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Yamaha XTZ690 2020, Service Manual

The Yamaha XTZ690 2020 Service Manual is an essential resource for motorcycle enthusiasts. This comprehensive manual provides detailed instructions and maintenance procedures to ensure optimal performance and longevity of your bike. Download the manual for free from manualshive.com and unleash the full potential of your XTZ690.

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7

FUEL SYSTEM

FUEL TANK

..................................................................................................... 7-1

REMOVING THE FUEL TANK .................................................................. 7-3
REMOVING THE FUEL PUMP ................................................................. 7-3
CHECKING THE FUEL PUMP BODY....................................................... 7-3
CHECKING THE CYLINDER HEAD BREATHER HOSE ......................... 7-3
CHECKING THE ROLLOVER VALVE ...................................................... 7-3
INSTALLING THE CANISTER .................................................................. 7-3
INSTALLING THE FUEL PUMP................................................................ 7-4
INSTALLING THE FUEL TANK................................................................. 7-4

THROTTLE BODIES

....................................................................................... 7-5

REMOVING THE THROTTLE BODIES .................................................... 7-8
CHECKING THE INJECTORS (BEFORE REMOVING) ........................... 7-8
REMOVING THE INJECTORS ................................................................. 7-8
CHECKING THE INJECTORS .................................................................. 7-8
CHECKING AND CLEANING THE THROTTLE BODIES ......................... 7-8
CHECKING THE THROTTLE BODY JOINTS ........................................ 7-11
ADJUSTING THE THROTTLE POSITION SENSOR.............................. 7-11
INSTALLING THE FUEL INJECTORS .................................................... 7-11
CHECKING THE INJECTOR PRESSURE.............................................. 7-12
CHECKING THE FUEL PRESSURE ...................................................... 7-12
INSTALLING THE THROTTLE BODY JOINTS ...................................... 7-13
INSTALLING THE AIR FILTER CASE JOINTS ...................................... 7-13
INSTALLING THE THROTTLE BODIES................................................. 7-14

Summary of Contents for XTZ690 2020

Page 1: ...2020 SERVICE MANUAL Ténéré 700 XTZ690 XTZ690 U BW3 F8197 E0 ...

Page 2: ......

Page 3: ...e TIP If the contents of the manual are revised the last digit of the manual number will be increased by one This Service Manual contains information regarding periodic maintenance to the emission control sys tem Please read this material carefully Designs and specifications are subject to change without notice EAS30001 IMPORTANT MANUAL INFORMATION Particularly important information is distinguish...

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

Page 8: ......

Page 9: ...1 GENERAL INFORMATION IDENTIFICATION 1 1 VEHICLE IDENTIFICATION NUMBER 1 1 MODEL LABEL 1 1 FEATURES 1 2 MULTI FUNCTION METER UNIT 1 2 SPECIAL TOOLS 1 7 ...

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

Page 11: ...2423 Be sure to stop the vehicle before making any setting changes to the multi function meter unit Changing settings while riding can distract the operator and increase the risk of an accident Speedometer The speedometer shows the vehicle s traveling speed Tachometer The tachometer shows the engine speed NOTICE ECA26220 Do not operate the engine in the tachometer high r min zone Fuel meter 1 Top ...

Page 12: ...ated by Clock The clock uses a 12 hour time system TIP When the main switch is turned off the clock can be viewed by pushing the top set button To set the clock 1 Turn the key to ON 2 Push the bottom set button and top set button together until the hour digits start flashing 3 Push the bottom set button to set the hours 4 Push the top set button and the minute digits will start flashing 5 Push the...

Page 13: ...ti cally reset Push the top set button to switch the display in the following order ODO TRIP 1 TRIP 2 TRIP CD TRIP F km L or L 100 km or MPG AVE_ _ _ km L or AVE_ _ _ L 100 km or AVE_ _ _ MPG _ _ C Air_ _ C ODO TIP Push the bottom set button to switch the dis play in the reverse order The display changes to fuel reserve tripmeter TRIP F when the last segment of the fuel me ter starts flashing To r...

Page 14: ...mp tion unit is MPG km L The distance that can be traveled on 1 0 L of fuel under the current riding conditions is shown L 100 km The amount of fuel necessary to travel 100 km under the current riding condi tions is shown MPG The distance that can be traveled on 1 0 Imp gal of fuel under the current riding con ditions is shown To switch the instantaneous fuel consumption settings push and hold the...

Page 15: ... be displayed The temperature displayed may vary from the ambient temperature Brightness control mode The brightness level of the multi function meter unit panel can be adjusted To adjust the brightness 1 Turn the key to OFF 2 Push and hold the top set button 3 Turn the key to ON and continue pushing the top set button until the display switches to the brightness control mode 4 Push the bottom set...

Page 16: ...e 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 9 4 49 4 50 8 34 8 105 8 125 Yamaha diagnostic tool A I 90890 03262 3 4 3 9 4 49 4 50 8 34 8 105 8 125 Thickness gauge 90890 03268 Feeler gauge set Y...

Page 17: ... 90890 01426 Oil filter wrench YU 38411 3 24 Pressure gauge 90890 03153 Pressure gauge YU 03153 3 26 7 12 7 13 Oil pressure adapter H 90890 03139 3 26 Fork spring compression tool 90890 01573 Fork spring compression tool YM 01573 4 61 4 66 Rod holder 90890 01434 Damper rod holder double ended YM 01434 4 61 4 66 Damper rod holder ø27 90890 01423 Damping rod holder YM 01423 4 62 4 63 Tool name Tool ...

Page 18: ...8703 4 65 Rod puller attachment M10 long 90890 01578 Universal damping rod bleeding tool set YM A8703 4 65 Ring nut wrench 90890 01268 Spanner wrench YU 01268 4 70 Engine alignment tool 90890 11097 4 77 4 78 Compression gauge extension 122mm 90890 04136 Compression gauge extension 122mm YM 04136 5 1 Tool name Tool No Illustration Reference pages YM A8703 90890 01578 YM A8703 ...

Page 19: ... 90890 04019 Valve spring compressor YM 04019 5 28 5 32 Valve spring compressor attachment ø26 90890 01243 Valve spring compressor adapter 26 mm YM 01253 1 5 28 5 32 Valve guide remover ø4 5 90890 04116 Valve guide remover 4 5 mm YM 04116 5 29 Valve guide installer ø4 5 90890 04117 Valve guide installer 4 5 mm YM 04117 5 29 Valve guide reamer ø4 5 90890 04118 Valve guide reamer 4 5 mm YM 04118 5 2...

Page 20: ...tester CD732 90890 03243 Model 88 Multimeter with tachometer YU A1927 5 40 8 130 8 131 8 132 8 133 8 133 8 133 8 134 8 135 8 135 8 136 8 137 8 137 8 137 8 138 8 139 8 139 8 140 Universal clutch holder 90890 04086 Universal clutch holder YM 91042 5 46 5 48 Piston pin puller set 90890 01304 Piston pin puller YU 01304 5 67 Tool name Tool No Illustration Reference pages YU 01304 ...

Page 21: ...r kit YU 24460 A 6 4 Radiator cap tester adapter 90890 01352 Pressure tester adapter YU 33984 6 4 Mechanical seal installer ø33 90890 04132 Water pump seal installer ø33 YM 33221 A 6 13 Middle driven shaft bearing driver 90890 04058 Middle drive bearing installer 40 50 mm YM 04058 6 13 Tool name Tool No Illustration Reference pages YU 24460 A YU 33984 ...

Page 22: ...essure adapter 90890 03176 Fuel pressure adapter YM 03176 7 13 OBD GST Leadwire kit 90890 03249 8 34 Ignition checker 90890 06754 Oppama pet 4000 spark checker YM 34487 8 135 Test harness lean angle sensor 6P 90890 03209 Test harness lean angle sensor 6P YU 03209 8 136 Tool name Tool No Illustration Reference pages ...

Page 23: ... GENERAL SPECIFICATIONS 2 1 ENGINE SPECIFICATIONS 2 2 CHASSIS SPECIFICATIONS 2 7 ELECTRICAL SPECIFICATIONS 2 10 TIGHTENING TORQUES 2 12 ENGINE TIGHTENING TORQUES 2 12 CHASSIS TIGHTENING TORQUES 2 13 CABLE ROUTING 2 15 ...

Page 24: ...90P B BW34 XTZ690_AUS Dimensions Overall length 2370 mm 93 3 in Overall width 905 mm 35 6 in Overall height 1455 mm 57 3 in Wheelbase 1595 mm 62 8 in Ground clearance 240 mm 9 45 in Minimum turning radius 2 8 m 9 47 ft Weight Curb weight 204 kg 450 lb Loading Maximum load 190 kg 419 lb Riding capacity 2 person ...

Page 25: ...ity grades 10W 40 Recommended engine oil grade API service SG type or higher JASO standard MA Lubrication system Wet sump Engine oil quantity Without oil filter cartridge replacement 2 30 L 2 43 US qt 2 02 Imp qt With oil filter cartridge replacement 2 60 L 2 75 US qt 2 29 Imp qt Quantity disassembled 3 00 L 3 17 US qt 2 64 Imp qt Oil filter Oil filter type Cartridge Relief valve operating pressur...

Page 26: ...610 35 710 mm 1 4020 1 4059 in Limit 35 510 mm 1 3980 in Lobe height Exhaust 35 710 35 810 mm 1 4059 1 4098 in Limit 35 610 mm 1 4020 in Camshaft runout limit 0 030 mm 0 0012 in Valve valve seat valve guide Valve clearance cold Intake 0 11 0 20 mm 0 0043 0 0079 in Exhaust 0 24 0 30 mm 0 0094 0 0118 in Valve dimensions Valve seat contact width intake 0 90 1 10 mm 0 0354 0 0433 in Limit 1 6 mm 0 06 ...

Page 27: ... 970 mm 0 7075 in Piston pin to piston pin bore clearance 0 009 0 025 mm 0 0004 0 0010 in Piston ring Top ring End gap limit 0 50 mm 0 0197 in Ring side clearance 0 030 0 065 mm 0 0012 0 0026 in Side clearance limit 0 115 mm 0 0045 in 2nd ring End gap limit 0 80 mm 0 0315 in Ring side clearance 0 020 0 055 mm 0 0008 0 0022 in Side clearance limit 0 115 mm 0 0045 in Connecting rod Oil clearance 0 0...

Page 28: ...ckness 1 90 2 10 mm 0 075 0 083 in Plate quantity 6 pcs Warpage limit 0 10 mm 0 004 in Clutch spring free length 50 00 mm 1 97 in Limit 47 50 mm 1 87 in Drivetrain Primary reduction ratio 1 925 77 40 Transmission type Constant mesh 6 speed Gear ratio 1st 2 846 37 13 2nd 2 125 34 16 3rd 1 632 31 19 4th 1 300 26 20 5th 1 091 24 22 6th 0 964 27 28 Main axle runout limit 0 08 mm 0 0032 in Drive axle r...

Page 29: ...perature 85 105 C 185 221 F Engine oil temperature 60 80 C 140 176 F Intake vacuum 39 3 41 6 kPa 295 312 mmHg 11 6 12 3 inHg Difference in vacuum pressure between the cylinders 0 kPa 1 3 kPa 0 mmHg 10 mmHg 0 inHg 0 4 inHg CO 0 0 2 0 Fuel line pressure at idle 300 390 kPa 3 0 3 9 kgf cm 43 5 56 6 psi Throttle grip free play 3 0 5 0 mm 0 12 0 20 in ...

Page 30: ... SCORPION RALLY STR Tire air pressure measured on cold tires 1 person Front 220 kPa 2 20 kgf cm 32 psi Rear 250 kPa 2 50 kgf cm 36 psi 2 persons Front 220 kPa 2 20 kgf cm 32 psi Rear 250 kPa 2 50 kgf cm 36 psi Off road riding Front 200 kPa 2 00 kgf cm 29 psi Rear 200 kPa 2 00 kgf cm 29 psi Front brake Type Hydraulic dual disc brake Front disc brake Disc outside diameter thickness 282 0 4 5 mm 11 1...

Page 31: ...p oz Level 85 0 mm 3 35 in Rebound damping Adjusting system Mechanical adjustable type Unit for adjustment Click Adjustment value from the start position Soft 31 Adjustment value from the start position STD 17 Adjustment value from the start position Hard 0 Compression damping Adjusting system Mechanical adjustable type Unit for compression damping adjustment Click Adjustment value from the start ...

Page 32: ...Unit for adjustment Click Adjustment value from the start position Soft 18 Adjustment value from the start position STD 15 Adjustment value from the start position Hard 0 Drive chain Size 525V11 Chain type Sealed type Number of links 122 Drive chain slack 43 0 48 0 mm 1 69 1 89 in Limit 55 0 mm 2 17 in 15 link length limit 239 3 mm 9 42 in ...

Page 33: ...V Charging system Charging system AC magneto Standard output 14 0 V 29 3 A at 5000 r min Stator coil resistance 0 128 0 192 Ω Rectifier regulator Regulator type Three phase Regulated voltage DC 14 3 14 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 10 0 W 2 Rear turn signal light 10 0 W 2 Auxiliary light LED Licen...

Page 34: ...2 Ω Intake air temperature sensor resistance 5400 6600 Ω at 0 C 5400 6600 Ω at 32 F Intake air temperature sensor resistance 290 390 Ω at 80 C 290 390 Ω at 176 F Coolant temperature sensor resistance 2510 2780 Ω at 20 C 2510 2780 Ω at 68 F Coolant temperature sensor resistance 210 221 Ω at 100 C 210 221 Ω at 212 F Fuse s Main fuse 30 0 A Headlight fuse 10 0 A Signaling system fuse 7 5 A Ignition f...

Page 35: ...3 kgf m 9 6 lb ft Cylinder head cover bolt M6 4 10 N m 1 0 kgf m 7 4 lb ft Generator rotor bolt M12 1 70 N m 7 0 kgf m 52 lb ft Generator cover bolt M6 2 12 N m 1 2 kgf m 8 9 lb ft Generator cover bolt M6 8 12 N m 1 2 kgf m 8 9 lb ft Clutch boss nut M20 1 95 N m 9 5 kgf m 70 lb ft Stake Clutch spring bolt M6 6 8 N m 0 8 kgf m 5 9 lb ft Clutch cover bolt M6 10 12 N m 1 2 kgf m 8 9 lb ft Oil filter ...

Page 36: ...gf m 59 lb ft Rear wheel axle nut M18 1 105 N m 10 5 kgf m 77 lb ft Brake caliper bleed screw M8 3 10 N m 1 0 kgf m 7 4 lb ft Front brake caliper bolt M10 4 40 N m 4 0 kgf m 30 lb ft Upper handlebar holder bolt M8 4 28 N m 2 8 kgf m 21 lb ft See TIP Lower handlebar holder nut M10 2 32 N m 3 2 kgf m 24 lb ft Clutch cable locknut M8 1 7 N m 0 7 kgf m 5 2 lb ft Lower bracket pinch bolt M8 4 20 N m 2 ...

Page 37: ... bolts less than 20 N m 2 0 kgf m 15 lb ft temporally 2 Tighten the upper handlebar holder bolt on the front side and then on the rear side to specified torque TIP Lower bracket pinch bolt Tighten the pinch bolt to specification in order Pinch bolt 1 Pinch bolt 2 Pinch bolt 1 Pinch bolt 2 1 2 ...

Page 38: ...CABLE ROUTING 2 15 EAS20021 CABLE ROUTING Handlebar front view A B C D E F G H E F G G H I G H E G F H G H H J J K L K M M N N O 1 2 3 2 3 4 4 5 5 6 7 7 8 9 11 9 10 11 12 12 13 14 15 ...

Page 39: ...ith the meter assembly B Fasten the left handlebar switch lead and clutch cable with the holder Position the holder to the upper edge of the clutch cable protector C 90 100 mm 3 54 3 94 in D To meter assembly E Upward F Downward G Rearward H Forward I Route the wire harness through the hole in the headlight stay J 15 25 mm 0 59 0 98 in K Face the buckle of the plastic locking tie downward with the...

Page 40: ...G 2 17 Frame front right side view A C C C D E G H I L M N O P R 1 2 3 4 5 6 7 8 8 8 8 9 9 9 10 11 11 12 13 14 15 10 11 16 17 18 19 18 19 20 21 22 23 24 25 26 27 J K L M J K L M J K P O J K P O J K O P F F B 8 9 Q ...

Page 41: ... the main switch lead outside of the bracket C Insert the projection on the coupler into the hole in the coupler holder D Insert the projection on the handlebar switch lead and main switch lead into the hole in the bracket E Route the headlight lead through the guide on the right windshield inner panel F Route the headlight lead through the lower hole in the right windshield inner panel G To headl...

Page 42: ...E ROUTING 2 19 Frame and engine right side view G H G G H G H H G G H H A B C L K M N 1 2 3 4 5 6 7 G H D E F E F 10 11 12 13 15 16 N 16 N 16 23 23 17 18 18 19 21 20 22 24 25 I J I J I J I J I J 8 9 O 8 14 ...

Page 43: ...overflow hose rollover valve to canister 22 Canister 23 Frame 24 O2 sensor lead 25 Oil pressure switch lead A Face the blue paint mark on the fuel tank breather hose outward B Route the sub wire harness above the rear brake pipes and under the frame C Fasten the O2 sensor lead and oil pressure switch lead with the holder on the engine D Insert the projection on the wire harness holder into the hol...

Page 44: ... L M J K L M N O P Q R S 1 2 3 4 5 6 7 5 8 8 8 34 35 8 8 8 9 10 11 12 13 13 12 2 14 15 16 17 18 2 2 2 2 19 19 22 22 19 20 20 14 14 20 20 21 19 22 20 21 22 23 24 25 26 27 19 28 29 30 31 32 33 G H L M E F G H E F G H E F L M P K J L M E F L T M K J F E G H L M J K U L M ...

Page 45: ...ess to hydraulic unit 35 Frame A To Auxiliary DC jack B Route the wire harness through the guide on the left windshield inner panel C Route the auxiliary DC jack lead through the lower hole in the left windshield inner panel D Fasten the fog light coupler and auxiliary DC jack lead with the plastic locking tie Face the buckle of the plastic locking tie upward with the end pointing upward Cut off t...

Page 46: ...E G H F G E H F E G H N P O E F N O F E N O E F F M U T V A Q B E G H F E G H F E G H G H J K F E G R H 1 2 3 4 5 6 7 8 7 8 7 8 8 7 8 7 7 8 9 10 11 12 13 17 14 18 18 20 20 22 17 21 21 20 21 18 21 23 23 23 24 24 24 24 23 18 18 19 20 21 18 19 20 21 M 8 F E N O I 8 15 16 17 F S E H G 22 15 15 16 17 8 ...

Page 47: ...frame E Downward F Upward G Outward H Inward I Insert the projection on the wire harness holder into the hole in the bracket J Forward K Rearward L Face the buckle of the plastic locking tie upward with the end pointing inward M Face the buckle of the plastic locking tie downward with the end pointing downward N Left side O Right side P Face the buckle of the plastic band inward Q Face the paint m...

Page 48: ...ABLE ROUTING 2 25 Frame top view D E F 1 2 3 5 4 5 6 7 9 10 11 12 13 14 15 16 17 18 19 20 8 A B C D E F J K C D I C J D I C G C D E F H I J I J 21 22 21 22 23 25 26 31 31 30 30 22 27 27 29 28 24 25 L 24 ...

Page 49: ... crankshaft position sensor coupler 26 Rectifier regulator coupler black 27 Frame 28 Rectifier regulator lead 29 Crankshaft position sensor coupler 30 Stator coil lead 31 Coolant reservoir hose A Fasten the leads at the ends of wire harness protectors B Face the buckle of the plastic band rearward with the end pointing downward Do not cut off the excess end of the plastic band C Forward D Rearward...

Page 50: ...CABLE ROUTING 2 27 Battery and rear fender top view A E H 1 2 3 4 5 6 7 8 9 10 11 14 12 13 15 16 17 18 12 19 B C D 28 29 30 31 11 13 23 24 25 26 27 28 12 20 21 22 C D F G 32 ...

Page 51: ...ake light lead 23 Starter relay 24 Fuse box 2 lead 25 FI diagnostic tool connector lead 26 Fuse box 1 lead 27 Negative battery lead 28 Battery 29 Wire harness to joint coupler 30 Wire harness to relay unit 31 Air filter case 32 Rear wheel sensor lead A Insert the projection on the joint coupler holder into the hole in the battery box B Face the buckle of the plastic locking tie upward Cut off the ...

Page 52: ...CABLE ROUTING 2 29 Rear brake hose right side view B C D E F H G 1 2 3 2 2 2 2 2 3 4 3 G 2 3 3 3 5 5 6 4 3 4 A J I K H J I K L M ...

Page 53: ...stopper on the rear brake caliper C Make sure that the pin of the brake hose contacts the stopper on the rear brake master cylinder D Fasten the rear wheel sensor lead and the brake hose with the holder Position the holder between the rear brake hose lead guide wire E Position the holder within the 50 70 mm 1 97 2 76 in range from the grommet of the brake hose as shown in the illustration F Face t...

Page 54: ...CABLE ROUTING 2 31 Front brake hose left and right side view 1 1 1 1 2 2 2 2 2 2 2 5 2 2 2 3 3 3 3 3 3 3 3 4 4 4 4 4 A B H G J K L M F N 2 2 3 3 4 4 C D E O P I Q T U V R S ...

Page 55: ...older into the hole in the radiator cover J Insert the holder into the hole in the frame Face the catch of the holder forward and then close the holder until three clicks or more are heard K Insert the holder into the hole in the frame Face the catch of the holder outward and then close the holder until three clicks or more are heard L 5 15 mm 0 20 0 59 in M Route the front wheel sensor lead to th...

Page 56: ...CABLE ROUTING 2 33 Hydraulic unit assembly top and left side view 1 2 3 4 3 4 ...

Page 57: ... Brake hose hydraulic unit to rear brake caliper 2 Brake hose rear brake master cylinder to hydraulic unit 3 Brake hose front brake master cylinder to hydraulic unit 4 Brake hose hydraulic unit to right front brake caliper ...

Page 58: ...CABLE ROUTING 2 35 Radiator front and right side view A B C 1 2 3 3 4 5 ...

Page 59: ...r inlet hose Make sure not to install the hose clamp on the raised portion of the hose fitting B Align the yellow paint mark on the radiator inlet hose with the projection on the radiator pipe Install the radiator inlet hose onto the radiator pipe so that the hose contacts the projection on the pipe C Point the ends of the hose clamp rearward Position the hose clamp 3 mm 0 12 in or more away from ...

Page 60: ...CABLE ROUTING 2 37 Radiator left side view A B C D D F E G 1 1 2 2 3 4 5 6 6 7 5 ...

Page 61: ...nward B Fasten the radiator inlet hose and coolant reservoir hose at the white paint mark on each hose with the holder C Align the white paint mark on the radiator inlet hose with the projection on the thermostat housing Install the radiator inlet hose onto the thermostat housing so that the hose contacts the projection on the housing D Point the ends of the hose clamp in the direction shown in th...

Page 62: ...CABLE ROUTING 2 39 ...

Page 63: ...OSES 3 14 BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS 3 14 CHECKING THE BRAKE FLUID LEVEL 3 16 CHECKING THE WHEELS 3 16 CHECKING AND TIGHTENING THE SPOKES 3 16 CHECKING THE TIRES 3 17 CHECKING THE WHEEL BEARINGS 3 18 CHECKING THE SWINGARM OPERATION 3 18 LUBRICATING THE SWINGARM PIVOT 3 18 ADJUSTING THE DRIVE CHAIN SLACK 3 18 LUBRICATING THE DRIVE CHAIN 3 19 CHECKING AND ADJUSTING THE STEERING HEAD 3 1...

Page 64: ...THE FRONT BRAKE LIGHT SWITCH 3 29 ADJUSTING THE REAR BRAKE LIGHT SWITCH 3 29 CHECKING AND LUBRICATING THE CABLES 3 29 CHECKING THE THROTTLE GRIP OPERATION 3 29 CHECKING AND CHARGING THE BATTERY 3 30 CHECKING THE FUSES 3 30 ADJUSTING THE HEADLIGHT BEAMS 3 30 REPLACING THE LICENSE PLATE LIGHT BULB 3 31 ...

Page 65: ......

Page 66: ...should be performed by your Yamaha dealer because these items re quire special tools data and technical skills From 50000 km 30000 mi repeat the maintenance intervals starting from 10000 km 6000 mi The annual checks must be performed every year except if a distance based maintenance is performed instead NO ITEM CHECK OR MAINTENANCE JOB ODOMETER READING ANNUAL CHECK 1000 km 600 mi 10000 km 6000 mi ...

Page 67: ...1000 km 600 mi and after washing the motorcycle riding in the rain or riding in wet areas 14 Steering bearings Check bearing assemblies for looseness Moderately repack with lithi um soap based grease 15 Chassis fasteners Make sure that all nuts bolts and screws are properly tight ened 16 Brake lever pivot shaft Lubricate with silicone grease 17 Brake pedal pivot shaft Lubricate with lithium soap b...

Page 68: ...s or sooner if cracked or damaged 25 Engine oil Change warm engine before draining Check oil level and vehicle for oil leakage 26 Engine oil filter cartridge Replace 27 Cooling system Check coolant level and vehi cle for coolant leakage Change Every 3 years 28 Front and rear brake switches Check operation 29 Moving parts and cables Lubricate 30 Throttle grip housing and ca ble Check operation and ...

Page 69: ...ha diagnostic tool version 3 0 and after to perform the dynamic inspection For information about using the Yamaha diagnostic tool refer to the operation manual that is included with the tool 5 Install Rider seat Refer to GENERAL CHASSIS 1 on page 4 1 EAS30619 CHECKING THE FUEL LINE 1 Remove Rider seat Refer to GENERAL CHASSIS 1 on page 4 1 Air scoops Air ducts Fuel tank side covers Refer to GENERA...

Page 70: ...ve Brake hose from the holder 1 Holder 2 from the radiator cover 3 Remove Hydraulic unit bracket bolts 1 Intake air pressure sensor bolt 2 TIP Remove the hydraulic unit assembly bracket bolts 1 and intake air pressure sensor bolt 2 Then move the hydraulic unit assembly togeth er with the bracket to the left 4 Remove Radiator bolt 1 TIP Remove the radiator bolt 1 and then move the radiator to the r...

Page 71: ...5 Install Rectifier regulator Refer to ABS ANTI LOCK BRAKE SYS TEM on page 4 44 Windshield inner panel left Refer to GENERAL CHASSIS 4 on page 4 8 Fuel tank Refer to FUEL TANK on page 7 1 Fuel tank side covers Air ducts Air scoops Refer to GENERAL CHASSIS 3 on page 4 5 Rider seat Refer to GENERAL CHASSIS 1 on page 4 1 EAS30622 ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of...

Page 72: ...ark a on the generator rotor with the slot b in the gen erator rotor cover 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 in the following sequence d To measure the valve clearances of cylin der 2 turn the crankshaft 270 counter clockwise 6 Remove Camshaft TIP Refer to CAMSHAFTS on page 5 10 When...

Page 73: ...m 0 0641 in The valve pad number is 163 e Round off the valve pad number according to the following table and then select the suitable valve pad TIP Refer to the following table for the available valve pads Example Valve pad number 163 Rounded value 165 New valve pad number 165 f Install the new valve pad and the valve lift er TIP Lubricate the valve pad with molybdenum di sulfide oil Lubricate th...

Page 74: ...he diagnostic code number 67 Refer to SELF DIAGNOSTIC FUNC TION AND DIAGNOSTIC CODE TABLE on page 9 1 b Check the ISC idle speed control leaning value EAS30797 SYNCHRONIZING THE THROTTLE BODIES TIP Before synchronizing the throttle bodies check the following items Valve clearance Spark plugs Air filter element Throttle body joints Fuel hose Exhaust system Cylinder head breather hose Vacuum hoses C...

Page 75: ... check the synchronization again If a bypass air screw was removed turn the screw in fully and be sure to synchronize the throttle bodies If the throttle body synchronization can not be adjusted using the bypass air screw clean or replace the throttle bodies The difference in vacuum pressure between the throttle bodies should not exceed 1 33 kPa 10 mmHg 2 Stop the engine and remove the measuring e...

Page 76: ...l tank side covers Refer to GENERAL CHASSIS 3 on page 4 5 Fuel tank Refer to FUEL TANK on page 7 1 2 Check Canister Canister purge hose Fuel tank breather overflow hoses Canister breather hose Cracks damage Replace 3 Install Fuel tank Refer to FUEL TANK on page 7 1 Fuel tank side covers Air ducts Air scoops Refer to GENERAL CHASSIS 3 on page 4 5 Rider seat Refer to GENERAL CHASSIS 1 on page 4 1 Th...

Page 77: ... filter element Air duct cover NOTICE ECA14401 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 carburetor synchronization leading to poor engine per formance and possible overheating 5 Install Fuel tank Refer to FUEL TANK on page 7 1 ...

Page 78: ...e lever TIP While pushing the brake lever forward turn the adjusting dial 1 until the brake lever is in the desired position Be sure to align the setting on the adjusting dial with the arrow mark a on the brake lever hold er WARNING EWA13050 A soft or spongy feeling in the brake lever can indicate the presence of air in the brake system Before the vehicle is operated the air must be removed by ble...

Page 79: ...Refer to ADJUSTING THE REAR BRAKE LIGHT SWITCH on page 3 29 EAS30634 CHECKING THE REAR BRAKE PADS The following procedure applies to all of the brake pads 1 Operate the brake 2 Check Rear brake pad Worn almost to the wear indicator a Re place the brake pads as a set Refer to REAR BRAKE on page 4 35 EAS30894 CHECKING THE BRAKE HOSES The following procedure applies to all of the brake hoses and brak...

Page 80: ...htly to the bleed screw 2 d Place the other end of the hose into a con tainer e Slowly apply the brake several times f Fully squeeze the brake lever or fully de press the brake pedal and hold it in posi tion g Loosen the bleed screw TIP Loosening the bleed screw will release the pres sure and cause the brake lever to contact the throttle grip or the brake pedal to fully extend h Tighten the bleed ...

Page 81: ...CE ECA13540 Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately TIP In order to ensure a correct reading of the brake fluid level make sure the top of the brake fluid reservoir is horizontal EAS30638 CHECKING THE WHEELS The following procedure applies to both of the wheels 1 Check Wheel Damage out of round Replace WARNING EWA13260 N...

Page 82: ... 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 done TIP For tires with a...

Page 83: ...cle on the sidestand WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over 2 Shift the transmission into the neutral posi tion 3 Check Drive chain slack Out of specification Adjust TIP Measure the distance a between the rib end b on the drive chain guide 1 and the center of the drive chain 2 NOTICE ECA20870 Improper drive chain slack will overload the engine a...

Page 84: ... chains Do not use any other lubricants on the drive chain since they may contain solvents that could damage the O rings EAS30645 CHECKING AND ADJUSTING THE STEERING HEAD 1 Stand the vehicle on a level surface WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over TIP Place the vehicle on a suitable stand so that the front wheel is elevated 2 Check Steering hea...

Page 85: ...E CHASSIS FASTENERS Make sure that all nuts bolts and screws are properly tightened EAS30804 LUBRICATING THE BRAKE LEVER Lubricate the pivoting point and metal to metal moving parts of the lever EAS30895 LUBRICATING THE PEDALS Lubricate the pivoting point and metal to metal moving parts of the pedals EAS30805 LUBRICATING THE CLUTCH LEVER Lubricate the pivoting point and metal to metal moving parts...

Page 86: ... adjustment positions 1 Adjust Rebound damping a Turn the adjusting screw 1 in direction a or b TIP Although the total number of clicks of a damping force adjusting mechanism may not exactly match the above specifications due to small dif ferences in production the actual number of clicks always represents the entire adjusting range To obtain a precise adjustment it would be advisable to check the...

Page 87: ...RBER ASSEMBLY on page 4 73 EAS30655 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over Spring preload NOTICE ECA13590 Never go beyond the maximum or minimum adjustment positions 1 Adjust Spring preload a Turn the adjusting knob 1 in direction a or b Direction a Compression damping is increased suspension is harder ...

Page 88: ...ual total number of turns of the damping force adjusting mechanism This ad justment range may not exactly match the spec ifications listed due to small differences in production Direction a Rebound damping is increased sus pension is harder Direction b Rebound damping is decreased sus pension is softer Rebound damping Adjustment value from the start position Soft 23 Adjustment value from the start...

Page 89: ... oils with a grade of CD or higher and do not use oils labeled ENERGY CONSERVING II Do not allow foreign materials to enter the crankcase 4 Start the engine warm it up for several min utes and then turn it off 5 Check the engine oil level again TIP Before checking the engine oil level wait a few minutes until the oil has settled EAS30657 CHANGING THE ENGINE OIL 1 Remove Engine guard Refer to ENGIN...

Page 90: ... vehicle on a suitable stand Make sure that the vehicle is upright 2 Check Engine oil level Below the minimum level mark a Add the recommended engine oil to the proper level 3 Start the engine warm it up for several min utes and then turn it off NOTICE ECA13410 When the engine is cold the engine oil will have a higher viscosity causing the engine oil pressure to increase Therefore be sure to measu...

Page 91: ...a and maximum level mark b Below the minimum level mark Add the recommended coolant to the proper level NOTICE ECA13470 Adding water instead of coolant lowers the antifreeze content of the coolant If water is used instead of coolant check and if nec essary correct the antifreeze concentra tion of the coolant Pressure gauge 90890 03153 Pressure gauge YU 03153 Oil pressure adapter H 90890 03139 Oil ...

Page 92: ...age 6 5 and WATER PUMP on page 6 10 EAS30813 CHANGING THE COOLANT 1 Remove Air scoop right Refer to GENERAL CHASSIS 3 on page 4 5 2 Remove Radiator cap bolt 1 Radiator cap 2 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...

Page 93: ... available soft water may be used If coolant comes into contact with painted surfaces immediately wash them with wa ter Do not mix different types of antifreeze 9 Install Radiator cap Radiator cap bolt 10 Fill Coolant reservoir with the recommended coolant to the maxi mum level mark a 11 Install Coolant reservoir cap 12 Start the engine warm it up for several min utes and then turn it off 13 Check...

Page 94: ...e TIP Hold the cable end upright and pour a few drops of lubricant into the cable sheath or use a suit able lubricating device EAS30861 CHECKING THE THROTTLE GRIP OPERATION 1 Check Throttle cables Damage deterioration Replace Throttle cable installation Incorrect Reinstall the throttle cables Refer to CABLE ROUTING on page 2 15 and HANDLEBAR on page 4 52 2 Check Throttle grip movement Rough moveme...

Page 95: ... Turn the adjusting nut 3 until the speci fied throttle grip free play is obtained d Tighten the locknut e Slide the rubber cover to its original posi tion TIP Make sure that the adjusting nut is covered com pletely by the rubber cover EAS30816 CHECKING AND CHARGING THE BATTERY Refer to CHECKING AND CHARGING THE BATTERY on page 8 130 EAS30662 CHECKING THE FUSES Refer to CHECKING THE FUSES on page ...

Page 96: ...icense plate light unit nuts 1 License plate light cover 2 3 Remove License plate light bulb 1 4 Install License plate light bulb 5 Install License plate light cover License plate light unit Lower fender cover 1 2 1 1 1 2 1 New T R License plate light cover nut 3 8 N m 0 38 kgf m 2 8 lb ft Lower fender cover bolt 4 0 N m 0 40 kgf m 3 0 lb ft ...

Page 97: ...LY 4 10 INSTALLING THE WINDSHIELDS 4 10 INSTALLING THE METER ASSEMBLY 4 10 FRONT WHEEL 4 11 REMOVING THE FRONT WHEEL 4 13 DISASSEMBLING THE FRONT WHEEL 4 13 CHECKING THE FRONT WHEEL 4 13 MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR 4 14 ASSEMBLING THE FRONT WHEEL 4 15 ADJUSTING THE FRONT WHEEL STATIC BALANCE 4 15 INSTALLING THE FRONT WHEEL 4 15 REAR WHEEL 4 18 REMOVING THE REAR WHEEL 4 2...

Page 98: ...EAR BRAKE MASTER CYLINDER 4 42 CHECKING THE REAR BRAKE MASTER CYLINDER 4 42 ASSEMBLING THE REAR BRAKE MASTER CYLINDER 4 42 INSTALLING THE REAR BRAKE MASTER CYLINDER 4 43 ASSEMBLING THE BRAKE PEDAL 4 43 ABS ANTI LOCK BRAKE SYSTEM 4 44 REMOVING THE HYDRAULIC UNIT ASSEMBLY 4 46 CHECKING THE HYDRAULIC UNIT ASSEMBLY 4 46 INSTALLING THE HYDRAULIC UNIT ASSEMBLY 4 46 HYDRAULIC UNIT OPERATION TESTS 4 48 CH...

Page 99: ...AY ARM 4 73 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 4 73 INSTALLING THE RELAY ARM 4 74 SWINGARM 4 75 REMOVING THE SWINGARM 4 77 CHECKING THE SWINGARM 4 77 INSTALLING THE SWINGARM 4 78 CHAIN DRIVE 4 80 REMOVING THE DRIVE SPROCKET 4 82 CHECKING THE DRIVE CHAIN 4 82 CHECKING THE DRIVE SPROCKET 4 83 CHECKING THE REAR WHEEL SPROCKET 4 83 CHECKING THE REAR WHEEL DRIVE HUB 4 83 INSTALLING THE DRIVE S...

Page 100: ...ats and battery Order Job Parts to remove Q ty Remarks 1 Passenger seat 1 2 Rider seat 1 3 Battery band 1 4 Negative battery lead 1 Disconnect 5 Positive battery lead 1 Disconnect 6 Battery 1 1 3 5 6 4 2 2 3 N m 0 23 kgf m 1 7 lb ft T R 7 N m 0 7 kgf m 5 2 lb ft T R ...

Page 101: ...brake light assembly 1 6 License plate light coupler 1 7 Rear turn signal light coupler right 1 Disconnect 8 Rear turn signal light coupler left 1 Disconnect 9 Rear fender assembly 1 10 ECU cover 1 11 ECU coupler 1 Disconnect 12 ECU Engine Control Unit 1 4 0 N m 0 40 kgf m 3 0 lb ft T R 4 0 N m 0 40 kgf m 3 0 lb ft T R 4 0 N m 0 40 kgf m 3 0 lb ft T R 11 N m 1 1 kgf m 8 1 lb ft T R 9 N m 0 9 kgf m...

Page 102: ...nnect ECU coupler TIP While pushing the projection a and move the lock lever b of the ECU coupler in the direction of the arrow shown in the illustration to discon nect the coupler EAS31642 INSTALLING THE ECU engine control unit 1 Connect ECU coupler TIP Push the lock lever a of the ECU coupler in the direction of the arrow shown in the illustration to connect the coupler EAS33140 INSTALLING THE T...

Page 103: ...GENERAL CHASSIS 2 4 4 TIP Fit the projections a on the side cover to the holes b in the tail cover and then fit the projec tions c to the grommets d 1 c a b d ...

Page 104: ...op right 1 6 Front turn signal light coupler right 1 Disconnect 7 Front turn signal light right 1 8 Air duct right 1 9 Fuel tank side cover left 1 10 Fuel tank side cover right 1 3 0 N m 0 30 kgf m 2 2 lb ft T R 3 0 N m 0 30 kgf m 2 2 lb ft T R 4 0 N m 0 40 kgf m 3 0 lb ft T R 4 0 N m 0 40 kgf m 3 0 lb ft T R 4 0 N m 0 40 kgf m 3 0 lb ft T R 4 0 N m 0 40 kgf m 3 0 lb ft T R 4 0 N m 0 40 kgf m 3 0 ...

Page 105: ...es to both of the fuel tank side covers 1 Remove Fuel tank side cover 1 TIP Remove the projection a on the fuel tank side cover from the hole b EAS32778 INSTALLING THE FUEL TANK SIDE COVERS The following procedure applies to both of the fuel tank side covers 1 Install Fuel tank side cover 1 TIP Fit the projection a on the fuel tank side cover to the hole b in the fuel tank Engage the hook c on the...

Page 106: ...GENERAL CHASSIS 3 4 7 EAS31773 INSTALLING THE AIR SCOOPS The following procedure applies to both of the air scoops 1 Install Air scoop 1 TIP Fit the projections a on the air scoop to the holes b 1 b a ...

Page 107: ...4 Meter assembly coupler 1 Disconnect 5 Meter assembly 1 6 Intake air temperature sensor coupler 1 Disconnect 7 Intake air temperature sensor 1 8 Auxiliary DC jack coupler left 1 Disconnect 9 Windshield inner panel left 1 4 0 N m 0 40 kgf m 3 0 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 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 23 N m 2 3 kgf m 17 lb ft...

Page 108: ...r panel right 1 13 Headlight inner cover 1 14 Headlight assembly 1 4 0 N m 0 40 kgf m 3 0 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 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 23 N m 2 3 kgf m 17 lb ft T R 9 N m 0 9 kgf m 6 6 lb ft T R 0 5 N m 0 05 kgf m 0 37 lb ft T R 0 5 N m 0 05 kgf m 0 37 lb ft T R 0 5 N m 0 05 kgf m 0 37 lb ft T R 14 13 10 11 12 4 4...

Page 109: ...llowing procedure applies to both of wind shields 1 Install Windshield left right 1 TIP Install the windshield to the inward of the por tion a on the windshield inner panel Fit the projection b on the windshield to the hole c in the windshield inner panel EAS31774 INSTALLING THE METER ASSEMBLY 1 Install Meter assembly TIP Fit the projections a on the meter assembly to the holes b in the headlight ...

Page 110: ...oosen 10 Front wheel axle 1 11 Front wheel 1 12 Collar 2 13 Front brake disc 2 14 Front wheel sensor rotor 1 LT LT New New New LT 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 8 N m 0 8 kgf m 5 9 lb ft T R 8 N m 0 8 kgf m 5 9 lb ft T R 8 N m 0 8 kgf m 5 9 lb ft T R 18 N m 1 8 kgf m 13 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 21 N m 2 1 kgf m 15 lb f...

Page 111: ...FRONT WHEEL 4 12 Disassembling the front wheel Order Job Parts to remove Q ty Remarks 1 Oil seal 2 2 Wheel bearing 2 3 Spacer 1 New New New New LS LS 2 1 1 2 3 ...

Page 112: ...outer tube 3 Elevate Front wheel TIP Place the vehicle on a suitable stand so that the front wheel is elevated EAS30146 DISASSEMBLING THE FRONT WHEEL 1 Remove Oil seal Wheel bearings a Clean the surface of the front wheel hub b Remove the oil seals 1 with a flat head screwdriver TIP To prevent damaging the wheel place a rag 2 between the screwdriver and the wheel surface c Remove the wheel bearing...

Page 113: ...talled on the inner side of the wheel hub When cleaning the wheel sensor rotor be careful not to damage the surface of the sensor rotor 3 Measure Wheel sensor rotor deflection Out of specification Clean the installation surface of the wheel sensor rotor and correct the wheel sensor rotor deflection or replace the wheel sensor rotor a Hold the dial gauge at a right angle against the wheel sensor ro...

Page 114: ...ire wheel or both the front wheel static balance should be adjusted Adjust the front wheel static balance with the brake disc installed 1 Remove Balancing weight s 2 Find Front wheel s heavy spot 3 Adjust Front wheel static balance 4 Check Front wheel static balance EAS32231 INSTALLING THE FRONT WHEEL 1 Install Front wheel sensor rotor Front brake discs NOTICE ECA21011 Do not drop the wheel sensor...

Page 115: ... front wheel sensor TIP a Fit the projection a on the front fork into the hole b on the front wheel sensor lead holder When installing the front wheel sensor check the wheel sensor lead for twists To route the front wheel sensor lead refer to CABLE ROUTING on page 2 15 6 Measure Distance a between the front wheel sensor rotor 1 and front wheel sensor 2 Out of specification Check the wheel bear ing...

Page 116: ...tion of the front wheel Do not turn the front wheel while the thickness gauge is installed This may damage the front wheel sen sor rotor and the front wheel sensor Distance a between the front wheel sensor rotor and front wheel sensor 0 7 1 6 mm 0 03 0 06 in Thickness gauge 90890 03268 Feeler gauge set YU 26900 9 1 1 2 2 a G088903 ...

Page 117: ...2 Loosen 3 Adjusting bolt 2 Loosen 4 Rear wheel axle nut 1 5 Washer 1 6 Adjusting block 2 7 Rear wheel axle 1 8 Rear wheel 1 9 Rear brake caliper 1 10 Collar left 1 11 Collar right 1 LT 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 16 N m 1 6 kgf m 12 lb ft T R 105 N m 10 5 kgf m 77 lb ft T R 4 5 6 6 7 10 8 11 1 3 2 9 ...

Page 118: ...ket 1 3 Rear wheel drive hub 1 4 Rear wheel drive hub damper 6 5 Collar 1 6 Oil seal 1 7 Bearing 1 8 Rear brake disc 1 9 Rear brake disc plate 1 10 Rear wheel sensor rotor 1 11 Rear wheel 1 LT LT New New New LS LS 8 N m 0 8 kgf m 5 9 lb ft T R 30 N m 3 0 kgf m 22 lb ft T R 80 N m 8 0 kgf m 59 lb ft T R 5 5 6 2 6 7 5 3 4 4 4 4 1 11 8 10 9 ...

Page 119: ...REAR WHEEL 4 20 Disassembling the rear wheel Order Job Parts to remove Q ty Remarks 1 Oil seal 1 2 Wheel bearing 2 3 Spacer 1 New New New LS 2 2 3 1 ...

Page 120: ...ve Rear wheel axle nut Washer Rear wheel axle Adjusting blocks Rear wheel TIP Push the rear wheel forward and remove the drive chain from the rear wheel sprocket EAS30158 DISASSEMBLING THE REAR WHEEL 1 Remove Oil seal Wheel bearings Refer to DISASSEMBLING THE FRONT WHEEL on page 4 13 EAS30159 CHECKING THE REAR WHEEL 1 Check Rear wheel axle Wheel bearings Oil seal Refer to CHECKING THE FRONT WHEEL ...

Page 121: ... Rear wheel sensor Refer to MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR on page 4 14 2 Check Rear wheel sensor rotor Refer to MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR on page 4 14 3 Measure Wheel sensor rotor deflection Refer to MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR on page 4 14 EAS30163 ASSEMBLING THE REAR WHEEL NOTICE ECA21050 Do not drop the wheel senso...

Page 122: ...rake disc Refer to CHECKING THE REAR BRAKE DISC on page 4 40 4 Lubricate Oil seal lips 5 Install Collar right Collar left Rear brake caliper 1 Rear wheel Adjusting blocks Rear wheel axle Washer Rear wheel axle nut TIP Install the rear wheel with the mark a on the rear tire pointing in the direction of wheel rota tion Align the projection b in the swingarm with the slot c of the brake caliper brack...

Page 123: ... sensor and sensor rotor installation conditions warpage caused by overtorque wrong in stallation direction rotor decentering LOC TITE on the mounting surface of the rotor deformation caused by an impact during ser vice and caught foreign materials If there is any defective part repair or replace the de fective part TIP Measure the distance between the rear wheel sensor rotor and rear wheel sensor...

Page 124: ...ve Q ty Remarks The following procedure applies to both of the front brake calipers 1 Brake caliper bleed screw 1 Loosen 2 Front brake caliper 1 3 Brake pad clip 2 4 Brake pad pin 1 5 Brake pad 2 6 Brake pad spring 1 1 2 3 4 6 5 New 40 N m 4 0 kgf m 30 lb ft T R 10 N m 1 0 kgf m 7 4 lb ft T R ...

Page 125: ...linder reservoir diaphragm 1 4 Brake lever 1 5 Front brake light switch connector 2 Disconnect 6 Front brake light switch 1 7 Front brake hose union bolt 1 8 Brake hose gasket 2 9 Brake hose front brake master cylinder to hy draulic unit 1 10 Front brake master cylinder holder 1 11 Front brake master cylinder assembly 1 1 2 3 4 5 6 7 8 9 11 10 S New 1 5 N m 0 15 kgf m 1 1 lb ft T R 1 2 N m 0 12 kg...

Page 126: ...FRONT BRAKE 4 27 Disassembling the front brake master cylinder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder kit 1 2 Brake master cylinder body 1 2 1 New BF BF S ...

Page 127: ...EDING THE HYDRAULIC BRAKE SYSTEM ABS on page 3 14 1 Front brake hose union bolt 1 2 Brake hose gasket 2 3 Brake hose gasket 1 Right side only 4 Brake hose right front brake caliper to left front brake caliper 1 5 Brake hose hydraulic unit to right front brake caliper 1 Right side only 6 Front brake caliper 1 5 1 2 4 3 6 New New 30 N m 3 0 kgf m 22 lb ft T R 40 N m 4 0 kgf m 30 lb ft T R ...

Page 128: ...move 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 2 4 Brake pad spring 1 5 Brake pad support 1 6 Boot 1 7 Boot 1 8 Brake caliper bleed screw 1 New 10 N m 1 0 kgf m 7 4 lb ft T R 4 8 3 2 1 7 6 5 ...

Page 129: ... brake disc a Place the vehicle on a suitable 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 deflection 1 5 mm 0 06 in below the edge of the brake disc 3 Measure Brake disc thickness Measure the brake disc thickness at a few dif ferent locations Out of specification Replace 4 Adjust Brake disc...

Page 130: ...e caliper 4 Check Brake fluid level Below the minimum level mark Add the specified brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 16 5 Check Brake lever operation Soft or spongy feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS on page 3 14 EAS30724 REMOVING THE FRONT BRAKE CALIPERS The following procedure applies to both of the bra...

Page 131: ... the pins b of the brake hose hydraulic unit to right front brake and brake hose right front brake caliper to left brake caliper 2 Remove Front brake caliper 3 Install Brake pad spring Brake pads Brake pad pin Brake pad clips Refer to REPLACING THE FRONT BRAKE PADS on page 4 30 4 Fill Brake master cylinder reservoir with the specified amount of the specified brake fluid WARNING EWA13090 Use only t...

Page 132: ...ke master cylinder to hydraulic unit TIP To collect any remaining brake fluid place a container under the master cylinder and the end of the brake hose EAS30725 CHECKING THE FRONT BRAKE MASTER CYLINDER 1 Check Brake master cylinder Damage scratches wear Replace Brake fluid delivery passages brake master cylinder body Obstruction Blow out with compressed air 2 Check Brake master cylinder kit Damage...

Page 133: ...e of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake performance When refilling be careful that water does not enter the brake master cylinder reser voir Water will significantly lower the boil ing point of the brake fluid and could cause vapor lock NOTICE ECA13540 Brake fluid may damage painted surfaces and plastic part...

Page 134: ... rear brake pads Order Job Parts to remove Q ty Remarks Rear wheel Refer to REAR WHEEL on page 4 18 1 Brake pad clip 1 2 Brake pad pin 1 3 Brake pad 2 4 Brake pad spring 1 5 Brake caliper bleed screw 1 Loosen 1 3 2 4 5 10 N m 1 0 kgf m 7 4 lb ft T R ...

Page 135: ...2 Brake fluid reservoir cap 1 3 Brake fluid reservoir diaphragm holder 1 4 Brake fluid reservoir diaphragm 1 5 Brake fluid reservoir hose 1 6 Rear brake hose union bolt 1 7 Brake hose gasket 2 8 Brake hose rear brake master cylinder to hy draulic unit 1 9 Rear brake master cylinder 1 8 9 5 1 4 3 2 New 6 New 7 23 N m 2 3 kgf m 17 lb ft T R 4 0 N m 0 40 kgf m 3 0 lb ft T R 30 N m 3 0 kgf m 22 lb ft ...

Page 136: ...brake master cylinder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder yoke 1 2 Brake master cylinder kit 1 3 Hose joint 1 4 Bushing 1 5 Brake master cylinder body 1 1 2 2 3 4 5 S BF BF New New New 18 N m 1 8 kgf m 13 lb ft T R ...

Page 137: ...ake fluid Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS on page 3 14 Rear wheel Refer to REAR WHEEL on page 4 18 1 Rear brake hose union bolt 1 2 Brake hose gasket 2 3 Brake hose hydraulic unit to rear brake caliper 1 4 Rear brake caliper 1 1 3 2 4 New 30 N m 3 0 kgf m 22 lb ft T R ...

Page 138: ...brake caliper Order Job Parts to remove Q ty Remarks 1 Brake pad clip 1 2 Brake pad pin 1 3 Brake pad 2 4 Brake pad spring 1 5 Brake pad support 1 6 Boot 1 7 Boot 1 8 Brake caliper bleed screw 1 10 N m 1 0 kgf m 7 4 lb ft T R 4 3 1 2 6 8 7 5 ...

Page 139: ...the brake disc deflection or replace the brake disc Refer to CHECKING THE FRONT BRAKE DISCS on page 4 30 3 Measure Brake disc thickness Measure the brake disc thickness at a few dif ferent locations Out of specification Replace Refer to CHECKING THE FRONT BRAKE DISCS on page 4 30 4 Adjust Brake disc deflection Refer to CHECKING THE FRONT BRAKE DISCS on page 4 30 EAS30185 REPLACING THE REAR BRAKE P...

Page 140: ...d carefully 2 Remove Rear wheel Rear brake caliper Refer to REMOVING THE REAR WHEEL on page 4 21 EAS30188 CHECKING THE REAR BRAKE CALIPER Brake caliper body Cracks damage Replace the brake caliper assembly 1 Check Rear brake caliper bracket Cracks damage Replace EAS30190 INSTALLING THE REAR BRAKE CALIPER 1 Install Rear brake caliper Rear wheel Refer to INSTALLING THE REAR WHEEL on page 4 22 2 Inst...

Page 141: ...ling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS on page 3 14 EAS30193 REMOVING THE REAR BRAKE MASTER CYLINDER 1 Remove Brake hose union bolt Brake hose gaskets Brake hose rear brake master cylinder to hy draulic unit 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 MASTE...

Page 142: ... a harmful chemical reaction leading to poor brake performance When refilling be careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock NOTICE ECA13540 Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 3 Bleed Brake system Refer to ...

Page 143: ...FUEL TANK on page 7 1 Brake fluid Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS on page 3 14 1 Stator coil coupler 1 Disconnect 2 Rectifier regulator coupler 1 Disconnect 3 Rectifier regulator 1 4 Intake air pressure sensor 1 5 ABS ECU coupler 1 Disconnect 6 Brake hose union bolt 4 7 Gasket 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 7 N m 0 7 kgf m 5 2 lb ft T R 30 N m ...

Page 144: ...ake caliper 1 Disconnect 10 Brake hose rear brake master cylinder to hy draulic unit 1 Disconnect 11 Brake hose front brake master cylinder to hy draulic unit 1 Disconnect 12 Hydraulic unit bracket 1 13 Hydraulic unit assembly 1 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 7 N m 0 7 kgf m 5 2 lb ft T R 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 FWD FWD New New Ne...

Page 145: ...sconnect ABS ECU coupler 1 TIP While pushing the portion a of the ABS ECU coupler move the lock lever b in the direction of the arrow shown to disconnect the coupler 2 Remove Brake hoses TIP Do not operate the brake lever and brake pedal while removing the brake hoses NOTICE ECA14530 When removing the brake hoses cover the area around the hydraulic unit to catch any spilt brake fluid Do not allow ...

Page 146: ...se front brake master cylinder to hydraulic unit c Temporarily tighten the union bolt for the brake hose rear brake master cylinder to hydraulic unit 4 TIP Make sure that the pipe section b of the brake hose rear brake master cylinder to hydraulic unit does not contact the hydraulic unit d Position the brake hose hydraulic unit to right front brake caliper 2 so that its pro jection c contacts the ...

Page 147: ...to B 3 DE LETING THE FAULT CODES on page 8 125 9 Perform a trial run Refer to CHECKING THE ABS WARNING LIGHT on page 4 51 EAS31040 HYDRAULIC UNIT OPERATION TESTS The reaction force pulsating action generated in the brake lever and brake pedal when the ABS is activated can be tested when the vehicle is stopped The hydraulic unit operation can be tested using the following two methods Brake line rou...

Page 148: ... screen indicate when the brakes are being applied and released respectively NOTICE ECA18280 Check that the pulse is felt in the brake le ver brake pedal and again in the brake le ver in this order If the pulse is felt in the brake pedal 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...

Page 149: ...ver and brake pedal are not being operated 9 A reaction force pulsating action is generated in the brake lever 1 and continues for a few seconds TIP The reaction force pulsating action consists of quick pulses Be sure to continue operating the brake lever and brake pedal even after the pulsating action has stopped ON and OFF on the tool screen indicate when the brakes are being applied and re leas...

Page 150: ... brake pipes are connected cor rectly to the hydraulic unit assembly 12 Turn the main switch to OFF 13 Remove the Yamaha diagnostic tool from the Yamaha diagnostic tool coupler and then in stall the protective cap 14 Turn the main switch to ON 15 Set the start engine stop switch to 16 Check for brake fluid leakage around the hy draulic unit Brake fluid leakage Replace the hydraulic unit brake hose...

Page 151: ...S LS LS LT LT LT LT 18 N m 1 8 kgf m 13 lb ft T R 26 N m 2 6 kgf m 19 lb ft T R 2 0 N m 0 20 kgf m 1 5 lb ft T R 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 28 N m 2 8 kgf m 21 lb ft T R 32 N m 3 2 kgf m 24 lb ft T R 3 0 N m 0 30 kgf m 2 2 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 7 N m 0 7 kgf m 5 2 lb ft T R 11 N m 1 1 kgf m 8 1 lb ft T R 26 N m 2 ...

Page 152: ... handlebar holder 1 LT LS LS LS LS LS LT LT LT LT 18 N m 1 8 kgf m 13 lb ft T R 26 N m 2 6 kgf m 19 lb ft T R 2 0 N m 0 20 kgf m 1 5 lb ft T R 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 28 N m 2 8 kgf m 21 lb ft T R 32 N m 3 2 kgf m 24 lb ft T R 3 0 N m 0 30 kgf m 2 2 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 7 N m 0 7 kgf m 5 2 lb ft T R 11 N m 1 1...

Page 153: ...at there is no danger of it falling over 2 Install Lower handlebar holder 1 Handlebar 2 Upper handlebar holder 3 NOTICE ECA19130 First tighten the bolts on the front side of the upper handlebar holder and then on the rear side Turn the handlebar all the way to the left and right If there is any contact with the fuel tank adjust the handlebar position TIP The lower handlebar holder should be instal...

Page 154: ...lithium soap based grease Fit the projection b on the bottom of the bolt head into the slot c in the bolt hole in the clutch lever holder While squeezing the clutch lever fit the projec tion d on the clutch switch into the slot e in the clutch lever holder 7 Install Handlebar switch left TIP Align the projection a on the left handlebar switch with the hole b in the handlebar T R Throttle cable hou...

Page 155: ...24 in of clear ance a between the throttle grip and the grip end 10 Install Throttle cable holder 1 TIP Align the throttle cable holder 1 with the edge of the front brake master cylinder 11 Adjust Throttle grip free play Refer to CHECKING THE THROTTLE GRIP OPERATION on page 3 29 12 Adjust Clutch lever free play Refer to ADJUSTING THE CLUTCH LEVER FREE PLAY on page 3 12 13 Install Handguard bracket...

Page 156: ...rview mirror left 17 N m 1 7 kgf m 13 lb ft Rearview mirror right 17 N m 1 7 kgf m 13 lb ft Left hand threads Handguard bolt grip end 18 N m 1 8 kgf m 13 lb ft Handguard bolt rearview mirror 7 N m 0 7 kgf m 5 2 lb ft LOCTITE ...

Page 157: ...s to both of the front fork legs Front brake calipers Front fender Front wheel Refer to FRONT WHEEL on page 4 11 1 Upper bracket pinch bolt 2 Loosen 2 Front fork cap bolt 1 Loosen 3 Lower bracket pinch bolt 2 Loosen 4 Front fork leg 1 20 N m 2 0 kgf m 15 lb ft T R 23 N m 2 3 kgf m 17 lb ft T R 30 N m 3 0 kgf m 22 lb ft T R 4 1 1 3 2 3 ...

Page 158: ...ing 1 3 Fork spring seat 1 4 Fork spring 1 5 Damper rod locknut 1 6 Fork spring guide 1 7 Damper adjusting rod 1 8 Outer tube 1 9 Inner tube bushing 1 10 Outer tube bushing 1 11 Washer 1 12 Oil seal 1 13 Oil seal clip 1 14 Dust seal 1 1 2 7 5 3 4 6 New New New LT LT LT LS 8 10 11 12 13 14 New New New New New 9 15 N m 1 5 kgf m 11 lb ft T R 55 N m 5 5 kgf m 41 lb ft T R ...

Page 159: ...Parts to remove Q ty Remarks 15 Cap 1 16 Damper rod assembly 1 17 Damper rod assembly bolt 1 18 O ring 2 19 Copper washer 1 20 Inner tube 1 17 15 19 18 New New New LT LT LT LS 20 16 New New New New New 15 N m 1 5 kgf m 11 lb ft T R 55 N m 5 5 kgf m 41 lb ft T R ...

Page 160: ...emove Cap bolt 1 from the damper rod assembly Locknut 2 Fork spring seat 3 Fork spring a Press down on the fork spring with the fork spring compression tool 4 b Install the rod holder 5 between the lock nut 2 and the fork spring seat 3 TIP Use the side of the rod holder that is marked A c Hold the locknut and remove the cap bolt d Remove the rod holder and fork spring compression tool e Remove the...

Page 161: ...E 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 may dangerously weaken it 2 Measure Fork spring free length a Out of specification Replace 3 Check Damper rod assembly Damage wear Replace Obstruction Blow out all of the oil passag es w...

Page 162: ...ube Be careful not to damage the inner tube 2 Tighten Damper rod assembly bolt along with the O rings and the copper washer TIP While holding the damper rod assembly with the damper rod holder 1 tighten the damper rod assembly bolt 3 Lubricate Inner tube s outer surface 4 Install Dust seal 1 Oil seal clip 2 Oil seal 3 Washer 4 Outer tube bushing 5 Inner tube bushing 6 NOTICE ECA19170 Make sure the...

Page 163: ...om mended fork oil NOTICE ECA14230 Be sure to use the recommended fork oil Other oils may have an adverse effect on front fork performance Fork seal driver 90890 01442 Adjustable fork seal driver 36 46 mm YM 01442 Fork seal driver 90890 01442 Adjustable fork seal driver 36 46 mm YM 01442 New New New New New 1 3 6 2 4 5 1 2 3 G088923 1 2 G088924 Fork seal driver 90890 01442 Adjustable fork seal dri...

Page 164: ... specification Correct 14 Install Damper adjusting rod Fork spring guide Locknut a Install the fork spring guide TIP Install the fork spring guide with its shorter end a pointing up A b Install the locknut all the way onto the damper rod assembly 15 Install Rod puller 1 Rod puller attachment M10 long 2 onto the damper rod 3 16 Install Fork spring Fork spring seat a Install the fork spring b Instal...

Page 165: ...inch bolts EAS30210 INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Install Front fork leg Temporarily tighten the lower bracket pinch bolts TIP Put the mark b to specified length and then in stall the front fork legs to align the mark b with the top of the lower bracket 2 Tighten Lower bracket pinch bolts TIP Tighten each bolt to specification in th...

Page 166: ...FRONT FORK 4 67 T R Front fork cap bolt 30 N m 3 0 kgf m 22 lb ft Upper bracket pinch bolt 23 N m 2 3 kgf m 17 lb ft ...

Page 167: ...ont brake calipers Front fender Front wheel Refer to FRONT WHEEL on page 4 11 Front fork legs Refer to FRONT FORK on page 4 58 Handlebar Refer to HANDLEBAR on page 4 52 1 Main switch coupler 2 Disconnect 2 Immobilizer coupler 1 Disconnect 3 Front brake hose wheel sensor lead holder 1 4 Steering stem nut 1 5 Washer 1 6 Upper bracket 1 7 N m 0 7 kgf m 5 2 lb ft T R 1st 75 N m 7 5 kgf m 55 lb ft 2nd ...

Page 168: ...ng nut 1 9 Rubber washer 1 10 Lower ring nut 1 11 Lower bracket 1 12 Lower bearing 1 13 Lower bracket cap 1 14 Upper bearing cover 1 15 Upper bearing 1 7 N m 0 7 kgf m 5 2 lb ft T R 1st 75 N m 7 5 kgf m 55 lb ft 2nd 7 N m 0 7 kgf m 5 2 lb ft T R 148 N m 14 8 kgf m 110 lb ft T R LS LS 7 8 9 10 12 11 FWD 13 14 15 ...

Page 169: ...mage pitting Replace the bearings and bearing races as a set 3 Replace Bearings Bearing races 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 low er bracket with a floor chisel 4 and ham mer c Install a new dust seal and new bearing races NOTICE ECA14270 If the bearing race is not installed properly the steering head pipe ...

Page 170: ...t fork legs Refer to INSTALLING THE FRONT FORK LEGS on page 4 66 TIP Temporarily tighten the upper and lower bracket pinch bolts 5 Tighten Steering stem nut 6 Tighten Upper and lower bracket pinch bolts TIP Tighten each lower bracket pinch bolt to specifi cation in the order Pinch bolt 1 Pinch bolt 2 Pinch bolt 1 Pinch bolt 2 Recommended lubricant Lithium soap based grease T R Steering stem nut 14...

Page 171: ...GENERAL CHASSIS 2 on page 4 2 Exhaust pipe Refer to ENGINE REMOVAL on page 5 3 1 Connecting arm 2 2 Relay arm 1 3 Collar 1 4 Collar 1 5 Collar 1 6 Oil seal 6 7 Bearing 2 8 Bearing 2 9 Bearing 1 10 Rear shock absorber assembly 1 7 6 3 6 8 2 7 8 New 6 New 6 1 5 4 9 10 1 New LS LS New LS 48 N m 4 8 kgf m 35 lb ft T R 60 N m 6 0 kgf m 44 lb ft T R 45 N m 4 5 kgf m 33 lb ft T R ...

Page 172: ...ill a 2 3 mm 0 08 0 12 in hole through the rear shock absorber at the point a as shown WARNING EWA13760 Wear eye protection to prevent eye damage from released gas or metal chips EAS30219 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 1 Stand the vehicle on a level surface WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over TIP Pass a suitable rod 1 through the h...

Page 173: ... 4 TIP When installing the oil seals to the relay arm face the character stamps of the oil seals out ward 2 Install Relay arm 1 TIP Install the relay arm bolt 2 so that the bolt head fits between the projections a on the frame as shown in the illustration T R Rear shock absorber assembly nut upper side 45 N m 4 5 kgf m 33 lb ft Installed depth a bearing 3 5 mm 0 14 in Installed depth b oil seal 0 ...

Page 174: ...y Refer to REAR SHOCK ABSORBER AS SEMBLY on page 4 72 1 Drive chain case 1 2 Stay 1 3 Rear brake hose lead holder 1 4 Rear brake hose lead guide 1 5 Pivot shaft nut 1 6 Washer 1 7 Adjusting bolt 1 Loosen 8 Pivot shaft 1 9 Swingarm 1 10 Damper 1 1 New 7 3 2 10 9 4 8 5 6 LS LS LS New New New LS LS 7 N m 0 7 kgf m 5 2 lb ft T R 110 N m 11 kgf m 81 lb ft T R 7 N m 0 7 kgf m 5 2 lb ft T R 7 N m 0 7 kgf...

Page 175: ...guide 1 12 Dust cover 2 13 Oil seal 2 14 Collar 1 15 Bearing 3 16 Collar 1 17 Oil seal 2 18 Bearing 2 12 13 14 15 15 13 New 12 17 16 18 11 17 18 LS LS LS New New New LS LS 7 N m 0 7 kgf m 5 2 lb ft T R 110 N m 11 kgf m 81 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 ...

Page 176: ...ent B by moving the swingarm up and down If the swingarm vertical movement is not smooth or if there is binding check the piv ot shaft collars bearings dust covers and adjusting bolt 3 Loosen Adjusting bolt TIP Loosen the adjusting bolt with the engine align ment tool 1 4 Remove Pivot shaft Swingarm EAS30227 CHECKING THE SWINGARM 1 Check Swingarm Bends cracks damage Replace 2 Check Pivot shaft Rol...

Page 177: ...specification with the engine alignment tool 1 Make sure that the flange on the adjusting bolt contacts the dust cover on the swingarm Recommended lubricant Lithium soap based grease Installed depth a 28 3 29 7 mm 1 11 1 17 in Installed depth b 11 5 13 0 mm 0 45 0 51 in Installed depth c 24 3 25 7 mm 0 96 1 01 in Installed depth d 1 0 mm 0 04 in Installed depth e 8 0 mm 0 31 in Installed depth f 3...

Page 178: ... shaft nut 7 Install Rear wheel Refer to REAR WHEEL on page 4 18 8 Adjust Drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3 18 T R Pivot shaft nut 110 N m 11 kgf m 81 lb ft Drive chain slack 43 0 48 0 mm 1 69 1 89 in 1 ...

Page 179: ... Rear shock absorber assembly Refer to REAR SHOCK ABSORBER AS SEMBLY on page 4 72 Swingarm Refer to SWINGARM on page 4 75 1 Shift rod locknut shift arm side 1 Loosen 2 Shift rod locknut shift pedal side 1 Loosen Left hand threads 3 Shift rod 1 4 Shift rod joint 1 5 Shift arm 1 4 1 5 3 2 LT LT LT LT E New LT LS 10 N m 1 0 kgf m 7 4 lb ft T R 9 N m 0 9 kgf m 6 6 lb ft T R 14 N m 1 4 kgf m 10 lb ft T...

Page 180: ...cket cover 1 7 Drive chain guide 1 8 Drive chain 1 9 Drive sprocket nut 1 10 Washer 1 11 Drive sprocket 1 6 7 9 11 8 10 LT LT LT LT E New LT LS 10 N m 1 0 kgf m 7 4 lb ft T R 9 N m 0 9 kgf m 6 6 lb ft T R 14 N m 1 4 kgf m 10 lb ft T R 95 N m 9 5 kgf m 70 lb ft T R 10 N m 1 0 kgf m 7 4 lb ft T R ...

Page 181: ...outer sides 2 TIP When measuring a 15 link section of the drive chain make sure that the drive chain is taut Perform this procedure 2 3 times at a different location each time 2 Check Drive chain Stiffness Clean and lubricate or replace 3 Clean Drive chain a Wipe the drive chain with a clean cloth b Put the drive chain in kerosene and re move any remaining dirt c Remove the drive chain from the ke...

Page 182: ... drive chain and rear wheel sprocket as a set EAS30232 CHECKING THE REAR WHEEL SPROCKET Refer to CHECKING AND REPLACING THE REAR WHEEL SPROCKET on page 4 21 EAS30233 CHECKING THE REAR WHEEL DRIVE HUB Refer to CHECKING THE REAR WHEEL DRIVE HUB on page 4 21 EAS31116 INSTALLING THE DRIVE SPROCKET 1 Install Drive sprocket Washer 1 Drive sprocket nut 2 TIP While applying the rear brake tighten the driv...

Page 183: ...s left hand threads b Turn the shift rod 2 to obtain the correct shift pedal position c Tighten both locknuts d Make sure that the angle between the shift arm and the shift rod is about 90 6 Adjust Drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3 18 Recommended lubricant Chain lubricant suitable for O ring chains T R Shift arm pinch bolt 14 N m 1 4 kgf m 10 lb ft Installed leng...

Page 184: ...t is too tight will overload the engine and other vital parts and one that is too loose can skip and damage the swing arm or cause an accident Therefore keep the drive chain slack within the specified lim its Drive chain slack 43 0 48 0 mm 1 69 1 89 in ...

Page 185: ...VING THE CYLINDER HEAD 5 24 CHECKING THE TIMING CHAIN GUIDES 5 24 CHECKING THE CYLINDER HEAD 5 24 INSTALLING THE CYLINDER HEAD 5 25 VALVES AND VALVE SPRINGS 5 27 REMOVING THE VALVES 5 28 CHECKING THE VALVES AND VALVE GUIDES 5 28 CHECKING THE VALVE SEATS 5 30 CHECKING THE VALVE SPRINGS 5 31 CHECKING THE VALVE LIFTERS 5 31 INSTALLING THE VALVES 5 31 GENERATOR AND STARTER CLUTCH 5 33 REMOVING THE GEN...

Page 186: ...FT SHAFT 5 53 OIL PUMP 5 54 CHECKING THE SPROCKET AND CHAIN 5 56 CHECKING THE OIL PUMP 5 56 CHECKING THE RELIEF VALVE 5 56 ASSEMBLING THE OIL PUMP 5 56 INSTALLING THE OIL PUMP 5 57 OIL PAN 5 58 REMOVING THE OIL PAN 5 59 CHECKING THE OIL STRAINER 5 59 INSTALLING THE OIL PAN 5 59 CRANKCASE 5 60 DISASSEMBLING THE CRANKCASE 5 62 CHECKING THE CRANKCASE 5 62 ASSEMBLING THE CRANKCASE 5 62 INSTALLING THE ...

Page 187: ...ER SHAFT ASSEMBLY 5 77 CHECKING THE CRANKSHAFT 5 79 INSTALLING THE CRANKSHAFT 5 81 INSTALLING THE BALANCER SHAFT ASSEMBLY 5 81 TRANSMISSION 5 82 REMOVING THE TRANSMISSION 5 86 CHECKING THE SHIFT FORKS 5 86 CHECKING THE SHIFT DRUM ASSEMBLY 5 86 CHECKING THE TRANSMISSION 5 87 ASSEMBLING THE MAIN AXLE AND DRIVE AXLE 5 87 INSTALLING THE TRANSMISSION 5 88 ...

Page 188: ...l the reading on the compression gauge stabilizes WARNING EWA12940 To prevent sparking ground all spark plug leads before cranking the engine TIP The difference in compression pressure be tween cylinders should not exceed 100 kPa 1 kg cm 14 psi c If the compression pressure is above the maximum specification check the cylinder head valve surfaces and piston crown for carbon deposits Carbon deposit...

Page 189: ...ENGINE INSPECTION 5 2 7 Install Spark plugs Ignition coils T R Spark plug 13 N m 1 3 kgf m 9 6 lb ft ...

Page 190: ... cap 1 7 Engine guard 1 8 O2 sensor coupler 1 Disconnect 9 Exhaust pipe 1 10 Gasket 2 11 Exhaust pipe bracket 1 12 O2 sensor 1 Remove the O2 sensor only when neces sary New 6 4 1 5 9 7 11 8 12 2 New 10 3 4 LS 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 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 20 N m 2 0 kgf m 15 lb ft T R 20 N m 2 0 kgf m 15 lb ft T R 20 N m ...

Page 191: ... 2 Air scoop left Air duct left Fuel tank side cov ers Refer to GENERAL CHASSIS 3 on page 4 5 Fuel tank Canister Refer to FUEL TANK on page 7 1 Drive sprocket Refer to CHAIN DRIVE on page 4 80 Starter motor Refer to ELECTRIC STARTER on page 5 38 Oil pressure switch Refer to CRANKCASE on page 5 60 Coolant reservoir Radiator Refer to RADIATOR on page 6 2 Water jacket joint Oil cooler Thermostat Refe...

Page 192: ... Clutch cable 1 Disconnect 2 Gear position sensor coupler 1 Disconnect 3 Crankshaft position sensor coupler 1 Disconnect 4 Stator coil coupler 1 Disconnect 5 Ignition coil coupler 2 Disconnect 6 Sidestand switch coupler and lead 1 Disconnect the coupler and then remove the lead from the down tube left 7 Engine ground lead 1 Disconnect 5 5 2 7 4 3 6 1 7 N m 0 7 kgf m 5 2 lb ft T R ...

Page 193: ...ing nut rear lower side 1 9 Washer 1 10 Engine mounting nut rear upper side 1 11 Washer 1 12 Engine mounting bolt front right side 1 13 Collar 1 LT LT LT LT LT LT LT LT LT LT 3 4 2 1 6 5 5 7 12 13 8 9 10 11 2 0 N m 0 20 kgf m 1 5 lb ft T R 30 N m 3 0 kgf m 22 lb ft T R 30 N m 3 0 kgf m 22 lb ft T R 34 N m 3 4 kgf m 25 lb ft T R 34 N m 3 4 kgf m 25 lb ft T R 55 N m 5 5 kgf m 41 lb ft T R 55 N m 5 5...

Page 194: ...ght 1 18 Engine mounting bolt front left side 1 19 Washer 1 20 Engine mounting bolt rear lower side 1 21 Engine mounting bolt rear upper side 1 22 Engine 1 LT LT LT LT LT LT LT LT LT LT 14 22 19 18 20 21 17 16 15 2 0 N m 0 20 kgf m 1 5 lb ft T R 30 N m 3 0 kgf m 22 lb ft T R 30 N m 3 0 kgf m 22 lb ft T R 34 N m 3 4 kgf m 25 lb ft T R 34 N m 3 4 kgf m 25 lb ft T R 55 N m 5 5 kgf m 41 lb ft T R 55 N...

Page 195: ... 2 inch hexagon bit sock et Make sure that the flange of the engine mount ing adjust bolt contacts the engine 3 Install Collar 14 Engine mounting bolt front right side 15 TIP Temporarily tighten the bolt 4 Tighten Engine mounting nut rear upper side 5 5 Tighten Engine mounting nut rear lower side 8 6 Tighten Engine mounting bolt front left side 10 7 Install Engine bracket left 16 Engine mounting b...

Page 196: ... in the il lustration 2 Install Damper 1 to the frame TIP Install the damper with the mark a facing rear wheel side 3 Install Exhaust pipe bracket 1 to the frame TIP Install the exhaust pipe bracket with the mark a facing the left side of the vehicle T R Engine mounting bolt right up per side 55 N m 5 5 kgf m 41 lb ft T R Engine bracket bolts 30 N m 3 0 kgf m 22 lb ft T R Engine mounting bolt fron...

Page 197: ...de covers Refer to GENERAL CHASSIS 3 on page 4 5 Fuel tank Refer to FUEL TANK on page 7 1 Coolant Drain Refer to CHANGING THE COOLANT on page 3 27 Radiator Refer to RADIATOR on page 6 2 Throttle cables Disconnect Refer to THROTTLE BODIES on page 7 5 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 4 0 N m 0 40 kgf m 3 0 lb ft T R 13 N m 1 3 kgf m 9 6 lb ft T R New New LT 6 4 ...

Page 198: ...oupler 2 Disconnect 3 Ignition coil 2 4 Spark plug 2 5 Cylinder head cover 1 6 Cylinder head cover gasket 1 7 Breather plate 1 8 Breather plate gasket 1 9 Timing chain guide upper side 1 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 4 0 N m 0 40 kgf m 3 0 lb ft T R 13 N m 1 3 kgf m 9 6 lb ft T R New New LT 6 4 1 7 3 3 4 4 8 5 2 6 9 ...

Page 199: ...t 1 10 Intake camshaft sprocket 1 11 Exhaust camshaft sprocket 1 12 Decompressor lever 2 1 13 Decompressor lever 1 1 14 Decompressor lever pin 2 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 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 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 15 N m 1 5 kgf m 11 lb ft T R 24 N m 2 4 kgf m 18 lb ft T R 24 N m 2 4...

Page 200: ...228 00 into the timing chain ten sioner b Remove the timing chain tensioner 4 Remove 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 the timing chain from falling into...

Page 201: ...wel pins and camshaft caps TIP Tighten the camshaft cap bolts in stages and in a crisscross pattern working from the inner caps out Do not turn the camshaft when measuring the camshaft journal to camshaft cap clearance with the Plastigauge d Remove the camshaft caps and then measure the width of the Plastigauge 1 Camshaft lobe dimensions Lobe height Intake 35 610 35 710 mm 1 4020 1 4059 in Limit 3...

Page 202: ...ioner housing by hand TIP While pressing the timing chain tensioner rod wind it counterclockwise with a hexagon wrench 1 Parts No 1WS 12228 00 until it stops b Make sure that the timing chain tensioner rod moves in and out of the timing chain tensioner housing smoothly If there is rough movement replace the timing chain tensioner EAS30267 CHECKING THE DECOMPRESSION SYSTEM 1 Check Decompression sys...

Page 203: ... b as shown in the illustration While holding the intake camshaft sprocket with the rotor holding tool 2 tighten the intake camshaft sprocket bolts in the proper tighten ing sequence as shown 3 Install Decompressor lever pins 1 Decompressor lever 1 2 Decompressor lever 2 3 TIP Face the cutout a in each decompressor le ver pin toward the exhaust camshaft sprocket Install the decompressor lever pins...

Page 204: ...ming chain start with the exhaust camshaft and be sure to keep the tim ing chain as tight as possible on the exhaust side Make sure that the match marks a on the ex haust camshaft sprocket and cam lobe 1 b are aligned with the cylinder head edge c as shown in the illustration Temporarily tighten the exhaust camshaft cap bolts and then tighten the bolts to specification in a crisscross pattern 6 In...

Page 205: ... chain tensioner bolts 5 on the cyl inder block TIP Be sure to install the timing chain tensioner gas ket so that the portion a of the gasket is pro truding from the upper inner side of the timing chain tensioner d Tighten the timing chain tensioner bolts to specification e Screw the hexagon wrench by hand until the timing chain tensioner rod touches the timing chain guide and then tighten 1 4 tur...

Page 206: ...274 INSTALLING THE CYLINDER HEAD COVER 1 Install Timing chain guide top side Cylinder head cover gasket 1 to the cylinder head cover Cylinder head cover 2 TIP Apply Yamaha bond No 1215 3 onto the mat ing surfaces of the cylinder head cover gasket and cylinder head After installing the cylinder head cover gasket 1 to the cylinder head cover cut off the a section Make sure that the projection b on t...

Page 207: ...CAMSHAFTS 5 20 2 Install Spark plugs Ignition coils 1 TIP Install the ignition coils 1 in the direction shown in the illustration A Exhaust side T R Spark plug 13 N m 1 3 kgf m 9 6 lb ft 2 1 c b A New 1 ...

Page 208: ... Air ducts Fuel tank side covers Refer to GENERAL CHASSIS 3 on page 4 5 Fuel tank Refer to FUEL TANK on page 7 1 Throttle bodies Refer to THROTTLE BODIES on page 7 5 Radiator Refer to RADIATOR on page 6 2 6 New New E LT 10 N m 1 0 kgf m 7 4 lb ft T R 10 N m 1 0 kgf m 7 4 lb ft T R 10 N m 1 0 kgf m 7 4 lb ft T R 30 N m 3 0 kgf m 22 lb ft T R 30 N m 3 0 kgf m 22 lb ft T R 55 N m 5 5 kgf m 41 lb ft T...

Page 209: ...2 1 Oil cooler inlet hose 1 Disconnect 2 Engine bracket bolt left 2 3 Engine mounting bolt left upper side 1 4 Engine bracket left 1 5 Engine mounting bolt front right side 1 6 Collar 1 6 5 3 4 2 2 6 1 New New E LT 10 N m 1 0 kgf m 7 4 lb ft T R 10 N m 1 0 kgf m 7 4 lb ft T R 10 N m 1 0 kgf m 7 4 lb ft T R 30 N m 3 0 kgf m 22 lb ft T R 30 N m 3 0 kgf m 22 lb ft T R 55 N m 5 5 kgf m 41 lb ft T R 55...

Page 210: ...linder head 1 12 Timing chain guide exhaust side 1 13 Cylinder head 1 14 Cylinder head gasket 1 15 Dowel pin 2 16 Timing chain 1 17 Timing chain guide intake side 1 11 7 12 17 16 6 13 9 10 8 8 14 15 15 New New E LT 10 N m 1 0 kgf m 7 4 lb ft T R 10 N m 1 0 kgf m 7 4 lb ft T R 10 N m 1 0 kgf m 7 4 lb ft T R 30 N m 3 0 kgf m 22 lb ft T R 30 N m 3 0 kgf m 22 lb ft T R 55 N m 5 5 kgf m 41 lb ft T R 55...

Page 211: ...of a turn at a time After all of the bolts are fully loosened remove them M6 45 mm 1 2 M10 100 mm 3 8 EAS30278 CHECKING THE TIMING CHAIN GUIDES 1 Check Timing chain guide exhaust side Timing chain guide intake side Damage wear Replace EAS30277 CHECKING THE CYLINDER HEAD 1 Eliminate Combustion chamber carbon deposits with a rounded scraper TIP Do not use a sharp instrument to avoid damag ing or scr...

Page 212: ...mating surface with engine oil 2 Tighten Cylinder head bolts 1 6 Cylinder head bolts 7 8 Following the tightening order loosen the bolt one by one and then retighten it to the specific torque and angle TIP Tighten the cylinder head bolts in the tightening sequence as shown and torque them in 3 stag es 3 Tighten Engine mounting adjust bolt TIP Tighten the engine mounting adjust bolt to specificatio...

Page 213: ...CYLINDER HEAD 5 26 ...

Page 214: ... remove Q ty Remarks Cylinder head Refer to CYLINDER HEAD on page 5 21 1 Valve lifter 8 2 Valve pad 8 3 Valve cotter 16 4 Valve spring retainer 8 5 Valve spring 8 6 Exhaust valve 4 7 Intake valve 4 8 Valve stem seal 8 9 Valve spring seat 8 10 Valve guide 8 New New New New E E M M M M 2 2 3 3 4 4 5 5 10 10 8 8 9 1 1 9 7 6 ...

Page 215: ... should be no leakage at the valve seat 1 3 Remove Valve cotters TIP Remove the valve cotters by compressing the valve spring with the valve spring compressor 1 and the valve spring compressor attachment 2 4 Remove Valve spring retainer 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 EAS3...

Page 216: ...learance TIP After replacing the valve guide reface the valve seat 3 Eliminate Carbon deposits from the valve face and valve seat Valve stem to valve guide clear ance intake 0 010 0 037 mm 0 0004 0 0015 in Limit 0 080 mm 0 0032 in Valve stem to valve guide clear ance exhaust 0 025 0 052 mm 0 0010 0 0020 in Limit 0 100 mm 0 0039 in G088960 G088961 G088962 Valve guide position 14 8 15 2 mm 0 58 0 60...

Page 217: ...ecification Replace the cylinder head a Apply blue layout fluid b onto the valve face b Install the valve into the cylinder head c Press the valve through the valve guide and onto the valve seat to make a clear impression d Measure the valve seat width TIP Where the valve seat and valve face contacted one another the blueing will have been re moved 4 Lap Valve face Valve seat TIP After replacing t...

Page 218: ...r head i Press the valve through the valve guide and onto the valve seat to make a clear impression j Measure the valve seat width c again If the valve seat width is out of specification 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 EAS3...

Page 219: ...sor attachment 2 5 To secure the valve cotters onto the valve stem lightly tap the valve tip with a soft face hammer NOTICE ECA13800 Hitting the valve tip with excessive force could damage the valve 6 Lubricate Valve 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...

Page 220: ...ct 2 Crankshaft position sensor coupler 1 Disconnect 3 Crankshaft end cover 1 4 Timing mark accessing bolt 1 5 Oil filler cap 1 6 Generator cover 1 7 Generator cover gasket 1 8 Bearing 1 3 8 3 1 2 7 8 5 6 3 4 New New New New New FWD FWD LT LT LT LT LT LT LT LT LT LT LT LT E E E E E E LS LS 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 10 N m 1 0 kgf m 7 4 lb ft T R 12 N m 1 2 kgf m...

Page 221: ... 15 Starter clutch 1 16 Woodruff key 1 17 Starter clutch idle gear shaft 1 18 Starter clutch idle gear 1 19 Starter clutch gear 1 16 18 3 8 3 13 17 12 19 15 14 9 9 11 10 New New New New New FWD FWD LT LT LT LT LT LT LT LT LT LT LT LT E E E E E E LS LS 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 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 12 N m 1 2 kgf m 8 9 lb ...

Page 222: ...ed over the generator rotor EAS30868 REMOVING THE STARTER CLUTCH 1 Remove Starter clutch bolts 1 Starter clutch TIP While holding the generator rotor 2 with the ro tor holding tool 3 loosen the starter clutch bolts EAS30869 CHECKING THE STARTER CLUTCH 1 Check Starter clutch rollers Damage wear Replace 2 Check Starter clutch idle gear Starter clutch gear Burrs chips roughness wear Replace the defec...

Page 223: ...the arrow mark a is toward the generator rotor 2 While holding the generator rotor with the rotor holding tool 3 tighten the starter clutch bolts 4 EAS30872 INSTALLING THE GENERATOR 1 Install Woodruff key Generator rotor Washer Generator rotor bolt TIP Clean the tapered portion of the crankshaft and the generator rotor hub When installing the generator rotor make sure the woodruff key is properly ...

Page 224: ...ket Generator cover TIP Tighten the generator cover bolts in stages and in a crisscross pattern Apply LOCTITE to the threads of only the generator cover bolts 1 shown in the illustra tion 7 Connect Stator coil coupler Crankshaft position sensor coupler TIP To route the stator coil lead refer to CABLE ROUTING on page 2 15 Yamaha bond No 1215 90890 85505 Three bond No 1215 1 2 3 G088979 1 1 a T R Ge...

Page 225: ...ER Removing the starter motor Order Job Parts to remove Q ty Remarks Canister Refer to FUEL TANK on page 7 1 1 Starter motor lead 1 Disconnect 2 Starter motor 1 3 Canister holder 1 3 1 2 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 ...

Page 226: ...move Q ty Remarks 1 O ring 1 2 Starter motor front cover 1 3 Starter motor yoke 1 4 Armature assembly 1 5 Gasket 2 6 Brush holder set 1 7 Starter motor rear cover 1 8 Lead guide 1 5 5 2 7 8 6 1 3 4 LS New New New New 5 N m 0 5 kgf m 3 7 lb ft T R 11 N m 1 1 kgf m 8 1 lb ft T R ...

Page 227: ...otor 4 Measure Brush length a Out of specification Replace the brush holder set 5 Measure Brush spring force Out of specification Replace the brush holder set 6 Check Gear teeth Damage wear Replace the starter motor 7 Check Bearing Oil seal Damage wear Replace the starter motor front cover EAS30326 ASSEMBLING THE STARTER MOTOR 1 Install Lead guide 1 TIP Make sure that the slot a in the lead guide ...

Page 228: ... Align the match marks a on the starter motor yoke with the match marks b on the front cover and rear covers EAS30327 INSTALLING THE STARTER MOTOR 1 Install Canister holder Starter motor TIP Pass the starter motor front cover bolts 1 through the slots a in the canister holder to se cure it a 1 2 1 b a b 3 1 1 a ...

Page 229: ... to CHANGING THE COOLANT on page 3 27 Water pump housing Refer to WATER PUMP on page 6 10 1 Clutch cable 1 Disconnect 2 Circlip 1 3 Pull lever 1 4 Pull lever spring 1 5 Clutch cable holder 1 6 Pull lever shaft cover 1 7 Clutch cover 1 8 Clutch cover gasket 1 1 5 8 7 6 8 2 4 3 LS New New E E LT LT FWD FWD 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 12 N m 1 2 kgf m 8 9 lb ft T R ...

Page 230: ...r Job Parts to remove Q ty Remarks 9 Dowel pin 2 10 Circlip 1 11 Pull lever shaft 1 12 Oil seal 1 13 Bearing 1 14 Bearing 1 8 9 9 11 12 14 10 13 LS New New E E LT LT FWD FWD 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 12 N m 1 2 kgf m 8 9 lb ft T R ...

Page 231: ...ure plate 1 3 Pull rod 1 4 Bearing 1 5 Friction plate 1 2 6 Clutch plate 6 7 Friction plate 2 5 8 Clutch boss nut 1 9 Conical spring washer 1 LT LT E E E LS New E FWD FWD 8 9 5 5 6 6 6 6 6 6 1 6 6 2 3 4 7 7 7 7 7 10 N m 1 0 kgf m 7 4 lb ft T R 8 N m 0 8 kgf m 5 9 lb ft T R 95 N m 9 5 kgf m 70 lb ft T R ...

Page 232: ...oss 1 12 Thrust plate 1 13 Spacer 1 14 Bearing 1 15 Clutch housing 1 16 Thrust plate 1 17 Oil pump drive chain 1 18 Oil pump drive chain guide 1 LT LT E E E LS New E FWD FWD 6 6 11 10 17 16 14 13 12 18 15 10 N m 1 0 kgf m 7 4 lb ft T R 8 N m 0 8 kgf m 5 9 lb ft T R 95 N m 9 5 kgf m 70 lb ft T R ...

Page 233: ...lutch boss nut 6 Remove Spacer Bearing Clutch housing a Remove the spacer and bearing b Remove the oil pump drive chain 1 from the oil pump driven sprocket a and then remove the clutch housing 2 EAS30348 CHECKING THE FRICTION PLATES The following procedure applies to all of the fric tion plates 1 Check Friction plate Damage wear Replace the friction plates as a set 2 Measure Friction plate thickne...

Page 234: ... Cracks damage wear Replace 3 Check Bearing Damage wear Replace the bearing and clutch housing EAS30353 CHECKING THE CLUTCH BOSS 1 Check Clutch boss splines Damage pitting wear Replace the clutch boss TIP Pitting on the clutch boss splines will cause er ratic clutch operation EAS30354 CHECKING THE PRESSURE PLATE 1 Check Pressure plate Cracks damage Replace Bearing Damage wear Replace EAS30356 CHEC...

Page 235: ... oil Install the washer on the main axle with the OUT mark facing away from the vehicle While holding the clutch boss 1 with the uni versal clutch holder 3 tighten the clutch boss nut Stake the clutch boss nut at a cutout a in the main axle 3 Install Friction plates 1 1 Friction plates 2 2 TIP First install a friction plate and then alternate between a clutch plate and a friction plate Align a pro...

Page 236: ...e the serrations on the clutch pull rod 1 rearward and align the rod with the hole c in the clutch cover Make sure that the pull rod teeth and pull lever shaft pinion gear are engaged Tighten the bolts in stages and in a crisscross pattern 7 Install Pull lever TIP Install the pull lever with the UP mark a fac ing toward upper side When installing the pull lever push the pull le ver and check that ...

Page 237: ...ter installing the clutch cable bend the pro jection b on the pull lever 9 Adjust Clutch lever free play Refer to ADJUSTING THE CLUTCH LEVER FREE PLAY on page 3 12 Clutch lever free play 5 0 10 0 mm 0 20 0 39 in a b ...

Page 238: ...INE OIL on page 3 24 Coolant Drain Refer to CHANGING THE COOLANT on page 3 27 Shift arm Refer to CHAIN DRIVE on page 4 80 Water pump housing Refer to WATER PUMP on page 6 10 Clutch housing Refer to CLUTCH on page 5 42 1 Circlip 1 2 Washer 1 3 Shift shaft 1 4 Washer 1 5 Circlip 1 6 Washer 1 22 N m 2 2 kgf m 16 lb ft T R E E LS New New New LT E FWD FWD 2 1 3 4 5 6 ...

Page 239: ...er Order Job Parts to remove Q ty Remarks 7 Stopper lever 1 8 Stopper lever spring 1 9 Collar 1 10 Shift shaft spring 1 11 Shift shaft spring stopper 1 12 Oil seal 1 13 Bearing 1 22 N m 2 2 kgf m 16 lb ft T R E E LS New New New LT E FWD FWD 12 13 11 7 8 9 10 ...

Page 240: ... bearing does not protrude past the line b shown in the illustration Lubricate the oil seal lips with lithium soap based grease 2 Install Shift shaft spring stopper Washer Shift shaft assembly Stopper lever spring TIP Hook the end of the shift shaft spring 2 onto the shift shaft spring stopper 1 Hook the ends of the stopper lever spring 3 onto the stopper lever 4 and the stopper lever spring hook ...

Page 241: ...nt Drain Refer to CHANGING THE COOLANT on page 3 27 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 24 Clutch housing Refer to CLUTCH on page 5 42 1 Oil pump assembly 1 2 Holder 1 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 12 N m 1 2 kgf m 8 9 lb ft T R LT FWD FWD 1 2 ...

Page 242: ...1 2 Oil pump rotor assembly 1 3 Oil pump inner rotor 1 4 Oil pump outer rotor 1 5 Pin 1 6 Oil pump driven sprocket 1 7 Circlip 1 Hold down the washer when removing the circlip 8 Washer 1 9 Spring 1 10 Relief valve 1 11 Dowel pin 2 3 8 N m 0 38 kgf m 2 8 lb ft T R New E E 2 3 4 5 10 11 11 8 1 9 7 6 ...

Page 243: ...ps 1 and 2 or replace the oil pump assembly EAS30338 CHECKING THE RELIEF VALVE 1 Check Relief valve Spring Damage wear Replace the oil pump as sembly EAS30342 ASSEMBLING THE OIL PUMP 1 Lubricate Inner rotor Outer rotor with the recommended lubricant 2 Lubricate Oil pump driven sprocket with the recommended lubricant 3 Install Oil pump driven sprocket Pin Outer rotor Inner rotor Oil pump cover Oil ...

Page 244: ... OIL PUMP on page 5 56 EAS30343 INSTALLING THE OIL PUMP 1 Install Oil pump 1 Oil pump bolts 2 NOTICE ECA20940 After installing the oil pump drive chain and driven sprocket make sure the oil pump turns smoothly T R Oil pump bolt 12 N m 1 2 kgf m 8 9 lb ft a 1 1 2 2 ...

Page 245: ...NERAL CHASSIS 2 on page 4 2 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 24 Exhaust pipe Refer to ENGINE REMOVAL on page 5 3 1 Engine oil drain bolt 1 2 Oil pan 1 3 Oil pan gasket 1 4 Oil strainer 1 4 1 3 2 11 LT LT New 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 43 N m 4 3 kgf m 32 lb ft T R ...

Page 246: ...loosened remove them Insert a flat head screwdriver into the slots a in the oil pan to remove the oil pan EAS31069 CHECKING THE OIL STRAINER 1 Check Oil strainer Damage Replace Contaminants Clean with solvent EAS31070 INSTALLING THE OIL PAN 1 Install Oil pan gasket Oil pan TIP Tighten the oil pan bolts in stages and in a criss cross pattern T R Oil pan bolt 10 N m 1 0 kgf m 7 4 lb ft a a 1 New ...

Page 247: ...CH on page 5 33 Clutch housing Refer to CLUTCH on page 5 42 Oil strainer Refer to OIL PAN on page 5 58 2 5 6 3 8 2 E E E E E New New New New LT LT LT LT LT LT LS LS LS 24 N m 2 4 kgf m 18 lb ft 17 N m 1 7 kgf m 13 lb ft 1st 2nd Final Specified angle 60 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 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 1 8 N m 0 18 kgf m ...

Page 248: ...3 8 Blind plate 1 2 5 6 3 8 2 1 2 3 4 6 7 7 8 5 E E E E E New New New New LT LT LT LT LT LT LS LS LS 24 N m 2 4 kgf m 18 lb ft 17 N m 1 7 kgf m 13 lb ft 1st 2nd Final Specified angle 60 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 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 1 8 N m 0 18 kgf m 1 3 lb ft T R 4 0 N m 0 40 kgf m 3 0 lb ft T R 8 N m 0 8 kgf m 5 9 ...

Page 249: ...with a soft face hammer Tap only on reinforced por tions of the crankcase not on the crankcase mating surfaces Work slowly and carefully and make sure the crankcase halves sepa rate evenly EAS30390 CHECKING THE CRANKCASE 1 Thoroughly wash the crankcase halves in a mild solvent 2 Thoroughly clean all the gasket surfaces and crankcase mating surfaces 3 Check Crankcase Cracks damage Replace Oil deliv...

Page 250: ... mat ing surfaces with engine oil M9 80 mm bolt 5 bolts with washers 1 3 6 M9 90 mm bolt 1 bolt with washer 2 M8 70 mm bolt 6 bolts with new O rings 7 12 M8 65 mm bolt 2 13 14 M6 65 mm bolt 2 15 16 M6 40 mm bolt 8 17 18 21 24 26 27 M6 60 mm bolt 3 19 20 25 7 Tighten Crankcase bolts 1 6 Following the tightening order loosen the bolt one by one and then retighten it to the specific torque WARNING EW...

Page 251: ...2 2 Apply Sealant onto the oil pressure switch threads TIP Apply Three bond No 1215 to the threads a of the oil pressure switch However do not ap ply Three bond No 1215 to the portion b of the oil pressure switch Install the oil pressure switch lead so that it is routed within the range shown in the illustra tion T R Crankcase bolts 7 14 24 N m 2 4 kgf m 18 lb ft Crankcase bolts 15 27 10 N m 1 0 k...

Page 252: ...CRANKCASE 5 65 a 1 2 2 b 45 10 1 ...

Page 253: ...to all of the connecting rods and pistons Crankcase Separate Refer to CRANKCASE on page 5 60 1 Connecting rod cap 1 2 Big end lower bearing 1 3 Big end upper bearing 1 4 Piston pin clip 2 5 Piston pin 1 6 Piston 1 7 Connecting rod 1 8 Top ring 1 9 2nd ring 1 10 Oil ring 1 2 1 3 4 4 6 7 5 9 10 8 1st 20 N m 2 0 kgf m 15 lb ft 2nd Specified angle 180 T R New New New New E E E E E M M ...

Page 254: ... ton pin clip groove and the piston pin bore ar ea If both areas are debarred and the piston pin is still difficult to remove remove it with the piston pin puller set 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 The following procedure appl...

Page 255: ...and piston rings 2 Install Piston ring into the cylinder TIP Use the piston crown to level the piston ring near the bottom of the cylinder where the cylinder wear is lowest 3 Measure Piston ring end gap Out of specification Replace the piston ring 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 Diameter 79 970 79...

Page 256: ...ods NOTICE ECA13930 Do not interchange the big end bearings and connecting rods To obtain the correct crankshaft pin to big end bearing clear ance and prevent engine damage the big end 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 b...

Page 257: ...em 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 position should not be out of alignment f Loose...

Page 258: ...ECA20890 Do not use a torque wrench to tighten the bolt to the specified angle j After the installation check that the sec tion shown a is flush with each other by touching the surface k Remove the connecting rod and big end bearings l Measure the compressed Plastigauge width on the crankshaft pin If the crank shaft pin to big end bearing clearance is out of specification select replacement big en...

Page 259: ...ign the projections a on the big end bear ings with the notches b in the connecting rods and connecting rod caps Make sure that the projection c on the con necting rod cap faces the same direction as the Y mark d on the connecting rod 2 Tighten Connecting rod bolts NOTICE ECA18390 Tighten the connecting rod bolts using the plastic region tightening angle method Al ways install new bolts TIP Instal...

Page 260: ...h the big end bearing kept in the current condition 3 Install Oil ring expander 1 Lower oil ring rail 2 Upper oil ring rail 3 2nd ring 4 Top ring 5 TIP Be sure to install the piston rings so that the manufacturer s marks a face up 4 Install Piston 1 onto the respective connecting rod 2 Piston pin 3 Piston pin clips 4 TIP Apply engine oil onto the piston pin Make sure that the Y mark a on the conne...

Page 261: ...ction as the Y mark a on the connecting rod Apply Molybdenum disulfide oil to the threads and seats of the connecting rod bolt 9 Tighten Connecting rod bolts TIP Tighten the connecting rod bolts using the fol lowing procedure a Tighten the connecting rod bolts with a torque wrench b Put a mark 1 on the corner of the con necting rod bolt 2 and the connecting rod cap 3 c Tighten the connecting rod b...

Page 262: ...e again NOTICE ECA20890 Do not use a torque wrench to tighten the bolt to the specified angle d After the installation check that the sec tion shown a is flush with each other by touching the surface WARNING EWA17120 If the connecting rod and cap are not flush with each other remove the connecting rod bolts and big end bearing and restart from step 1 In this case make sure to replace the connectin...

Page 263: ...ase Separate Refer to CRANKCASE on page 5 60 Connecting rod Refer to CONNECTING RODS AND PIS TONS on page 5 66 1 Balancer shaft assembly 1 2 Balancer shaft journal lower bearing 3 3 Balancer shaft journal upper bearing 3 4 Crankshaft assembly 1 5 Crankshaft journal lower bearing 3 6 Crankshaft journal upper bearing 3 1 2 3 3 3 2 4 6 6 6 5 5 5 2 E E E E E E E E E ...

Page 264: ...assembly Cracks damage wear Replace the balanc er shaft assembly and journal bearings Dirt Clean Bearings Damage wear Replace 4 Measure Balancer shaft journal to balancer shaft jour nal bearing clearance Out of specification Replace the balancer shaft journal bearings NOTICE ECA18400 Do not interchange the balancer shaft jour nal bearings To obtain the correct balancer shaft journal to balancer sh...

Page 265: ...SE on page 5 60 f Remove the crankcase and the balancer shaft journal lower bearings g Measure the compressed Plastigauge width e on each balancer shaft journal If the balancer shaft journal to balancer shaft journal bearing clearance is out of specification select replacement balancer shaft journal bearings 5 Select Balancer shaft journal bearings J1 J3 TIP The numbers A stamped into the crankcas...

Page 266: ...TICE ECA13920 Do not interchange the crankshaft journal bearings To obtain the correct crankshaft journal to crankshaft journal bearing clear ance and prevent engine damage the crank shaft journal bearings must be installed in their original positions a Clean the crankshaft journal bearings crankshaft journals and bearing portions of the cylinder and crankcase b Install the crankshaft journal uppe...

Page 267: ...width g on each crankshaft journal If the crankshaft journal to crankshaft journal bearing clearance is out of specifi cation select replacement crankshaft journal bearings 5 Select Crankshaft journal bearings J1 J3 TIP The numbers A stamped into the crankcase and the numbers B stamped into the crank shaft web are used to determine the replace ment crankshaft journal bearing sizes J1 J3 refer to t...

Page 268: ...AFT ASSEMBLY 1 Install Balancer shaft journal upper bearings into the upper crankcase Balancer shaft journal lower bearings into the lower crankcase TIP Align the projections a on the balancer shaft journal bearings 1 with the notches b in the crankcase Be sure to install each balancer shaft journal bearing in its original place 2 Install Balancer shaft 1 TIP Align the punch mark a in the balancer...

Page 269: ...rankcase Separate Refer to CRANKCASE on page 5 60 1 Drive axle assembly 1 2 Shift drum retainer 1 3 Shift fork guide bar 2 4 Shift fork L 1 5 Shift fork R 1 6 Shift drum assembly 1 7 Shift fork C 1 8 Bearing retainer 1 9 Main axle assembly 1 LT LT E LT E E E E E 1 2 3 3 6 4 5 7 9 8 10 N m 1 0 kgf m 7 4 lb ft T R 12 N m 1 2 kgf m 8 9 lb ft T R ...

Page 270: ...ty Remarks 1 2nd pinion gear 1 2 Toothed lock washer 1 3 Toothed lock washer retainer 1 4 6th pinion gear 1 5 Collar 1 6 Washer 1 7 Circlip 1 8 3rd pinion gear 1 9 Circlip 1 10 Washer 1 11 5th pinion gear 1 12 Collar 1 13 Main axle 1 M M M M M M M New New 8 10 11 12 9 7 6 5 4 3 1 2 13 ...

Page 271: ...Q ty Remarks 1 1st wheel gear 1 2 Collar 1 3 5th wheel gear 1 4 Circlip 1 5 Washer 1 6 3rd wheel gear 1 7 Collar 1 8 Toothed lock washer 1 9 Toothed lock washer retainer 1 10 4th wheel gear 1 11 Collar 1 12 Washer 1 10 11 12 1 2 3 4 5 6 7 8 9 LS M M M M M M M M M New New New New New ...

Page 272: ...Job Parts to remove Q ty Remarks 13 Circlip 1 14 6th wheel gear 1 15 Circlip 1 16 Washer 1 17 Collar 1 18 2nd wheel gear 1 19 Oil seal 1 20 Circlip 1 21 Bearing 1 22 Collar 1 23 Drive axle 1 13 14 15 16 17 18 20 19 21 22 23 LS M M M M M M M M M New New New New New ...

Page 273: ... SHIFT FORKS The following procedure applies to all of the shift forks 1 Check Shift fork cam follower 1 Shift fork pawl 2 Bends damage scoring wear Replace the shift fork 2 Check Shift fork guide bar Roll the shift fork guide bar on a flat surface Bends Replace WARNING EWA12840 Do not attempt to straighten a bent shift fork guide bar 3 Check Shift fork movement along the shift fork guide bar Roug...

Page 274: ...Check Transmission gear engagement each pinion gear to its respective wheel gear Incorrect Reassemble the transmission axle assemblies 5 Check Transmission gear movement Rough movement Replace the defective part s 6 Check Circlips Bends damage looseness Replace EAS30435 ASSEMBLING THE MAIN AXLE AND DRIVE AXLE 1 Install Toothed washer 1 Circlip 2 TIP Be sure the circlip sharp edged corner a is posi...

Page 275: ...s the cylinder 2 Install Shift fork C Shift drum assembly Shift fork guide bar TIP The embossed marks on the shift forks should face towards the right side of the engine Install shift fork C into the groove in the 3rd pinion gear on the main axle 3 Install Shift fork L 1 Shift fork R 2 Shift fork guide bar Shift drum retainer Drive axle assembly 3 TIP Install shift fork L into the groove in the 6t...

Page 276: ...TRANSMISSION 5 89 4 Check Transmission Rough movement Repair TIP Oil each gear shaft and bearing thoroughly 3 2 1 c b a ...

Page 277: ...OOLER 6 5 CHECKING THE OIL COOLER 6 7 CHECKING THE WATER JACKET JOINT 6 7 CHECKING THE THERMOSTAT 6 7 INSTALLING THE OIL COOLER 6 7 INSTALLING THE THERMOSTAT 6 8 THERMOSTAT 6 9 WATER PUMP 6 10 DISASSEMBLING THE WATER PUMP 6 12 CHECKING THE WATER PUMP 6 12 ASSEMBLING THE WATER PUMP 6 12 INSTALLING THE CLUTCH COVER 6 14 ...

Page 278: ...IAGRAMS 1 2 3 4 5 6 7 7 8 9 10 6 3 4 5 8 1 Thermostat 2 Oil cooler inlet hose 3 Oil cooler 4 Oil cooler outlet hose 5 Water jacket joint inlet hose 6 Water pump outlet pipe 7 Water pump inlet pipe 8 Radiator outlet hose 9 Water jacket joint 10 Water pump ...

Page 279: ...rvoir hose 1 3 Coolant reservoir cap 1 4 Coolant reservoir cover 1 5 Coolant reservoir 1 6 Holder 1 7 Holder 1 Open 8 Radiator cover 1 9 Horn connector 2 Disconnect 10 Radiator fan motor coupler 1 Disconnect LT LT 1 0 N m 0 10 kgf m 0 73 lb ft T R 2 0 N m 0 20 kgf m 1 5 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 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...

Page 280: ...et hose 1 13 Radiator cap 1 14 Radiator 1 15 Radiator fan motor 1 16 Horn 1 LT LT 1 0 N m 0 10 kgf m 0 73 lb ft T R 2 0 N m 0 20 kgf m 1 5 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 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 8 N m 0 8 kgf m 5 9 lb ft T R 14 16 15 13 11 12 ...

Page 281: ... onds and make sure there is no drop in pressure 4 Check Radiator fan Damage Replace Malfunction Check and repair Refer to COOLING SYSTEM on page 8 27 EAS30440 INSTALLING THE RADIATOR 1 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 27 2 Check Cooling system Leaks Repair or replace any faulty part 3 Measure Radiator cap opening pre...

Page 282: ...1 Oil filter cartridge 1 2 Water jacket joint 1 3 Water jacket joint inlet hose 1 4 Oil cooler inlet hose 1 5 Oil cooler outlet hose 1 6 Oil filter cartridge union bolt 1 7 Oil cooler 1 8 Gasket 1 E LS LS New New New 10 N m 1 0 kgf m 7 4 lb ft T R 2 0 N m 0 20 kgf m 1 5 lb ft T R 40 N m 4 0 kgf m 30 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 2 0 N m 0 20 kgf m 1 5 lb ft...

Page 283: ...diator inlet hose 1 Disconnect 10 Thermostat cover 1 11 Thermostat 1 E LS LS New New New 10 N m 1 0 kgf m 7 4 lb ft T R 2 0 N m 0 20 kgf m 1 5 lb ft T R 40 N m 4 0 kgf m 30 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 2 0 N m 0 20 kgf m 1 5 lb ft T R 10 9 11 ...

Page 284: ...rheating or overcooling 2 Check Thermostat cover Cracks damage Replace EAS30442 INSTALLING THE OIL COOLER 1 Clean Mating surfaces of the oil cooler and the crankcase with a cloth dampened with lacquer thinner 2 Install Gasket Oil cooler 1 Oil filter cartridge union bolt TIP Before installing the oil cooler apply engine oil lightly to the oil filter cartridge union bolt Align the projection a on th...

Page 285: ...E THERMOSTAT 1 Install Thermostat TIP Install the thermostat with its breather valve a facing inward 2 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 27 3 Check Cooling system Leaks Repair or replace any faulty part 4 Measure Radiator cap opening pressure Below the specified pressure Replace the radiator cap Refer to CHECKING THE R...

Page 286: ... thermostat Order Job Parts to remove Q ty Remarks Coolant Drain Refer to CHANGING THE COOLANT on page 3 27 1 Radiator inlet hose 1 Disconnect 2 Thermostat cover 1 3 Thermostat 1 2 0 N m 0 20 kgf m 1 5 lb ft T R 12 N m 1 2 kgf m 8 9 lb ft T R 1 2 3 ...

Page 287: ... 1 Clutch cable 1 Disconnect 2 Water pump outlet hose 1 Disconnect 3 Oil cooler outlet hose 1 Disconnect 4 Radiator outlet hose 1 Disconnect 5 Water pump inlet pipe 1 6 Water pump outlet pipe 1 7 Water pump housing 1 LT LT LT LT E LS New New 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 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 12 N m 1 2 kgf m 8 9 lb ft T...

Page 288: ...older 1 10 Clutch cover 1 11 Impeller shaft 1 12 Water pump seal assembly 1 13 Oil seal 1 14 Bearing 1 LT LT LT LT E LS New New 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 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 12 N m 1 2 kgf m 8 9 lb ft T R 3 8 12 11 10 13 14 9 8 ...

Page 289: ...er shaft Cracks damage wear Replace 2 Check Bearing Rough movement Replace 3 Check Water pump outlet pipe Water pump inlet pipe Cracks damage wear Replace EAS30448 ASSEMBLING THE WATER PUMP 1 Install Oil seal 1 Bearing into the clutch cover 2 TIP Install the oil seal with a socket 3 that matches its outside diameter 2 Install Mechanical seal housing side 1 into the clutch cover 2 NOTICE ECA20330 N...

Page 290: ...cts the mechanical seal housing side is dirty clean it 5 Install Impeller shaft 1 Circlip 2 TIP Be sure the circlip sharp edged corner a is positioned opposite side to the bearing After installation check that the impeller shaft rotates smoothly Mechanical seal installer ø33 90890 04132 Water pump seal installer ø33 YM 33221 A Middle driven shaft bearing driv er 90890 04058 Middle drive bearing in...

Page 291: ...e clutch cover make sure that the alignment mark d on the clutch cover is aligned with the punch mark e on the pull le ver 6 2 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 27 3 Check Cooling system Leaks Repair or replace the faulty part 4 Measure Radiator cap opening pressure Below the specified pressure Replace the radiator cap...

Page 292: ...WATER PUMP 6 15 ...

Page 293: ...DIES 7 5 REMOVING THE THROTTLE BODIES 7 8 CHECKING THE INJECTORS BEFORE REMOVING 7 8 REMOVING THE INJECTORS 7 8 CHECKING THE INJECTORS 7 8 CHECKING AND CLEANING THE THROTTLE BODIES 7 8 CHECKING THE THROTTLE BODY JOINTS 7 11 ADJUSTING THE THROTTLE POSITION SENSOR 7 11 INSTALLING THE FUEL INJECTORS 7 11 CHECKING THE INJECTOR PRESSURE 7 12 CHECKING THE FUEL PRESSURE 7 12 INSTALLING THE THROTTLE BODY ...

Page 294: ... 1 Fuel tank cap 1 2 Fuel tank cover 1 3 Fuel tank mounting bracket rear side 1 4 Fuel tank breather overflow hose 1 Disconnect 5 Fuel pump coupler 1 Disconnect 6 Fuel hose 1 7 Fuel tank 1 8 Fuel pump 1 9 Fuel tank mounting bracket front side 1 10 N m 1 0 kgf m 7 4 lb ft T R 4 0 N m 0 40 kgf m 3 0 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 4 0 N m 0 40 kgf m 3 0 lb ft T ...

Page 295: ...Fuel tank Refer to Removing the fuel tank on page 7 1 1 Fuel tank breather overflow hose fuel tank to rollover valve 1 2 Rollover valve 1 3 Fuel tank breather overflow hose rollover valve to canister 1 4 Canister purge hose 1 5 Canister breather hose 1 6 Canister 1 1 2 3 4 6 5 ...

Page 296: ...here it will be removed 3 Remove Fuel tank TIP Do not set the fuel tank down on the installation surface of the fuel pump Be sure to lean the fuel tank against a wall or the like EAS30451 REMOVING THE FUEL PUMP 1 Remove Fuel pump NOTICE ECA14721 Do not drop the fuel pump or give it a strong shock Do not touch the base section of the fuel sender EAS30454 CHECKING THE FUEL PUMP BODY 1 Check Fuel pum...

Page 297: ...uel pump bolts in the proper tight ening sequence as shown EAS30457 INSTALLING THE FUEL TANK 1 Install Fuel hose NOTICE ECA18420 When installing the fuel hose make sure that it is securely connected and that the fuel hose connector cover on the fuel hose is in the correct position otherwise the fuel hose will not be properly installed TIP Install the fuel hose securely onto the fuel rail and fuel ...

Page 298: ...ead breather hose 1 2 Sub wire harness 1 3 Coolant temperature sensor 1 4 Canister purge hose hose joint to throttle bod ies 2 5 Hose joint 1 6 Intake air pressure sensor coupler 1 Disconnect 7 Intake air pressure sensor 1 8 Intake air pressure sensor hose 1 Disconnect 3 0 N m 0 30 kgf m 2 2 lb ft T R 3 8 N m 0 38 kgf m 2 8 lb ft T R 3 0 N m 0 30 kgf m 2 2 lb ft T R 15 N m 1 5 kgf m 11 lb ft T R 4...

Page 299: ...ody joint clamp screw 4 Loosen 12 Air filter case joint clamp screw 2 Loosen 13 Throttle bodies 1 Refer to REMOVING THE THROTTLE BODIES on page 7 8 14 Throttle body joint 2 3 0 N m 0 30 kgf m 2 2 lb ft T R 3 8 N m 0 38 kgf m 2 8 lb ft T R 3 0 N m 0 30 kgf m 2 2 lb ft T R 15 N m 1 5 kgf m 11 lb ft T R 4 5 N m 0 45 kgf m 3 3 lb ft T R 4 5 N m 0 45 kgf m 3 3 lb ft T R 11 9 10 11 11 14 11 14 12 13 New...

Page 300: ...ks 1 ISC Idle Speed Control valve plate 1 2 ISC Idle Speed Control valve 1 3 Spring 1 4 Throttle position sensor 1 5 Fuel rail 1 6 Fuel injector 2 7 Cap 1 New New New New New 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 5 N m 0 5 kgf m 3 7 lb ft T R 6 6 3 1 2 5 4 7 ...

Page 301: ...bustible materials Make sure that there is no smoking or use of electric tools in the vicinity of the injectors Be careful when disconnecting the fuel hose Any remaining pressure in the fuel hose may cause the fuel to spray out Place a container or rag under the hose to catch any fuel that spills Always clean up any spilt fuel immediately Turn the main switch to OFF and discon nect the negative ba...

Page 302: ...ith the air filter case side facing up b Install the caps 895 14169 00 onto the hose fittings a c Push the lever in the direction shown in the illustration to hold the throttle valves in the open position WARNING EWA16680 When cleaning the throttle bodies be careful not to injure yourself on the throttle valves or other components of the throttle bodies NOTICE ECA21190 Do not use tools to open the...

Page 303: ...lve or throttle bodies and do not immerse them in the cleaning agent To prevent scratching the components do not use a brush metal file or other abra sive tool Do not clean with compressed air Do not allow the removed deposits or for eign materials to adhere to the sealing sur faces of the O ring Do not scratch or deform the ISC valve or air passage otherwise poor starting per formance an unstable...

Page 304: ...hrottle position sensor to the wire harness d Remove the protective cap and then con nect the Yamaha diagnostic tool to cou pler TIP For information about using the Yamaha diag nostic tool refer to the operation manual that is included with the tool Refer to YAMAHA DIAGNOSTIC TOOL on page 8 34 e Diagnostic code number 01 is selected f Adjust the position of the throttle position sensor angle so th...

Page 305: ...ctor pres sure adapter until the specified pressure is reached NOTICE ECA18440 Never exceed the specified air pressure or damage could occur f Close the valve on the fuel injector pres sure adapter g Check that the specified air pressure is held for about one minute Pressure drops Check the pressure gauge and adapter Check the seals and O rings and then re install Replace the fuel injectors EAS304...

Page 306: ...THROTTLE BODY JOINTS 1 Install Throttle body joints 1 TIP Be sure to install the throttle body joints 1 as shown in the illustration EAS33279 INSTALLING THE AIR FILTER CASE JOINTS 1 Install Air filter case joint clamps 1 TIP Align the projection on the air filter case joint with the slot in the air filter case joint clamp Face the screw head of the air filter case joint clamp outward Pressure gaug...

Page 307: ...ders 2 into the holes in the frame and battery box d Tighten the air filter case bolts left right e Install the battery box bracket 1 and then tighten the battery box bracket bolts 2 and battery box bolts 3 a 1 Cylinder b 2 Cylinder A Left B Right T R Air filter case bolt left 10 N m 1 0 kgf m 7 4 lb ft Air filter case bolt right 10 N m 1 0 kgf m 7 4 lb ft T R Battery box bracket bolt 9 N m 0 9 kg...

Page 308: ...THROTTLE BODIES 7 15 ...

Page 309: ... 8 19 CIRCUIT DIAGRAM 8 19 TROUBLESHOOTING 8 21 COOLING SYSTEM 8 27 CIRCUIT DIAGRAM 8 27 TROUBLESHOOTING 8 29 FUEL INJECTION SYSTEM 8 31 CIRCUIT DIAGRAM 8 31 ECU SELF DIAGNOSTIC FUNCTION 8 33 TROUBLESHOOTING METHOD 8 33 YAMAHA DIAGNOSTIC TOOL 8 34 TROUBLESHOOTING DETAILS FAULT CODE 8 34 TROUBLESHOOTING DETAILS EVENT CODE 8 80 FUEL PUMP SYSTEM 8 83 CIRCUIT DIAGRAM 8 83 TROUBLESHOOTING 8 85 IMMOBILI...

Page 310: ... 8 125 TROUBLESHOOTING FOR THE ABS CANCEL FUNCTION 8 126 ELECTRICAL COMPONENTS 8 127 CHECKING THE SWITCHES 8 129 CHECKING THE FUSES 8 130 REPLACING THE ECU engine control unit 8 130 CHECKING AND CHARGING THE BATTERY 8 130 CHECKING THE RELAYS 8 131 CHECKING THE TURN SIGNAL HAZARD RELAY 8 132 CHECKING THE DIODE 8 133 CHECKING THE RELAY UNIT DIODE 8 133 CHECKING THE IGNITION COILS 8 134 CHECKING THE ...

Page 311: ......

Page 312: ...Br W W G P L R G G W W Y R L R B P B B W R Y B Gy G Br L G Y O Gy R Gy W L L R L B Y L B L P W B R W L Y B R R B B Y G B L W Y G Br W W G P L R G G W W Y R L R B P B B W R Y B Gy G Br L G Y Gy R O Gy W L L W L W L W L W R W R W R W R W R W R W R W Y Y Y Y L R L R L R B L B L B L Gy B Gy B L R R R R W Br L Br L R W R W Br L B W B B B R B R W R W R W R B Sb B R B R L G R B R W B L B L R W B R L G B ...

Page 313: ...se 23 Relay unit diode 26 Joint coupler 27 Sidestand switch 29 Crankshaft position sensor 32 ECU Engine Control Unit 33 Ignition coil 1 34 Ignition coil 2 35 Spark plug 43 Lean angle sensor 66 Gear position switch 67 Handlebar switch right 69 Engine stop switch C for XTZ690 D for XTZ690 U ...

Page 314: ...e en gine continues to run under the following conditions The transmission is in gear the neutral circuit of the gear position switch is open and the sidestand is up the sidestand switch circuit is closed The transmission is in neutral the neutral circuit of the gear position switch is closed and the side stand is down the sidestand switch circuit is open 10 11 9 1 4 5 7 2 6 3 8 1 Battery 2 Main f...

Page 315: ...TERY on page 8 130 Clean the battery terminals Recharge or replace the battery 3 Check the spark plugs Refer to CHECKING THE SPARK PLUGS on page 3 5 Re gap or replace the spark plug s 4 Check the ignition spark gap Refer to CHECKING THE IGNI TION SPARK GAP on page 8 135 Ignition system is OK 5 Check the ignition coils Refer to CHECKING THE IGNI TION COILS on page 8 134 Replace the ignition coil s ...

Page 316: ...Check the sidestand switch Refer to CHECKING THE SWITCHES on page 8 129 Replace the sidestand switch 11 Check the relay unit diode Refer to CHECKING THE RELAY UNIT DIODE on page 8 133 Replace the relay unit 12 Check the lean angle sensor Refer to CHECKING THE LEAN ANGLE SENSOR on page 8 136 Replace the lean angle sensor 13 Check the entire ignition system wiring Refer to CIRCUIT DIAGRAM on page 8 ...

Page 317: ...IGNITION SYSTEM 8 6 ...

Page 318: ...R W L G B R B Y Sb W Sb R L W R W B R B B B L W L R R W R W L W B B L R R B B B R B Y Y Br W L R Dg B Y Ch P W Y R Y B R Dg R Y Ch Y Br W L R B Y B R W Y P B L W L W L W L W R W R W R W R W R W R W R W Y Y Y Y L R L R L R B L B L B L R R R R W Br L Br L R W Br L B B B B B B R B Y B L W R B R W R W R W R B B B L W R B Y Sb B R B R B R L G R B R W L W L W L W R W B Y L G R B R B R R B R B Sb Sb Br L...

Page 319: ...round 19 Main fuse 20 Starter relay 21 Starter motor 23 Relay unit diode 24 Starting circuit cut off relay 26 Joint coupler 27 Sidestand switch 28 Diode 66 Gear position switch 67 Handlebar switch right 69 Engine stop switch 70 Start switch 73 Handlebar switch left 74 Clutch switch ...

Page 320: ...he starter motor from operating when neither of these condi tions has been met In this instance the starting circuit cut off relay is open so current cannot reach the starter motor When at least one of the above conditions has been met the starting circuit cut off relay is closed and the engine can be started by pressing the start switch 14 1 13 4 5 7 7 7 7 a b 9 7 10 8 6 2 3 11 12 a WHEN THE TRAN...

Page 321: ...tion Refer to CHECKING THE START ER MOTOR OPERATION on page 8 136 Starter motor is OK Perform the electric starting system troubleshooting starting with step 5 4 Check the starter motor Refer to CHECKING THE START ER MOTOR on page 5 40 Repair or replace the starter motor 5 Check the relay unit starting circuit cut off relay Refer to CHECKING THE RE LAYS on page 8 131 Replace the relay unit 6 Check...

Page 322: ...on page 8 129 Replace the clutch switch 12 Check the engine stop switch Refer to CHECKING THE SWITCHES on page 8 129 The engine stop switch is faulty Replace the right handlebar switch 13 Check the start switch Refer to CHECKING THE SWITCHES on page 8 129 The start switch is faulty Replace the right handlebar switch 14 Check the Diode Refer to CHECKING THE DIODE on page 8 133 Replace the diode 15 ...

Page 323: ...RGING SYSTEM 8 12 EAS20074 CHARGING SYSTEM EAS30496 CIRCUIT DIAGRAM B R B W W W R L W R W B R R B R R B R B B R 15 16 17 18 19 15 Stator coil 16 Rectifier regulator 17 Battery 18 Engine ground 19 Main fuse ...

Page 324: ...er to CHECKING AND CHARGING THE BATTERY on page 8 130 Clean the battery terminals Recharge or replace the battery 3 Check the stator coil Refer to CHECKING THE STATOR COIL on page 8 136 Replace the stator coil assembly 4 Check the rectifier regulator Refer to CHECKING THE RECTI FIER REGULATOR on page 8 137 Replace the rectifier regulator 5 Check the entire charging system wiring Refer to CIRCUIT D...

Page 325: ...CHARGING SYSTEM 8 14 ...

Page 326: ...L Y B Y L R B W Y Br W L R Dg B Y Ch P W Y R Y B R Dg R Y Ch Y Br W L R B Y B R W Y P L W L W L W L W R W R W R W R W R W R W R W Y Y Y Y L R L R L R B L B L B L Br Y B Y L B B Br W Y B Y L B R R R R W Br L Br L L R R W Br L R Br L L L R Y Y W Y Y Br L B R Y B B W B L R Y B B B W B B W R Y L L R R W R W R B B R B L R L R B W Y R W Br L W Y Y R Y Y B R L B Y B Y B B G B G 1 8 9 10 17 18 19 26 51 61...

Page 327: ...ttery 18 Engine ground 19 Main fuse 26 Joint coupler 51 Meter assembly 54 Meter light 61 High beam indicator light 73 Handlebar switch left 75 Dimmer switch 76 Pass switch 84 Headlight assembly 85 Headlight high beam 86 Headlight low beam 87 Auxiliary light 88 License plate light 89 Tail brake light ...

Page 328: ...and main Refer to CHECKING THE FUS ES on page 8 130 Replace the fuse s 3 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 130 Clean the battery terminals Recharge or replace the battery 4 Check the main switch Refer to CHECKING THE SWITCHES on page 8 129 Replace the main switch immobilizer unit 5 Check the dimmer switch Refer to CHECKING THE SWITCHES on page 8 129 The dimmer ...

Page 329: ...LIGHTING SYSTEM 8 18 ...

Page 330: ...R B Y B R W Y P Br Y L R L B Y L B L P W B R W L Y B R R B B Y G B L W Y G Br W W G P L R G G W W Y R L R B P B B W R Y B Gy G Br L G Y O Gy R Gy W L L R L B Y L B L P W B R W L Y B R R B B Y G B L W Y G Br W W G P L R G G W W Y R L R B P B B W R Y B Gy G Br L G Y Gy R O Gy W L L W L W L W L W R W R W R W R W R W R W R W Y Y Y Y L R L R L R B L B L B L W B B W R R R R W Br L Br L Br R Br W L R L R...

Page 331: ...er 57 Multi function meter 58 Oil pressure warning light 60 Coolant temperature warning light 62 Turn signal indicator light left 63 Turn signal indicator light right 65 Horn 66 Gear position switch 67 Handlebar switch right 68 Front brake light switch 72 Turn signal hazard relay 73 Handlebar switch left 77 Turn signal switch 78 Hazard switch 79 Horn switch 80 Rear turn signal light right 81 Front...

Page 332: ...t ignition signaling system and main Refer to CHECKING THE FUS ES on page 8 130 Replace the fuse s 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 130 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 129 Replace the main switch immobilizer unit 4 Check the entire signaling system wiring Refer to CI...

Page 333: ...ght switch 3 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 8 19 Properly connect or replace the wiring har ness Replace the tail brake light 1 Check the turn signal light bulbs and sockets Refer to CHECKING THE BULBS AND BULB SOCKETS in BASIC INFORMATION separate volume Replace the turn signal light bulb s sock et s or both 2 Check the turn signal switch Refer to CHECKI...

Page 334: ...r position switch 2 Check the relay unit diode Refer to CHECKING THE RELAY UNIT DIODE on page 8 133 Replace the relay unit 3 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 8 19 Properly connect or replace the wiring har ness Replace the meter assembly 1 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 8 19 Properly connect or replace the wiring h...

Page 335: ...eal oil filter or oil pump Replace the oil pressure switch 1 Check the fuel sender Refer to CHECKING THE FUEL SENDER on page 8 137 Replace the fuel pump assembly 2 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 8 19 Properly connect or replace the wiring har ness Replace the meter assembly 1 Check the coolant temperature sen sor Refer to CHECKING THE COOL ANT TEMPERATURE...

Page 336: ... AND SENSOR ROTOR on page 4 14 Replace the front wheel sensor 2 Check the entire front wheel sensor wiring See TIP Properly connect or replace the wiring har ness Replace the ECU ABS ECU or meter assembly Refer to REPLACING THE ECU engine control unit on page 8 130 1 Check the crankshaft position sen sor Refer to CHECKING THE CRANK SHAFT POSITION SENSOR on page 8 135 Replace the starter coil assem...

Page 337: ...SIGNALING SYSTEM 8 26 ...

Page 338: ...W R W R W R W Y Y Y Y L R L R L R B L B L B L L R L B Y L B L P W B R W L Y B R R B B Y G B L W Y G Br W W G P L R G G W W Y R L R B P B B W R Y B Gy G Br L G Y O Gy R Gy W L L R L B Y L B L P W B R W L Y B R R B B Y G B L W Y G Br W W G P L R G G W W Y R L R B P B B W R Y B Gy G Br L G Y Gy R O Gy W L R R R R R W Br L Br L R R R W R W Br L L B B B B B W B G Y R R W R W R W R B B R B R W B L R W B...

Page 339: ...r fuse 17 Battery 18 Engine ground 19 Main fuse 26 Joint coupler 32 ECU Engine Control Unit 40 Coolant temperature sensor 90 Radiator fan motor relay 91 Radiator fan motor A Wire harness B Sub wire harness Refer to SIGNALING SYSTEM on page 8 19 C for XTZ690 D for XTZ690 U ...

Page 340: ...NG THE BATTERY on page 8 130 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 129 Replace the main switch immobilizer unit 4 Check the radiator fan motor Refer to CHECKING THE RADIA TOR FAN MOTOR on page 8 138 Replace the radiator fan motor 5 Check the radiator fan motor relay Refer to CHECKING THE RE LAYS on page 8 131 Re...

Page 341: ... 8 30 NG OK 7 Check the entire cooling system wiring Refer to CIRCUIT DIAGRAM on page 8 27 Properly connect or replace the wiring har ness Replace the ECU Refer to REPLAC ING THE ECU engine control unit on page 8 130 ...

Page 342: ...R W L Y B R R B B Y G B L W Y G Br W W G P L R G G W W Y R L R B P B B W R Y B Gy G Br L G Y O Gy R Gy W L L R L B Y L B L P W B R W L Y B R R B B Y G B L W Y G Br W W G P L R G G W W Y R L R B P B B W R Y B Gy G Br L G Y Gy R O Gy W L L R G Y R W Br Y B Y L B B Br W Y B Y L B W B B W R R R R R W Br L Br L R Br W R W R W R B R W Br L Br L B G B W B B W B B B B B R B Y R B R W R W R W R W R B R R W...

Page 343: ...2 36 Fuel injector 1 37 Fuel injector 2 38 ISC Idle Speed Control unit 39 Intake air temperature sensor 40 Coolant temperature sensor 41 Intake air pressure sensor 43 Lean angle sensor 44 Front wheel sensor 46 ABS ECU 47 Yamaha diagnostic tool coupler 49 Fuel pump 51 Meter assembly 57 Multi function meter 59 Engine trouble warning light 66 Gear position switch 67 Handlebar switch right 69 Engine s...

Page 344: ... the specified values that are programmed for each sensor in order to provide the engine with alternate operating instructions that enable the engine to continue operating or stop operating depending on the conditions EAS30506 TROUBLESHOOTING METHOD The engine operation is not normal and the engine trouble warning light comes on 1 Check Fault code number a Check the fault code numbers that have a ...

Page 345: ... the protective cap 1 and then connect the Yamaha diagnostic tool to the coupler EAS31791 TROUBLESHOOTING DETAILS FAULT CODE This section describes the measures per fault code number displayed on the Yamaha diagnostic tool Check and service the items or components that are the probable cause of the malfunction following the order given After the check and service of the malfunctioning part have be...

Page 346: ...e number P0122 first If fault code numbers P0030 and P0123 are both indicated take the actions specified for fault code number P0123 first Crankshaft position sensor O2 sensor Fuel injector 1 Lean angle sensor Fuel injector 2 ABS ECU Ignition coil 1 ISC Idle Speed Control unit Ignition coil 2 Relay unit diode Throttle position sensor Headlight assembly Intake air pressure sensor Radiator fan motor...

Page 347: ...in switch to ON and then check the condition of the fault code using the mal function mode of the Yamaha di agnostic tool Condition is Recover Go to item 6 and finish the service Condition is Malfunction Start the engine and then check the condition of the fault code Condition is Recover Go to item 6 and finish the service Condition is Malfunction Go to item 3 TIP For this check also set the en gi...

Page 348: ...n delete the fault code Fault code No P0107 P0108 Item P0107 Intake air pressure sensor ground short circuit detected P0108 Intake air pressure sensor open or power short circuit de tected Fail safe system Able to start engine Able to drive vehicle Diagnostic code No 03 Tool display Displays the intake air pressure Procedure Operate the throttle while pushing the start switch If the display value ...

Page 349: ...ss continuity Open or short circuit Replace the wire harness Turn the main switch to ON and then check the condition of the fault code using the mal function mode of the Yamaha di agnostic tool Condition is Recover Go to item 7 and finish the service Condition is Malfunction Go to item 4 3 1 1 Intake air pressure sensor 2 ECU 3 Sensor input lead 4 Sensor output lead 5 Sensor ground lead 3 2 Discon...

Page 350: ...rts connected to the ECU on page 8 35 3 8 For P0107 P0108 Short circuit Between intake air pressure sensor output terminal pink white a of ECU coupler and any other ECU coupler terminal b If there is continuity replace the wire harness B L P W L L R L B Y L B L P W R W L Y B R R B B Y G B L W Y G Br W W G P L R G G W W Y R L R B P B B W R Y B Gy G Br L G Y O Gy R Gy W L B L P W L L R L B Y L B L P...

Page 351: ... above sea lev el Approx 70 kPa 525 0 mmHg 20 7 inHg When engine is cranking Make sure that the indication value changes The value does not change when engine is cranking Check the intake air pressure sensor Replace if defective Crank the engine and then check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recover Go to item 7 and finish the s...

Page 352: ... of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the coupler securely or re place the wire harness Turn the main switch to ON and then check the condition of the fault code using the mal function mode of the Yamaha di agnostic tool Condition is Recover Go to item 7 and finish the service Condition is ...

Page 353: ...ect the couplers from the parts that are connected to the ECU Refer to Parts connected to the ECU on page 8 35 3 7 For P0112 P0113 Short circuit Between intake air temperature sensor output terminal brown white a of ECU coupler and any other ECU coupler terminal b If there is continuity replace the wire harness B L Br W B L Br W L R L B Y L B L P W R W L Y B R R B B Y G B L W Y G Br W W G P L R G ...

Page 354: ...0 Service is finished 7 Delete the fault code and check that the engine trouble warning light goes off Confirm that the fault code has a condition of Recover using the Yamaha diagnostic tool and then delete the fault code Fault code No P0117 P0118 Item P0117 Coolant temperature sensor ground short circuit detected P0118 Coolant temperature sensor open or power short circuit detected Fail safe syst...

Page 355: ...n switch to ON and then check the condition of the fault code using the mal function mode of the Yamaha di agnostic tool Condition is Recover Go to item 8 and finish the service Condition is Malfunction Go to item 4 4 Wire harness and or sub wire harness continuity Open or short circuit Replace the wire harness and or sub wire harness Turn the main switch to ON and then check the condition of the ...

Page 356: ... terminal b If there is continuity replace the wire harness and or sub wire harness 5 Installed condition of coolant temperature sensor Check for looseness or pinch ing Improperly installed sensor Reinstall or replace the sensor Turn the main switch to ON and then check the condition of the fault code using the mal function mode of the Yamaha di agnostic tool Condition is Recover Go to item 8 and ...

Page 357: ...drive vehicle Diagnostic code No 01 Tool display Throttle position sensor signal 11 21 fully closed position 96 106 fully open position Procedure Check with throttle valves fully closed Check with throttle valves fully open Item Probable cause of malfunc tion and check Maintenance job Confirmation of service com pletion 1 Connection of throttle position sensor coupler Check the locking condition o...

Page 358: ...arness and or sub wire harness Turn the main switch to ON and then check the condition of the fault code using the mal function mode of the Yamaha di agnostic tool Condition is Recover Go to item 9 and finish the service Condition is Malfunction Go to item 5 4 1 1 Throttle position sensor 2 ECU 3 Sensor input lead 4 Sensor output lead 5 Sensor ground lead 4 2 Disconnect the ECU coupler from the EC...

Page 359: ...ss 4 7 Disconnect the couplers from the parts that are connected to the ECU Refer to Parts connected to the ECU on page 8 35 4 8 For P0122 P0123 Short circuit Between throttle position sensor output terminal white a of ECU coupler and any other ECU cou pler terminal b If there is continuity replace the wire harness and or sub wire harness L R L B Y L B L P W R W L Y B R R B B Y G B L W Y G Br W W ...

Page 360: ...Defective throttle position sen sor Check throttle position sensor signal Execute the diagnostic mode Code No 01 When the throttle valves are ful ly closed A value of 11 21 is indicated When throttle valves are fully open A value of 96 106 is indicated Turn the main switch to ON and then check the condition of the fault code using the mal function mode of the Yamaha di agnostic tool Condition is R...

Page 361: ...d then check the condition of the fault code using the mal function mode of the Yamaha di agnostic tool Condition is Recover Go to item 7 and finish the service Condition is Malfunction Go to item 4 4 Wire harness continuity Open or short circuit Properly connect or replace the wire har ness Between ECU coupler and O2 sensor coupler gray green gray green Between O2 sensor coupler and joint coupler...

Page 362: ...ce Replace if out of specification Refer to CHECKING THE FUEL INJECTORS on page 8 140 Execute the diagnostic mode Code No 36 Operating sound Go to item 7 No operating sound Go to item 3 3 Connection of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the coupler ...

Page 363: ...injector 2 coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the coupler securely or re place the wire harness Execute the diagnostic mode Code No 37 Operating sound Go to item 7 No operating sound Go to item 2 2 Defective fuel injector 2 Measure the fuel injector res...

Page 364: ...tion sensor Fail safe system Unable to start engine Unable to drive vehicle Diagnostic code No Tool display Procedure Item Probable cause of malfunc tion and check Maintenance job Confirmation of service com pletion 1 Connection of crankshaft posi tion sensor coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition ...

Page 365: ...ING THE CRANKSHAFT POSITION SENSOR on page 8 135 Replace if defective Crank the engine and then check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recover Go to item 7 and finish the service Condition is Malfunction Go to item 6 6 Malfunction in ECU Replace the ECU Refer to REPLACING THE ECU engine control unit on page 8 130 Service is finis...

Page 366: ...een cylinder 1 ignition coil coupler and ECU coupler orange orange Start the engine and let it idle for approximately 5 seconds Check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recover Go to item 7 and finish the service Condition is Malfunction Go to item 4 4 Installed condition of cylinder 1 ignition coil Check for looseness or pinch ing...

Page 367: ...als and locking condition of the pins Improperly connected Con nect the coupler securely or re place the wire harness Start the engine and let it idle for approximately 5 seconds Check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recover Go to item 7 and finish the service Condition is Malfunction Go to item 2 2 Connection of ECU coupler Che...

Page 368: ... Go to item 7 and finish the service Condition is Malfunction Go to item 6 6 Malfunction in ECU Execute the diagnostic mode Code No 31 No spark Replace the ECU Refer to REPLACING THE ECU engine control unit on page 8 130 Service is finished 7 Delete the fault code and check that the engine trouble warning light goes off Confirm that the fault code has a condition of Recover using the Yamaha diagno...

Page 369: ...f the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the coupler securely or re place the wire harness Execute the diagnostic mode Code No 07 Rotate the front wheel by hand and check that the indicated val ue increases Value increases Go to item A 8 Value does not increase Go to item A 4 A 4 Connection of E...

Page 370: ...eel sensor no normal signals are received from the front wheel sensor B Gear position switch open or short circuit is detected C Clutch switch open or short circuit is detected Fail safe system Able to start engine Able to drive vehicle Diagnostic code No 21 Tool display Gear position switch ON when the transmission is in neutral OFF when the transmission is in gear or the clutch lever released Pr...

Page 371: ... harness continuity Open or short circuit Replace the wire harness Between ECU coupler and joint coupler black red black red Between joint coupler and relay unit coupler black red black red Between relay unit coupler and gear position switch coupler sky blue sky blue Execute the diagnostic mode Code No 21 When the transmission is in neutral ON When the transmission is in gear with the clutch lever...

Page 372: ... 20 to 30 km h 12 to 19 mph Confirm that the fault code has a condition of Recover using the malfunction mode of the Yamaha diagnostic tool and then delete the fault code Delete this fault code even if it has a condition of Malfunction Fault code No P0500 Item A Front wheel sensor no normal signals are received from the front wheel sensor B Gear position switch open or short circuit is detected C ...

Page 373: ...em C 3 C 3 Connection of clutch switch cou pler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the coupler securely or re place the wire harness Execute the diagnostic mode Code No 21 When the clutch lever is re leased with the transmission in gear and when the sidestand i...

Page 374: ...xecute the diagnostic mode Code No 21 When the clutch lever is re leased 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 Correct indication Go to item C 10 Incorrect indication Go to item C 7 C 7 Defective clutch switch Check the clutch switch Replace if defective Refer to C...

Page 375: ...s a condition of Malfunction Fault code No P0507 Item A Component other than ISC idle speed control unit is defec tive ISC operating sound is heard B Defective ISC idle speed control unit ISC operating sound is not heard Fail safe system Able to start engine Able to drive vehicle Diagnostic code No 54 Actuation Fully closes the ISC valve and then opens the valve This operation is performed 3 times...

Page 376: ...he ISC idle speed control valve on page 7 10 Start the engine and let it idle for approximately 10 seconds Check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recover Go to item A 6 and finish the service Condition is Malfunction Go to item A 5 A 5 Malfunction in ECU Replace the ECU Refer to REPLACING THE ECU engine control unit on page 8 130...

Page 377: ...upler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the coupler securely or re place the wire harness Execute the diagnostic mode Code No 54 ISC operating sound is heard Go to item B 9 ISC operating sound is not heard Go to item B 5 B 5 Wire harness and or sub wire harness continuity Open or short circuit Replace ...

Page 378: ...witch to ON and then check the condition of the fault code using the mal function mode of the Yamaha di agnostic tool Condition is Recover Go to item 7 and finish the service Condition is Malfunction Go to item 2 2 Connection of sub wire har ness 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 I...

Page 379: ...he Yamaha di agnostic tool Condition is Recover Go to item 7 and finish the service Condition is Malfunction Go to item 6 6 Malfunction in ECU Replace the ECU Refer to REPLACING THE ECU engine control unit on page 8 130 Service is finished 7 Delete the fault code and check that the engine trouble warning light goes off Confirm that the fault code has a condition of Recover using the Yamaha diagnos...

Page 380: ...o ON Check that the engine trouble warning light does not come on Fault code No P062F Item EEPROM fault code number an error is detected while reading or writing on EEPROM Fail safe system Able Unable to start engine Able Unable to drive vehicle Diagnostic code No 60 Tool display 00 No malfunctions detected If the self diagnosis fault code P062F is indi cated the ECU is defective 01 02 CO adjustme...

Page 381: ...tic tool Set the main switch to ON and then check the condition of the fault code using the mal function mode of the Yamaha di agnostic tool Condition is Recover Go to item 6 and finish the service Condition is Malfunction Repeat item 1 If the same number is indicated go to item 5 4 11 is indicated in diagnostic mode code No 60 EEPROM data error for ISC idle speed control learning values 12 is ind...

Page 382: ...finish the service Condition is Malfunction Go to item 2 2 Connection of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the coupler securely or re place the wire harness Start the engine and let it idle for approximately 5 seconds Check the condition of the fau...

Page 383: ...t the engine trouble warning light goes off Confirm that the fault code has a condition of Recover using the Yamaha diagnostic tool and then delete the fault code Fault code No P1601 Item Sidestand switch open or short circuit of the black red lead of the ECU is detected Fail safe system Unable to start engine Unable to drive vehicle Diagnostic code No 20 Tool display Sidestand switch ON sidestand...

Page 384: ...ness continuity Open or short circuit Replace the wire harness Between sidestand switch cou pler and relay unit coupler blue green blue green Between relay unit coupler and joint coupler black red black red Between joint coupler and ECU coupler black red black red Turn the main switch to ON and then extend and retract the sidestand Check the condition of the fault code using the malfunction mode o...

Page 385: ...ion of the pins Improperly connected Con nect the coupler securely or re place the wire harness Turn the main switch to ON and then check the condition of the fault code using the mal function mode of the Yamaha di agnostic tool Condition is Recover Go to item 7 and finish the service Condition is Malfunction Go to item 3 3 Check the fuel injection system fuse Blown fuse Replace the fuse or wire h...

Page 386: ...Diagnostic code No 08 Tool display Lean angle sensor output voltage 0 4 1 4 upright 3 7 4 4 overturned Procedure Remove the lean angle sensor and incline it more than 65 degrees Item Probable cause of malfunc tion and check Maintenance job Confirmation of service com pletion 1 Connection of lean angle sensor coupler Check the locking condition of the coupler Disconnect the coupler and check the pi...

Page 387: ...tput lead 5 Sensor ground lead 3 2 Disconnect the ECU coupler from the ECU Disconnect the lean angle sensor coupler from the lean angle sensor 3 3 For P1604 Ground short circuit Between lean angle sensor coupler and ground yellow green ground If there is continuity replace the wire harness 3 4 For P1605 Open circuit Between lean angle sensor coupler and ECU coupler blue blue If there is no continu...

Page 388: ...nal b If there is continuity replace the wire harness 4 Defective lean angle sensor Refer to CHECKING THE LEAN ANGLE SENSOR on page 8 136 Turn the main switch to ON then to OFF and then back to ON Check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recover Go to item 6 and finish the service Condition is Malfunction Go to item 5 B L L Y G L R...

Page 389: ...ck for looseness or pinch ing Improperly installed sensor Reinstall or replace the sensor Start the engine and let it idle for approximately 10 seconds Check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recover Go to item 8 and finish the service Condition is Malfunction Go to item 2 Also delete this fault code which has a condition of Mal f...

Page 390: ...pproximately 10 seconds Check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool Condition is Recover Go to item 8 and finish the service Condition is Malfunction Go to item 5 Also delete this fault code which has a condition of Mal function 5 Check fuel pressure Refer to CHECKING THE FUEL PRESSURE on page 7 12 Start the engine and let it idle for approximatel...

Page 391: ...function mode of the Yamaha di agnostic tool Condition is Recover Go to item 6 and finish the service Condition is Malfunction Go to item 2 2 Connection of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the coupler securely or re place the wire harness Turn the...

Page 392: ... The vehicle has overturned Raise the vehicle upright Turn the main switch to ON then to OFF and then back to ON Engine trouble warning light does not come on Service is finished Engine trouble warning light comes on Go to item 2 2 Installed condition of lean angle sensor Check the installed direction and condition of the sensor Turn the main switch to ON then to OFF and then back to ON Engine tro...

Page 393: ...FUEL INJECTION SYSTEM 8 82 ...

Page 394: ... Y Y Y Y L R L R L R B L B L B L L R L B Y L B L P W B R W L Y B R R B B Y G B L W Y G Br W W G P L R G G W W Y R L R B P B B W R Y B Gy G Br L G Y O Gy R Gy W L L R L B Y L B L P W B R W L Y B R R B B Y G B L W Y G Br W W G P L R G G W W Y R L R B P B B W R Y B Gy G Br L G Y Gy R O Gy W L R R R R W Br L Br L R W R W Br L B G B W B R B R W R W R W R B R R W R L L Y R B B G R W R W R W R L R L R B ...

Page 395: ...8 Ignition fuse 17 Battery 18 Engine ground 19 Main fuse 23 Relay unit diode 25 Fuel pump relay 26 Joint coupler 28 Diode 32 ECU Engine Control Unit 49 Fuel pump 67 Handlebar switch right 69 Engine stop switch C for XTZ690 D for XTZ690 U ...

Page 396: ...n the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 129 Replace the main switch immobilizer unit 4 Check the engine stop switch Refer to CHECKING THE SWITCHES on page 8 129 The engine stop switch is faulty Replace the right handlebar switch 5 Check the diode Refer to CHECKING THE DIODE on page 8 133 Replace the diode 6 Check the ...

Page 397: ... 8 86 NG OK 8 Check the entire fuel pump system wiring Refer to CIRCUIT DIAGRAM on page 8 83 Properly connect or replace the wiring har ness Replace the ECU Refer to REPLAC ING THE ECU engine control unit on page 8 130 ...

Page 398: ... R W R W R W Y Y Y Y L R L R L R B L B L B L L R L B Y L B L P W B R W L Y B R R B B Y G B L W Y G Br W W G P L R G G W W Y R L R B P B B W R Y B Gy G Br L G Y O Gy R Gy W L L R L B Y L B L P W B R W L Y B R R B B Y G B L W Y G Br W W G P L R G G W W Y R L R B P B B W R Y B Gy G Br L G Y Gy R O Gy W L B W Y L R W G B B Lg R G R R R R R W Br L Br L R R G R W Br L B W B W B R B R B R W R W R W R W Y...

Page 399: ...in switch 8 Ignition fuse 12 Backup fuse 14 Immobilizer unit 17 Battery 18 Engine ground 19 Main fuse 26 Joint coupler 32 ECU Engine Control Unit 51 Meter assembly 52 Immobilizer system indicator light C for XTZ690 D for XTZ690 U ...

Page 400: ...ering key is lost regis tering new codes in the standard keys is impossible The standard keys can still be used to start the vehicle However if code re registering is required e g if a new standard key is made or all keys are lost the entire immobilizer system must be replaced Therefore it is highly rec ommended to use either standard key for driving and to keep the code re registering key in a sa...

Page 401: ...the ignition key to OFF 30 seconds later the indicator light will start flashing continuously in the standby flashing mode pattern for up to 24 hours After that time the indicator light will stop flashing but the immobilizer system is still enabled Standby mode Parts to be replaced Key registration re quirement Main switch immobi lizer unit Standard key ECU Accessory lock and key Main switch Immob...

Page 402: ...mory when the key registration mode is activated When the key registration mode is activated the immobilizer system indicator light flashes rapidly 4 While the indicator light is flashing turn the main switch to OFF remove the key and within 5 sec onds insert the second standard key to be registered into the main switch TIP If the immobilizer system indicator light stops flashing 5 seconds after t...

Page 403: ...m the memory thus disabling the lost standard key To re register refer to Standard key registration Standard key code voiding method a Main switch ON b Main switch OFF c LED on d LED off e Less than 5 0 s f Code re registering key g Remaining standard key h Registration mode A If the immobilizer system indicator light stops flashing 5 seconds after the first standard key is registered the second s...

Page 404: ... the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 130 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 129 Replace the main switch immobilizer unit 4 Check the entire immobilizer sys tem wiring Refer to CIRCUIT DIAGRAM on page 8 87 Properly connect or replace the wiring har ness Check the condition each of ...

Page 405: ... dard key 53 IMMOBILIZER UNIT Codes cannot be transmitted between the ECU and the im mobilizer unit Noise interference or dis connected lead cable 1 Interference due to ra dio wave noise 2 Disconnected commu nication harness 3 Immobilizer unit mal function 4 ECU malfunction 1 Check the wire harness and con nector 2 Replace the main switch immobiliz er unit 3 Replace the ECU Refer to REPLAC ING THE...

Page 406: ...for 0 5 second and off for 0 5 second Example fault code 52 56 ECU Unidentified code is received Noise interference or dis connected lead cable 1 Check the wire harness and con nector 2 Replace the main switch immobiliz er unit 3 Replace the ECU Refer to REPLAC ING THE ECU en gine control unit on page 8 130 Fault code Part Symptom Cause Action a Light on b Light off ...

Page 407: ...IMMOBILIZER SYSTEM 8 96 ...

Page 408: ... Y L B L P W B R W L Y B R R B B Y G B L W Y G Br W W G P L R G G W W Y R L R B P B B W R Y B Gy G Br L G Y O Gy R Gy W L L R L B Y L B L P W B R W L Y B R R B B Y G B L W Y G Br W W G P L R G G W W Y R L R B P B B W R Y B Gy G Br L G Y Gy R O Gy W L B R B B R R R R W Br L Br L R Br W L R R W R W R L R W Br L Br L B W B B W B B Y L R L R L R R W R W R B R R B B G L R Y Y Br R W Y Y L R L R R W Y R...

Page 409: ... Battery 18 Engine ground 19 Main fuse 22 Rear brake light switch 26 Joint coupler 32 ECU Engine Control Unit 42 Resistor unit 44 Front wheel sensor 45 Rear wheel sensor 46 ABS ECU 47 Yamaha diagnostic tool coupler 51 Meter assembly 57 Multi function meter 64 ABS warning light 67 Handlebar switch right 68 Front brake light switch 69 Engine stop switch C for XTZ690 D for XTZ690 U ...

Page 410: ... B W B W B R L R W B G B B W B W G R G W Y Y Br W L R G R B L B B G L R L B R W B B W G B L B Dg Sb W Y Ch R G G R G W R W W P W G Y G L R Y W W R O Gy Gy 1 Front wheel sensor coupler 2 Rear wheel sensor coupler 3 Yamaha diagnostic tool coupler 4 ABS ECU coupler 5 Meter assembly coupler ...

Page 411: ...rform a final check before delivering the vehicle to the customer TIP To final check refer to C 1 FINAL CHECK on page 8 125 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 mai...

Page 412: ...es will be displayed again if another malfunction occurs EAS30993 BASIC INSTRUCTIONS FOR TROUBLESHOOTING WARNING EWA17420 Perform the troubleshooting A B C in order Be sure to follow the order since a wrong diagnosis could result if the steps are followed in a different order or omitted Use sufficiently charged regular batteries only A Malfunction check using the ABS warning light B Use the Yamaha...

Page 413: ...checks completed normally Finished Yes No A Turn the main switch to ON and check the ABS warning light Fails to come on Comes on The ABS control unit fuse is blown The ABS ECU coupler is disconnected The wire harness is defective The hydraulic unit assembly is defective The connection with the Yamaha diagnostic tool is defective The wire harness is defective Cannot communicate Can communicate B 1 ...

Page 414: ...BS warning light comes on the ABS ECU is defective Replace the hydraulic unit assembly EAS30997 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 8 129 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 13...

Page 415: ...S ECU coupler and blue black terminal of the Yamaha diagnostic tool coupler CANL 4 ABS ECU malfunction Replace the hydraulic unit assembly EAS31136 A 5 ABS ECU AND FI ECU FAIL TO COMMUNICATE 1 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 130 If the battery is defective clean the battery terminals and recharge it or replace the battery 2 Yamaha dia...

Page 416: ...ed or are re ceived intermittently while the vehicle is traveling Foreign material adhered around the front wheel sen sor Incorrect installation of the front wheel Defective sensor rotor or incorrect installation of the rotor Defective front wheel sen sor or incorrect installation of the sensor 12 Rear wheel sensor intermit tent pulses or no pulses Rear wheel sensor signal is not received properly...

Page 417: ... or short circuit in the wire harness between the rear wheel sensor and the hydraulic unit assembly Defective rear wheel sen sor or hydraulic unit as sembly 17 45 Front wheel sensor missing pulses Front wheel sensor signal is not received properly Miss ing pulses are detected in the signal while the vehicle is traveling Foreign material adhered around the front wheel sen sor Incorrect installation...

Page 418: ...r supply circuit Short circuit is detected in the solenoid power supply circuit in the hydraulic unit assembly Defective hydraulic unit as sembly 33 Hydraulic unit assembly ab normal ABS motor power supply Power is not supplied to the motor circuit in the hydraulic unit assembly Blown ABS motor fuse Defective coupler between the battery and the hydrau lic unit assembly Open or short circuit in the...

Page 419: ...or signal is not received properly Miss ing pulses are detected in the signal while the vehicle is traveling Foreign material adhered around the rear wheel sen sor Incorrect installation of the rear wheel Defective sensor rotor or incorrect installation of the rotor Defective rear wheel sen sor or incorrect installation of the sensor 51 52 Vehicle system power sup ply voltage of ABS ECU power supp...

Page 420: ...upply voltage of power supply is low Power voltage supplied from the ABS ECU to the front wheel sensor is too low Short circuit in the wire har ness between the front wheel sensor and the ABS ECU Defective front wheel sen sor Defective ABS ECU 64 Rear wheel sensor power supply voltage of power supply is low Power voltage supplied from the ABS ECU to the rear wheel sensor is too low Short circuit i...

Page 421: ...ensor or incorrect installation of the sensor Check the wheel sensor for damage and the installed condition of the sensor Repair or replace the wheel sensor if necessary Refer to MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR on page 4 14 Fault code No 12 Item Rear wheel sensor intermittent pulses or no pulses Symptom Rear wheel sensor signal is not received properly Pulses are not re ceiv...

Page 422: ...r damage Re place the sensor rotor if there is visible damage Refer to MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR on page 4 14 4 Defective front wheel sensor or incorrect installation of the sensor Check the wheel sensor for damage and the installed condition of the sensor Repair or replace the wheel sensor if necessary Refer to MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR on...

Page 423: ...d the hydraulic unit assembly Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the cou pler securely See TIP 2 Open or short circuit in the wire harness between the front wheel sensor and the hydraulic unit assembly Check for continuity between the black terminal 1 and the black terminal 5 and between t...

Page 424: ...hydraulic unit assembly Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the cou pler securely See TIP 2 Open or short circuit in the wire harness between the rear wheel sensor and the hydraulic unit assembly Check for continuity between the white terminal 1 and the white terminal 4 and between the blac...

Page 425: ...tom Open or short circuit is detected in the rear wheel sensor Order Item components and probable cause Check or maintenance job Fault code No 17 45 Item Front wheel sensor missing pulses Symptom Front wheel sensor signal is not received properly Missing pulses are detected in the signal while the vehicle is traveling Order Item components and probable cause Check or maintenance job 1 Foreign mate...

Page 426: ...nd the installed condition of the sensor Repair or replace the wheel sensor if necessary Refer to MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR on page 4 22 Fault code No 21 Item Hydraulic unit assembly defective solenoid drive circuit Symptom Solenoid drive circuit in the hydraulic unit assembly is open or short circuited Order Item components and probable cause Check or maintenance job 1...

Page 427: ...hicle is travel ing Brake light circuit or front or rear brake light switch circuit Order Item components and probable cause Check or maintenance job Fault code No 31 Item Hydraulic unit assembly abnormal ABS solenoid power supply Symptom Power is not supplied to the solenoid circuit in the hydraulic unit as sembly Order Item components and probable cause Check or maintenance job 1 Blown ABS solen...

Page 428: ...to CHECKING THE FUSES on page 8 130 2 Defective coupler between the battery and the hydraulic unit assembly Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the cou pler securely See TIP 3 Open or short circuit in the wire harness between the battery and the hydraulic unit assembly Replace if there is a...

Page 429: ...ake caliper when the brake lever is operated and that the pressure decreases when the lever is re leased Refer to CHECKING THE FRONT BRAKE DISCS on page 4 30 4 Defective hydraulic unit assembly If the above items were performed and no malfunctions were found replace the hydraulic unit assembly Refer to ABS ANTI LOCK BRAKE SYSTEM on page 4 44 Fault code No 42 47 Item Rear wheel ABS intermittent whe...

Page 430: ...hydraulic pressure Order Item components and probable cause Check or maintenance job Fault code No 43 Item Front wheel sensor missing pulses Symptom Front wheel sensor signal is not received properly Missing pulses are detected in the signal while the vehicle is traveling Order Item components and probable cause Check or maintenance job 1 Foreign material adhered around the front wheel sensor Chec...

Page 431: ...visible damage Refer to MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR on page 4 22 4 Defective rear wheel sensor or incorrect installation of the sensor Check the wheel sensor for damage and the installed condition of the sensor Repair or replace the wheel sensor if necessary Refer to MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR on page 4 22 Fault code No 51 52 Item Vehicle system...

Page 432: ...ARGING SYSTEM on page 8 12 Fault code No 54 Item Hydraulic unit assembly defective ABS solenoid and ABS motor power supply circuits Symptom Abnormality is detected in the solenoid or motor power supply circuit in the hydraulic unit assembly Order Item components and probable cause Check or maintenance job 1 Defective battery Recharge or replace the battery Refer to CHECKING AND CHARGING THE BATTER...

Page 433: ...le cause Check or maintenance job 1 Short circuit in the wire harness between the front wheel sensor and the hydraulic unit assembly Check that there is no short circuit between the white terminal 1 and the black terminal 2 Check that there is no short circuit between the black terminal 3 and the white terminal 1 If there is a short circuit the wire harness is defective Replace the wire harness 4 ...

Page 434: ...tenance job 1 Short circuit in the wire harness between the rear wheel sensor and the hydraulic unit assembly Check that there is no short circuit between the white terminal 1 and the black terminal 2 Check that there is no short circuit between the black terminal 3 and the white terminal 1 If there is a short circuit the wire harness is defective Replace the wire harness 4 ABS ECU 5 Rear wheel se...

Page 435: ...een the meter as sembly and the ABS ECU Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the cou pler securely See TIP 2 Open or short circuit in the wire harness between the meter assembly and the ABS ECU Replace if there is an open or short circuit Between meter assembly coupler and ABS ECU cou pler b...

Page 436: ...ION TESTS on page 4 48 If it does not have reaction force properly the brake hose is not properly routed or connected 4 Delete the fault codes Refer to B 3 DELETING THE FAULT CODES on page 8 125 5 Checking the ABS warning light Refer to CHECKING THE ABS WARNING LIGHT on page 4 51 If the ABS warning light does not turn off the possible causes are following The problem is not solved Open circuit bet...

Page 437: ...n ABS turns on The ABS on off indicator light goes off A Turn the main switch to ON and check the ABS on off indicator light The meter assembly is defective The meter assembly is defective Check if the ABS cancel function operates by pushing the OFF ROAD ABS ON OFF switch on the meter and checking the ABS on off indicator light Start the engine with the ABS turned off the ABS on off indicator ligh...

Page 438: ...2 Intake air temperature sensor 3 Front brake light switch 4 Clutch switch 5 Rectifier regulator 6 Ignition coil 7 Gear position switch 8 Battery 9 Lean angle sensor 10 Fuse box 1 11 Fuse box 2 12 Sidestand switch 13 Rear brake light switch 14 O2 sensor 15 Oil pressure switch 16 Coolant temperature sensor 17 Horn 18 Radiator fan motor ...

Page 439: ...y 2 Intake air pressure sensor 3 Fuel pump 4 Main fuse 5 Starter relay 6 Relay unit diode 7 ECU Engine Control Unit 8 Rear wheel sensor 9 Turn signal hazard relay 10 Radiator fan motor relay 11 Crankshaft position sensor 12 Fuel injector 13 Throttle position sensor 14 Front wheel sensor ...

Page 440: ...I LO R L N ON OFF 1 2 3 4 5 11 10 9 8 7 6 13 12 R W Br L Br R Br Y G G W B W G B W Y R W L W B B L R R B B B R B Y Y Br W L R Dg B Y Ch P W Y R Y B R R W Br L Br R Y Br G G W B L W R B R W Y L R W GB W Y W Y Ch Ch Dg Dg P R Y R Y Br W Br W L R 1 Main switch 2 Engine stop switch 3 Start switch 4 Select switch 5 Front brake light switch 6 Rear brake light switch 7 Clutch switch 8 Hazard switch 9 Tur...

Page 441: ... EAS31006 REPLACING THE ECU engine control unit 1 Turn the main switch to OFF 2 Replace the ECU engine control unit Refer to REMOVING THE ECU engine con trol unit on page 4 3 3 Clean the throttle bodies and reset the ISC Idle speed control learning value Refer to Cleaning the ISC idle speed con trol valve on page 7 10 4 Reset the O2 feedback learning value Use the diagnostic code number 87 Refer t...

Page 442: ...oose connection Connect properly 8 Lubricate Battery terminals 9 Install Rider seat Refer to GENERAL CHASSIS 1 on page 4 1 EAS30553 CHECKING THE RELAYS Check each switch for continuity with the digital circuit tester If the continuity reading is incor rect replace the relay 1 Disconnect the relay from the wire harness 2 Connect the digital circuit tester and battery 12 V to the relay terminal as s...

Page 443: ...ltage Out of specification Replace 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 1 Positive battery terminal R W L W R R L L W L W L Y R W L G B R B Y Sb W Sb R W L W R R...

Page 444: ...r no continuity EAS30795 CHECKING THE RELAY UNIT DIODE 1 Check Relay unit diode Out of specification Replace Turn signal hazard relay output voltage DC 12V Digital circuit tester CD732 90890 03243 Model 88 Multimeter with ta chometer YU A1927 Positive tester probe brown white 1 Negative tester probe Ground Digital circuit tester CD732 90890 03243 Model 88 Multimeter with ta chometer YU A1927 Conti...

Page 445: ... black yellow 1 Negative tester probe sky blue 2 No continuity Positive tester probe sky blue 2 Negative tester probe black yellow 1 Continuity Positive tester probe black red 3 Negative tester probe sky blue 2 No continuity Positive tester probe sky blue 2 Negative tester probe black red 3 Continuity Positive tester probe sky blue white 4 Negative tester probe sky blue 2 No continuity Positive te...

Page 446: ...0560 CHECKING THE CRANKSHAFT POSITION SENSOR 1 Disconnect Crankshaft position sensor coupler from the wire harness 2 Check Crankshaft position sensor resistance Out of specification Replace the crank shaft position sensor a Connect the digital circuit tester to the crankshaft position sensor coupler as shown Digital circuit tester CD732 90890 03243 Model 88 Multimeter with ta chometer YU A1927 Neg...

Page 447: ... 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 lead may burn This check is likely to produce sparks therefore make sure no flammable gas or fluid is in the vicinity b Check the sta...

Page 448: ...ation Replace the fuel pump assembly a Connect the digital circuit tester to the fuel sender terminals as shown Stator coil resistance 0 128 0 192 Ω Digital circuit tester CD732 90890 03243 Model 88 Multimeter with ta chometer YU A1927 Positive tester probe white 1 Negative tester probe white 2 Positive tester probe white 1 Negative tester probe white 3 Positive tester probe white 2 Negative teste...

Page 449: ...ion Replace a Connect the digital circuit tester to the coolant temperature sensor as shown b Immerse the coolant temperature sensor 1 in a container filled with coolant 2 TIP Make sure the coolant temperature sensor ter minals do not get wet c Place a thermometer 3 in the coolant d Heat the coolant or let it cool down to the specified temperatures e Measure the coolant temperature sensor resistan...

Page 450: ... Out of specification Replace the gear posi tion switch Resistance 2 64 6 16 kΩ Digital circuit tester CD732 90890 03243 Model 88 Multimeter with ta chometer YU A1927 Positive tester probe Sensor terminal 1 Negative tester probe Sensor terminal 2 2 1 Digital circuit tester CD732 90890 03243 Model 88 Multimeter with ta chometer YU A1927 Result Neutral position Continuity Positive tester probe sky b...

Page 451: ...el injec tor a Disconnect the fuel injector coupler from the fuel injector b Connect the digital circuit tester to the fuel injector coupler as shown c Measure the fuel injector resistance Resistance 12 0 Ω 20 C 12 0 Ω 68 F Digital circuit tester CD732 90890 03243 Model 88 Multimeter with ta chometer YU A1927 Positive tester probe Fuel injector terminal 1 Negative tester probe Fuel injector termin...

Page 452: ...ELECTRICAL COMPONENTS 8 141 ...

Page 453: ...TIC CODE TABLE 9 1 SELF DIAGNOSTIC FUNCTION TABLE FOR FUEL INJECTION SYSTEM 9 1 SELF DIAGNOSTIC FUNCTION TABLE FOR IMMOBILIZER SYSTEM 9 7 DIAGNOSTIC CODE SENSOR OPERATION TABLE 9 8 DIAGNOSTIC CODE ACTUATOR OPERATION TABLE 9 10 EVENT CODE TABLE 9 12 ...

Page 454: ...es not oper ate O2 feedback is not carried out P0107 P0108 P0107 Intake air pressure sensor ground short circuit detected P0108 Intake air pressure sensor open or power short circuit detected P0107 Low voltage of the intake air pres sure sensor circuit 0 2 V or less P0108 High voltage of the intake air pres sure sensor circuit 4 8 V or more Defective coupler between intake air pressure sensor and ...

Page 455: ...k is not carried out ISC learning is not carried out P0117 P0118 P0117 Coolant tem perature sensor ground short circuit detected P0118 Coolant tem perature sensor open or power short circuit detected P0117 Low voltage of the coolant tem perature sensor circuit 0 2 V or less P0118 High voltage of the coolant tem perature sensor circuit 4 8 V or more Defective coupler between coolant temperature sen...

Page 456: ...ottle open ing Output is restricted ISC feedback is not carried out ISC learning is not carried out P0132 O2 sensor short cir cuit detected power short circuit P0132 High voltage of the O2 sensor cir cuit 4 8 V or more Improperly installed O2 sensor Defective coupler between O2 sensor and ECU Open or short cir cuit in wire harness between O2 sensor and ECU Incorrect fuel pres sure Defective O2 sen...

Page 457: ...C feedback is not carried out ISC learning is not carried out P0500 Front wheel sensor no normal signals are received from the front wheel sen sor Gear position switch open or short circuit is detected Clutch switch open or short circuit is de tected Open or short cir cuit in wire harness between front wheel sensor and ABS ECU Open or short cir cuit in wire harness between ABS ECU and ECU Open or ...

Page 458: ...Defective coupler between ISC unit and ECU Open or short cir cuit in wire harness between ISC unit and ECU Defective ISC step ping motor Malfunction in ECU Engine is difficult to start Engine idling speed is unstable Engine idling speed is high Power is not supplied to the ISC unit ISC learning is not carried out P0560 Charging voltage is abnormal Battery overcharg ing defective rectifi er regulat...

Page 459: ...t to start Engine idling speed is unstable OBD memory value is not correct CO adjustment value for the faulty cylinder 0 default value ISC learning values Default values OBD memory value is initialized P0657 Fuel system voltage incorrect voltage sup plied to the fuel injec tor and fuel pump Open or short cir cuit in wire harness between relay unit and ECU Open circuit in wire harness between batte...

Page 460: ...n angle sen sor circuit 4 8 V or more Open or short cir cuit in wire harness between lean angle sensor and ECU Defective lean an gle sensor Malfunction in ECU Engine cannot be started Engine cannot be started P2195 O2 sensor open cir cuit detected Signal voltage is 0 25 0 53 V Improperly installed O2 sensor Defective coupler between O2 sensor and ECU Open or short cir cuit in wire harness between ...

Page 461: ...r to air temperature When engine is hot Displays current coolant temperature Compare the actually mea sured coolant temperature with the tool display value 07 Front wheel vehicle speed pulses Front wheel speed pulse 0 999 Check that the number in creases when the front wheel is rotated The num ber is cumulative and does not reset each time the wheel is stopped 08 Lean angle sensor Lean angle senso...

Page 462: ...is defective the display al ternates every two seconds to show all the detected cylinder numbers When all cylinder numbers are shown the display re peats the same process 11 Data error for ISC idle speed control learning val ues 12 O2 feedback learning value 13 OBD memory value 67 ISC idle speed control learning condition display ISC idle speed control learning data erasure 00 ISC idle speed contr...

Page 463: ...1 is actuated five times by listen ing for the operating sound 37 Fuel injector 2 Actuates fuel injector 2 five times at one second inter vals The indicator on the Yamaha diagnostic tool screen come on each time the fuel injector is actuated Disconnect the fuel pump coupler Check that fuel injector 2 is actuated five times by listen ing for the operating sound 50 Relay unit Actuates the relay unit...

Page 464: ...opens the valve This operation is performed 3 times and takes approxi mately 6 seconds each time The indicator on the Yamaha diagnostic tool screen come on during the operation Check that the ISC unit is ac tuated three times by listen ing for the operating sound Diagnostic code No Item Actuation Procedure ...

Page 465: ...ber P0122 and P0123 Perform the checks and maintenance jobs for fault code number P0122 and P0123 195 Sidestand switch Brief abnormality de tected in black red in put lead of ECU Same as for fault code number P1601 Perform the checks and maintenance jobs for fault code number P1601 196 Coolant temperature sensor Brief abnormality de tected in coolant tem perature sensor Same as for fault code numb...

Page 466: ...rst Event code number 241 may be indicated even if the system is normal 242 ISC idle speed con trol Correction value re mains at upper limit Correction value re mains at upper limit while the engine is idling Low engine idling speed Clogged throttle body Improperly adjusted throttle cable Improperly adjusted clutch cable Defective fuel injec tion system Dirty or worn spark plug Defective battery D...

Page 467: ...ault code first Event code number 244 may be indicated even if the system is normal 245 Engine stall Engine stall detected Empty fuel tank Improperly adjusted throttle cable Improperly adjusted clutch cable Defective fuel injec tion system Dirty or worn spark plug Defective battery Defective ECU If a fault code is indi cated perform the checks and mainte nance jobs for the fault code first Event c...

Page 468: ...ght 61 High beam indicator light 62 Turn signal indicator light left 63 Turn signal indicator light right 64 ABS warning light 65 Horn 66 Gear position switch 67 Handlebar switch right 68 Front brake light switch 69 Engine stop switch 70 Start switch 71 Select switch 72 Turn signal hazard relay 73 Handlebar switch left 74 Clutch switch 75 Dimmer switch 76 Pass switch 77 Turn signal switch 78 Hazar...

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Page 471: ... B Y Y Br W L R Dg B Y Ch P W Y R Y B R Dg R Y Ch Y Br W L R B Y B R W Y P Br Y B Br Y B B W Y L R W G B B Lg R G R R R R R R W Br L Br L Br R R R R Br L Br W Br Y L R R W L R R W Br R W R G R G R B L R R W R L R W Br R Br L Br L R W R W R W B R W R W Br Y B Br Y B R W R W Br Y Br Y B L L B L R Y R Y Y W Y Ch Dg P Y Y B Br L B R Y B B Y B W B L R Y Ch B Dg B Dg B Ch B Dg Ch P B B B B B B B B Y B B...

Page 472: ...USH ON OFF ON OFF HI PUSH FREE RUN OFF R L N ON OFF LO D C B B Gy Gy B B B B B B B B B B Gy B B B B B B B B Gy Gy Gy Gy Gy Gy B B B B B B L B B B 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 26 26 26 27 28 29 30 31 32 33 34 35 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 55 54 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84...

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