G Y Y W 29 ON OFF Br G B Y B Br G B Y 30 4 3 9 3 10 11 12 14 16 3 17 18 19 20 B W 62 W B 63 W B Br L R B B W Y B L W L B L B L W Y B W ...

Page 439: ...e 19 ABS motor fuse 20 Backup fuse 23 Battery 24 Engine ground 28 Clutch switch 29 Front brake light switch 30 Rear brake light switch 49 ECU Engine Control Unit 61 Hydraulic unit assembly ABS ECU 62 Front wheel sensor 63 Rear wheel sensor 64 IMU Inertial Measurement Unit 67 YDT coupler 68 Meter assembly 69 Multi function meter 76 MIL Malfunction indicator light 82 ABS warning light 93 Tail brake ...

Page 440: ...eter assembly 2 Hydraulic unit assembly ABS ECU 3 Fuse box ABS motor fuse ABS ECU fuse ABS solenoid fuse 4 YDT coupler 5 Rear wheel sensor 6 Rear wheel sensor rotor 7 Rear brake caliper 8 Front brake caliper left 9 Front wheel sensor 10 Front wheel sensor rotor 11 Front brake caliper right ...

Page 441: ... Y Br R G R G R W B W Lg L W L B G W Y W G W R G B W W G W BSb W G L W Y W L Br L B G OBr WBr B G Br W B R GY B R L W B B W W G G Y L R B Br L W G OW Y L B W Y L B 5 4 2 1 3 1 Meter assembly coupler 2 YDT coupler 3 ABS ECU coupler 4 Rear wheel sensor coupler 5 Front wheel sensor coupler ...

Page 442: ... perform a final check before delivering the vehicle to the customer TIP To final check refer to C 1 FINAL CHECK on page 9 41 ABS operation when the ABS warning light comes on 1 The ABS warning light remains on ABS operates as a normal brake system A malfunction was detected using the ABS self diagnosis function The ABS self diagnosis has not been completed The ABS self diagnosis starts when the m...

Page 443: ... not to damage components by subjecting them to shocks or pulling on them with too much force since the ABS components are precisely adjusted The ABS ECU and hydraulic unit are united assemblies and cannot be disassembled The malfunction history is stored in the memory of the ABS ECU Delete the DTC when the service is finished This is because the past DTC will be displayed again if another malfunc...

Page 444: ... customer Finished Is there automatic deactivation history for the cruise control system Check the malfunction history using the malfunction mode of the YDT Is there any malfunction history Diagnosis using the DTC Yes Yes OK The cruise control power switch is defective The cruise control fuse is blown The ECU is defective Delete the DTC Final check Return to A Return to A When turning the main swi...

Page 445: ...c unit assembly ABS ECU EAS32899 A 2 ALL INDICATOR LIGHTS FAIL TO COME ON 1 Main switch Check the main switch for continuity Refer to CHECKING THE SWITCHES on page 8 39 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 41 If the battery is defective clean the battery terminals and rec...

Page 446: ...pen circuit in the wire harness between the ABS ECU coupler and the YDT coupler Check for continuity between blue white terminal of the ABS ECU coupler and blue white terminal of the YDT coupler CANH Check for continuity between blue black terminal of the ABS ECU coupler and blue black terminal of the YDT coupler CANL 4 ABS ECU malfunction Replace the hydraulic unit assembly ABS ECU EAS32902 A 5 A...

Page 447: ... 1 EAS33339 B 3 DELETING THE DTC To delete the DTCs use the YDT For information about deleting the DTCs refer to the operation man ual of the YDT Check that all the displayed DTCs are deleted TIP Yamaha diagnostic tool A I 90890 03264 includes YDT sub harness 6P 90890 03266 If you already have Yamaha diagnostic tool A I 90890 03262 YDT sub harness 6P 90890 03266 is separately required EAS32905 C 1...

Page 448: ...force properly the brake hose is not properly routed or connected 4 Delete the DTCs Refer to B 3 DELETING THE DTC on page 9 41 5 Checking the ABS warning light Confirm the ABS warning light go off If the ABS warning light does not come on or does not go off refer to A CHECKING THE ABS WARNING LIGHT on page 9 39 If the ABS warning light does not turn off the possible causes are following The proble...

Page 449: ...erturn is detected Unable Unable 17 31_ABS Hydraulic unit assembly ABS ECU de fective ABS solenoid power circuit 33_ABS Hydraulic unit assembly ABS ECU ab normal ABS motor power supply 34_ABS Hydraulic unit assembly ABS ECU short circuit in ABS motor power supply circuit 41_ABS Front wheel ABS intermittent wheel speed pulses or incorrect depressuriza tion 42_ABS Rear wheel ABS intermittent wheel s...

Page 450: ...N communication between meter as sembly and hydraulic unit assembly ABS ECU 90_ABS CAN communication between ECU and hydraulic unit assembly ABS ECU 91_ABS CAN communication between IMU and hydraulic unit assembly ABS ECU C0520 Abnormal IMU Normal signal is not re ceived from the IMU or failure signal is re ceived from IMU Able Unable depending on the situa tion Able Unable depending on the situa ...

Page 451: ... P0113 P0112 Intake air temperature sensor short to ground circuit is detected Nor mal signal is not received from the intake air temperature sensor circuit P0113 Intake air temperature sensor open or short to power circuit is detected Normal signal is not received from the in take air temperature sensor circuit Able Able 05 P0115 Coolant temperature sensor signal stuck Normal signal is not receiv...

Page 452: ...power circuit is de tected Normal signal is not received from the O2 sensor Able Able P0133 O2 sensor deterioration is detected O2 sensor output signal response speed is slow Able Able P0134 O2 sensor signal stuck O2 sensor signal value does not change Able Able P0201 Injector 1 malfunction in injector 1 Normal signal is not received from the in jector circuit Able depending on the num ber of faul...

Page 453: ...l Normal sig nal is not received from the ignition cir cuit Able depending on the num ber of faulty cylinder Able depending on the num ber of faulty cylinder 31 P0353 Cylinder 3 ignition coil open or short circuit is detected in the primary lead of the cylinder 3 ignition coil Normal sig nal is not received from the ignition cir cuit Able depending on the num ber of faulty cylinder Able depending ...

Page 454: ...t sent to ECU Able Able 82 83 P0601 ROM error Internal malfunction in ECU When this malfunction is detected in the ECU the DTC might not appear on the tool display Unable Unable P0606 Processor error Internal malfunction in ECU When this malfunction is detected in the ECU the DTC might not appear on the tool display Able Unable depending on the situa tion Able Unable depending on the situa tion P0...

Page 455: ...ternal circuit mal function of ECU power cut off function Able Unable depending on the situa tion Able Unable depending on the situa tion P1606 P1607 P1606 Intake air pressure sensor 2 short to ground circuit is detected Nor mal signal is not received from the intake air pressure sensor 2 circuit P1607 Intake air pressure sensor 2 open or short to power circuit is detected Normal signal is not rec...

Page 456: ...rom the accelera tor position sensor P2138 Deviation error Normal signal is not received from the accelerator posi tion sensor Able depending on the situa tion Able depending on the situa tion 14 15 P2135 Throttle position sensor output voltage deviation error Normal signal is not re ceived from the throttle position sensor circuit Able depending on the situa tion Able depending on the situa tion ...

Page 457: ...s received from IMU Defective IMU coupler or ECU coupler Open or short cir cuit in wire har ness between IMU and ECU Improperly in stalled IMU Malfunction in IMU Malfunction in ECU Engine cannot be started depending on the circumstanc es Engine cannot be started depending on the circumstanc es Cruise control fixed to OFF P0030 O2 sensor heater defective heater or heater driver ON OFF command and e...

Page 458: ...the in take air pressure sensor 1 circuit Defective coupler between intake air pressure sensor 1 and ECU Open or short cir cuit in wire har ness between intake air pressure sensor 1 and ECU Poor circuit conti nuity in wire har ness between intake air pressure sensor 1 and ECU Defective intake air pressure sen sor 1 Malfunction in ECU Engine idling speed is unstable Engine response is poor Loss of ...

Page 459: ...ignal is not received from the in take air pressure sensor 1 circuit P0108 Intake air pressure sensor 1 open or short to power circuit is de tected Normal sig nal is not received from the intake air pressure sensor 1 circuit P0107 Lowvoltage of the intake air pressure sensor 1 circuit 0 5 V or less P0108 High volt age of the intake air pressure sensor 1 circuit 4 8 V or more Defective coupler betw...

Page 460: ... signal out of range Normal signal is not re ceived from the in take air temperature sensor circuit Defective coupler between intake air temperature sen sor and ECU Open or short cir cuit in wire har ness between intake air tempera ture sensor and ECU Improperly in stalled intake air temperature sen sor Poor circuit conti nuity in wire har ness between intake air tempera ture sensor and ECU Defect...

Page 461: ...fective intake air temperature sensor Malfunction in ECU Engine is difficult to start Increased exhaust emissions Engine idling speed is unstable The intake air tem perature is fixed to 20 C O2 sensor heater driving is not carried out O2 feedback is not carried out ISC feedback is not carried out ISC learning is not carried out Quick shift system is not carried out Cruise control fixed to OFF P011...

Page 462: ...t tempera ture sensor and ECU Improperly in stalled coolant temperature sen sor Defective coolant temperature sen sor Malfunction in ECU Engine is difficult to start Increased exhaust emissions Engine idling speed is unstable Radiator fan motor relay is ON only when the vehicle is traveling at low speeds O2 feedback is not carried out ISC feedback is not carried out ISC learning is not carried out...

Page 463: ...erature sen sor and ECU Open or short cir cuit in wire har ness between coolant tempera ture sensor and ECU Poor circuit conti nuity in wire har ness between coolant tempera ture sensor and ECU Improperly in stalled coolant temperature sen sor Defective coolant temperature sen sor Malfunction in ECU Engine is difficult to start Increased exhaust emissions Engine idling speed is unstable Radiator f...

Page 464: ...or less P0123 P0223 High voltage of the throttle position sen sor circuit 4 75 V or more P2135 Difference in output voltage 1 and output voltage 2 of the throttle posi tion sensor Defective coupler between throttle position sensor and ECU Open or short cir cuit in wire har ness between throttle position sensor and ECU Improperly in stalled throttle po sition sensor Defective throttle position sens...

Page 465: ... condition Improperly in stalled O2 sensor Incorrect fuel pres sure Defective O2 sen sor Malfunction in ECU Increased exhaust emissions Quick shift system is not carried out Cruise control fixed to OFF P0201 P0202 P0203 P0201 Injector 1 malfunction in injec tor 1 Normal sig nal is not received from the injector cir cuit P0202 Injector 2 malfunction in injec tor 2 Normal sig nal is not received fro...

Page 466: ... pow er Engine idling speed is unstable Drivability is unsta ble Increased exhaust emissions P0302 Misfire in cylinder 2 Large difference value in angular ve locity of crankshaft Ignition system malfunction abnor mal Fuel system mal function abnormal Engine is difficult to start Loss of engine pow er Engine idling speed is unstable Drivability is unsta ble Increased exhaust emissions P0303 Misfire...

Page 467: ...mal signal is not re ceived from the ignition circuit P0353 Cylinder 3 ignition coil open or short circuit is de tected in the primary lead of the cylinder 3 ignition coil Nor mal signal is not re ceived from the ignition circuit Defective coupler between ignition coil and ECU Open or short cir cuit in wire har ness between ignition coil and ECU Improperly in stalled ignition coil Defective igniti...

Page 468: ...ulic unit as sembly ABS ECU and ECU Defective rear wheel sensor Malfunction in ECU Vehicle speed is not displayed on the meter P1500 Indication of the neutral indica tor light is incorrect Engine idling speed is unstable Traction control does not work Vehicle speed dis played on the meter 0 km h O2 feedback is not carried out Fuel cut off control when the rear wheel sensor or neutral switch malfun...

Page 469: ...re har ness between cruise control set ting switch and ECU Defective cruise control setting switch Malfunction in ECU Cruise control can not be used Cruise control fixed to OFF P056C Front brake light switch open or short circuit is de tected Normal sig nal is not sent to ECU Rear brake light switch open or short circuit is de tected Normal sig nal is not sent to ECU Open or short cir cuit in wire...

Page 470: ...roperly written Malfunction in ECU Increased exhaust emissions Engine cannot be started or is difficult to start Engine idling speed is unstable OBD memory value is not correct CO adjustment val ue for the faulty cyl inder 0 default value ISC learning values Default values OBD memory value is initialized Initialization of O2 feedback learning value Cruise control fixed to OFF P0638 YCC T drive sys...

Page 471: ...mproper display for gear position Engine response is poor Quick shift system is not carried out Cruise control fixed to OFF P0915 Gear position sen sor out of control signal range and normal signal is not received from the gear position sensor to ECU Defective coupler between gear po sition sensor and ECU Open or short cir cuit in wire har ness between gear position sen sor and ECU Poor circuit co...

Page 472: ...aintains the gear position value at the previous value Quick shift system is not carried out Cruise control fixed to OFF P1004 Intake air pressure sensor 1 and intake air pressure sensor 2 When the main switch is ON the standard voltage values of Intake air pressure sensor 1 and intake air pres sure sensor 2 are large different Intake air pressure sensor 1 hose or intake air pressure sensor 2 hose...

Page 473: ...tral switch Defective clutch switch Improper adjust ment of clutch le ver Malfunction in ECU Vehicle speed is not displayed on the meter Indication of the neutral indicator light is incorrect Engine idling speed is unstable Traction control does not work Vehicle speed dis played on the meter 0 km h O2 feedback is not carried out Fuel cut off control when the rear wheel sensor or neutral switch mal...

Page 474: ...in ECU Engine cannot be started Engine is forcefully stopped theinjector output is stopped Cruise control fixed to OFF P1602 Malfunction in ECU internal circuit mal function of ECU power cut off func tion Open or short cir cuit in wire har ness between ECU and battery Open or short cir cuit in wire har ness between ECU and main switch Blown backup fuse 2 Malfunction in ECU Engine idling speed is u...

Page 475: ...ake air pressure sensor 2 clogging of hose or sensor in stallation improper ly Stable pressure is not supplied Intake air pressure sensor 2 hose is not installed Intake air pressure sensor 2 hose is not installed cor rectly Detached clogged twisted or pinching Intake air pressure sensor 2 hole is clogged or intake air pressure sen sor is not installed correctly Engine idling speed is high Engine i...

Page 476: ...er between accelera tor position sensor and ECU Open or short cir cuit in wire har ness between accelerator posi tion sensor and ECU Improperly in stalled accelerator position sensor Defective acceler ator position sen sor Malfunction in ECU Engine response is poor Loss of engine pow er Engine idling speed is unstable No change in accel erator opening transient control is not carried out Accelerat...

Page 477: ... out Quick shift system is not carried out Cruise control fixed to OFF U0125 Signals cannot be transmittedbetween the ECU and the IMU Defective IMU coupler or ECU coupler Open or short cir cuit in wire har ness between IMU and ECU Malfunction in IMU Malfunction in ECU Engine cannot be started Engine cannot be started Cruise control fixed to OFF DTC Item 51 Immobilizer unit Code cannot be transmitt...

Page 478: ...while the vehicle is traveling Foreign material ad hered around the rear wheel sensor Incorrect installation of the rear wheel Defective sensor rotor or incorrect installation of the rotor Defective rear wheel sensor or incorrect in stallation of the sensor 13 26 Front wheel sensor ab normal pulse period Front wheel sensor signal is not received properly The pulse period is ab normal while the veh...

Page 479: ...S ECU Open or short circuit in the wire harness be tween the rear wheel sensor and the hydraulic unit assembly ABS ECU Defective rear wheel sensor or hydraulic unit assembly ABS ECU 21 Hydraulic unit assembly ABS ECU defective so lenoid drive circuit Solenoid drive circuit in the hydraulic unit assem bly ABS ECU is open or short circuited Defective hydraulic unit assembly ABS ECU 31 Hydraulic unit...

Page 480: ... the signal is transmitted from the ABS ECU to re duce the hydraulic pres sure Incorrect installation of the front wheel sensor Incorrect rotation of the front wheel Front brake dragging Defective hydraulic unit assembly ABS ECU 42 Rear wheel ABS intermit tent wheel speed pulses or incorrect depressuriza tion Pulses from the rear wheel sensor are re ceived intermittently while the vehicle is trav ...

Page 481: ...t assembly ABS ECU Open or short circuit in the wire harness be tween the battery and the hydraulic unit assembly ABS ECU Defective charging sys tem 55 Hydraulic unit assembly ABS ECU defective ABS ECU Abnormal data is detected in the hydraulic unit as sembly ABS ECU Defective hydraulic unit assembly ABS ECU 56 Hydraulic unit assembly ABS ECU abnormal in ternal circuit Abnormality detected in of h...

Page 482: ... short circuit between meter assembly and hy draulic unit assembly ABS ECU Defective meter assem bly Defective hydraulic unit assembly ABS ECU 90 CAN communication be tween ECU and hydraulic unit assembly ABS ECU Transmitted data from the FI ECU cannot be normal ly received Defective coupler be tween FI ECU and hy draulic unit assembly ABS ECU Harness is broken or short circuit between FI ECU and ...

Page 483: ...not carried out Cruise control fixed to OFF Diagnostic code No Item Tool display Procedure 01 Throttle position sensor signal 1 0 125 Fully closed position 11 21 Check the fully closed throttle valve Fully opened position 96 107 Check the fully opened throttle valve 03 Intake air pressure Displays the intake air pressure 0 126 kPa When engine is stopped Atmospheric pressure at the current altitude...

Page 484: ... creases when the rear wheel is rotated The num ber is cumulative and does not reset each time the wheel is stopped 09 Fuel system voltage battery voltage Displays the fuel system voltage 0 18 7 V Standard voltage Approx 12 0 V Compare the actually measured battery voltage with the tool displayed val ue If the actually mea sured battery voltage is low recharge the battery 13 Throttle position sens...

Page 485: ...isplays the bank angle in increments of 5 0 60 0 5 vehicle is vertical Less than 30 when the sidestand is used Check that 0 5 is dis played when the vehicle is vertical and that the dis played value increases as the vehicle continues to in cline 20 Sidestand switch Extend and retract the sidestand Sidestand retracted ON Sidestand extended OFF 21 Neutral switch and clutch switch Operate the transmi...

Page 486: ...Speed Control learning data erasure 00 ISC Idle Speed Control learning data has been erased 01 It is not necessary to erase the ISC Idle Speed Con trol learning data 02 It is necessary to erase the ISC Idle Speed Control learning data To erase the ISC Idle Speed Control learning data push the Operation button 3 times within 5 seconds 70 Programmed unit Ver number 0 254 Check the programmed unit Ve...

Page 487: ...eezed ON Brake lever is released OFF Brake pedal is depressed ON Brake pedal is released OFF 87 O2 feedback learning data erasure 00 O2 feedback learning data has been erased 01 O2 feedback learning data has not been erased To erase the O2 feedback learning data push the Operation button 3 times within 5 seconds 95 Shift sensor Check the sensor condi tion by operating the shift pedal Shift sensor ...

Page 488: ...ck the sparking per formance on the spark plug 36 Injector 1 Actuates the injector 1 five times at one second intervals The check indicator on the YDT screen comes on each time the injector is actuated Disconnect the fuel pump coupler before doing this procedure Check that injector 1 is actuated five times by lis tening for the operating sound 37 Injector 2 Actuates the injector 2 five times at on...

Page 489: ... check indicator on the YDT screen comes on each time the relay is actu ated Check that the radiator fan motor relay is actuated five times by listening for the operating sound 52 Headlight relay Actuates the headlight re lay five times at five sec onds intervals The check indicator on the YDT screen comes on each time the headlight re lay is actuated Check that the headlight relay comes on five t...

Page 490: ...m perature sensor Brief abnormality detected in the in takeairtemperature sensor Same as for DTC num ber P0112 and P0113 Perform the inspection items listed for DTC num ber P0112 and P0113 199 Intake air pres sure sensor 2 Brief abnormality detected in the in take air pressure sensor 2 Same as for DTC No P1606 and P1607 Perform the inspection items listed for DTC No P1606 and P1607 207 Accelerator...

Page 491: ...n the sys tem is functioning properly 243 ISC Stuck at the lower limit for adjustment During idling the adjustment is main tained at the lower limit Idling engine speed is fast Poorly adjusted clutch cable Malfunction in the fuel injection system Dirty or worn spark plug Malfunction in the battery Malfunction in ECU If a DTC is occurring respond to that first Rarely Code 243 oc curs even when the ...

Page 492: ...traveling up a steep slope Wheel slip detected Engine stalls Sidestand is extend ed Engine stop switch is set to the posi tion The automatic turning off of the cruise control sys tem does not indicate a malfunction in the sys tem 251 Shift sensor Brief abnormality detected in the shift sensor Same as for DTC num ber P1806 and P1807 Perform the inspection items listed for DTC num ber P1806 and P180...

Page 493: ...e 4 1 Check the grommet for cracks 3 Defective IMU Execute the diagnostic mode Code 17 Check that 0 5 is displayed when the vehicle is vertical and that the displayed value increases as the vehicle continues to incline Is the MIL on YES Go to step 2 NO Service is completed Is check result OK YES Go to step 3 NO a Fix the IMU installation condition b Turn the main switch to ON then to OFF and then ...

Page 494: ...9 88 30_EVENT 4 Malfunction in ECU Replace the ECU and complete the service Refer to REPLACING THE ECU Engine Control Unit on page 8 41 Is the MIL on YES Go to step 4 NO Service is completed ...

Page 495: ...s displayed at the same time check the other error code first and repair it 1 Allow to idle for a long period Turn the main switch to OFF Check whether it is possible to start the engine 2 Malfunction in ECU Replace the ECU and complete the service Refer to REPLACING THE ECU Engine Control Unit on page 8 41 Can the engine starting YES Service is completed NO Go to step 2 ...

Page 496: ... or broken terminals and locking condition of the pins 3 Wire harness continuity Disconnect the ECU coupler 1 IMU coupler 3 and ignition fuse 2 4 Remove the joint coupler cap 2 Open circuit check Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Turn the main switch to ON and then check the DTC using the malfunction mode of the YDT Is ...

Page 497: ...er 3 red white red white Is resistance 0 Ω YES Go to Short circuit check NO a Replace the wire harness b Turn the main switch to ON and then check the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to Short circuit check Between ECU coupler 1 and ground blue black ground blue white ground Between IMU coupler 3 and ground b...

Page 498: ...ire harness b Turn the main switch to ON and then check the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to step 4 Is check result OK YES Go to step 5 NO a Fix the IMU installation condition b Turn the main switch to ON and then check the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go t...

Page 499: ...of the YDT 6 Malfunction in ECU Replace the ECU and complete the service Refer to REPLACING THE ECU Engine Control Unit on page 8 41 7 Delete the DTC and check that the MIL goes off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to step 6 ...

Page 500: ... switch to ON 2 Connection of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Turn the main switch to ON and then check the DTC using the malfunction mode of the YDT Is it in the ...

Page 501: ...sensor coupler 1 and ECU cou pler 2 pink black pink black Between O2 sensor coupler 1 and ignition fuse holder 3 red red Is resistance 0 Ω YES Go to Short circuit check NO a Replace the wire harness b Turn the main switch to ON and then check the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 6 and complete the service NO Start the engine and then check t...

Page 502: ...etween O2 sensor coupler 1 and ground red ground pink black ground O2 sensor coupler 1 red any other coupler terminal pink black any other coupler terminal ECU coupler 2 pink black any other coupler terminal Is resistance Ω YES Go to step 4 NO a Replace the wire harness b Turn the main switch to ON and then check the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go...

Page 503: ...ontrol Unit on page 8 41 6 Delete the DTC and check that the MIL goes off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC Is it in the Recovered condition YES Go to step 6 and complete the service NO Start the engine and then check the DTC Is it in the Recovered condition YES Go to step 6 and complete the service NO Go to step 5 ...

Page 504: ...eck the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Is check result OK YES Go to step 2 NO a Reinstall or replace the O2 sensor Refer to ENGINE REMOVAL on page 5 9 b Start the engine and let it idle for approximately 1 minute c Check the DTC using the malfunction mode of the YDT Is it in the Recovered conditi...

Page 505: ...using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 8 and complete the service NO Go to step 4 Between O2 sensor coupler 1 and ECU cou pler 2 gray green gray green pink black pink black black blue black blue Between O2 sensor coupler 1 and ignition fuse holder 3 red red Is resistance 0 Ω YES Go to Short circuit check NO a Replace the wire harness b Start the engin...

Page 506: ...her coupler terminal pink black any other coupler terminal black blue any other coupler terminal red any other coupler terminal ECU coupler 2 gray green any other coupler terminal pink black any other coupler terminal black blue any other coupler terminal Is resistance Ω YES Go to step 5 NO a Replace the wire harness b Start the engine and let it idle for approximately 1 minute c Check the DTC usi...

Page 507: ... 8 Delete the DTC and check that the MIL goes off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC Is it in the Recovered condition YES Go to step 8 and complete the service NO Go to step 5 Is check result OK YES Go to step 6 NO a Replace the fuel pump Refer to REMOVING THE FUEL PUMP on page 7 4 b Start the engine and let it idle for approximately 1 minute c ...

Page 508: ...essure sensor 1 Replace the intake air pressure sensor 1 Refer to THROTTLE BODIES on page 7 6 Turn the main switch to ON and then check the DTC using the malfunction mode of the YDT 3 Defective wire harness Replace the wire harness Turn the main switch to ON and then check the DTC using the malfunction mode of the YDT Is the coupler condition normal YES Go to step 2 NO a Connect the coupler secure...

Page 509: ...eplace the ECU and complete the service Refer to REPLACING THE ECU Engine Control Unit on page 8 41 5 Delete the DTC and check that the MIL goes off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC ...

Page 510: ...the diagnostic mode Code 03 When engine is stopped Atmospheric pressure at the current altitude and weather conditions is in dicated When engine is cranking Make sure that the indication value changes Is check result OK YES Go to step 2 NO a Repair or replace the intake air pressure sensor 1 hose Refer to THROTTLE BODIES on page 7 6 b Start the engine and let it idle for approximately 5 seconds wi...

Page 511: ...Is check result OK YES Go to step 3 and complete the service NO a Replace the intake air pressure sensor 1 Refer to THROTTLE BODIES on page 7 6 b Start the engine and let it idle for approximately 5 seconds with the throttle fully closed and then check the DTC using the malfunction mode of the YDT c Confirm the Recovered condition then go to step 3 ...

Page 512: ...k the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins 3 Wire harness continuity Disconnect the intake air pressure sensor 1 coupler 1 and ECU coupler 3 Remove the joint coupler cap 2 Open circuit check Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b...

Page 513: ...e sensor 1 coupler 1 and joint coupler 2 P0108 black black Is resistance 0 Ω YES Go to Short circuit check NO a Replace the wire harness b Turn the main switch to ON and then check the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to Short circuit check Between intake air pressure sensor 1 coupler 1 and ground blue ground...

Page 514: ...k any other coupler terminal P0107 P0108 pink white any other coupler terminal Joint coupler 2 P0108 black blue any other coupler terminal P0108 black any other coupler terminal Is resistance Ω YES Go to step 4 NO a Replace the wire harness b Turn the main switch to ON and then check the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the se...

Page 515: ...sensor b Turn the main switch to ON and then check the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to step 5 At sea level Approx 101 kPa 757 6 mmHg 29 8 inHg ap prox 3 64 V 1000 m 3300 ft above sea level Approx 90 kPa 675 1 mmHg 26 6 inHg ap prox 3 30 V 2000 m 6700 ft above sea level Approx 80 kPa 600 0 mmHg 23 6 inHg a...

Page 516: ...sor Measure and note the intake air temperature sensor resistance at ambient temperature Heat the intake air temperature sensor using warm water or hot air and measure the intake air tem perature sensor resistance then compare the noted resistance at ambient temperature Is check result OK YES Go to step 2 NO a Clean around the intake air temperature sensor then reinstall it b Turn the main switch ...

Page 517: ...to REPLACING THE ECU Engine Control Unit on page 8 41 4 Delete the DTC and check that the MIL goes off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC Is it in the Recovered condition YES Go to step 4 and complete the service NO Go to step 3 ...

Page 518: ...dition of the pins 2 Connection of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Execute the diagnostic mode Code 05 When engine is cold Displayed temperature is close to the am...

Page 519: ...r b Execute the diagnostic mode Code 05 When engine is cold Displayed temperature is close to the ambient temperature Is check result OK YES Go to step 7 and complete the service NO Go to step 4 Intake air temperature sensor resistance 6 0 0 6 kΩ at 0 C 6 0 0 6 kΩ at 32 F 0 29 0 39 kΩ at 80 C 0 29 0 39 kΩ at 176 F Is check result OK YES Go to step 5 NO a Replace the intake air temperature sensor R...

Page 520: ...eplace the ECU and complete the service Refer to REPLACING THE ECU Engine Control Unit on page 8 41 7 Delete the DTC and check that the MIL goes off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC ...

Page 521: ...k the pins bent or broken terminals and locking condition of the pins 2 Connection of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Turn the main switch to ON and then check the...

Page 522: ... Between ECU coupler 3 and joint coupler 2 P0113 black blue black blue Between intake air temperature sensor coupler 1 and joint coupler 2 P0113 black black Is resistance 0 Ω YES Go to Short circuit check NO a Replace the wire harness b Turn the main switch to ON and then check the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service ...

Page 523: ...t coupler 2 P0113 black blue any other coupler terminal P0113 black any other coupler terminal ECU coupler 3 P0112 P0113 brown white any other coupler terminal P0113 black blue any other coupler terminal Is resistance Ω YES Go to step 5 NO a Replace the wire harness b Turn the main switch to ON and then check the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to ...

Page 524: ...TC and check that the MIL goes off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC Is check result OK YES Go to step 5 NO a Reinstall or replace the sensor b Turn the main switch to ON and then check the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to step 5 Is check result OK YES ...

Page 525: ...rm up the vehicle Measure the coolant temperature sensor resistance at engine warmed up then compare the noted resistance at ambient temperature 2 Malfunction in ECU Replace the ECU and complete the service Refer to REPLACING THE ECU Engine Control Unit on page 8 41 3 Delete the DTC and check that the MIL goes off Confirm that the DTC has a condition of Recovered using the YDT and then delete the ...

Page 526: ...on of the pins 2 Connection of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Execute the diagnostic mode Code 06 When engine is cold Displayed temperature is close to the ambien...

Page 527: ... to step 4 NO a Reinstall or replace the sensor b Execute the diagnostic mode Code 06 When engine is cold Displayed temperature is close to the ambient temperature Is check result OK YES Go to step 7 and complete the service NO Go to step 4 Coolant temperature sensor resistance 2 645 kΩ 5 at 20 C 2 645 kΩ 5 at 68 F 0 216 kΩ 2 5 at 100 C 0 216 kΩ 2 5 at 212 F Is check result OK YES Go to step 5 NO ...

Page 528: ... Refer to REPLACING THE ECU Engine Control Unit on page 8 41 7 Delete the DTC and check that the MIL goes off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC Is check result OK YES Go to step 7 and complete the service NO Go to step 6 ...

Page 529: ...ns bent or broken terminals and locking condition of the pins 2 Connection of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Turn the main switch to ON and then check the DTC usi...

Page 530: ...en coolant temperature sensor coupler 1 and joint coupler 2 P0118 black black Between joint coupler 2 and ECU coupler 3 P0118 black blue black blue Is resistance 0 Ω YES Go to step Short circuit check NO a Replace the wire harness b Turn the main switch to ON and then check the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO G...

Page 531: ...ler 2 P0118 black blue any other coupler terminal P0118 black any other coupler terminal ECU coupler 3 P0117 P0118 green white any other coupler terminal P0118 black blue any other coupler terminal Is resistance Ω YES Go to step 4 NO a Replace the wire harness b Turn the main switch to ON and then check the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7...

Page 532: ...DTC and check that the MIL goes off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC Is check result OK YES Go to step 5 NO a Reinstall or replace the sensor b Turn the main switch to ON and then check the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to step 5 Is check result OK YES...

Page 533: ... situation Procedure 1 Connection of throttle position sensor coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins 2 Connection of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Is the coupler...

Page 534: ...on sensor coupler 1 and ECU coupler 2 P0122 P0123 P0222 P0223 white white P0123 P0223 black blue black blue P0122 P0222 blue blue P0122 P0123 P0222 P0223 black black Is resistance 0 Ω YES Go to Short circuit check NO a Replace the wire harness b Turn the main switch to ON and then check the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 8 and complete the...

Page 535: ...oupler terminal P0122 P0123 P0222 P0223 black any other coupler terminal ECU coupler 2 P0122 P0123 P0222 P0223 white any other coupler terminal P0123 P0223 black blue any other coupler terminal P0122 P0222 blue any other coupler terminal P0122 P0123 P0222 P0223 black any other coupler terminal Is resistance Ω YES Go to step 4 NO a Replace the wire harness b Turn the main switch to ON and then chec...

Page 536: ...ion YES Go to step 8 and complete the service NO Go to step 5 When the throttle valves are fully closed 11 21 When throttle valves are fully open 96 107 Is check result OK YES Go to step 6 NO a Replace the throttle position sensor Refer to ADJUSTING THE THROTTLE POSITION SENSOR on page 7 12 b Turn the main switch to ON and then check the DTC using the malfunction mode of the YDT Is it in the Recov...

Page 537: ...ce Refer to REPLACING THE ECU Engine Control Unit on page 8 41 8 Delete the DTC and check that the MIL goes off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC Is it in the Recovered condition YES Go to step 8 and complete the service NO Go to step 7 ...

Page 538: ...ction of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Is check result OK YES Go to step 2 NO a Reinstall or replace the sensor b Turn the main switch to ON and then check the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the servi...

Page 539: ... 7 and complete the service NO Go to step 4 Between O2 sensor coupler 1 and ECU cou pler 3 gray green gray green Between O2 sensor coupler 1 and joint coupler 2 black blue black blue Between joint coupler 2 and ECU coupler 3 black blue black blue Is resistance 0 Ω YES Go to Short circuit check NO a Replace the wire harness b Turn the main switch to ON and then check the DTC using the malfunction m...

Page 540: ...ue any other coupler terminal Joint coupler 2 black blue any other coupler terminal ECU coupler 3 gray green any other coupler terminal black blue any other coupler terminal Is resistance Ω YES Go to step 5 NO a Replace the wire harness b Turn the main switch to ON and then check the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the servic...

Page 541: ...n mode of the YDT 6 Malfunction in ECU Replace the ECU and complete the service Refer to REPLACING THE ECU Engine Control Unit on page 8 41 7 Delete the DTC and check that the MIL goes off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to step 6 ...

Page 542: ...mory of the ECU Then if the abnormality is detected in the next two driving cycles the MIL comes on and the DTC and FFD are stored If the vehicle is judged to be operating normally for three consecutive driving cycles the MIL goes off However the DTC pending DTC and FFD will not be deleted even if a battery terminal is dis connected Reproduction test Perform the test using the driving pattern acco...

Page 543: ...rform reproduction test and connect the YDT Check that the pending DTC is not detected and readiness status is Complete Then complete the troubleshooting 60 40 A B C D E F G A Speed km h B Time min C Start the engine D Idle warm up E 5 min F Total 15 min G Stop the engine Is pending DTC displayed Yes Delete the pending DTC then go to step 4 No Check the readiness status Readiness status is Complet...

Page 544: ...of O2 sensor Check for looseness or pinching Refer to ENGINE REMOVAL on page 5 9 Is check result OK YES Go to step 2 NO a Check the ignition spark gap Refer to CHECKING THE IGNITION SPARK GAP on page 8 44 b Test ride the vehicle according to the test ride conditions for the O2 deterioration diagnosis Refer to step 2 in TROUBLESHOOTING on page 9 137 At this time do not check the malfunction diagnos...

Page 545: ...Delete the DTC and check that the MIL goes off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC Is it in the Recovered condition YES Go to step 6 and complete the service NO Go to step 3 Is check result OK YES Go to step 4 NO a Replace the fuel pump Refer to REMOVING THE FUEL PUMP on page 7 4 b Test ride the vehicle according to the test ride conditions for t...

Page 546: ... 2 Defective injector 1 Measure the injector resistance Refer to CHECKING THE FUEL INJECTORS on page 8 49 3 Connection of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Execute t...

Page 547: ...t hear operating sound YES Go to step 6 NO Go to step 4 Between injector 1 coupler 1 and ECU cou pler 2 red black red black Between injector 1 coupler 1 and relay unit coupler 3 red blue red Is resistance 0 Ω YES Go to Short circuit check NO a Replace the wire harness b Execute the diagnostic mode Code 36 Is it hear operating sound YES Go to step 6 NO Go to Short circuit check R B R L W L W R L B ...

Page 548: ...of Recovered using the malfunction mode of the YDT and then delete the DTC Between injector 1 coupler 1 and ground red black ground red blue ground Injector 1 coupler 1 red black any other coupler terminal red blue any other coupler terminal ECU coupler 2 red black any other coupler terminal Relay unit coupler 3 red any other coupler terminal Is resistance Ω YES Go to step 5 NO a Replace the wire ...

Page 549: ... 2 Defective injector 2 Measure the injector resistance Refer to CHECKING THE FUEL INJECTORS on page 8 49 3 Connection of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Execute t...

Page 550: ...hear operating sound YES Go to step 6 NO Go to step 4 Between injector 2 coupler 1 and ECU cou pler 2 green black green black Between injector 2 coupler 1 and relay unit coupler 3 red blue red Is resistance 0 Ω YES Go to Short circuit check NO a Replace the wire harness b Execute the diagnostic mode Code 37 Is it hear operating sound YES Go to step 6 NO Go to Short circuit check G B R L W L W R L ...

Page 551: ...Recovered using the malfunction mode of the YDT and then delete the DTC Between injector 2 coupler 1 and ground green black ground red blue ground Injector 2 coupler 1 green black any other coupler terminal red blue any other coupler terminal ECU coupler 2 green black any other coupler terminal Relay unit coupler 3 red any other coupler terminal Is resistance Ω YES Go to step 5 NO a Replace the wi...

Page 552: ... 2 Defective injector 3 Measure the injector resistance Refer to CHECKING THE FUEL INJECTORS on page 8 49 3 Connection of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Execute t...

Page 553: ... hear operating sound YES Go to step 6 NO Go to step 4 Between injector 3 coupler 1 and ECU cou pler 2 blue black blue black Between injector 3 coupler 1 and relay unit coupler 3 red blue red Is resistance 0 Ω YES Go to Short circuit check NO a Replace the wire harness b Execute the diagnostic mode Code 38 Is it hear operating sound YES Go to step 6 NO Go to Short circuit check L B R L W L W R L B...

Page 554: ... Recovered using the malfunction mode of the YDT and then delete the DTC Between injector 3 coupler 1 and ground blue black ground red blue ground Injector 3 coupler 1 blue black any other coupler terminal red blue any other coupler terminal ECU coupler 2 blue black any other coupler terminal Relay unit coupler 3 red any other coupler terminal Is resistance Ω YES Go to step 5 NO a Replace the wire...

Page 555: ...es not damage the catalyst but affect the exhaust gas emission level the DTC is stored in the ECU and the MIL comes on Requirement for detection Related sensors for detection Intake air pressure sensor coolant temperature sensor or engine temperature sensor front wheel sensor rear wheel sensor crankshaft position sensor and throttle position sensor Frequency of detection Always Time required for d...

Page 556: ...tion Able Unable to drive vehicle depending on the situation EAS32820 TROUBLESHOOTING TIP If more than one DTC is detected at the same time perform troubleshooting of DTCs listed below first DTC except P0300 P0301 P0302 P0303 If more than one misfire DTC has been detected at the same time open each FFD and check the total ECU energization time at the time of failure or event and refer to the lates...

Page 557: ...ngine Conversion table of steady driving time Engine speed r min Time sec 2000 240 3000 160 4000 120 5000 96 6000 80 7000 70 8000 60 9000 54 10000 48 Is the pending DTC displayed Yes Delete the pending DTC then go to step 4 No Confirm the engine speed vehicle speed and gear position to the customer when the customer feels an abnormality Go to step 2 If the pending DTC is not displayed after severa...

Page 558: ...oolant temperature sensor or Engine temperature sensor Front wheel sensor Rear wheel sensor Crankshaft position sensor Throttle position sensor Gear position sensor 6 Perform a reproduction test and connect the YDT Check that the pending DTC is not detected then complete the troubleshooting Is the inspection result OK Yes Go to step 5 No Repair or replace the defective part then go to step 6 ...

Page 559: ...oken terminals and locking condition of the pins 3 Wire harness continuity Disconnect the crankshaft position sensor coupler 1 and ECU coupler 3 Remove the joint coupler cap 2 Open circuit check Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Crank the engine and then check the DTC using the malfunction mode of the YDT Is it in the R...

Page 560: ...e engine and then check the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to Short circuit check Between crankshaft position sensor coupler 1 and ground gray ground Crankshaft position sensor coupler 1 black blue any other coupler terminal gray any other coupler terminal Joint coupler 2 black any other coupler terminal bl...

Page 561: ...ace the wire harness b Crank the engine and then check the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to step 4 Is check result OK YES Go to step 5 NO a Reinstall or replace the sensor b Crank the engine and then check the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and c...

Page 562: ... Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC Is check result OK YES Go to step 6 NO a Replace the stator coil assembly Refer to GENERATOR AND STARTER CLUTCH on page 5 37 b Crank the engine and then check the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to step 6 ...

Page 563: ...CU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Start the engine and let it idle for approximately 5 seconds c Check the DTC using the malfunction mode of the YDT Is it in the Reco...

Page 564: ... orange Is resistance 0 Ω YES Go to Short circuit check NO a Replace the wire harness b Start the engine and let it idle for approximately 5 seconds c Check the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to Short circuit check Between cylinder 1 ignition coil coupler 1 and ground orange ground Cylinder 1 ignition coil ...

Page 565: ...et it idle for approximately 5 seconds c Check the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to step 4 Is check result OK YES Go to step 5 NO a Reinstall or replace the ignition coil b Start the engine and let it idle for approximately 5 seconds c Check the DTC using the malfunction mode of the YDT Is it in the Recove...

Page 566: ... check that the MIL goes off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC Is check result OK YES Go to step 6 NO a Replace the cylinder 1 ignition coil Refer to CAMSHAFTS on page 5 16 b Start the engine and let it idle for approximately 5 seconds c Check the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and co...

Page 567: ...CU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Start the engine and let it idle for approximately 5 seconds c Check the DTC using the malfunction mode of the YDT Is it in the Reco...

Page 568: ... red Is resistance 0 Ω YES Go to Short circuit check NO a Replace the wire harness b Start the engine and let it idle for approximately 5 seconds c Check the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to Short circuit check Between cylinder 2 ignition coil coupler 1 and ground gray red ground Cylinder 2 ignition coil c...

Page 569: ...it idle for approximately 5 seconds c Check the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to step 4 Is check result OK YES Go to step 5 NO a Reinstall or replace the ignition coil b Start the engine and let it idle for approximately 5 seconds c Check the DTC using the malfunction mode of the YDT Is it in the Recovered...

Page 570: ... check that the MIL goes off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC Is check result OK YES Go to step 6 NO a Replace the cylinder 2 ignition coil Refer to CAMSHAFTS on page 5 16 b Start the engine and let it idle for approximately 5 seconds c Check the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and co...

Page 571: ...CU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Start the engine and let it idle for approximately 5 seconds c Check the DTC using the malfunction mode of the YDT Is it in the Reco...

Page 572: ...een Is resistance 0 Ω YES Go to Short circuit check NO a Replace the wire harness b Start the engine and let it idle for approximately 5 seconds c Check the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to Short circuit check Between cylinder 3 ignition coil coupler 1 and ground orange green ground Cylinder 3 ignition coi...

Page 573: ... it idle for approximately 5 seconds c Check the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to step 4 Is check result OK YES Go to step 5 NO a Reinstall or replace the ignition coil b Start the engine and let it idle for approximately 5 seconds c Check the DTC using the malfunction mode of the YDT Is it in the Recovere...

Page 574: ... check that the MIL goes off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC Is check result OK YES Go to step 6 NO a Replace the cylinder 3 ignition coil Refer to CAMSHAFTS on page 5 16 b Start the engine and let it idle for approximately 5 seconds c Check the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and co...

Page 575: ...dition of the pins 3 Wire harness continuity Disconnect the ignition fuse 1 purge cut valve solenoid coupler 2 ECU coupler 3 and main switch coupler 4 Open circuit check Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Turn the main switch to ON and then check the DTC using the malfunction mode of the YDT Is it in the Recovered condit...

Page 576: ...heck NO a Replace the wire harness b Turn the main switch to ON and then check the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to Short circuit check Between purge cut valve solenoid coupler 2 and ground red white ground yellow red ground Between main switch coupler 4 and ground brown blue ground Purge cut valve solenoi...

Page 577: ...ion mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to step 4 Is check result OK YES Go to step 5 NO a Reinstall or replace the purge cut valve solenoid Refer to FUEL TANK on page 7 1 b Turn the main switch to ON and then check the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO...

Page 578: ...alfunction mode of the YDT and then delete the DTC Is it hear operating sound YES Go to step 7 and complete the service NO Check the purge cut valve solenoid Refer to CHECKING THE PURGE CUT VALVE SOLENOID on page 8 50 Is check result OK YES Go to step 6 NO a Replace the purge cut valve solenoid Refer to FUEL TANK on page 7 1 b Turn the main switch to ON and then check the DTC using the malfunction...

Page 579: ... of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Turn the main switch to ON and then check the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 6 and complete the service NO Go t...

Page 580: ... coupler 2 green yellow green yellow Is resistance 0 Ω YES Go to Short circuit check NO a Replace the wire harness b Turn the main switch to ON and then check the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 6 and complete the service NO Go to Short circuit check Between radiator fan motor relay 1 and ground green yellow ground red ground Radiator fan m...

Page 581: ...es off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC Is resistance Ω YES Go to step 4 NO a Replace the wire harness b Turn the main switch to ON and then check the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 6 and complete the service NO Go to step 4 Is it in the Recovered condition YES Go to step 6 and complet...

Page 582: ...is detected or both P0500 and P1500 are detected proceed from step 1 If more than one DTC is detected at the same time perform troubleshooting of DTC listed below first P0335 1 Locate the malfunction DTCs P0500 or P0500 and P1500 detected a Execute the diagnostic mode Code 07 b Rotate the rear wheel by hand and check that the indicated value increases TIP Perform the procedure from step 2 to step ...

Page 583: ...clutch lever squeezed and the sidestand retracted ON Is check result OK YES Go to step 20 NO Go to step 15 Is the coupler condition normal YES Go to step 3 NO a Connect the coupler securely or replace the wire harness b Execute the diagnostic mode Code 07 c Rotate the rear wheel by hand and check that the indicated value increases Is that value increased YES Go to step 20 NO Go to step 3 Is the co...

Page 584: ... rear wheel by hand and check that the indicated value increases Is that value increased YES Go to step 20 NO Go to step 5 Between rear wheel sensor coupler 1 and ABS ECU coupler 2 black black white white Between ABS ECU coupler 2 and ECU cou pler 3 white yellow white yellow Is resistance 0 Ω YES Go to Short circuit check NO a Replace the wire harness b Execute the diagnostic mode Code 07 c Rotate...

Page 585: ... 1 black any other coupler terminal white any other coupler terminal ABS ECU coupler 2 black any other coupler terminal white any other coupler terminal white yellow any other coupler terminal ECU coupler 3 white yellow any other coupler terminal Is resistance Ω YES Go to step 6 NO a Replace the wire harness b Execute the diagnostic mode Code 07 c Rotate the rear wheel by hand and check that the i...

Page 586: ...nd locking condition of the pins Is that value increased YES Go to step 20 NO Go to step 7 Is the coupler condition normal YES Go to step 9 NO a Connect the coupler securely or replace the wire harness b Execute the diagnostic mode Code 21 When the transmission is in neutral ON When the transmission is in gear with the clutch lever released OFF Is it correct indication YES Go to step 20 NO Go to s...

Page 587: ...int coupler 4 and ECU coupler 2 black yellow black yellow Between relay unit coupler 1 and neutral switch coupler 3 sky blue sky blue Is resistance 0 Ω YES Go to Short circuit check NO a Replace the wire harness b Execute the diagnostic mode Code 21 When the transmission is in neutral ON When the transmission is in gear with the clutch lever released OFF Is it correct indication YES Go to step 20 ...

Page 588: ...Is resistance Ω YES Go to step 11 NO a Replace the wire harness b Execute the diagnostic mode Code 21 When the transmission is in neutral ON When the transmission is in gear with the clutch lever released OFF Is it correct indication YES Go to step 20 NO Go to step 11 Is check result OK YES Go to step 12 NO a Replace the neutral switch Refer to CRANKCASE on page 5 64 b Execute the diagnostic mode ...

Page 589: ...and locking condition of the pins When the transmission is in neutral ON When the transmission is in gear with the clutch lever released OFF Is it correct indication YES Go to step 20 NO Go to step 12 Is check result OK YES Go to step 13 NO Replace the shift drum and go to step 20 Refer to TRANSMISSION on page 5 87 When the clutch lever is released with the transmission in gear and when the sidest...

Page 590: ...ion YES Go to step 20 NO Go to step 16 Is the coupler condition normal YES Go to step 17 NO a Connect the coupler securely or replace the wire harness b Execute the diagnostic mode Code 21 When the clutch lever is released with the transmission in gear and when the sidestand is retracted OFF When the clutch lever is squeezed with the transmission in gear and when the sidestand is retracted ON Is i...

Page 591: ...er is squeezed with the transmission in gear and when the sidestand is retracted ON Is it correct indication YES Go to step 20 NO Go to Short circuit check Between relay unit coupler 1 and ground black ground blue ground Relay unit coupler 1 black any other coupler terminal blue any other coupler terminal ECU coupler 2 black yellow any other coupler terminal Clutch switch coupler 3 black yellow an...

Page 592: ...tracted ON Is it correct indication YES Go to step 20 NO Go to step 18 Is check result OK YES Go to step 19 NO a Replace the clutch switch Refer to HANDLEBAR on page 4 60 b Execute the diagnostic mode Code 21 When the clutch lever is released with the transmission in gear and when the sidestand is retracted OFF When the clutch lever is squeezed with the transmission in gear and when the sidestand ...

Page 593: ... the main switch to ON and then rotate the rear wheel by hand Start the engine and input the vehicle speed signals by operating the vehicle at 20 to 30 km h 12 to 19 mph Confirm that the DTC has a condition of Recovered using the malfunction mode of the YDT and then delete the DTC Delete this DTC even if it has a condition of Detected Is it correct indication YES Go to step 20 NO Go to step 19 ...

Page 594: ...dure TIP If more than one DTC is detected at the same time perform troubleshooting of DTC listed below first P0335 1 Malfunction in charging system Check the charging system Refer to CHARGING SYSTEM on page 8 13 2 Delete the DTC and check that the MIL goes off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC Is check result OK YES Repeat step 1 NO a Defective...

Page 595: ...xecute the diagnostic mode Code 80 TIP Perform the procedure from step 3 to step 5 and from step 9 to step 10 b Execute the diagnostic mode Code 81 Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Turn the main switch to ON and then push the RES side and SET side of the cruise con trol setting switch c Check the DTC using the malfunct...

Page 596: ...elease the RES side of the cruise control setting switch and then check the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 10 and complete the service NO Go to step 4 Between ignition fuse holder 4 and cruise con trol fuse holder 1 red white red Between cruise control fuse holder 1 and han dlebar switch coupler left 2 yellow white yellow white Between han...

Page 597: ...e NO Go to Short circuit check Between handlebar switch coupler left 2 and ground brown blue ground yellow white ground Handlebar switch coupler left 2 brown blue any other coupler terminal yellow white any other coupler terminal ECU coupler 3 brown blue any other coupler terminal Is resistance Ω YES Go to step 5 NO a Replace the wire harness b Turn the main switch to ON c Push and release the RES...

Page 598: ...Is it in the Recovered condition YES Go to step 10 and complete the service NO Go to step 9 Is check result OK YES Go to step 7 NO a Replace the fuse b Turn the main switch to ON c Push and release the SET side of the cruise control setting switch and then check the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 10 and complete the service NO Go to step 7...

Page 599: ...ion YES Go to step 10 and complete the service NO Go to Short circuit check Between handlebar switch coupler left 2 and ground green blue ground yellow white ground Between main switch coupler 6 and ground red ground brown blue ground Handlebar switch coupler left 2 green blue any other coupler terminal yellow white any other coupler terminal ECU coupler 3 green blue any other coupler terminal Mai...

Page 600: ...condition of Recovered using the YDT and then delete the DTC Is resistance Ω YES Go to step 8 NO a Replace the wire harness b Turn the main switch to ON c Push and SET side of the cruise control setting switch and then check the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 10 and complete the service NO Go to step 8 Is it in the Recovered condition YES ...

Page 601: ...6 TIP Perform the procedure from step 6 to step 11 2 Connection of ECU coupler front brake light switch coupler brake light relay coupler and main 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 When the front brake is applied ON When the front brake is not applied OFF Is check result OK ...

Page 602: ...mode of the YDT Is it in the Recovered condition YES Go to step 11 and complete the service NO Go to step 4 Between brake light fuse holder 1 and front brake light switch coupler 2 green white green white Between front brake light switch coupler 2 and rear brake light switch coupler 3 green yellow green yellow Between rear brake light switch coupler 3 and brake light relay coupler 4 light green bl...

Page 603: ...brake light relay coupler 4 and ground light green black ground Between front brake light switch coupler 2 and ground green white ground green yellow ground Brake light relay coupler 4 light green black any other coupler terminal Front brake light switch coupler 2 green white any other coupler terminal green yellow any other coupler terminal Rear brake light switch coupler 3 green yellow any other...

Page 604: ...e pins Is resistance Ω YES Go to step 5 NO a Replace the wire harness b Turn the main switch to ON c Operate the front brake lever and then check the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 11 and complete the service NO Go to step 5 Is it in the Recovered condition YES Go to step 11 and complete the service NO Go to step 10 Is the coupler conditio...

Page 605: ...front brake light switch coupler 2 green white green white Between front brake light switch coupler 2 and rear brake light switch coupler 3 green yellow green yellow Between rear brake light switch coupler 3 and brake light relay coupler 4 light green black light green black Between brake light relay coupler 4 and ground black ground Between brake light relay coupler 4 and ECU coupler 5 light gree...

Page 606: ...reen black any other coupler terminal Front brake light switch coupler 2 green white any other coupler terminal green yellow any other coupler terminal Rear brake light switch coupler 3 green yellow any other coupler terminal light green black any other coupler terminal ECU coupler 5 light green black any other coupler terminal Is resistance Ω YES Go to step 9 NO a Replace the wire harness b Turn ...

Page 607: ... check that the MIL goes off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC Is it in the Recovered condition YES Go to step 11 and complete the service NO Go to step 9 Is check result OK YES Go to step 10 NO a Turn the main switch to ON b Operate the rear brake pedal and then check the DTC using the malfunction mode of the YDT Is it in the Recovered conditi...

Page 608: ...function is detected in the ECU the DTC might not appear on the tool display Fail safe system Unable to start engine Unable to drive vehicle Procedure 1 Malfunction in ECU Replace the ECU Refer to REPLACING THE ECU Engine Control Unit on page 8 41 Turn the main switch to ON Check that the MIL does not come on ...

Page 609: ...s P0122 P0123 P0222 P0223 and P2135 if they are detected at the same time correct the P0122 P0123 P0222 P0223 and P2135 first Turn the main switch to ON and then check the DTC using the malfunction mode of the YDT 2 Malfunction in ECU Replace the ECU Refer to REPLACING THE ECU Engine Control Unit on page 8 41 Turn the main switch to ON Check that the MIL does not come on 3 Delete the DTC and check...

Page 610: ... VOLUME on page 3 11 After this adjustment is made turn the main switch to OFF Turn the main switch to ON and then check the DTC using the malfunction mode of the YDT 3 02 is indicated in diagnostic mode Code 60 EEPROM data error for adjustment of CO concen tration of cylinder 2 Change the CO concentration of cylinder 2 and rewrite in EEPROM Refer to ADJUSTING THE EXHAUST GAS VOLUME on page 3 11 A...

Page 611: ...g learning memory values Turn the main switch to OFF Turn the main switch to ON and then check the DTC using the malfunction mode of the YDT 6 Malfunction in ECU Replace the ECU and complete the service Refer to REPLACING THE ECU Engine Control Unit on page 8 41 7 Delete the DTC and check that the MIL goes off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC ...

Page 612: ...and check the pins bent or broken terminals and locking condition of the pins 3 Check the fuse Check the electronic throttle valve fuse Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Turn the main switch to ON and then check the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete ...

Page 613: ...YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to step 4 Between throttle servo motor coupler 1 and ECU coupler 2 yellow red yellow red light green red light green red Between ECU coupler 2 and electronic throttle valve fuse holder 3 red blue red blue Is resistance 0 Ω YES Go to Short circuit check NO a Replace the wire harness b Turn the main switch to ON and...

Page 614: ...s resistance Ω YES Go to step 5 NO a Replace the wire harness b Turn the main switch to ON and then check the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to step 5 Is check result OK YES Go to step 6 NO a Replace the throttle bodies Refer to REPLACING THE THROTTLE BODIES on page 7 10 b Turn the main switch to ON and the...

Page 615: ...eplace the ECU and complete the service Refer to REPLACING THE ECU Engine Control Unit on page 8 41 7 Delete the DTC and check that the MIL goes off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC ...

Page 616: ... the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Refer to HANDLEBAR on page 4 60 Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Start the engine and let it idle for approximately 5 seconds c Check the DTC using the malfunction mode of the YDT Is it in the Recovered con...

Page 617: ...t the engine and let it idle for approximately 5 seconds c Check the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 8 and complete the service NO Go to step 4 Between fuel injection system fuse holder 1 and relay unit coupler 2 brown brown Between ignition fuse holder 3 and handlebar switch coupler right 4 red red white Between handlebar switch coupler ri...

Page 618: ... relay unit coupler 2 and ground brown ground blue white ground red ground Between handlebar switch coupler right 4 and ground red white ground red white ground Relay unit coupler 2 brown any other coupler terminal blue white any other coupler terminal red any other coupler terminal Handlebar switch coupler right 4 red white any other coupler terminal red white any other coupler terminal ECU coupl...

Page 619: ...pproximately 5 seconds c Check the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 8 and complete the service NO Go to step 5 Is check result OK YES Go to step 6 NO a Replace the relay unit b Start the engine and let it idle for approximately 5 seconds c Check the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 8 a...

Page 620: ...ooseness or pinching Refer to CRANKCASE on page 5 64 2 Defective gear position sensor Disconnect the ECU coupler 1 Measure the gear position sensor resistance Shift the transmission to each position Is check result OK YES Go to step 2 NO a Reinstall or replace the sensor Refer to CRANKCASE on page 5 64 b Make sure that the position of each gear is correctly displayed on the meter Is check result O...

Page 621: ...e MIL goes off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC Is the resistance change YES Go to step 3 NO a Replace the gear position sensor Refer to CRANKCASE on page 5 64 b Make sure that the position of each gear is correctly displayed on the meter Is check result OK YES Go to step 4 and complete the service NO Go to step 3 ...

Page 622: ... position sensor coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Is check result OK YES Go to step 2 NO a Reinstall or replace the sensor Refer to CRANKCASE on page 5 64 b Make sure that the position of each gear is correctly displayed on the meter Is check result OK YES Go to step 7 and complet...

Page 623: ...ter 6 Malfunction in ECU Replace the ECU and complete the service Refer to REPLACING THE ECU Engine Control Unit on page 8 41 7 Delete the DTC and check that the MIL goes off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC Is the coupler condition normal YES Go to step 4 NO a Connect the coupler securely or replace the wire harness b Make sure that the posit...

Page 624: ...ondition of the pins 2 Connection of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Turn the main switch to ON and then check the DTC using the malfunction mode of the YDT Is it ...

Page 625: ... a Replace the wire harness b Turn the main switch to ON and then check the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to Short circuit check Between gear position sensor coupler 1 and ground green white ground blue ground Gear position sensor coupler 1 black blue any other coupler terminal green white any other couple...

Page 626: ...Go to step 7 and complete the service NO Go to step 4 Is check result OK YES Go to step 5 NO a Reinstall or replace the sensor b Turn the main switch to ON and then check the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to step 5 Is check result OK YES Go to step 6 NO a Replace the gear position sensor Refer to CRANKCASE...

Page 627: ...er to REPLACING THE ECU Engine Control Unit on page 8 41 7 Delete the DTC and check that the MIL goes off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to step 6 ...

Page 628: ...ther conditions is in dicated 2 Defective intake air pressure sensor 2 Execute the diagnostic mode Code 04 When engine is stopped Atmospheric pressure at the current altitude and weather conditions is in dicated At sea level Approx 101 kPa 757 6 mmHg 29 8 inHg ap prox 3 64 V 1000 m 3300 ft above sea level Approx 90 kPa 675 1 mmHg 26 6 inHg ap prox 3 30 V 2000 m 6700 ft above sea level Approx 80 kP...

Page 629: ...0 m 3300 ft above sea level Approx 90 kPa 675 1 mmHg 26 6 inHg ap prox 3 30 V 2000 m 6700 ft above sea level Approx 80 kPa 600 0 mmHg 23 6 inHg ap prox 3 00 V 3000 m 9800 ft above sea level Approx 70 kPa 525 0 mmHg 20 7 inHg ap prox 2 70 V Is check result OK YES Go to step 3 NO a Replace the intake air pressure sensor 2 Refer to THROTTLE BODIES on page 7 6 b Turn the main switch to ON and then che...

Page 630: ...e locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Turn the main switch to ON then to OFF and back to ON c Check the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to ...

Page 631: ... white blue black blue black Between IMU coupler 3 and ground black white ground Between ignition fuse 2 holder 4 and IMU cou pler 3 red white red white Is resistance 0 Ω YES Go to Short circuit check NO a Replace the wire harness b Turn the main switch to ON then to OFF and back to ON c Check the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and compl...

Page 632: ... black any other coupler terminal IMU coupler 3 blue white any other coupler terminal blue black any other coupler terminal red white any other coupler terminal Is resistance Ω YES Go to step 4 NO a Replace the wire harness b Turn the main switch to ON then to OFF and back to ON c Check the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the...

Page 633: ...Unit on page 8 41 7 Delete the DTC and check that the MIL goes off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC Is check result OK YES Go to step 5 NO a Fix the IMU installation condition b Turn the main switch to ON c Check the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to st...

Page 634: ...nnection 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 Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Turn the main switch to ON and then extend and retract the sidestand c Check the DTC using the malfunction mode ...

Page 635: ...rvice NO Go to step 4 Between relay unit coupler 1 and joint coupler cap 4 blue blue Between joint coupler 4 and ECU coupler 2 blue yellow blue yellow Between relay unit coupler 1 and sidestand switch coupler 3 blue black blue black Is resistance 0 Ω YES Go to Short circuit check NO a Replace the wire harness b Turn the main switch to ON and then extend and retract the sidestand c Check the DTC us...

Page 636: ...al ECU coupler 2 blue yellow any other coupler terminal Sidestand switch coupler 3 blue black any other coupler terminal Is resistance Ω YES Go to step 5 NO a Replace the wire harness b Turn the main switch to ON and then extend and retract the sidestand c Check the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to step 5 ...

Page 637: ...s off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC Is check result OK YES Go to step 6 NO a Replace the sidestand switch b Turn the main switch to ON and then extend and retract the sidestand c Check the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to step 6 ...

Page 638: ...dition of the pins 3 Connection of main 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 Is check result OK YES Go to step 2 NO a Reinstall or replace the battery leads b Turn the main switch to ON and then check the DTC using the malfunction mode of the YDT Is it in the Recovered conditio...

Page 639: ...T Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to step 4 Is check result OK YES Go to step 5 NO a Replace the fuse b Turn the main switch to ON and then check the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to step 5 Between battery 1 and backup fuse 2 holder 2 red red Between backup ...

Page 640: ... YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to Short circuit check Between battery 1 and ground red ground Between ECU coupler 3 and ground red green ground red white ground Between main switch coupler 4 and ground brown blue ground ECU coupler 3 red green any other coupler terminal red white any other coupler terminal Main switch coupler 4 brown blue any ...

Page 641: ... Go to step 6 NO a Replace the wire harness b Turn the main switch to ON and then check the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to step 6 O Gy R O G P B Y R B R B G B L B Lg R B G Y R L B W B W R L L W Y B Y R R G R W Br Y L G W R Y R W Y Br B L Y B B W B O Gy R O G P B Y R B R B G B L B Lg R B G Y R L B W B W R...

Page 642: ...rminals and locking condition of the pins 2 Connection of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Turn the main switch to ON and then check the DTC using the malfunction m...

Page 643: ...ke air pres sure sensor 2 coupler 1 P1607 blue blue P1606 P1607 pink pink Between intake air pressure sensor 2 coupler 1 and joint coupler 2 P1607 black black Is resistance 0 Ω YES Go to Short circuit check NO a Replace the wire harness b Turn the main switch to ON and then check the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the servic...

Page 644: ...r 2 coupler 1 P1607 blue any other coupler terminal P1607 black any other coupler terminal P1606 P1607 pink any other coupler terminal Joint coupler 2 P1607 black blue any other coupler terminal P1607 black any other coupler terminal Is resistance Ω YES Go to step 4 NO a Replace the wire harness b Turn the main switch to ON and then check the DTC using the malfunction mode of the YDT Is it in the ...

Page 645: ...sensor b Turn the main switch to ON and then check the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to step 5 At sea level Approx 101 kPa 757 6 mmHg 29 8 inHg ap prox 3 64 V 1000 m 3300 ft above sea level Approx 90 kPa 675 1 mmHg 26 6 inHg ap prox 3 30 V 2000 m 6700 ft above sea level Approx 80 kPa 600 0 mmHg 23 6 inHg a...

Page 646: ...essure sensor 2 Replace the intake air pressure sensor 2 Refer to THROTTLE BODIES on page 7 6 Turn the main switch to ON and then check the DTC using the malfunction mode of the YDT 3 Defective wire harness Replace the wire harness Turn the main switch to ON and then check the DTC using the malfunction mode of the YDT Is the coupler condition normal YES Go to step 2 NO a Connect the coupler secure...

Page 647: ...eplace the ECU and complete the service Refer to REPLACING THE ECU Engine Control Unit on page 8 41 5 Delete the DTC and check that the MIL goes off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC ...

Page 648: ...take air pressure sensor 2 Execute the diagnostic mode Code 04 When engine is stopped Atmospheric pressure at the current altitude and weather conditions is in dicated Is check result OK YES Go to step 2 NO a Repair or replace the intake air pressure sensor 2 hose Refer to THROTTLE BODIES on page 7 6 b Start the engine and let it idle for approximately 5 seconds and then check the DTC using the ma...

Page 649: ...ng the YDT and then delete the DTC Is check result OK YES Go to step 3 and complete the service NO a Replace the intake air pressure sensor Refer to THROTTLE BODIES on page 7 6 b Start the engine and let it idle for approximately 5 seconds with the throttle fully closed and then check the DTC using the malfunction mode of the YDT c Confirm the Recovered condition then go to step 3 ...

Page 650: ...Connection of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Turn the main switch to ON and then check the condition of the auxiliary system warning Is the auxiliary system warni...

Page 651: ... sensor coupler 1 and joint cou pler 3 black black Between joint coupler 3 and ECU coupler 2 black blue black blue Is resistance 0 Ω YES Go to Short circuit check NO a Replace the wire harness b Turn the main switch to ON and then check the condition of the auxiliary system warning Is the auxiliary system warning OFF YES Go to step 7 and complete the service NO Go to Short circuit check Gy L L V P...

Page 652: ... coupler terminal violet any other coupler terminal blue any other coupler terminal Joint coupler 3 black blue any other coupler terminal black any other coupler terminal Is resistance Ω YES Go to step 4 NO a Replace the wire harness b Turn the main switch to ON and then check the condition of the auxiliary system warning Is the auxiliary system warning OFF YES Go to step 7 and complete the servic...

Page 653: ... the main switch to ON and then check the condition of the auxiliary system warning Is the auxiliary system warning OFF YES Go to step 7 and complete the service NO Go to step 5 Shift sensor output voltage display 0 2 4 8 V With no shift weighting input Approx 2 5 V Shift up weighting Changes to the low side Shift down weighting Changes to the high side Is check result OK YES Go to step 6 NO a Rep...

Page 654: ...n Able to drive vehicle depending on the situation Procedure TIP If a DTC other than P2138 P2122 P2123 P2127 or P2128 is indicated perform troubleshooting first 1 Connection of accelerator position sensor coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins 2 Connection of ECU coupler Check the locki...

Page 655: ... sensor coupler 1 and ECU coupler 2 P2122 P2127 yellow red yellow red P2122 P2127 white red white red P2122 P2123 P2127 P2128 P2138 yellow yellow P2123 P2128 white black white black P2123 P2128 yellow black yellow black P2122 P2123 P2127 P2128 P2138 brown brown Is resistance 0 Ω YES Go to Short circuit check NO a Replace the wire harness b Turn the main switch to ON and then check the DTC using th...

Page 656: ...122 P2127 yellow red any other coupler terminal P2122 P2123 P2127 P2128 P2138 yellow any other coupler terminal P2123 P2128 yellow black any other coupler terminal P2123 P2128 white black any other coupler terminal ECU coupler 2 P2122 P2123 P2127 P2128 P2138 brown any other coupler terminal P2122 P2127 white red any other coupler terminal P2122 P2127 yellow red any other coupler terminal P2122 P21...

Page 657: ...arness b Turn the main switch to ON and then check the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 6 and complete the service NO Go to step 4 When the throttle valves are fully closed 14 18 When the throttle valves are fully open 82 92 Turn the throttle grip past the closed position in the deceleration direction 7 12 When the throttle valves are fully ...

Page 658: ...on sensor coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Unable to starting the engine and racing the engine YES Go to step 2 NO a Replace the throttle position sensor Refer to ADJUSTING THE THROTTLE POSITION SENSOR on page 7 12 b Turn the main switch to ON and then check the DTC using the malf...

Page 659: ...b Turn the main switch to ON and then check the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 8 and complete the service NO Go to step 4 Is check result OK YES Go to step 5 NO a Reinstall or adjust the sensor b Turn the main switch to ON and then check the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 8 and com...

Page 660: ...ered using the YDT and then delete the DTC Is it in the Recovered condition YES Go to step 8 and complete the service NO Go to step 6 When the throttle valves are fully closed 9 23 When throttle valves are fully open 93 109 Is check result OK YES Go to step 7 NO a Replace the throttle position sensor Refer to ADJUSTING THE THROTTLE POSITION SENSOR on page 7 12 b Turn the main switch to ON and then...

Page 661: ... or broken terminals and locking condition of the pins 4 Connection of ABS ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Is the ABS warning light on YES Refer to BASIC INSTRUCTIONS FOR TROUBLESHOOTING on page 9 37 NO Go to step 2 Is that value increased YES Go to step 10 and complete the s...

Page 662: ...value increases Is that value increased YES Go to step 10 and complete the service NO Go to step 5 Is the coupler condition normal YES Go to step 6 NO a Connect the coupler securely or replace the wire harness b Execute the diagnostic mode Code 16 c Rotate the front wheel by hand and check that the indicated value increases Is that value increased YES Go to step 10 and complete the service NO Go t...

Page 663: ...alue increased YES Go to step 10 and complete the service NO Go to Short circuit check Between ABS ECU coupler 2 and ground brown ground yellow ground white green ground Front wheel sensor coupler 1 brown any other coupler terminal yellow any other coupler terminal ABS ECU coupler 2 brown any other coupler terminal yellow any other coupler terminal white green any other coupler terminal ECU couple...

Page 664: ...rvice Is resistance Ω YES Go to step 7 NO a Replace the wire harness b Execute the diagnostic mode Code 16 c Rotate the front wheel by hand and check that the indicated value increases Is that value increased YES Go to step 10 and complete the service NO Go to step 7 Is check result OK YES Go to step 8 NO a Reinstall or replace the front wheel sensor Refer to FRONT WHEEL on page 4 12 b Execute the...

Page 665: ...ate the front wheel by hand Start the engine and input the vehicle speed signals by operating the vehicle at 20 to 30 km h 12 to 19 mph Confirm that the DTC has a condition of Recovered using the malfunction mode of the YDT and then delete the DTC Delete this DTC even if it has a condition of Detected ...

Page 666: ...er Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Turn the main switch to ON and then check the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 6 an...

Page 667: ...d ground black white ground Between ignition fuse 2 holder 4 and IMU cou pler 3 red white red white Is resistance 0 Ω YES Go to Short circuit check NO a Replace the wire harness b Turn the main switch to ON and then check the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 6 and complete the service NO Go to Short circuit check Between ECU coupler 1 and gr...

Page 668: ...l blue black any other coupler terminal IMU coupler 3 blue white any other coupler terminal blue black any other coupler terminal red white any other coupler terminal Is resistance Ω YES Go to step 4 NO a Replace the wire harness b Turn the main switch to ON and then check the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 6 and complete the service NO Go...

Page 669: ...Connection of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Turn the main switch to ON and then check the DTC using the malfunction mode of the YDT Is it in the Recovered condit...

Page 670: ...white blue white Between joint coupler 2 and ECU coupler 4 blue black blue black Between joint coupler 3 and ECU coupler 4 blue white blue white Is resistance 0 Ω YES Go to Short circuit check NO a Replace the wire harness b Turn the main switch to ON and then check the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 6 and complete the service NO Go to Sho...

Page 671: ...e black any other coupler terminal Is resistance Ω YES Go to step 4 NO a Replace the wire harness b Turn the main switch to ON and then check the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 6 and complete the service NO Go to step 4 Is it in the Recovered condition YES Go to step 6 and complete the service NO Go to step 5 R G R G R W B W Lg L W L B G W...

Page 672: ...U Replace the ECU and complete the service Refer to REPLACING THE ECU Engine Control Unit on page 8 41 6 Delete the DTC and check that the MIL goes off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC ...

Page 673: ... can be identified by the flashing pattern Refer to HOW TO CHECK DTC on page 9 23 1 Keep magnets metal objects and other immobilizer system keys away from the keys and antennas Turn the main switch to ON 2 Turn the main switch to ON with another key 3 Replace the main switch immobilizer unit ECU and all key and complete the service Refer to REPLACING THE ECU Engine Control Unit on page 8 41 Is DTC...

Page 674: ... flashing pattern Refer to HOW TO CHECK DTC on page 9 23 1 Place the immobilizer unit at least 50 mm away from the transponder of other vehicles Turn the main switch to ON 2 Register the standard key Turn the main switch to ON 3 Turn the main switch to ON with another key 4 Replace the main switch immobilizer unit ECU and all key and complete the service Refer to REPLACING THE ECU Engine Control U...

Page 675: ... coupler and 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 2 Turn the main switch to ON 3 Wire harness continuity Disconnect the immobilizer unit coupler 1 ECU coupler 2 and backup fuse 2 3 Open circuit check Is the coupler condition normal YES Go to step 2 NO Connect the coupler securely ...

Page 676: ... terminal red any other coupler terminal Immobilizer unit coupler 1 yellow blue any other coupler terminal light green any other coupler terminal red green any other coupler terminal red any other coupler terminal black any other coupler terminal ECU coupler 2 yellow blue any other coupler terminal Is resistance Ω YES Go to step 4 NO Replace the wire harness 2 Gy L L V P P W Lg L O W Y L L B B L B...

Page 677: ...rn the main switch to ON 5 Replace the main switch immobilizer unit ECU and all key and complete the service Refer to REPLACING THE ECU Engine Control Unit on page 8 41 Is DTC displayed YES Go to step 5 NO Service is completed ...

Page 678: ...nection of Immobilizer unit coupler and 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 2 Turn the main switch to ON 3 Register the code re registering key and standard keys Turn the main switch to ON 4 Replace the main switch immobilizer unit ECU and all key and complete the service Refer t...

Page 679: ...e Same standard key was attempted to be registered two consecutive times Procedure TIP When a system malfunction occurs the immobilizer system indicator light will flash The DTC can be identified by the flashing pattern Refer to HOW TO CHECK DTC on page 9 23 1 Register another standard key and complete the service ...

Page 680: ...coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins 2 Turn the main switch to ON 3 Wire harness continuity Disconnect the immobilizer unit coupler 1 ECU coupler 2 and backup fuse 2 3 Open circuit check Is the coupler condition normal YES Go to step 2 NO Connect the coupler securely or replace the wi...

Page 681: ... terminal red any other coupler terminal Immobilizer unit coupler 1 yellow blue any other coupler terminal light green any other coupler terminal red green any other coupler terminal red any other coupler terminal black any other coupler terminal ECU coupler 2 yellow blue any other coupler terminal Is resistance Ω YES Go to step 4 NO Replace the wire harness 2 Gy L L V P P W Lg L O W Y L L B B L B...

Page 682: ...rn the main switch to ON 5 Replace the main switch immobilizer unit ECU and all key and complete the service Refer to REPLACING THE ECU Engine Control Unit on page 8 41 Is DTC displayed YES Go to step 5 NO Service is completed ...

Page 683: ...ct installation of the rotor Check the surface of the sensor rotor for damage Refer to MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR on page 4 16 4 Defective front wheel sensor or incorrect installation of the sensor Check the wheel sensor for damage and the installed condition of the sensor Refer to MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR on page 4 16 Is check result OK YE...

Page 684: ... rotor for damage Refer to MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR on page 4 24 4 Defective rear wheel sensor or incorrect installation of the sensor Check the wheel sensor for damage and the installed condition of the sensor Refer to MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR on page 4 24 Is check result OK YES Go to step 2 NO Clean the sensor rotor and wheel sensor Is ch...

Page 685: ... WHEEL on page 4 14 3 Defective sensor rotor or incorrect installation of the rotor Check the surface of the sensor rotor for damage Refer to MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR on page 4 16 4 Defective front wheel sensor or incorrect installation of the sensor Check the wheel sensor for damage and the installed condition of the sensor Refer to MAINTENANCE OF THE FRONT WHEEL SEN...

Page 686: ...HEEL on page 4 22 3 Defective sensor rotor or incorrect installation of the rotor Check the surface of the sensor rotor for damage Refer to MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR on page 4 24 4 Defective rear wheel sensor or incorrect installation of the sensor Check the wheel sensor for damage and the installed condition of the sensor Refer to MAINTENANCE OF THE REAR WHEEL SENSOR A...

Page 687: ... 2 Wire harness continuity Disconnect the ABS ECU coupler 1 and front wheel sensor coupler 2 Open circuit check Short circuit check TIP Disconnect the ABS ECU related connectors before checking Refer to PARTS CONNECTED TO THE ABS ECU on page 9 4 Is check result OK YES Go to step 2 NO If there is a malfunction repair it and connect the coupler securely Between ABS ECU coupler 1 and front wheel sens...

Page 688: ...tive Replace the front wheel sensor or hydraulic unit assembly ABS ECU Refer to FRONT WHEEL on page 4 12 and ABS ANTI LOCK BRAKE SYSTEM on page 4 52 Between ABS ECU coupler 1 and ground yellow ground brown ground ABS ECU coupler 1 yellow any other coupler terminal brown any other coupler terminal Is resistance Ω YES Go to step 3 NO Replace the wire harness R L W B B W W G G Y L R B Br L W G OW Y L...

Page 689: ...er 2 Wire harness continuity Disconnect the ABS ECU coupler 1 and rear wheel sensor coupler 2 Open circuit check Short circuit check TIP Disconnect the ABS ECU related connectors before checking Refer to PARTS CONNECTED TO THE ABS ECU on page 9 4 Is check result OK YES Go to step 2 NO If there is a malfunction repair it and connect the coupler securely Between ABS ECU coupler 1 and rear wheel sens...

Page 690: ...ctive Replace the rear wheel sensor or hydraulic unit assembly ABS ECU Refer to REAR WHEEL on page 4 19 and ABS ANTI LOCK BRAKE SYSTEM on page 4 52 Between ABS ECU coupler 1 and ground white ground black ground ABS ECU coupler 1 white any other coupler terminal black any other coupler terminal Is resistance Ω YES Go to step 3 NO Replace the wire harness R L W B B W W G G Y L R B Br L W G OW Y L B ...

Page 691: ...320 TROUBLESHOOTING Item Hydraulic unit assembly ABS ECU defective solenoid drive circuit Procedure 1 Defective hydraulic unit assembly ABS ECU Replace the hydraulic unit assembly ABS ECU Refer to ABS ANTI LOCK BRAKE SYSTEM on page 4 52 ...

Page 692: ...er TIP Turn the main switch to OFF before disconnecting or connecting a coupler 3 Wire harness continuity Disconnect the ABS solenoid fuse 1 and ABS ECU coupler 2 Open circuit check Short circuit check Is check result OK YES Go to step 2 NO Replace the fuse and check the wire harness Is check result OK YES Go to step 3 NO If there is a malfunction repair it and connect the coupler securely Between...

Page 693: ...ulic unit assembly ABS ECU Replace the hydraulic unit assembly ABS ECU Refer to ABS ANTI LOCK BRAKE SYSTEM on page 4 52 Between ABS ECU coupler 2 and ground blue white ground ABS ECU coupler 2 blue white any other coupler terminal Is resistance Ω YES Go to step 4 NO Replace the wire harness R L W B B W W G G Y L R B Br L W G OW Y L B W Y L B R L W B B W W G G Y L R B Br L W G OW Y L B W Y L B B A ...

Page 694: ...n of the coupler TIP Turn the main switch to OFF before disconnecting or connecting a coupler 3 Wire harness continuity Disconnect the ABS motor fuse 1 and ABS ECU coupler 2 Open circuit check Is check result OK YES Go to step 2 NO Replace the fuse and check the wire harness Is check result OK YES Go to step 3 NO If there is a malfunction repair it and connect the coupler securely Between ABS moto...

Page 695: ...4 Defective hydraulic unit assembly ABS ECU Replace the hydraulic unit assembly ABS ECU Refer to ABS ANTI LOCK BRAKE SYSTEM on page 4 52 Between ABS ECU coupler 2 and ground red ground ABS ECU coupler 2 red any other coupler terminal Is resistance Ω YES Go to step 4 NO Replace the wire harness R L W B B W W G G Y L R B Br L W G OW Y L B W Y L B R L W B B W W G G Y L R B Br L W G OW Y L B W Y L B B...

Page 696: ...BLESHOOTING Item Hydraulic unit assembly ABS ECU short circuit in ABS motor power supply circuit Procedure 1 Defective hydraulic unit assembly ABS ECU Replace the hydraulic unit assembly ABS ECU Refer to ABS ANTI LOCK BRAKE SYSTEM on page 4 52 ...

Page 697: ...E FRONT WHEEL on page 4 14 and CHECKING THE FRONT BRAKE DISCS on page 4 33 3 Front brake dragging Check that the brake fluid pressure is correctly transmitted to the brake caliper when the brake lever is operated and that the pressure decreases when the lever is released Refer to CHECKING THE FRONT BRAKE DISCS on page 4 33 4 Defective hydraulic unit assembly ABS ECU Replace the hydraulic unit asse...

Page 698: ...HE REAR WHEEL on page 4 22 and CHECKING THE REAR BRAKE DISC on page 4 46 3 Rear brake dragging Check that the brake fluid pressure is correctly transmitted to the brake caliper when the brake pedal is operated and that the pressure decreases when the pedal is released Refer to CHECKING THE REAR BRAKE DISC on page 4 46 4 Defective hydraulic unit assembly ABS ECU Replace the hydraulic unit assembly ...

Page 699: ...f the rotor Check the surface of the sensor rotor for damage Refer to MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR on page 4 16 4 Defective front wheel sensor or incorrect installation of the sensor Check the wheel sensor for damage and the installed condition of the sensor Refer to MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR on page 4 16 Is check result OK YES Go to step 2 NO...

Page 700: ...f the rotor Check the surface of the sensor rotor for damage Refer to MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR on page 4 24 4 Defective rear wheel sensor or incorrect installation of the sensor Check the wheel sensor for damage and the installed condition of the sensor Refer to MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR on page 4 24 Is check result OK YES Go to step 2 NO Cl...

Page 701: ...ARGING THE BATTERY on page 8 41 2 Disconnected battery terminal Check the connection 3 Defective charging system Check the charging system Refer to CHARGING SYSTEM on page 8 13 Is check result OK YES Go to step 3 NO Replace or reconnect the terminal Is check result OK YES Replace the hydraulic unit assembly ABS ECU Refer to ABS ANTI LOCK BRAKE SYSTEM on page 4 52 NO Confirm the cause of the proble...

Page 702: ...e coupler TIP Turn the main switch to OFF before disconnecting or connecting a coupler 3 Wire harness continuity Disconnect the ABS ECU fuse 1 and ABS ECU coupler 2 Open circuit check Short circuit check TIP Disconnect the ABS ECU related connectors before checking Refer to PARTS CONNECTED TO THE ABS ECU on page 9 4 Is check result OK YES Go to step 3 NO If there is a malfunction repair it and con...

Page 703: ...und ABS ECU coupler 2 red black any other coupler terminal Is resistance Ω YES Go to step 4 NO Replace the wire harness Is check result OK YES Replace the hydraulic unit assembly ABS ECU Refer to ABS ANTI LOCK BRAKE SYSTEM on page 4 52 NO Confirm the cause of the problem and repair it and check again R L W B B W W G G Y L R B Br L W G OW Y L B W Y L B R L W B B W W G G Y L R B Br L W G OW Y L B W ...

Page 704: ...S EAS33328 TROUBLESHOOTING Item Hydraulic unit assembly ABS ECU defective ABS ECU Procedure 1 Defective hydraulic unit assembly ABS ECU Replace the hydraulic unit assembly ABS ECU Refer to ABS ANTI LOCK BRAKE SYSTEM on page 4 52 ...

Page 705: ...S33329 TROUBLESHOOTING Item Hydraulic unit assembly ABS ECU abnormal internal circuit Procedure 1 Defective hydraulic unit assembly ABS ECU Replace the hydraulic unit assembly ABS ECU Refer to ABS ANTI LOCK BRAKE SYSTEM on page 4 52 ...

Page 706: ...on page 9 4 Between ECM coupler 1 and joint coupler 3 blue black blue black Between ECM coupler 1 and joint coupler 4 blue white blue white Between joint coupler 2 and joint coupler 3 yellow black yellow black Between joint coupler 2 and joint coupler 4 white white Between joint coupler 2 and ABS ECU coupler 5 blue black blue black blue white blue white Is resistance 0 Ω YES Go to Short circuit ch...

Page 707: ... ground blue black ground ECU coupler 1 blue white any other coupler terminal blue black any other coupler terminal Joint coupler 2 yellow black any other coupler terminal white any other coupler terminal ABS ECU coupler 5 blue white any other coupler terminal blue black any other coupler terminal Is resistance Ω YES Go to step 2 NO Replace the wire harness R L W B B W W G G Y L R B Br L W G OW Y ...

Page 708: ...K YES Go to step 4 NO If there is a malfunction repair it and connect the coupler securely Between ABS ECU fuse holder 1 and ABS ECU coupler 3 red black red black Between ABS solenoid fuse holder 2 and ABS ECU coupler 3 blue white blue white Is resistance 0 Ω YES Go to Short circuit check NO Replace the wire harness Between ABS ECU coupler 3 and ground red black ground blue white ground ABS ECU co...

Page 709: ... to step 5 NO Replace the wire harness Is resistance Ω YES Replace the hydraulic unit assembly ABS ECU Refer to ABS ANTI LOCK BRAKE SYSTEM on page 4 52 NO Confirm the cause of the problem and repair it and check again R L W B B W W G G Y L R B Br L W G OW Y L B W Y L B R L W B B W W G G Y L R B Br L W G OW Y L B W Y L B B A 3 3 ...

Page 710: ...BS EAS33333 TROUBLESHOOTING Item Power supply voltage failure in pressure sensor Procedure 1 Defective hydraulic unit assembly ABS ECU Replace the hydraulic unit assembly ABS ECU Refer to ABS ANTI LOCK BRAKE SYSTEM on page 4 52 ...

Page 711: ...pressure sensor Procedure 1 Defective front brake line Check the front brake line 2 Defective hydraulic unit assembly ABS ECU Replace the hydraulic unit assembly ABS ECU Refer to ABS ANTI LOCK BRAKE SYSTEM on page 4 52 Is check result OK YES Go to step 2 NO If there is bending or blocking replace the front brake line ...

Page 712: ...t coupler cap 5 Open circuit check Is check result OK YES Go to step 2 NO If there is a malfunction repair it and connect the coupler securely Between meter assembly coupler 1 and joint coupler 4 blue black blue black Between meter assembly coupler 1 and joint coupler 5 blue white blue white Between joint coupler 2 and joint coupler 4 yellow black yellow black Between joint coupler 2 and joint cou...

Page 713: ...r coupler terminal blue black any other coupler terminal Joint coupler 2 blue white any other coupler terminal blue black any other coupler terminal ABS ECU coupler 3 blue white any other coupler terminal blue black any other coupler terminal Is resistance Ω YES Go to step 3 NO Replace the wire harness R L W B B W W G G Y L R B Br L W G OW Y L B W Y L B R L W B B W W G G Y L R B Br L W G OW Y L B ...

Page 714: ...ABS 3 Defective meter assembly Replace the meter assembly and check again 4 Defective hydraulic unit assembly ABS ECU Replace the hydraulic unit assembly ABS ECU Refer to ABS ANTI LOCK BRAKE SYSTEM on page 4 52 ...

Page 715: ...ler cap 4 Open circuit check Is check result OK YES Go to step 2 NO If there is a malfunction repair it and connect the coupler securely Between ECM coupler 1 and joint coupler 3 blue black blue black Between ECM coupler 1 and joint coupler 4 blue white blue white Between joint coupler 2 and joint coupler 3 yellow black yellow black Between joint coupler 2 and joint coupler 4 white white Between j...

Page 716: ... white any other coupler terminal blue black any other coupler terminal Joint coupler 2 yellow black any other coupler terminal white any other coupler terminal ABS ECU coupler 5 blue white any other coupler terminal blue black any other coupler terminal Is resistance Ω YES Go to step 3 NO Replace the wire harness R L W B B W W G G Y L R B Br L W G OW Y L B W Y L B B A Gy L L V P P W Lg L O W Y L ...

Page 717: ... Replace the ECU and check again Refer to REPLACING THE ECU Engine Control Unit on page 8 41 4 Defective hydraulic unit assembly ABS ECU Replace the hydraulic unit assembly ABS ECU Refer to ABS ANTI LOCK BRAKE SYSTEM on page 4 52 ...

Page 718: ...ecting a coupler 2 Wire harness continuity Disconnect the IMU coupler 1 and ABS ECU coupler 3 Remove the joint coupler cap 2 Open circuit check Is check result OK YES Go to step 2 NO If there is a malfunction repair it and connect the coupler securely Between IMU coupler 1 and joint coupler 2 blue white blue white blue black blue black Between joint coupler 2 and ABS ECU coupler 3 blue white blue ...

Page 719: ...lue white ground blue black ground IMU coupler 1 blue white any other coupler terminal blue black any other coupler terminal Joint coupler 2 blue white any other coupler terminal blue black any other coupler terminal ABS ECU coupler 3 blue white any other coupler terminal blue black any other coupler terminal Is resistance Ω YES Go to step 3 NO Replace the wire harness R W L B L W B W R W L B L W ...

Page 720: ...fective IMU Replace the IMU and check again Refer to GENERAL CHASSIS 1 on page 4 1 4 Defective hydraulic unit assembly ABS ECU Replace the hydraulic unit assembly ABS ECU Refer to ABS ANTI LOCK BRAKE SYSTEM on page 4 52 ...

Page 721: ... Injector 3 57 Grip warmer left OPTION 58 Grip warmer right OPTION 59 Throttle position sensor 60 Throttle servo motor 61 Hydraulic unit assembly ABS ECU 62 Front wheel sensor 63 Rear wheel sensor 64 IMU Inertial Measurement Unit 65 Purge cut valve solenoid 66 Shift sensor 67 YDT coupler 68 Meter assembly 69 Multi function meter 70 Neutral indicator light 71 Immobilizer system indicator light 72 O...

Page 722: ...O Green Orange G W Green White G Y Green Yellow Gy G Gray Green Gy R Gray Red L B Blue Black L R Blue Red L W Blue White L Y Blue Yellow Lg B Light green Black Lg L Light green Blue Lg R Light green Red O G Orange Green O W Orange White P B Pink Black P W Pink White R B Red Black R G Red Green R L Red Blue R W Red White R Y Red Yellow Sb W Sky blue White W B White Black W G White Green W L White B...

Page 723: ......

Page 724: ......

Page 725: ...O OFF ON RES SET FREE PUSH FREE OFF ON B W Gy Br L L B L R B Br L Gy Br L G L W Y W L L B W G W R G B Y W O W Y Y B 97 99 100 101 102 103 104 105 106 98 B Gy 94 L Y L B B 93 R W B R W Lg R G Y L 27 OFF ON Y B Y W Gy L Y B Y 28 OFF ON B G W Y B G Y Y W 29 ON OFF Br G B Y B Br G B Y 30 35 36 37 START OFF RUN R R L Y G W G R L L W W B W G B W R W B R W RY G Y B B W G W B Y R 31 32 33 34 38 B B B 39 4...

Page 726: ... 48 64 65 B 66 67 51 50 52 51 53 51 54 55 56 B 57 Gy 58 59 61 60 49 5 ON OFF 25 26 23 24 A 96 89 90 91 92 87 B B 88 86 84 82 83 81 80 79 78 77 76 75 70 68 71 72 73 69 74 B 85 PUSH FREE UP N DOWN L R N HI PASS LO OFF ON RES SET FREE PUSH FREE OFF ON L B Gy 97 99 100 101 102 103 104 105 106 98 Gy 94 B 93 27 OFF ON Gy 28 OFF ON B 29 ON OFF B 30 35 36 37 START OFF RUN B 31 32 33 34 38 B 39 40 41 2 4 3...

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Yamaha XSR900 2022, Service Manual

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