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Yamaha YZF-R1, Service Manual

The Yamaha YZF-R1 is a high-performance sport motorcycle designed to deliver adrenaline-fueled experiences on the road or track. Unlock the full potential of this exceptional machine with the free Owner's Manual, available for download at manualshive.com. Don't miss out on accessing the comprehensive manual that ensures optimal performance and safety.

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FRONT FORK (for YZF-R1M)

4-103

5. Remove:

• Front fork leg

EAS31649

DISASSEMBLING THE FRONT FORK LEGS 
(for YZF-R1M)

The following procedure applies to both of the 
front fork legs.
1. Turn the spring preload adjusting bolt “1” 

counterclockwise until it stops.

TIP

Turn the spring preload adjusting bolt “1” before 
removing the front fork from the vehicle.

2. Remove:

• Cap bolt “1”
• Locknut “2”
• Upper spring seat “3”
• Damper adjusting rod

a. Loosen the cap bolt “1” using the front fork 

cap bolt wrench “4” and then remove it 
from the outer tube.

b. Hold the spring preload adjusting bolt “5” 

and loosen the locknut.

c. Remove the cap bolt, damper adjusting 

rod, upper spring seat and fork spring.

3. Drain:

• Fork  oil

TIP

Separately from the fork oil in the inner tube, fork 
oil is in the inside cartridge of the lower part of 
the inner tube. The fork oil of the cartridge in the 
inner tube cannot be replaced.

4. Remove:

• Outer tube

5. Remove:

• Dust seal
• Oil seal clip “1”

(with a flat-head screwdriver)

• Oil  seal
• Washer

 

Front fork cap bolt wrench 42mm

90890-01575
YM-01575

5

1

1

4

2

3

5

1

Summary of Contents for YZF-R1

Page 1: ...2020 SERVICE MANUAL YZF R1 YZF R1M YZFR1L YZFR1LC YZFR1ML YZF1MLC LIT 11616 33 33 B3L 28197 10 ...

Page 2: ......

Page 3: ...tinually striving to improve all of its models Modifications and sig nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable TIP 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 period...

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 SELF DIAGNOSTIC 9 ...

Page 8: ......

Page 9: ...L INFORMATION IDENTIFICATION 1 1 VEHICLE IDENTIFICATION NUMBER 1 1 MODEL LABEL 1 1 FEATURES 1 2 GLOSSARY 1 2 DISPLAY 1 2 MENU SCREEN 1 6 BASIC SERVICE INFORMATION 1 20 ELECTRICAL SYSTEM 1 20 SPECIAL TOOLS 1 21 ...

Page 10: ... 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 passenger seat This information will be needed to order spare parts 1 1 ...

Page 11: ...ipped models Logging indicator CCU equipped models Clock Revolution peak hold indicator Lap timer Various warning icons Error mode warning Err TIP This model uses a thin film transistor liquid crys tal display TFT LCD for good contrast and readability in various lighting conditions Howev er due to the nature of this technology it is nor mal for a small number of pixels to be inactive STREET MODE T...

Page 12: ...9 has been reached When the fuel tank reserve level has been reached F TRIP appears automatically and begins recording distance traveled from that point After refueling and traveling some distance F TRIP will automatically disappear Refer to Unit on page 1 13 to change the fuel consumption units The air temperature displayed may vary from the actual ambient temperature In TRACK MODE information di...

Page 13: ...k To turn off the traction control system select TCS with the center button then push and hold the up button until TCS OFF is displayed To turn TCS back on select TCS OFF and then press the down button TCS will return to its previous set ting TIP Turning off the traction control system will turn off the SCS LCS and LIF systems for all YRC modes YRC items LCS QS LIF BC The on off status of YRC item...

Page 14: ...ashing long push the wheel switch to activate the lap timer or stop the lap timer 4 When the lap timer has been activated press the Pass LAP switch to start the lap timer TIP The engine must be running to use the lap tim er Set the information display to FASTEST or AV ERAGE for additional lap time information Accessing the MENU screen will automatically stop the lap timer Whenever the lap timer is...

Page 15: ...lay may not function properly and YRC settings may be impossible to change Additionally ABS may not function properly Use extra care when brak ing and check the vehicle immediately EAS31708 MENU SCREEN The MENU screen contains the following setting modules Select a module to make related set ting changes Although some settings can be changed or reset via the main screen the MENU screen offers acce...

Page 16: ...s you to customize the four YRC modes MODE A MODE B MODE C and MODE D by adjusting the setting levels or on off status as applicable of YRC items PWR TCS SCS LCS QSS LIF EBM and BC For YZF R1M you can select the ERS mode to be associated with each YRC mode and also ad just the setting levels of the ERS modes TIP TCS has 9 setting levels and ERS has 6 modes Whenever there are more selections settin...

Page 17: ...YRC mode the LCS indicator on the main screen will appear in a grey color to indicate that LCS is available When the launch control sys tem has been activated made ready for use via the mode switch the LCS indicator will turn white TIP LCS works in conjunction with the LIF system LCS cannot be used if LIF is turned off QSS The quick shift system is divided into QS up shift and QS downshift section...

Page 18: ...or D that you want to adjust 3 Select the YRC item PWR TCS SCS LCS QS QS LIF EBM BC or ERS YZF R1M that you want to adjust TIP When a YRC item is selected the current set ting level is indicated by a blue framed square and the factory preset level is indicated in a grey box Factory preset levels vary depending on the selected YRC mode 4 To customize other YRC modes or adjust in dividual YRC items ...

Page 19: ...amping of the front suspension REAR FIRM hardens H or softens S overall damping of the rear suspension TIP T 1 is preset for track use with racing slick tires T 2 is preset for track use with street tires R 1 is preset for road use with street tires For the manual setting modes M 1 M 2 and M 3 the following settings can be adjusted Fr COM front compression damping Fr REB front rebound damping Rr C...

Page 20: ...ype repeat from step 1 To switch types or when finished select the mark to return to the main YRC Setting menu Lap Time This module allows you to view and delete the lap time record The fastest lap and the average lap time stored in the lap time record are dis played at the top of the screen Use the wheel switch to scroll and see all lap times The top three fastest laps will be highlighted in silv...

Page 21: ... is not installed then the Logging mod ule cannot be selected 2 Select START to start logging TIP The arrow of the logging indicator is displayed in green 3 To stop the Logging function select STOP or turn the vehicle off 1 Fastest lap 2 Average lap time 3 Lap time record MPH 10 00 Reset Display Lap Time LAP 1 LAP 2 LAP 3 LAP 4 FASTEST LAP 12 02 54 56 02 55 20 02 56 04 02 56 80 02 34 56 02 53 00 A...

Page 22: ...units 1 From the MENU screen select Unit 2 Select the distance or consumption unit item you want to adjust TIP When km is selected km L or L 100km can be set as the fuel consumption units To set the fuel consumption units proceed as follows If mile is selected skip step 3 3 Select the units you want to use 4 Select the triangle symbol to exit Wallpaper This module allows you to individually set th...

Page 23: ...tep 2 or select the triangle symbol to exit this module Shift indicator The shift indicator module contains the following modules 1 Photo sensor 1 GP GPS Unit Maintenance Wallpaper Shift Indicator MENU Logging Display Setting MPH 10 00 GP GPS TRACK MODE day STREET MODE night TRACK MODE night Wallpaper STREET MODE day MPH 10 00 Module Description Shift IND Setting Set the shift indicator pattern to...

Page 24: ... The shift timing indicator light has six brightness levels Select Shift IND Brightness then use the wheel switch to adjust the setting Short push the wheel switch to confirm the setting and exit GP GPS Tach IND Setting Shift IND Brightness Peak Rev IND Setting Shift Indicator Shift IND Setting MPH 10 00 1000 r min Shift Indicator MPH GPS 10 00 Shift IND Setting IND Mode IND Start IND Stop ON 1000...

Page 25: ...8000 10000 r min 6 Select Tach IND 2nd 7 Set the orange color starting r min by rotating and then short pushing the wheel switch All r min above this figure until the 14000 r min red zone will be displayed in orange TIP Orange bar start setting range 8000 14000 r min GP GPS Tach IND Setting Shift IND Brightness Peak Rev IND Setting Shift Indicator Shift IND Setting MPH 10 00 1000 r min Shift Indic...

Page 26: ...splayed Shift Indicator MPH GPS 10 00 1000 r min Tach IND Setting IND Mode ON 8000 r min 11000 r min Tach IND 1st Tach IND 2nd GP GPS Tach IND Setting Shift IND Brightness Peak Rev IND Setting Shift Indicator Shift IND Setting MPH 10 00 IND Mode ON Peak Rev IND Setting Shift Indicator MPH GP GPS 10 00 1 Information display item STREET MODE 1 Information display item TRACK MODE 1 2 GPS N LCS QS LIF...

Page 27: ...e general brightness level of the display screen To set the brightness 1 Select Brightness 2 Select the desired brightness level by rotating the wheel switch and then short push the wheel switch to fix the setting Clock This module allows you to set the clock To set the clock 1 From the MENU screen select Clock STREET MODE 1 1 A TEMP C TEMP C TEMP Display Setting DISPLAY 1 MPH GPS 10 00 TRACK MODE...

Page 28: ...ort push the wheel switch 6 Short push the wheel switch again to exit and go back to the MENU screen All Reset This module resets everything except the odometer and clock to its factory preset or de fault setting Select YES to reset all items After selecting YES all items will be reset and the screen will automatically return to the MENU screen Clock MPH 10 00 11 34 Clock MPH 10 00 10 34 Clock MPH...

Page 29: ...nto the washer where con tacting the IMU grommet When installing the IMU use only a genuine bolt and washer and tighten the bolt to the specified torque Pay attention not to expose the IMU to strong shocks such as striking or drop ping it Do not place any foreign objects in and around the battery box Do not obstruct breather opening a of the IMU Do not clean the breather opening and do not blow it...

Page 30: ... to avoid any mistakes TIP For U S A and Canada use part numbers starting with YM YU or ACC For others use part numbers starting with 90890 Tool name Tool No Illustration Reference pages Yamaha diagnostic tool USB US 90890 03269 3 4 4 80 4 81 9 2 9 23 9 24 Yamaha diagnostic tool A I 90890 03264 3 4 4 80 4 81 9 2 9 23 9 24 Thickness gauge 90890 03268 Feeler gauge set YU 26900 9 3 6 3 7 3 7 3 7 4 42...

Page 31: ...pump gauge set 90890 06945 Pressure vacuum tester YB 35956 B 4 30 Wheel bearing ring nut tool 90890 01574 YM 01574 4 46 4 48 Fork spring compressor 90890 01441 Fork spring compressor YM 01441 4 92 4 97 Rod holder 90890 01434 Damper rod holder double ended YM 01434 4 92 4 97 Damper rod holder ø30 90890 01506 Damper rod holder YM 01506 4 93 4 95 Tool name Tool No Illustration Reference pages ø18 ...

Page 32: ...Rod puller attachment M10 90890 01436 Universal damping rod bleeding tool set YM A8703 4 96 4 97 Front fork cap bolt wrench 42mm 90890 01575 YM 01575 4 102 4 103 4 107 Ring nut wrench 90890 01268 Spanner wrench YU 01268 4 110 Ring nut wrench 90890 01507 Ring nut wrench YM 01507 4 122 4 124 Damper rod holder ø22 90890 01365 4 122 4 124 Tool name Tool No Illustration Reference pages YM A8703 YM A870...

Page 33: ...0890 04019 Valve spring compressor YM 04019 5 27 5 30 5 38 5 43 Valve spring compressor attachment ø26 90890 01243 Valve spring compressor adapter 26 mm YM 01253 1 5 38 5 43 Valve guide remover ø4 5 90890 04116 Valve guide remover 4 5 mm YM 04116 5 40 Valve guide remover ø5 90890 04097 Valve guide remover 5 0 mm YM 04097 5 40 Valve guide installer ø4 5 90890 04117 Valve guide installer 4 5 mm YM 0...

Page 34: ...M 04171 5 46 5 47 Crankshaft protector 90890 01382 Crankshaft protector YM 01382 5 46 Flywheel puller 90890 01404 Flywheel puller YM 01404 5 46 Yamaha bond No 1215 90890 85505 Three bond No 1215 5 47 5 74 Sheave holder 90890 01701 Primary clutch holder YS 01880 A 5 49 5 49 Digital circuit tester CD732 90890 03243 Model 88 Multimeter with tachometer YU A1927 5 52 8 41 8 42 8 43 8 44 8 45 8 45 8 46 ...

Page 35: ...ton pin puller set 90890 01304 Piston pin puller YU 01304 5 80 Connecting rod big end bearing installer 90890 04193 Connecting rod big end bearing installer YM 04193 5 83 5 86 Piston pin clip insertion tool 90890 04173 YM 04173 5 88 Piston pin clip installer tool 90890 04174 YM 04174 5 88 Tool name Tool No Illustration Reference pages YU 01304 ø7 ø8 1 ø9 1 ...

Page 36: ...ter pump seal installer ø33 YM 33221 A 6 16 Middle driven shaft bearing driver 90890 04058 Middle drive bearing installer 40 50 mm YM 04058 6 16 Pressure gauge 90890 03153 Pressure gauge YU 03153 7 18 7 18 Fuel injector pressure adapter 90890 03210 Fuel injector pressure adapter YU 03210 7 18 Fuel pressure adapter 90890 03176 Fuel pressure adapter YM 03176 7 18 Tool name Tool No Illustration Refer...

Page 37: ...arness 6P 90890 03266 If you already have Yamaha diagnostic tool A I 90890 03262 YDT sub harness 6P 90890 03266 is separately required Ignition checker 90890 06754 Oppama pet 4000 spark checker YM 34487 8 45 Test harness speed sensor 3P 90890 03208 Test harness speed sensor 3P YU 03208 8 50 Tool name Tool No Illustration Reference pages ...

Page 38: ...SPECIAL TOOLS 1 29 ...

Page 39: ... 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 14 CABLE ROUTING 2 17 ...

Page 40: ... YZFR1MLC_for California Dimensions Overall length 2055 mm 80 9 in Overall width 690 mm 27 2 in Overall height 1165 mm 45 9 in Wheelbase 1405 mm 55 3 in Ground clearance 130 mm 5 12 in Minimum turning radius 3 4 m 11 16 ft Weight Curb weight 203 kg 448 lb YZF R1 204 kg 450 lb YZF R1M Loading Maximum load 185 kg 408 lb YZF R1 184 kg 406 lb YZF R1M Riding capacity 2 person ...

Page 41: ...W 50 Recommended engine oil grade API service SG type or higher JASO standard MA Lubrication system Wet sump Engine oil quantity Oil change 3 90 L 4 12 US qt 3 43 Imp qt With oil filter removal 4 10 L 4 33 US qt 3 61 Imp qt Quantity disassembled 4 90 L 5 18 US qt 4 31 Imp qt Oil filter Oil filter type Cartridge Oil pump Oil pressure 200 0 kPa 5000 r min 2 00 kgf cm 5000 r min 29 0 psi 5000 r min C...

Page 42: ...imit 7 936 mm 0 3124 in Valve valve seat valve guide Valve clearance cold Intake 0 09 0 17 mm 0 0035 0 0067 in Exhaust 0 18 0 23 mm 0 0071 0 0091 in Valve dimensions Valve seat contact width intake 0 90 1 10 mm 0 0354 0 0433 in Limit 1 6 mm 0 06 in Valve seat contact width exhaust 1 10 1 30 mm 0 0433 0 0512 in Limit 1 8 mm 0 07 in Valve stem diameter intake 4 975 4 990 mm 0 1959 0 1965 in Limit 4 ...

Page 43: ...0 mm 0 6689 0 6693 in Limit 16 971 mm 0 6681 in Piston pin to piston pin bore clearance 0 002 0 022 mm 0 0001 0 0009 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 1 15 mm 0 0453 in Ring side clearance 0 020 0 055 mm 0 0008 0 0022 in Side clearance limit 0 115 mm 0 0045 in Co...

Page 44: ...it 2 62 mm 0 103 in Plate quantity 7 pcs Clutch plate 1 thickness 2 46 2 74 mm 0 097 0 108 in Plate quantity 1 pcs Warpage limit 0 10 mm 0 004 in Clutch plate 2 thickness 2 18 2 42 mm 0 086 0 095 in Plate quantity 7 pcs Warpage limit 0 10 mm 0 004 in Plate quantity 1 pcs Warpage limit 0 10 mm 0 004 in Clutch spring free length 47 36 mm 1 86 in Limit 44 99 mm 1 77 in Drivetrain Primary reduction ra...

Page 45: ...a B3L3 20 for California Idling condition Engine idling speed 1200 1400 r min AI system Inactive O2 feedback control Inactive Coolant temperature 90 110 C 194 230 F Intake vacuum 25 5 kPa 191 mmHg 7 5 inHg Difference in vacuum pressure between the cylinders 0 kPa 1 3 kPa 0 mmHg 10 mmHg 0 inHg 0 4 inHg CO 1 0 4 0 Fuel line pressure at idle 300 390 kPa 3 0 3 9 kgf cm 43 5 56 6 psi Air induction syst...

Page 46: ... Tubeless Size 190 55ZR17M C 75W YZF R1 200 55ZR17M C 78W YZF R1M Manufacturer model BRIDGESTONE BATTLAX RACING STREET RS11R Tire air pressure measured on cold tires Front 250 kPa 2 50 kgf cm 36 psi Rear 290 kPa 2 90 kgf cm 42 psi Front brake Type Hydraulic dual disc brake Disc outside diameter thickness 320 0 5 0 mm 12 60 0 20 in Brake disc thickness limit 4 5 mm 0 18 in Brake disc runout limit a...

Page 47: ...y right 470 0 cm 15 89 US oz 16 58 Imp oz YZF R1 263 0 cm 8 89 US oz 9 26 Imp oz YZF R1M Level left 84 mm 3 3 in YZF R1 180 mm 7 1 in YZF R1M Level right 84 mm 3 3 in YZF R1 180 mm 7 1 in YZF R1M Spring preload Adjusting system Mechanical adjustable type Unit for adjustment Turn Adjustment value Soft 0 Adjustment value STD 6 YZF R1 3 YZF R1M Adjustment value Hard 15 Rebound damping Adjusting syste...

Page 48: ...t position STD 12 YZF R1 Adjustment value from the start position Hard 1 YZF R1 Compression damping Adjusting system Mechanical adjustable type YZF R1 Electronically adjustable type YZF R1M Fast compression damping Unit for adjustment Turn YZF R1 Adjustment value from the start position Soft 5 5 YZF R1 Adjustment value from the start position STD 3 YZF R1 Adjustment value from the start position H...

Page 49: ...ator Regulator type Three phase Regulated voltage DC 14 3 14 7 V Battery Model YTZ7S F Voltage capacity 12 V 6 0 Ah 10 HR Bulb wattage Headlight LED Brake tail light LED Front turn signal position light LED Rear turn signal light LED Auxiliary light LED License plate light LED Meter lighting LED Indicator light Neutral indicator light LED Stability control indicator light LED Oil pressure and cool...

Page 50: ...perature sensor resistance 5400 6600 Ω at 0 C 5400 6600 Ω at 32 F Intake air temperature sensor resistance 289 391 Ω at 80 C 289 391 Ω at 176 F Coolant temperature sensor resistance 2513 2777 Ω at 20 C 2513 2777 Ω at 68 F Coolant temperature sensor resistance 210 221 Ω at 100 C 210 221 Ω at 212 F Fuse s Main fuse 50 0 A Headlight fuse 7 5 A Signaling system fuse 7 5 A Ignition fuse 15 0 A Radiator...

Page 51: ...m 2 0 kgf m 15 lb ft Muffler protector bolt M6 1 10 N m 1 0 kgf m 7 4 lb ft EXUP valve pulley cover bolt M6 3 10 N m 1 0 kgf m 7 4 lb ft Spark plug M10 4 13 N m 1 3 kgf m 9 6 lb ft Spark plug new M10 4 18 N m 1 8 kgf m 13 lb ft Cylinder head cover bolt M6 6 10 N m 1 0 kgf m 7 4 lb ft Generator rotor bolt M10 1 85 N m 8 5 kgf m 63 lb ft Generator cover bolt M6 8 See TIP Clutch boss nut M20 1 125 N ...

Page 52: ...ollowing the tightening order 2 Perform the following procedure to all the bolts one by one in the tightening sequence as shown in the illustration a Loosen the bolt b Tighten the bolt to 3 0 N m 0 30 kgf m 2 2 lb ft with a torque wrench c Tighten the bolt further to reach the specified angle 180 2 3 7 1 4 5 6 8 9 10 ...

Page 53: ... 4 pinch bolt 3 and pinch bolt 4 to 21 N m 2 1 kgf m 15 lb ft in this order Item Thread size Q ty Tightening torque Remarks Front wheel axle nut M24 1 115 N m 11 5 kgf m 85 lb ft Front wheel axle pinch bolt M8 4 21 N m 2 1 kgf m 15 lb ft See TIP Rear wheel sprocket nut M10 5 100 N m 10 kgf m 74 lb ft Rear wheel axle nut M24 1 190 N m 19 kgf m 140 lb ft Rear brake caliper bolt front M12 1 27 N m 2 ...

Page 54: ...TIGHTENING TORQUES 2 15 TIP Lower bracket pinch bolt Tighten each bolt to 23 N m 2 3 kgf m 17 lb ft in the order pinch bolt 1 pinch bolt 2 pinch bolt 1 pinch bolt 2 1 2 ...

Page 55: ...TIGHTENING TORQUES 2 16 ...

Page 56: ...CABLE ROUTING 2 17 EAS20021 CABLE ROUTING Handlebar front view A C D E F F G H I J K L N M 1 1 2 3 6 6 2 3 7 8 9 10 11 3 5 12 12 12 5 4 B ...

Page 57: ...off the excess end of the tie to 5 mm 0 2 in or less E To front wheel sensor F Route the clutch cable to the rear of the handlebar switch lead right G Route the handlebar switch lead right to the front of the main switch lead H Route the horn lead to the front of the lower bracket I For YZF R1M J Connect the front fork stepping motor coupler right which is identified by the tape on the lead to the...

Page 58: ...CABLE ROUTING 2 19 Frame front right side view A B C D E F G H I J K L M 1 1 1 2 3 5 5 4 4 4 6 5 7 8 9 ...

Page 59: ... the coolant reservoir For YZF R1M F Cross the coolant reservoir breather hose and clutch cable so that the hose is routed to the outside of the cable G Route the coolant reservoir breather hose along the clutch cable H Fasten the coolant reservoir breather hose at the paint mark to the clutch cable with the holder Route the coolant reservoir breather hose above the clutch cable I Route the front ...

Page 60: ...CABLE ROUTING 2 21 Frame rear right side view B A C D 2 1 2 3 4 5 6 7 ...

Page 61: ...Route the O2 sensor lead over the muffler protector bracket right B Route the rear wheel sensor lead to the outside of the EXUP cables and to the inside of the brake hose C Route the rear brake light switch lead to the outside of the rear wheel sensor lead D Push in the O2 sensor lead from the outside until it is aligned with the mating surface of the clutch cover ...

Page 62: ...ctrical components tray left side view A B C D E E F H I J K O L M N P W W W W X 1 2 3 4 5 6 7 W V W 8 F F E 9 10 11 12 13 14 14 15 16 17 14 G G 30 31 32 30 31 32 30 31 32 33 34 Q R S T U 18 19 20 21 23 22 24 25 26 27 28 29 ...

Page 63: ... D Fasten the right handlebar switch leads left handlebar switch leads and radiator fan motor leads with a plastic locking tie The leads may be fastened in any order Do not fasten the rectifier regulator lead with the plastic locking tie Face the buckle of the plastic locking tie upward and then cut off the excess end of the tie to 5 mm 0 2 in or less E Insert the projection on the coupler complet...

Page 64: ...eft side view A B C D G F E H I J K O N M L P Q 1 2 3 5 5 4 4 5 4 5 6 7 8 9 10 11 10 K K 11 12 12 K 10 K K 11 12 3 14 15 16 17 18 19 20 21 22 K 10 K K K K K K K K 11 12 13 R S T 5 4 8 9 23 23 23 24 24 25 25 N 5 4 K 10 K K 11 12 ...

Page 65: ... with the plastic locking tie Face the buckle of the plastic locking tie upward and then cut off the excess end of the tie to 5 mm 0 2 in or less J Fasten the sidestand switch lead O2 sensor lead left and oil pressure switch lead with the holder Position the holder between the coupler cover and the drive sprocket cover The catch of the holder may be facing in any direction K The leads may be route...

Page 66: ...CABLE ROUTING 2 27 Frame top view A B B C D D E F G H I I J K L M N O P 1 1 2 5 3 4 5 6 8 9 9 8 1 7 8 9 10 11 14 12 13 ...

Page 67: ...hat the edges of the coupler cover are not rolled up G Fasten the intake solenoid vacuum hose with the holders on the wire harness 2 locations H Insert the projection on the wire harness holder into the hole in the side cover bracket from the inside I To front turn signal position light left J Fasten the intake solenoid vacuum hose front turn signal position light lead left and auxiliary light lea...

Page 68: ...CABLE ROUTING 2 29 Frame top view for YZF R1M D A B C I E F G D H 1 2 7 3 4 4 5 6 6 8 9 9 8 6 5 10 10 11 11 12 13 ...

Page 69: ...e front turn signal position light lead right under the intake solenoid lead steering damper solenoid lead and sub wire harness front fork stepping motor C Connect the sub wire harness front fork stepping motor to the sub wire harness SCU steering damper solenoid sub wire harness D To front turn signal position light left E Connect the sub wire harness SCU steering damper solenoid sub wire harness...

Page 70: ...CABLE ROUTING 2 31 Frame top view E F G H O N P 2 2 3 4 5 7 7 7 16 17 17 17 17 18 19 20 23 A C B D 6 8 9 10 11 12 21 13 14 15 1 2 3 4 5 7 16 11 K L 22 M 8 I J ...

Page 71: ...tic locking tie as shown in the illustration Point the end of the plastic locking tie rearward Do not cut off the excess end of the plastic locking tie I Make sure that the end of the atmospheric pressure sensor hose contacts the air filter case duct Point the ends of the hose clamp to the rearward Position the hose clamp 0 4 mm 0 0 2 in from the end of the hose J Make sure that the atmospheric pr...

Page 72: ...CABLE ROUTING 2 33 Frame top view A A B C D E F G H I J K L M 1 2 3 4 5 6 7 8 9 10 11 12 5 6 7 13 14 15 16 17 18 ...

Page 73: ...rear shock absorber assembly stepping motor leads for YZF R1M to the lower portion of the brake hose with a plastic locking tie Position the plastic locking tie between the front of the frame and rear end of the coupler cover Be sure to fasten the plastic locking tie around the protective sleeves of the leads not the leads themselves Face the buckle of the plastic locking tie inward with the end p...

Page 74: ...w A 1 2 5 8 9 10 3 4 6 11 7 B C D E F G H I J L M O Q P S R X V W U 1 2 3 4 4 5 7 10 11 11 20 22 12 13 13 14 14 15 16 15 16 15 16 17 18 18 19 21 21 N 21 29 21 K 20 21 23 24 25 27 26 T 29 30 30 28 30 30 31 32 20 33 34 35 11 12 12 12 22 22 22 ...

Page 75: ...itch lead to the brake hose with a plastic locking tie Point the end of the plastic locking tie downward G Route the rear wheel sensor lead to the outside of the EXUP cables and between the brake hoses H Route the rear shock absorber assembly stepping motor lead to the inside of the brake hose and to the inside of rear brake light switch lead For YZF R1M I Route the rear shock absorber assembly st...

Page 76: ...CABLE ROUTING 2 37 Rear fender left side view A B C D G 1 2 3 4 5 6 7 7 8 8 7 10 10 11 E 2 9 3 3 9 F 3 ...

Page 77: ...ler left and rear turn signal light coupler right may be positioned in any order C Insert the projection on each rear turn signal light lead holder into the hole in the tail brake light bracket The rear turn signal light lead holders may be placed in any order D Make sure that the license plate light lead is not positioned on top of the nut on the mudguard assembly E Fasten the license plate light...

Page 78: ...CABLE ROUTING 2 39 Rear brake hose right side view A B C D E F G H I J K L M N O P 1 1 2 2 3 4 5 5 5 5 5 6 6 6 6 6 6 7 7 7 8 8 8 8 9 9 10 10 10 11 12 13 13 13 13 13 13 13 14 16 15 15 16 17 18 ...

Page 79: ... protector F Position the holder as shown in the illustration G Route the rear wheel sensor lead to the rear of the brake hose hydraulic unit to rear brake caliper H Position the holder 0 10 mm 0 0 39 in from the top edge of the brake hose protector I Fasten the rear wheel sensor lead under the white tape on the lead with the holder J Install the larger diameter side of the holder on the metal fit...

Page 80: ...CABLE ROUTING 2 41 Front brake hose left side view A B B C D E F G H I J K L M N O P 1 1 1 1 1 1 1 2 2 2 2 2 2 3 3 3 3 3 4 4 5 5 5 6 6 6 6 7 7 8 9 9 9 ...

Page 81: ...pers E Fasten the front wheel sensor lead at the white tape with the holder F Install the holder on the shrink tubing portion of the brake hose hydraulic unit to front brake calipers G Install the collar so that the edge of the collar is positioned 1 2 mm 0 04 0 08 in from the end of the projection H 90 I Install the collar so that its slit is positioned within the range shown in the illustration ...

Page 82: ...CABLE ROUTING 2 43 Front brake hose left side view A 1 1 1 1 2 2 2 3 3 3 4 4 4 3 4 ...

Page 83: ...r cylinder to hydraulic unit A Install the brake hose front brake master cylinder to hydraulic unit so that it is on the inside relative to the brake hose hydraulic unit to front brake calipers There is an identifying white paint mark on the upper surface of the pipe of the brake hose front brake master cylinder to hydraulic unit ...

Page 84: ...CABLE ROUTING 2 45 Hydraulic unit assembly top and left side view A B C 1 2 3 3 4 4 5 6 7 7 8 8 9 10 10 11 11 ...

Page 85: ...se joint to hydraulic unit 5 Brake hose rear brake master cylinder to hydraulic unit 6 Brake hose hydraulic unit to rear brake caliper 7 Hydraulic unit 8 Rear frame 9 Hydraulic tray 10 Rear brake hose bracket 11 Brake hose joint A 23 mm 0 91 in B 54 8 C 17 2 mm 0 68 in Install the hydraulic unit brake pipe front brake master cylinder to hydraulic unit and hydraulic unit brake pipe hydraulic unit t...

Page 86: ...CABLE ROUTING 2 47 Fuel tank top and left side view A B 1 2 3 4 5 2 5 ...

Page 87: ...el tank 2 Fuel pump 3 Fuel tank breather hose 4 Fuel tank drain hose 5 Fuel hose 1 fuel tank to fuel hose 2 A Point the end of the hose clamp outward B Install the fuel tank drain hose with its white paint mark facing outward ...

Page 88: ...CABLE ROUTING 2 49 Canister for California A E 1 2 3 4 5 6 B B B C D 7 8 9 10 E F G H E 7 10 11 ...

Page 89: ...nder the fuel tank breather hose fuel tank to canister B Point the ends of the hose clamp in the direction shown in the illustration C Install the fuel tank breather hose fuel tank to canister with its yellow paint mark facing upward D Install the canister with its stamped mark facing upward E To throttle bodies F To fuel tank G Install the fuel tank breather hose fuel tank to canister with its wh...

Page 90: ...CABLE ROUTING 2 51 Air filter case and throttle bodies top and left side view A C B 1 2 3 4 4 5 6 7 8 5 9 10 11 12 6 ...

Page 91: ...rottle body position sensor 8 Intake solenoid vacuum hose 9 Cooling system air bleed hose 10 Fuel hose 3 fuel hose 2 to throttle body 11 Service hose 12 Fuel hose 1 fuel tank to fuel hose 2 A To one way valve intake solenoid B Route the service hose to the under the cooling system air bleed hose C Point the ends of the hose clamp to the right Position the hose clamp 0 5 mm 0 0 2 in from the end of...

Page 92: ...CABLE ROUTING 2 53 Air cut off valve right side view A B C C D E 1 2 2 3 3 3 4 4 5 5 5 6 7 ...

Page 93: ...h its white paint mark facing outward Make sure that the clamp is not installed on the flange of the hose fitting of the air filter case When installing the air induction system hose air filter case to air cut off valve may apply water to the air induction system hose B Point the end of the clamp to the left C Point the end of the clamp upward D Insert the air induction system hose air cut off val...

Page 94: ...CABLE ROUTING 2 55 Air duct left and right side view A B C D E F G H I 1 1 2 2 3 4 5 5 6 7 8 1 2 2 3 4 4 5 6 7 8 ...

Page 95: ...e intake solenoid vacuum hose intake solenoid to air intake duct valve up to the bend in the hose fitting of the air intake duct valve D Install the surge tank hose with its white paint mark facing upward E Position the hose holder 13 mm 0 51 in or less from the end of the one way valve F Install the surge tank hose onto the one way valve making sure that the end of the hose contacts the valve G I...

Page 96: ...CABLE ROUTING 2 57 Radiator left side view A B C D E F G H I J G K L M N O 1 2 2 2 3 3 3 4 5 6 7 8 9 D ...

Page 97: ...diator inlet hose until it contacts the projection on the thermostat assembly D Hose clamp installation details E 2 mm 0 08 in or more F Installed length 20 mm 0 79 in G Make sure not to install the hose clamp on the raised portion of the hose fitting of the thermostat assembly H When installing the thermostat assembly make sure that the projection on the thermostat assembly fits into the slot in ...

Page 98: ...CABLE ROUTING 2 59 Radiator right side view A F B C E H I J K M L N H U R V W X Y T O P Q R S 2 1 2 9 4 5 5 7 6 8 G 3 D ...

Page 99: ...g and toward the bolt Make sure not to install the hose clamp on the raised portion of the hose fitting H Hose clamp installation details I 2 mm 0 08 in or more J Installed length 20 mm 0 79 in K Make sure not to install the hose clamp on the raised portion of the hose fitting L Install the hose clamp cover so that the end of the cover is pointed to the right M Position the yellow paint mark on th...

Page 100: ...CABLE ROUTING 2 61 Muffler top and left side view 1 1 2 3 3 4 5 5 6 6 4 4 5 6 5 6 A ...

Page 101: ...r 2 EXUP valve pulley cover 3 Muffler 4 EXUP servo motor 5 EXUP cable 2 6 EXUP cable 1 A Route EXUP cable 1 and EXUP cable 2 through the guide Route EXUP cable 1 above EXUP cable 2 Align the white paint mark on each cable with the guide ...

Page 102: ...CABLE ROUTING 2 63 CCU top and right side view for YZF R1M A B C D E F G H 1 2 3 2 3 4 5 6 4 5 6 7 7 8 9 9 10 ...

Page 103: ...cking tie B Fasten the CCU and CCU bracket with the band C Connect the CCU coupler sub wire harness to the CCU D Fasten the sub wire harness to the rear frame with the clamp Align the corrugated end of the sub wire harness with end of the clamp E Route the GPS unit lead between the passenger seat cover and the rear cover F Route the GPS unit lead as shown in the illustration G Route the GPS unit l...

Page 104: ...CABLE ROUTING 2 65 ...

Page 105: ...2 CHECKING THE BRAKE OPERATION 3 13 CHECKING THE BRAKE FLUID LEVEL 3 13 ADJUSTING THE FRONT DISC BRAKE 3 14 CHECKING THE FRONT BRAKE PADS 3 14 ADJUSTING THE REAR DISC BRAKE 3 14 CHECKING THE REAR BRAKE PADS 3 15 CHECKING THE FRONT BRAKE HOSES 3 15 CHECKING THE REAR BRAKE HOSE 3 15 BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS 3 16 CHECKING THE WHEELS 3 17 CHECKING THE TIRES 3 17 CHECKING THE WHEEL BEARI...

Page 106: ...R1M 3 27 CHECKING THE CONNECTING ARM AND RELAY ARM 3 28 CHECKING THE ENGINE OIL LEVEL 3 28 CHANGING THE ENGINE OIL 3 29 MEASURING THE ENGINE OIL PRESSURE 3 30 CHECKING THE COOLANT LEVEL 3 31 CHECKING THE COOLING SYSTEM 3 32 CHANGING THE COOLANT 3 32 ADJUSTING THE EXUP CABLES 3 34 CHECKING THE FRONT BRAKE LIGHT SWITCH 3 35 ADJUSTING THE REAR BRAKE LIGHT SWITCH 3 35 CHECKING AND LUBRICATING THE CABL...

Page 107: ......

Page 108: ...r 36 months repeat the maintenance intervals starting from 8000 mi 13000 km or 12 months Items marked with an asterisk require special tools data and technical skills have a Yamaha dealer perform the service No ITEM ROUTINE INITIAL ODOMETER READINGS 600 mi 1000 km or 1 month 4000 mi 7000 km or 6 months 8000 mi 13000 km or 12 months 12000 mi 19000 km or 18 months 16000 mi 25000 km or 24 months 2000...

Page 109: ...ssary Check air pressure Correct if necessary 10 Wheel bearings Check bearings for smooth operation Replace if necessary 11 Swingarm pivot bearings Check operation and for ex cessive play Moderately repack with lithi um soap based grease Every 32000 mi 50000 km 12 Drive chain Check chain slack alignment and condition Adjust and lubricate chain with a special O ring chain lu bricant thoroughly Ever...

Page 110: ... operation and for oil leakage Replace if necessary 23 Shock absorber assembly Check operation and for oil leakage Replace if necessary 24 Rear suspension link pivots Check operation Correct if necessary 25 Engine oil Change warm engine before draining 26 Engine oil filter cartridge Replace 27 Cooling system Check hoses for cracks or damage Replace if necessary Change coolant 28 EXUP system Check ...

Page 111: ...inspection function of the Yamaha 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 Battery cover Refer to GENERAL CHASSIS 1 on page 4 1 EAS30619 CHECKING THE FUEL LINE Primary injector The following procedure applies to all of the fuel drai...

Page 112: ...e spark plug wells with compressed air to prevent it from falling into the cylinders 3 Check Spark plug type Incorrect Change 4 Check Electrode 1 Damage wear Replace the spark plug Insulator 2 Abnormal color Replace the spark plug Normal color is medium to light tan 5 Clean Spark plug with a spark plug cleaner or wire brush 6 Measure Spark plug gap a with a wire thickness gauge Out of specificatio...

Page 113: ... on page 7 1 Air filter case Refer to AIR FILTER CASE on page 7 5 Air cut off valve Refer to AIR INDUCTION SYSTEM on page 7 20 Radiator Refer to RADIATOR on page 6 3 2 Remove Ignition coils Spark plugs Cylinder head cover Cylinder head cover gasket Refer to CAMSHAFTS on page 5 18 3 Remove Timing mark accessing bolt Crankshaft end cover Refer to GENERATOR on page 5 44 4 Measure Valve clearance Out ...

Page 114: ...rance 2 with a thickness gauge j Turn the crankshaft counterclockwise k When piston 4 is at TDC on the compres sion stroke align the TDC mark f on the generator rotor with the generator rotor cover slot b l Measure the valve clearance 4 with a thickness gauge 5 Remove Camshaft TIP Refer to CAMSHAFTS on page 5 18 When removing the timing chain and cam shafts fasten the timing chain with a wire to r...

Page 115: ...thickness is 1 60 mm 0 063 in If the valve pad is marked B30 the pad thickness is 2 30 mm 0 091 in d Calculate the sum of the values obtained in steps b and c to determine the re quired valve pad thickness and the valve pad number Example 1 60 mm 0 063 in 0 03 mm 0 001 in 1 63 mm 0 064 in The valve pad number is A63 e Round off the valve pad number according to the following table and then select ...

Page 116: ...1 Start the engine and let it warm up for several minutes 2 Check Engine idling speed Out of specification Go to next step 3 Check ISC Idle Speed Control learning value 00 or 01 Check the intake system 02 Clean the throttle bodies Refer to CHECKING AND CLEANING THE THROTTLE BODIES on page 7 15 a Connect the Yamaha diagnostic tool Use the diagnostic code number 67 Refer to SELF DIAGNOSTIC FUNC TION...

Page 117: ...n roughly at idle and the throttle bodies may not oper ate properly TIP Turn the bypass air screw using the carburetor angle driver After each step rev the engine two or three times each time for less than a second and check the synchronization again If a bypass air screw was removed turn the screw in fully and be sure to synchronize the throttle bodies If the throttle body synchronization can not...

Page 118: ...ectly 3 Install Fuel tank Refer to FUEL TANK on page 7 1 Rider seat Refer to GENERAL CHASSIS 1 on page 4 1 EAS30625 CHECKING THE EXHAUST SYSTEM 1 Check Exhaust pipe 1 Exhaust chamber 2 Muffler 3 Cracks damage Replace Gasket 4 Exhaust gas leaks Replace 2 Check Tightening torque Exhaust pipe nut 5 Exhaust pipe joint bolt 6 Exhaust chamber bolt 7 Muffler bolt 8 Muffler joint bolt 9 EAS30626 CHECKING ...

Page 119: ...n The air filter needs more frequent service if you are riding in unusually wet or dusty areas 4 Install Air filter element Upper air filter case NOTICE ECA20710 Never operate the engine without the air filter element installed Unfiltered air will cause rapid wear of engine parts and may damage the engine Operating the engine without the air filter element will also affect throttle body synchroniz...

Page 120: ... the front and rear brakes separately and check to see if the brakes are operating properly EAS30632 CHECKING THE BRAKE FLUID LEVEL 1 Stand the vehicle on a level surface TIP Place the vehicle on a maintenance stand Make sure the vehicle is upright 2 Check Brake fluid level Below the minimum level mark Add the specified brake fluid to the proper level WARNING EWA13090 Use only the designated brake...

Page 121: ...the brake system Air in the brake system will consid erably reduce brake performance resulting in loss of control and possibly cause an ac cident Therefore check and if necessary bleed the brake system NOTICE ECA13490 After adjusting the brake lever position make sure there is no brake drag EAS30633 CHECKING THE FRONT BRAKE PADS The following procedure applies to all of the brake pads 1 Operate th...

Page 122: ...G THE FRONT BRAKE HOSES The following procedure applies to all of the brake hoses and brake hose holders 1 Check Brake hose 1 Cracks damage wear Replace 2 Check Brake hose surface Partly blackened surface on the brake hose Replace 3 Check Brake hose holder 2 Loose Tighten the holder bolt 4 Hold the vehicle upright and apply the brake several times 5 Check Brake hose Brake fluid leakage Replace the...

Page 123: ...S a Fill the brake fluid reservoir to the proper level with the specified brake fluid b Install the diaphragm brake fluid reser voir c Connect a clear plastic hose 1 tightly 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 scre...

Page 124: ...ld cause tire damage an accident or an injury NEVER OVERLOAD THE VEHICLE 2 Check Tire surfaces Damage wear Replace the tire WARNING EWA13190 It is dangerous to ride with a worn out tire When the tire tread reaches the wear limit re place the tire immediately WARNING EWA14090 After extensive tests the tires listed below have been approved by Yamaha Motor Co Ltd for this model The front and rear tir...

Page 125: ...llars Refer to INSTALLING THE SWINGARM on page 4 123 EAS31923 DRIVE CHAIN SLACK Checking the drive chain slack WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over NOTICE ECA13550 A drive chain that is too tight will overload the engine and other vital parts and one that is too loose can skip and damage the swing arm or cause an accident Therefore keep the dr...

Page 126: ...se only kerosene to clean the drive chain Wipe the drive chain dry and thoroughly lubricate it with chain lubricant that is suitable for O ring chains Do not use any other lubricants on the drive chain since they may contain solvents that could damage the O rings EAS30645 CHECKING AND ADJUSTING THE STEERING HEAD 1 Stand the vehicle on a level surface WARNING EWA13120 Securely support the vehicle s...

Page 127: ...NG THE STEERING HEAD 1 Lubricate Upper bearing Lower bearing Bearing race EAS31634 CHECKING THE STEERING DAMPER Refer to CHECKING THE STEERING DAMP ER on page 4 111 EAS31186 CHECKING THE CHASSIS FASTENERS Make sure that all nuts bolts and screws are properly tightened Refer to CHASSIS TIGHTENING TORQUES on page 2 14 EAS30804 LUBRICATING THE BRAKE LEVER Lubricate the pivoting point and metal to met...

Page 128: ... several times and check if the front fork rebounds smoothly Rough movement Repair Refer to FRONT FORK for YZF R1 on page 4 89 or refer to FRONT FORK for YZF R1M on page 4 100 EAS30806 ADJUSTING THE FRONT FORK LEGS for YZF R1 The following procedure applies to both of the front fork legs WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over Spring preload WARN...

Page 129: ...licks of a damp ing force adjusting mechanism may not exactly match the above specifications due to small differences in production the actual number of clicks always represents the entire adjusting range To obtain a precise adjustment check the number of clicks and modify the minimum and standard specifications as necessary When turning the damping force adjusting bolt in direction a the 0 click ...

Page 130: ...AS30941 ADJUSTING THE DAMPING FORCE OF THE FRONT FORK LEGS AND REAR SHOCK ABSORBER ASSEMBLY for YZF R1M The ERS consists of three semi active automat ic modes T 1 T 2 and R 1 and three manual setting modes M 1 M 2 and M 3 When an au tomatic mode is selected the SCU will adjust the compression and rebound damping forces Direction a Spring preload is increased suspen sion is harder Direction b Sprin...

Page 131: ...r track use with street tires R 1 is preset for road use with street tires For the manual setting modes M 1 M 2 and M 3 the following settings can be adjusted Fr COM front compression damping Fr REB front rebound damping Rr COM rear compression damping Rr REB rear rebound damping TIP M 1 is preset for track use with racing slick tires M 2 is preset for track use with street tires M 3 is preset for...

Page 132: ... EAS30808 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY Refer to CHECKING THE REAR SHOCK AB SORBER ASSEMBLY on page 4 117 EAS30655 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY for YZF R1 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 Loosen the...

Page 133: ...cks and modify the minimum and standard specifications as necessary When turning the damping force adjusting screw in direction a the 0 click position and the 1 click position may be the same Compression damping for fast compres sion damping NOTICE ECA13590 Never go beyond the maximum or minimum adjustment positions 1 Adjust Compression damping for fast compression damping a Turn the adjusting bol...

Page 134: ...ain a precise adjustment check the number of clicks and modify the minimum and standard specifications as necessary When turning the damping force adjusting screw in direction a the 0 click position and the 1 click position may be the same EAS30942 ADJUSTING THE PRELOAD OF THE REAR SHOCK ABSORBER ASSEMBLY for YZF R1M WARNING EWA13120 Securely support the vehicle so that there is no danger of it fa...

Page 135: ...r to CHECKING THE CONNECTING ARM AND RELAY ARM on page 4 117 EAS30656 CHECKING THE ENGINE OIL LEVEL 1 Stand the vehicle on a level surface TIP Place the vehicle on a maintenance stand Make sure the vehicle is upright 2 Start the engine warm it up for several min utes and then turn it off 3 Check Engine oil level The engine oil level should be between the minimum level mark a and maximum level mark...

Page 136: ...Remove Engine oil filler cap 1 Engine oil drain bolt 2 Gasket 3 4 Drain Engine oil completely from the crankcase 5 If the oil filter cartridge is also to be replaced perform the following procedure a Remove the front side cowling left Refer to GENERAL CHASSIS 5 on page 4 16 b Remove the oil filter cartridge 1 with an oil filter wrench 2 c Lubricate the O ring of the new oil filter cartridge with a...

Page 137: ...to the proper level 2 Remove Front side cowling left 3 Remove Oil pressure switch joint bolt 1 Oil pressure switch joint with the oil pressure switch 2 WARNING EWA12980 The engine muffler and engine oil are ex tremely hot 4 Install Oil pressure gauge joint 18 mm 1 Oil pressure switch joint bolt 2 5 Install Oil pressure gauge 1 Adapter C 2 T R Engine oil drain bolt 23 N m 2 3 kgf m 17 lb ft Engine ...

Page 138: ...be between the maximum level mark a and minimum level mark b Below the minimum level mark Add the recommended coolant to the proper level NOTICE ECA21281 Adding water instead of coolant dilutes the antifreeze concentration of the coolant If water is used instead of coolant check and if necessary correct the antifreeze concentration of the coolant Use only distilled water However if dis tilled wate...

Page 139: ...e do not remove the radiator cap when the en gine is hot Scalding hot fluid and steam may be blown out which could cause serious in jury When the engine has cooled open the radiator cap as follows Place a thick rag or a towel over the radiator cap and slowly turn the radiator cap counter clockwise toward the detent to allow any re sidual pressure to escape When the hissing sound has stopped press ...

Page 140: ...of the coolant Use only distilled water However if dis tilled water is not available soft water may be used If coolant comes into contact with painted surfaces immediately wash them with wa ter Do not mix different types of antifreeze 10 Fill Coolant reservoir with the recommended coolant to the maxi mum level mark a 11 Install Coolant reservoir cap 12 Loosen the water pump air bleed bolt 1 to all...

Page 141: ... 9 11 b Set the start engine stop switch to c Check that the EXUP valve operates prop erly TIP Check that the projection a on the EXUP valve pulley contacts the stopper b fully open posi tion If the projection does not contact the stop per adjust the EXUP cable free play 3 Adjust EXUP cable free play a Turn the main switch to ON b Loosen the locknut 1 c Turn the adjusting nut 2 until the projec ti...

Page 142: ...le to corrode and interfere with its movement Re place damaged outer cable and inner cables as soon as possible 1 Check Outer cable Damage Replace 2 Check Cable operation Rough movement Lubricate TIP Hold the cable end upright and pour a few drops of lubricant into the cable sheath or use a suit able lubricating device EAS30815 CHECKING THE THROTTLE GRIP 1 Check Throttle grip movement Rough moveme...

Page 143: ...t a crosshead screwdriver into the holes a in the headlight cover and turn the adjusting screw a Turn the adjusting screws 1 2 Adjust Headlight beam horizontally TIP To adjust the headlight beam horizontally in sert a crosshead screwdriver into the holes a in the headlight cover and turn the adjusting screw a Turn the adjusting screws 1 a 1 1 a 1 1 ...

Page 144: ...PERIODIC MAINTENANCE 3 37 ...

Page 145: ... COWLING 4 14 INSTALLING THE FRONT UPPER COWLING 4 14 GENERAL CHASSIS 5 4 16 REMOVING THE FRONT MUFFLER PROTECTOR LEFT 4 18 REMOVING THE FRONT MUFFLER PROTECTOR RIGHT 4 18 REMOVING THE FRONT SIDE COWLING LEFT for YZF R1 4 18 REMOVING THE FRONT SIDE COWLING RIGHT for YZF R1 4 19 REMOVING THE FRONT SIDE COWLING LEFT for YZF R1M 4 19 REMOVING THE FRONT SIDE COWLING RIGHT for YZF R1M 4 19 INSTALLING T...

Page 146: ...G THE REAR WHEEL 4 46 CHECKING THE REAR WHEEL 4 47 CHECKING THE REAR WHEEL DRIVE HUB 4 47 CHECKING AND REPLACING THE REAR WHEEL SPROCKET 4 47 CHECKING THE REAR WHEEL SPROCKET BRACKET 4 47 ASSEMBLING THE REAR WHEEL 4 48 MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR 4 49 ADJUSTING THE REAR WHEEL STATIC BALANCE 4 49 INSTALLING THE REAR WHEEL DISC BRAKE 4 49 FRONT BRAKE 4 52 INTRODUCTION 4 57 ...

Page 147: ...ST 4 79 CHECKING THE ABS WARNING LIGHT 4 82 HANDLEBARS 4 83 REMOVING THE HANDLEBARS 4 86 CHECKING THE HANDLEBARS 4 86 INSTALLING THE HANDLEBARS 4 86 FRONT FORK for YZF R1 4 89 REMOVING THE FRONT FORK LEGS for YZF R1 4 92 DISASSEMBLING THE FRONT FORK LEGS for YZF R1 4 92 CHECKING THE FRONT FORK LEGS for YZF R1 4 94 ASSEMBLING THE FRONT FORK LEGS for YZF R1 4 94 INSTALLING THE FRONT FORK LEGS for YZ...

Page 148: ...Y ARM 4 117 ASSEMBLING THE REAR SHOCK ABSORBER ASSEMBLY 4 118 INSTALLING THE RELAY ARM 4 118 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 4 119 SWINGARM 4 120 REMOVING THE SWINGARM 4 122 CHECKING THE SWINGARM 4 122 INSTALLING THE SWINGARM 4 123 CHAIN DRIVE 4 125 REMOVING THE DRIVE CHAIN 4 126 CHECKING THE DRIVE CHAIN 4 126 CHECKING THE DRIVE SPROCKET 4 127 CHECKING THE REAR WHEEL SPROCKET 4 127 CHE...

Page 149: ......

Page 150: ...Rider seat 1 2 Passenger seat 1 3 Battery cover 1 4 Negative battery lead 1 Disconnect 5 Positive battery lead 1 Disconnect 6 Battery 1 7 IMU coupler 1 8 IMU Inertial Measurement Unit 1 1 2 3 4 5 6 7 8 4 4 4 4 4 4 1 5 N m 0 15 kgf m 1 1 lb ft 2 0 N m 0 20 kgf m 1 5 lb ft 7 N m 0 7 kgf m 5 2 lb ft 7 N m 0 7 kgf m 5 2 lb ft ...

Page 151: ...er cover left 1 5 Rear side inner cover right 1 6 Rear side outer cover right 1 7 Tail brake light bracket 1 8 Tail brake light coupler 1 Disconnect 9 Rear turn signal light coupler 2 Disconnect 10 License plate light coupler 1 Disconnect 11 Special washer 1 12 Mudguard assembly 1 13 Rear fender 1 14 Tail brake light 1 1 2 5 7 14 10 9 11 3 9 12 3 6 13 8 3 4 LT 7 N m 0 7 kgf m 5 2 lb ft T R 9 N m 0...

Page 152: ...eft 1 4 Rear side cover right 1 5 Tail brake light bracket 1 6 Tail brake light coupler 1 Disconnect 7 Rear turn signal light coupler 2 Disconnect 8 License plate light coupler 1 Disconnect 9 Special washer 1 10 Mudguard assembly 1 11 Rear fender 1 12 Tail brake light 1 1 2 4 5 12 8 7 9 10 3 3 7 11 6 3 LT 7 N m 0 7 kgf m 5 2 lb ft T R 9 N m 0 9 kgf m 6 6 lb ft T R 9 N m 0 9 kgf m 6 6 lb ft T R 9 N...

Page 153: ...o remove Q ty Remarks 1 Mudguard assembly cover 1 2 Clamp 1 3 Stay 2 4 Rear turn signal light 2 5 Cover 1 6 License plate light 1 7 Rear reflector 1 8 Rear reflector 2 9 Reflector bracket 1 FWD FWD 3 4 5 6 7 4 2 1 8 9 8 3 8 N m 0 38 kgf m 2 8 lb ft 1 8 N m 0 18 kgf m 1 3 lb ft ...

Page 154: ...gle adjustment of the IMU and battery box by pinching the washer and related parts When installing the IMU apply a thin coat of silicone grease onto the washer where con tacting the IMU grommet When installing the IMU use only a genuine bolt and washer and tighten the bolt to the specified torque Pay attention not to expose the IMU to strong shocks such as striking or drop ping it Do not place any...

Page 155: ...overs YZF R1M into the hole b in the rear fender and then tighten the rear side cov er bolts EAS33140 INSTALLING THE TAIL COVER 1 Install Tail cover 1 a Fit the projections a on the tail cover 1 into the holes b in the rear fender and then install the quick fasteners Recommended lubricant Silicone grease T R IMU bolt 2 0 N m 0 20 kgf m 1 5 lb ft T R Rear side cover bolt 9 N m 0 9 kgf m 6 6 lb ft S...

Page 156: ...coupler 1 Disconnect 3 Cushion 1 4 GPS unit 1 5 Tail cover 1 6 CCU coupler sub wire harness 1 Disconnect 7 Band 1 8 CCU Communication Control Unit 1 9 CCU bracket 1 1 10 CCU bracket 2 1 11 Wire harness coupler 1 Disconnect 12 Yamaha diagnostic tool coupler 1 13 Sub wire harness 1 1 1 4 2 3 4 6 7 8 9 10 11 12 13 5 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...

Page 157: ...s network TIP From the Google or Apple application store download the Y TRAC application to make use of the logging data and the YRC Setting appli cation to remotely adjust the YRC settings 1 Connect CCU wireless network a Remove the bolts 1 and then remove the passenger seat cover assembly 2 as shown b Note down the CCU serial number a c Turn the main switch to ON and ap proach the vehicle with a...

Page 158: ...o remove Q ty Remarks 1 Front panel left 1 2 Front panel cover left 1 3 Front panel right 1 For YZF R1 4 Front panel right 1 For YZF R1M 5 Front panel cover right 1 6 Storage compartment 1 3 5 N m 0 35 kgf m 2 6 lb ft T R 3 8 N m 0 38 kgf m 2 8 lb ft T R 3 8 N m 0 38 kgf m 2 8 lb ft T R 3 4 5 6 2 1 ...

Page 159: ... b on the side cover bracket b Unhook the projections c on the front panel cover left from the holes d on the side cover bracket c Unhook the projections e on the front panel cover left from the holes f on the front cowling d Unhook the projections g on the front panel cover left from the holes h on the front upper cowling EAS33346 REMOVING THE FRONT PANEL RIGHT 1 Remove Front panel right 1 a Remo...

Page 160: ... panel cover left into the holes b on the front upper cowling b Insert the projections c on the front panel cover left into the grommets d on the side cover bracket c Fit the projections e on the front panel cover left into the holes f on the front cowling d Fit the projections g on the front panel cover left into the grommets h on the side cover bracket EAS31353 INSTALLING THE FRONT PANEL LEFT 1 ...

Page 161: ...ont cowling d Fit the projections g on the front panel cover right into the grommets h on the side cover right EAS33352 INSTALLING THE FRONT PANEL RIGHT 1 Install Front panel right 1 a Fit the projections a on the front panel right 1 into the holes b in the front pan el cover right Slide the front panel right rearward b Fit the projections c on the front panel right 1 into the holes d in the front...

Page 162: ...ty Remarks Front panel cover Refer to GENERAL CHASSIS 3 on page 4 9 1 Front turn signal position light coupler 2 Disconnect 2 Rearview mirror 2 3 Front upper cowling 1 4 Windshield 1 2 1 3 4 1 2 0 4 N m 0 04 kgf m 0 30 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 7 N m 0 7 kgf m 5 2 lb ft T R ...

Page 163: ...jections a on the front up per cowling from the holes b on the front cowling assembly Unhook the projection c on the front upper cowling from the grommets d in the front cowling assem bly Unhook the projections e on the front upper cowling from the holes f on the front cowling assembly Slide the front up per cowling upward and then unhook the holes g in the front upper cowling from the projections...

Page 164: ...cowling assembly c Install the front upper cowling bolts 2 and then tighten the bolts to specification d Install the rearview mirrors 3 and rear view mirror nuts and then tighten the nuts to specification e Connect the front turn signal position light couplers 4 Fasten the front turn signal position light leads to the holders 5 T R Front upper cowling bolt 4 0 N m 0 40 kgf m 3 0 lb ft T R Rearview...

Page 165: ...fler protector right 1 4 Front side cowling right 1 5 Bottom cowling 1 6 Front side cowling bracket front left 1 7 Front side cowling bracket rear left 1 8 Front side cowling bracket front right 1 9 Front side cowling bracket rear right 1 4 2 3 1 5 7 8 9 6 9 N m 0 9 kgf m 6 6 lb ft T R 9 N m 0 9 kgf m 6 6 lb ft T R 9 N m 0 9 kgf m 6 6 lb ft T R 7 N m 0 7 kgf m 5 2 lb ft T R 7 N m 0 7 kgf m 5 2 lb ...

Page 166: ...er protector right 1 4 Front side cowling right 1 5 Front side cowling bracket front left 1 6 Front side cowling bracket rear left 1 7 Front side cowling bracket front right 1 8 Front side cowling bracket rear right 1 1 4 2 5 6 7 8 3 7 N m 0 7 kgf m 5 2 lb ft T R 9 N m 0 9 kgf m 6 6 lb ft T R 9 N m 0 9 kgf m 6 6 lb ft T R 9 N m 0 9 kgf m 6 6 lb ft T R 7 N m 0 7 kgf m 5 2 lb ft T R ...

Page 167: ...nhook the projections a on the front muffler protector right 1 from the holes b of the front cowling right EAS31696 REMOVING THE FRONT SIDE COWLING LEFT for YZF R1 1 Remove Front side cowling left 1 a Remove the quick fastener screws b Pull the front side cowling left 1 for ward and then unhook the projection a on the front side cowling left 1 from the hole b of the front cowling c Unhook the proj...

Page 168: ...E COWLING LEFT for YZF R1M 1 Remove Front side cowling left 1 a Remove the front side cowling bolts quick fastener screws and quick fasteners b Pull the front side cowling left 1 for ward and then unhook the projection a on the front side cowling left 1 from the hole b of the front cowling c Unhook the projection c on the front side cowling left 1 from the slit d on the front cowling EAS33351 REMO...

Page 169: ...E FRONT SIDE COWLING LEFT for YZF R1 1 Install Front side cowling left 1 a Fit the projection a on the front side cowl ing left 1 into the hole b on the front cowling b Fit the projection c on the front side cowl ing left 1 into the slits d on the front cowling c Fit the projections e on the front side cowling left 1 into the holes f on the bottom cowling d Fit the projections g on the front side ...

Page 170: ... INSTALLING THE FRONT MUFFLER PROTECTOR LEFT 1 Install Front muffler protector left 1 a Fit the projections a on the front muffler protector left 1 into the holes b of the front cowling left b Tighten the front muffler protector bolt EAS33368 INSTALLING THE FRONT MUFFLER PROTECTOR RIGHT 1 Install Front muffler protector right 1 a Fit the projections a on the front muffler protector right 1 into th...

Page 171: ...GENERAL CHASSIS 5 4 22 T R Front muffler protector bolt 7 N m 0 7 kgf m 5 2 lb ft b b a a 1 ...

Page 172: ...S 4 on page 4 13 Front side cowling Refer to GENERAL CHASSIS 5 on page 4 16 1 Side cover left 1 2 Side cover right 1 3 Fuse box 1 4 Front side cowling inner panel right 1 5 Front side cowling inner panel left 1 6 Steering damper solenoid coupler 1 Disconnect 7 Intake solenoid coupler 1 Disconnect 1 3 5 2 7 6 4 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 7 N m 0 7 kgf m 5 2 lb ft...

Page 173: ... 1 Disconnect 11 Sub wire harness coupler 1 Disconnect For YZF R1M 12 Front fork stepping motor coupler 1 Disconnect For YZF R1M 13 Intake solenoid vacuum hose 1 Disconnect 14 Surge tank hose 1 Disconnect 15 Front cowling assembly 1 16 Side cover bracket right 1 17 Damper 1 13 16 17 14 10 11 12 8 9 15 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 7 N m 0 7 kgf m 5 2 lb ft T R 7 N ...

Page 174: ...ight 1 4 SCU coupler 1 Disconnect For YZF R1M 5 SCU cover 1 For YZF R1M 6 SCU Suspension Control Unit 1 For YZF R1M 7 SCU bracket 1 For YZF R1M 8 Auxiliary light left 1 9 Auxiliary light right 1 10 Front cowling assembly stay 1 11 Front cowling 1 1 5 N m 0 15 kgf m 1 1 lb ft T R 1 5 N m 0 15 kgf m 1 1 lb ft T R 5 N m 0 5 kgf m 3 7 lb ft T R 5 N m 0 5 kgf m 3 7 lb ft T R 1 5 N m 0 15 kgf m 1 1 lb f...

Page 175: ...er right 1 downward and remove the hole a of the side cover right 1 from the projection b on the side cover bracket right EAS33356 INSTALLING THE SIDE COVER LEFT 1 Install Side cover left 1 a Fit the projections a on the side cover left into the holes b of the side cover bracket 1 and slide the side cover left forward b Install the side cover bolt left and quick fastener EAS33380 INSTALLING THE SI...

Page 176: ...e on the frame EAS33357 INSTALLING THE SIDE COVER RIGHT 1 Install Side cover right 1 a Fit the hole a in the side cover right 1 onto the projection b on the side cover bracket and slide the side cover right up ward TIP Position the front cowling assembly 2 on the side cover right 1 Make sure that there is projection c on the side cover right 1 in the hole d in the front cowling assembly 2 b Instal...

Page 177: ...GENERAL CHASSIS 5 on page 4 16 Side cover Front cowling assembly Refer to GENERAL CHASSIS 6 on page 4 23 1 Intake solenoid vacuum hose 1 2 Surge tank hose 1 3 One way valve 1 4 Intake solenoid vacuum hose one way valve to intake solenoid 1 5 Intake solenoid vacuum hose intake solenoid to air intake duct valve 1 1 2 3 4 5 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 11 N m 1 1 ...

Page 178: ...enoid bracket 1 8 Intake solenoid 1 9 Air duct 1 10 Surge tank 1 11 Diaphragm 1 12 Air intake duct assembly 1 13 Air intake duct 1 14 Air intake duct guard 1 15 Air intake duct valve 1 9 11 7 8 6 12 13 13 10 15 14 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 11 N m 1 1 kgf m 8 1 lb ft T R 11 N m 1 1 kgf m 8 1 lb ft T R LT LT ...

Page 179: ...ntake solenoid Damage Replace 5 Check Intake solenoid Refer to SELF DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE on page 9 32 6 Check Surge tank Cracks damage Replace EAS33358 ASSEMBLING THE AIR INTAKE DUCT ASSEMBLY 1 Install Air intake duct left Air intake duct right 1 Air intake duct valve 2 Air intake duct guard Rubber damper 3 TIP Install the air intake duct valve within the range of stopper ...

Page 180: ...nstall Air intake duct valve a Hook the end of the shaft a onto the plate 1 as shown b Align the tabs b on the air intake duct valve 2 with the cutouts c in the air in take duct 3 and then turn the air intake duct valve 90 clockwise a b c c 3 c 3 1 2 1 a 1 a c c 2 3 b b 3 2 ...

Page 181: ...t Refer to GENERAL CHASSIS 3 on page 4 9 Front side cowling left Refer to GENERAL CHASSIS 5 on page 4 16 Side cover left Refer to GENERAL CHASSIS 6 on page 4 23 1 ECU cover 1 2 ECU coupler 3 Disconnect 3 ECU Engine Control Unit 1 4 Wire harness holder 1 5 Side cover bracket 1 6 Side cover bracket damper 1 2 1 2 3 6 4 4 5 7 N m 0 7 kgf m 5 2 lb ft T R ...

Page 182: ...ng the portion a of the ECU cou pler move the lock lever b in the direction of the arrow shown to disconnect the coupler EAS31642 INSTALLING THE ECU engine control unit 1 Connect ECU coupler 1 TIP Connect the ECU coupler and then push the lock lever a of the coupler in the direction of the arrow shown 1 b a 1 a ...

Page 183: ...ERAL CHASSIS 5 on page 4 16 Side cover left Front side cowling inner panel left Refer to GENERAL CHASSIS 6 on page 4 23 1 Radiator fan motor coupler 2 Disconnect 2 Handlebar switch coupler right 4 Disconnect 3 Handlebar switch coupler left 2 Disconnect 4 Rectifier regulator coupler 1 Disconnect 5 Electrical components tray 1 6 Rectifier regulator 1 6 5 1 3 2 3 2 4 2 7 N m 0 7 kgf m 5 2 lb ft T R 7...

Page 184: ... 2 6 Wheel axle pinch bolt 4 Loosen 7 Front wheel axle nut 1 8 Front wheel axle 1 9 Front wheel 1 10 Collar 2 11 Front brake disc 2 12 Plate 2 1 2 3 4 5 6 7 8 9 10 11 12 11 12 10 6 1 2 3 5 7 N m 0 7 kgf m 5 2 lb ft 6 N m 0 6 kgf m 4 4 lb ft 6 N m 0 6 kgf m 4 4 lb ft 17 N m 1 7 kgf m 13 lb ft 35 N m 3 5 kgf m 26 lb ft 115 N m 11 5 kgf m 85 lb ft 21 N m 2 1 kgf m 15 lb ft 2 5 N m 0 25 kgf m 1 8 lb f...

Page 185: ...liper 2 7 Wheel axle pinch bolt 4 Loosen 8 Front wheel axle nut 1 9 Front wheel axle 1 10 Front wheel 1 11 Collar 2 12 Front brake disc 2 13 Plate 2 1 2 3 4 5 9 11 11 12 10 6 6 1 2 3 8 13 12 13 7 7 7 N m 0 7 kgf m 5 2 lb ft 6 N m 0 6 kgf m 4 4 lb ft 6 N m 0 6 kgf m 4 4 lb ft 21 N m 2 1 kgf m 15 lb ft 17 N m 1 7 kgf m 13 lb ft 35 N m 3 5 kgf m 26 lb ft 115 N m 11 5 kgf m 85 lb ft 2 5 N m 0 25 kgf m...

Page 186: ...WHEEL 4 37 Disassembling the front wheel Order Job Parts to remove Q ty Remarks 1 Front wheel sensor rotor 1 2 Oil seal 2 3 Wheel ring 1 4 Wheel bearing 2 5 Spacer 1 LT 8 N m 0 8 kgf m 5 9 lb ft 1 2 2 3 4 4 5 ...

Page 187: ...Place the vehicle on a maintenance stand so that the front wheel is elevated 4 Loosen Wheel axle pinch bolt 5 Remove Front wheel axle Front wheel EAS30146 DISASSEMBLING THE FRONT WHEEL NOTICE ECA21340 Do not drop the wheel sensor rotor or sub ject it to shocks If any solvent gets on the wheel sensor ro tor wipe it off immediately 1 Remove Oil seals Wheel bearings a Clean the surface of the front w...

Page 188: ...ll the new wheel bearing left side TIP Place a suitable washer 1 between the socket 2 and the bearing so that both the inner race 3 and outer race 4 are pressed at the same time and then press the bearing until the inner race makes contact with the spacer 5 d Install the new oil seals 2 Install Front wheel sensor rotor NOTICE ECA17200 Replace the wheel sensor rotor bolts with new ones TIP Install ...

Page 189: ...r rotor runout Out of specification Clean the installation surface of the wheel sensor rotor and correct the wheel sensor rotor runout or replace the wheel sensor rotor a Hold the dial gauge at a right angle against the wheel sensor rotor surface b Measure the wheel sensor rotor runout c If the runout is above specification re move the sensor rotor from the wheel ro tate it by two or three bolt ho...

Page 190: ...xle pinch bolt a Tighten the pinch bolt 2 pinch bolt 1 and pinch bolt 2 to the specified torque in this order b Check that the right end a of the front axle is flush with the front fork b If nec essary manually push the front axle or lightly tap it with a soft hammer until its end is flush with the front fork However if the surface of the front axle end is not parallel to the surface of the front ...

Page 191: ...n caused by an impact during ser vice and caught foreign materials If there is any defective part repair or replace the de fective part TIP Measure the distance between the front wheel sensor rotor and front wheel sensor in several places in one rotation of the front wheel Do not turn the front wheel while the thickness gauge is installed This may damage the front wheel sen sor rotor and the front...

Page 192: ...ensor protector 1 2 Rear wheel sensor 1 3 Locknut 2 Loosen 4 Adjusting bolt 2 Loosen 5 Rear wheel axle nut 1 6 Washer 1 7 Rear wheel axle 1 8 Adjusting block left 1 9 Adjusting block right 1 10 Rear wheel 1 11 Brake caliper bracket 1 1 2 3 4 5 6 7 8 9 11 10 3 4 7 N m 0 7 kgf m 5 2 lb ft 190 N m 19 kgf m 140 lb ft 16 N m 1 6 kgf m 12 lb ft 16 N m 1 6 kgf m 12 lb ft ...

Page 193: ...cket bracket 1 5 Rear wheel sprocket 1 6 Collar 1 7 Collar 1 8 Oil seal 1 9 Bearing 1 10 Rear wheel drive hub 1 1 11 Rear wheel drive hub damper 5 12 Rear wheel drive hub 2 1 13 Gasket 5 14 Rear wheel 1 8 N m 0 8 kgf m 5 9 lb ft 28 N m 2 8 kgf m 21 lb ft 100 N m 10 kgf m 74 lb ft 105 N m 10 5 kgf m 77 lb ft 30 N m 3 0 kgf m 22 lb ft T R LT LT LT LT 1 2 3 5 6 7 8 9 10 11 12 13 14 5 5 5 5 4 5 ...

Page 194: ...assembling the rear wheel Order Job Parts to remove Q ty Remarks 1 Collar 1 2 Oil seal 1 3 Wheel bearing 1 4 Spacer 1 5 Oil seal 1 6 Wheel bearing ring nut 1 7 Wheel bearing 1 LT LT 80 N m 8 0 kgf m 59 lb ft 5 6 7 2 1 3 4 ...

Page 195: ... brake pedal when re moving the brake caliper Be sure not to contact the sensor electrode to any metal part when removing the rear wheel sensor from the rear brake caliper bracket 3 Loosen Locknuts Adjusting bolts 4 Remove Rear wheel axle nut Washer Rear wheel axle Rear wheel Brake caliper bracket NOTICE ECA21400 Be sure to remove the rear wheel sensor be fore removing the brake caliper bracket ot...

Page 196: ...PROCKET 1 Check Rear wheel sprocket More than 1 4 tooth a wear Replace the drive sprocket the rear wheel sprocket and the drive chain as a set Bent teeth Replace the drive sprocket the rear wheel sprocket and the drive chain as a set 2 Replace Rear wheel sprocket a Remove the rear wheel sprocket nuts rear wheel sprocket bracket and the rear wheel sprocket b Clean the rear wheel drive hub with a cl...

Page 197: ...the two symmetric places on the circumference of the threads of the wheel bearing ring nut 3 Tighten Wheel bearing ring nut 1 TIP Use the wheel bearing ring nut tool 2 to tighten the wheel bearing ring nut by turning it counter clockwise a 4 Apply Sealant TIP Apply Three Bond No 1215B between the wheel bearing ring nut and the wheel surface a Width two grooves of the threaded portion b Length more...

Page 198: ...JUSTING THE REAR WHEEL STATIC BALANCE TIP After replacing the tire wheel or both the rear wheel static balance should be adjusted Adjust the rear wheel static balance with the brake disc and rear wheel drive hub installed Be sure to use stick on type balancing weights 1 Adjust Rear wheel static balance Refer to ADJUSTING THE FRONT WHEEL STATIC BALANCE on page 4 40 EAS30165 INSTALLING THE REAR WHEE...

Page 199: ...no clearance a between the adjust ing block 1 and adjusting bolt 2 7 Install Rear wheel sensor Rear wheel sensor protector NOTICE ECA21080 Make sure there are no foreign materials in the rear wheel sensor rotor and rear wheel sensor Foreign materials cause damage to the rear wheel sensor rotor and rear wheel sensor TIP When installing the rear wheel sensor check the rear wheel sensor lead for twis...

Page 200: ...used by an impact during ser vice and caught foreign materials If there is any defective part repair or replace the de fective part TIP Measure the distance between the rear wheel sensor rotor and rear wheel sensor in several places in one rotation of the rear wheel Do not turn the rear wheel while the thickness gauge is installed This may damage the rear wheel sen sor rotor and the rear wheel sen...

Page 201: ...es to both of the front brake calipers 1 Brake pad clip 2 2 Brake pad pin 1 3 Brake pad spring 1 4 Brake pad 2 5 Reflector 1 6 Front brake hose holder 1 7 Front brake caliper 1 8 Bleed screw 1 9 Bleed screw 1 Right brake caliper side 3 4 7 8 9 2 1 5 6 5 N m 0 5 kgf m 3 7 lb ft 6 N m 0 6 kgf m 4 4 lb ft 35 N m 3 5 kgf m 26 lb ft FWD FWD ...

Page 202: ...voir 1 6 Brake fluid reservoir hose 1 7 Brake lever 1 8 Front brake light switch lead connector 2 Disconnect 9 Brake hose union bolt 1 10 Brake hose gasket 2 11 Brake hose 1 12 Front brake master cylinder holder 1 13 Front brake master cylinder 1 14 Front brake light switch 1 FWD FWD S 1 2 3 4 5 6 7 8 9 10 11 12 13 14 2 5 N m 0 25 kgf m 1 8 lb ft 1 0 N m 0 10 kgf m 0 73 lb ft 3 5 N m 0 35 kgf m 2 ...

Page 203: ...54 Disassembling the front brake master cylinder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder kit 1 2 Bleed screw 1 3 Cap 1 4 Brake master cylinder body 1 BF BF S 5 N m 0 5 kgf m 3 7 lb ft 1 2 3 4 1 ...

Page 204: ...f the front brake calipers Brake fluid Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS on page 3 16 1 Reflector 1 2 Front brake hose holder 1 3 Brake hose union bolt 1 4 Brake hose gasket 2 5 Brake hose 1 6 Front brake caliper 1 3 4 5 6 1 2 6 N m 0 6 kgf m 4 4 lb ft 35 N m 3 5 kgf m 26 lb ft 32 N m 3 2 kgf m 24 lb ft FWD FWD ...

Page 205: ...o both of the front brake calipers 1 Brake pad clip 2 2 Brake pad pin 1 3 Brake pad spring 1 4 Brake pad 2 5 Brake caliper piston 4 6 Brake caliper piston dust seal 4 7 Brake caliper piston seal 4 8 Bleed screw 1 9 Bleed screw 1 Right brake caliper side FWD FWD BF BF S S 9 3 8 4 7 5 6 7 6 6 7 5 6 7 2 1 5 N m 0 5 kgf m 3 7 lb ft ...

Page 206: ...sc a Place the vehicle on a maintenance stand so that the front wheel is elevated b Remove the brake caliper c Hold the dial gauge at a right angle against the brake disc surface d Measure the runout 1 5 mm 0 06 in be low 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 runout a...

Page 207: ...w and push the brake caliper pistons into the brake caliper with your finger c Tighten the bleed screw d Install the brake pads and brake pad spring TIP The arrow mark a on the brake pad spring must point in the direction of disc rotation 6 Install Brake pad pin Brake pad clips Front brake caliper 7 Check Brake fluid level Below the minimum level mark Add the specified brake fluid to the proper le...

Page 208: ...e out the right side pistons from the brake caliper EAS30173 CHECKING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers 1 Check Brake caliper pistons Rust scratches wear Replace the brake caliper pistons Brake caliper cylinders Scratches wear Replace the brake caliper assembly Brake caliper body Cracks damage Replace the brake caliper assembly Brake fluid deliv...

Page 209: ... brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake performance When refilling be careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock NOTICE ECA13540 Brake fluid may damage pa...

Page 210: ... ASSEMBLING THE FRONT BRAKE MASTER CYLINDER WARNING EWA13520 Before installation all internal brake com ponents should be cleaned and lubricated with clean or new brake fluid Never use solvents on internal brake com ponents EAS30182 INSTALLING THE FRONT BRAKE MASTER CYLINDER 1 Install Front brake master cylinder Front brake master cylinder holder TIP Install the front brake master cylinder holder ...

Page 211: ...g 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 parts Therefore always clean up any spilt brake fluid immediately 4 Bleed Brake system Refer to BLEEDING THE HYDRAULIC ...

Page 212: ...g 1 2 Brake pad retaining bolt 1 3 Rear brake caliper 1 4 Brake pad 2 5 Brake pad shim 2 6 Brake pad insulator 2 7 Brake pad spring 1 8 Bleed screw 1 FWD FWD S LT 4 6 6 5 5 7 1 2 3 8 2 5 N m 0 25 kgf m 1 8 lb ft 5 N m 0 5 kgf m 3 7 lb ft 12 N m 1 2 kgf m 8 9 lb ft 17 N m 1 7 kgf m 13 lb ft 27 N m 2 7 kgf m 20 lb ft ...

Page 213: ...3 16 1 Brake fluid reservoir cap 1 2 Brake fluid reservoir diaphragm holder 1 3 Brake fluid reservoir diaphragm 1 4 Brake fluid reservoir 1 5 Brake fluid reservoir bracket 1 6 Brake fluid reservoir hose 1 7 Brake hose union bolt 1 8 Brake hose gasket 2 9 Brake hose 1 FWD FWD 8 1 2 3 4 5 6 7 9 3 8 N m 0 38 kgf m 2 8 lb ft 1 5 N m 0 15 kgf m 1 1 lb ft 7 N m 0 7 kgf m 5 2 lb ft 13 N m 1 3 kgf m 9 6 l...

Page 214: ...er cylinder assembly 1 Do not disassemble the rear brake master cylinder assembly 13 Rear brake light switch coupler 1 Disconnect 14 Rear brake light switch 1 FWD FWD 10 11 12 13 14 3 8 N m 0 38 kgf m 2 8 lb ft 1 5 N m 0 15 kgf m 1 1 lb ft 7 N m 0 7 kgf m 5 2 lb ft 13 N m 1 3 kgf m 9 6 lb ft 32 N m 3 2 kgf m 24 lb ft 4 4 N m 0 44 kgf m 3 2 lb ft T R ...

Page 215: ... ty Remarks Brake fluid Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS on page 3 16 1 Brake hose union bolt 1 2 Brake hose gasket 2 3 Brake hose 1 4 Rear brake caliper 1 FWD FWD S LT 12 N m 1 2 kgf m 8 9 lb ft 27 N m 2 7 kgf m 20 lb ft 32 N m 3 2 kgf m 24 lb ft 3 4 1 2 ...

Page 216: ...t 1 3 Brake pad 2 4 Brake pad shim 2 5 Brake pad insulator 2 6 Brake pad spring 1 7 Brake caliper piston 1 8 Brake caliper piston dust seal 1 9 Brake caliper piston seal 1 10 Bleed screw 1 11 Caliper bolt boot 1 FWD FWD S BF 1 2 6 7 8 9 10 11 3 5 5 4 4 2 5 N m 0 25 kgf m 1 8 lb ft 5 N m 0 5 kgf m 3 7 lb ft 17 N m 1 7 kgf m 13 lb ft ...

Page 217: ... Refer to CHECKING THE FRONT BRAKE DISCS on page 4 57 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 57 4 Adjust Brake disc runout Refer to CHECKING THE FRONT BRAKE DISCS on page 4 57 EAS30185 REPLACING THE REAR BRAKE PADS TIP When replacing the brake pads it is not neces s...

Page 218: ...ake pedal operation Soft or spongy feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS on page 3 16 EAS30186 REMOVING THE REAR BRAKE CALIPER TIP Before disassembling the brake caliper drain the brake fluid from the entire brake system 1 Remove Brake hose union bolt Brake hose gaskets Brake hose TIP Put the end of the brake hose into a container and pump out the brake f...

Page 219: ...WARNING EWA17080 Before installation all internal brake com ponents should be cleaned and lubricated with clean or new brake fluid Never use solvents on internal brake com ponents as they will cause the brake caliper piston dust seal and brake caliper piston seal to swell and distort Whenever a brake caliper is disassembled replace the brake caliper piston dust seal and brake caliper piston seal E...

Page 220: ...OTICE ECA13540 Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 5 Bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS on page 3 16 6 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 13 7 Check Brake pedal operat...

Page 221: ...touches the projection a as shown 2 Fill Brake fluid reservoir with the specified amount of the specified brake fluid WARNING EWA13090 Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical r...

Page 222: ...REAR BRAKE 4 73 6 Adjust Rear brake light operation timing Refer to ADJUSTING THE REAR BRAKE LIGHT SWITCH on page 3 35 ...

Page 223: ...HYDRAULIC BRAKE SYSTEM ABS on page 3 16 1 Fuel tank bracket 1 2 Fuse box 1 1 3 Radiator fan motor relay 1 4 Rear wheel sensor coupler 1 5 ABS ECU coupler 1 Disconnect 6 Rear brake hose bracket 1 7 Hydraulic unit brake pipe hydraulic unit to rear brake caliper 1 New 1 2 5 3 4 7 6 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 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...

Page 224: ...e light switch lead 1 12 Rear wheel sensor lead 1 13 Brake hose union bolt 2 14 Gasket 4 15 Brake hose hydraulic unit to front brake cali pers 1 16 Brake hose front brake master cylinder to hy draulic unit 1 17 Brake hose joint 1 18 Hydraulic unit tray 1 19 Hydraulic unit assembly 1 18 19 9 8 10 12 11 17 13 13 15 16 LT 14 New 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 kg...

Page 225: ...2 Hydraulic unit assembly 3 Fuse box 1 4 ABS solenoid fuse 5 YDT coupler 6 Starter relay 7 ABS motor fuse 8 Rear brake caliper 9 Rear wheel sensor rotor 10 Rear wheel sensor 11 Front brake caliper left 12 Front wheel sensor 13 Front wheel sensor rotor 14 Front brake caliper right 15 Fuse box 2 16 Signaling system fuse ...

Page 226: ... removed be sure to tighten them to the specified torque and bleed the brake system 1 Disconnect ABS ECU coupler 1 TIP While pushing the portion a of the ABS ECU coupler pull the lock lever up to release the lock NOTICE ECA20080 Do not use a tool to disconnect the ABS ECU coupler 2 Remove Brake hoses Brake pipes TIP Do not operate the brake lever and brake pedal while removing the brake hoses and ...

Page 227: ...c unit as sembly a Install the hydraulic unit assembly 1 on the hydraulic unit tray 2 b Temporarily tighten the hydraulic unit as sembly bolts 3 4 c Tighten the hydraulic unit assembly bolt 3 and bolt 4 to the specified torque in this order 2 Remove Rubber plugs or bolts M10 1 0 3 Install Hydraulic unit brake pipe 4 Tighten Hydraulic unit brake pipe flare nuts NOTICE ECA19820 If the brake pipe fla...

Page 228: ...ediately 8 Bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS on page 3 16 9 Check the operation of the hydraulic unit ac cording to the brake lever and the brake ped al response Refer to HYDRAULIC UNIT OPERATION TEST on page 4 79 NOTICE ECA14770 Always check the operation of the hydraulic unit according to the brake lever and the brake pedal response 10 Delete the DTC Refer to SE...

Page 229: ...P 90890 03266 is separately required Refer to YDT on page 9 2 6 Start the Yamaha diagnostic tool and display the diagnosis of function screen 7 Select code No 2 Brake line routing confir mation 8 Click Actuator Check and then operate the brake lever 1 and brake pedal 2 simulta neously TIP The hydraulic unit operates 1 second after the brake lever and brake pedal are operated si multaneously and co...

Page 230: ... 12 8 V Charge or replace the battery TIP If the battery voltage is lower than 12 8 V charge the battery and then perform ABS reaction force confirmation 5 Removing the protective cap and then con nect the Yamaha diagnostic tool to the Yamaha diagnostic tool coupler 6P TIP Yamaha diagnostic tool A I 90890 03264 in cludes YDT sub harness 6P 90890 03266 If you already have Yamaha diagnostic tool A I...

Page 231: ...TICE ECA17371 Check that the pulse is felt in the brake le ver brake pedal and again in the brake le ver in this order If the pulse is felt in the brake pedal before it is felt in the brake lever check that the brake hoses and brake pipes are connected correctly to the hydraulic unit assembly If the pulse is hardly felt in either the brake lever or brake pedal check that the brake hoses and brake ...

Page 232: ...Refer to FUEL TANK on page 7 1 Air filter case Refer to AIR FILTER CASE on page 7 5 1 Grip end left 1 2 Handlebar grip 1 3 Clutch switch connector 2 Disconnect 4 Clutch switch 1 2 3 1 4 LS LS 1 2 N m 0 12 kgf m 0 88 lb ft T R 2 5 N m 0 25 kgf m 1 8 lb ft T R 3 5 N m 0 35 kgf m 2 6 lb ft T R 3 5 N m 0 35 kgf m 2 6 lb ft T R 3 8 N m 0 38 kgf m 2 8 lb ft T R 3 8 N m 0 38 kgf m 2 8 lb ft T R 7 N m 0 7...

Page 233: ...t 1 14 Front brake master cylinder holder 1 15 Front brake master cylinder assembly 1 16 Grip end right 1 16 13 14 10 6 7 6 7 9 8 8 15 11 12 5 5 LS LS 1 2 N m 0 12 kgf m 0 88 lb ft T R 2 5 N m 0 25 kgf m 1 8 lb ft T R 3 5 N m 0 35 kgf m 2 6 lb ft T R 3 5 N m 0 35 kgf m 2 6 lb ft T R 3 8 N m 0 38 kgf m 2 8 lb ft T R 3 8 N m 0 38 kgf m 2 8 lb ft T R 7 N m 0 7 kgf m 5 2 lb ft T R 7 N m 0 7 kgf m 5 2 ...

Page 234: ...ket 1 24 Handlebar left 1 25 Handlebar right 1 19 18 18 20 20 24 22 23 25 21 21 21 17 17 17 LS LS 1 2 N m 0 12 kgf m 0 88 lb ft T R 2 5 N m 0 25 kgf m 1 8 lb ft T R 3 5 N m 0 35 kgf m 2 6 lb ft T R 3 5 N m 0 35 kgf m 2 6 lb ft T R 3 8 N m 0 38 kgf m 2 8 lb ft T R 3 8 N m 0 38 kgf m 2 8 lb ft T R 7 N m 0 7 kgf m 5 2 lb ft T R 7 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 16 N m 1 6 k...

Page 235: ...andlebar left Handlebar right Upper bracket 3 Install Main switch cover 1 TIP Pass the main switch cover 1 between the projection a of the upper bracket and main switch b and hook the hook on one end of the main switch cover into the hole on the other end Make sure that the main switch cover 1 cov ers the main switch bolt head c The main switch cover may be facing in any di rection 4 Install Handl...

Page 236: ...the grip end 5 Install Front brake master cylinder assembly Refer to INSTALLING THE FRONT BRAKE MASTER CYLINDER on page 4 61 6 Install Clutch lever holder 1 Clutch cable TIP Align the center of slit on the clutch lever holder with the punch mark a on the handlebar 7 Install Handlebar switch screw left TIP Align the projection a on the handlebar switch left with the hole b in the handlebar 2 1 b a ...

Page 237: ...r adhesive with a clean rag WARNING EWA13700 Do not touch the handlebar grip until the rub ber adhesive has fully dried TIP There should be 1 3 mm 0 04 0 12 in of clear ance a between the handlebar grip and the grip end 9 Adjust Clutch lever free play Refer to ADJUSTING THE CLUTCH LEVER FREE PLAY on page 3 12 T R Grip end bolt 3 8 N m 0 38 kgf m 2 8 lb ft Clutch lever free play 10 0 15 0 mm 0 39 0...

Page 238: ...er to FRONT WHEEL on page 4 35 Front panel cover Refer to GENERAL CHASSIS 3 on page 4 9 1 Front fender 1 2 Upper bracket pinch bolt 1 Loosen 3 Handlebar pinch bolt 1 Loosen 4 Handlebar bolt 1 Loosen 5 Cap bolt 1 Loosen 6 Lower bracket pinch bolt 2 Loosen 7 Front fork leg 1 1 2 3 4 5 6 7 7 N m 0 7 kgf m 5 2 lb ft 6 N m 0 6 kgf m 4 4 lb ft 32 N m 3 2 kgf m 24 lb ft 26 N m 2 6 kgf m 19 lb ft 23 N m 2...

Page 239: ...nt fork legs 1 Cap bolt 1 2 O ring 1 3 Guide 1 4 Spacer 1 5 Fork spring 1 6 Locknut 1 7 Damper adjusting rod 1 1 8 Damper adjusting rod 2 1 9 Dust seal 1 10 Oil seal clip 1 11 Outer tube 1 12 Oil seal 1 13 Washer 1 14 Outer tube bushing 1 11 14 8 13 12 10 9 7 21 N m 2 1 kgf m 15 lb ft 23 N m 2 3 kgf m 17 lb ft 15 N m 1 5 kgf m 11 lb ft 40 N m 4 0 kgf m 30 lb ft ...

Page 240: ...YZF R1 Order Job Parts to remove Q ty Remarks 15 Inner tube bushing 1 16 Damper rod assembly 1 17 Base valve assembly 1 18 O ring 1 19 Inner tube 1 15 16 19 18 17 21 N m 2 1 kgf m 15 lb ft 23 N m 2 3 kgf m 17 lb ft 15 N m 1 5 kgf m 11 lb ft 40 N m 4 0 kgf m 30 lb ft ...

Page 241: ...5 WARNING EWA13640 Before loosening the upper and lower brack et pinch bolts support the front fork leg 4 Remove Front fork leg EAS30207 DISASSEMBLING THE FRONT FORK LEGS for YZF R1 The following procedure applies to both of the front fork legs 1 Turn the spring preload adjusting nut 1 counterclockwise until it stops 2 Remove Cap bolt 1 from the damper rod assembly Guide 2 Spacer 3 Locknut 4 a Pre...

Page 242: ... Outer tube a Hold the front fork leg horizontally b Securely clamp the brake caliper bracket in a vise with soft jaws c Separate the outer tube from the inner tube by pulling the outer tube forcefully but carefully NOTICE ECA19880 Excessive force will damage the bushings Damaged bushings must be replaced 6 Remove Damper rod assembly TIP Remove the damper rod assembly with the damper rod holder 1 ...

Page 243: ... Check Cap bolt 1 Cap bolt collar projection 2 Cracks damage Replace EAS30209 ASSEMBLING THE FRONT FORK LEGS for YZF R1 The following procedure applies to both of the front fork legs WARNING EWA18360 If both front fork legs are not filled with the specified amount of the fork oil it may cause poor handling and a loss of stability TIP When assembling the front fork leg be sure to replace the follow...

Page 244: ...f the inner tube with fork oil Before installing the oil seal cover the top of the front fork leg with a plastic bag to protect the oil seal during installation 5 Install Outer tube to the inner tube 6 Install Outer tube bushing 1 Washer 2 with the fork seal driver 3 7 Install Oil seal 1 with the fork seal driver 2 Damper rod holder ø30 90890 01506 Damper rod holder YM 01506 Recommended oil Yamaha...

Page 245: ...ont fork leg do not allow any foreign ma terial to enter the front fork 12 After filling the front fork leg slowly stroke the damper rod 1 up and down at least ten times to distribute the fork oil TIP Be sure to stroke the damper rod slowly be cause the fork oil may spurt out Fork seal driver 90890 01442 Adjustable fork seal driver 36 46 mm YM 01442 1 2 G088924 1 G088925 1 2 G088926 Rod puller 908...

Page 246: ...with the smaller diameter a facing up A c Install the locknut all the way onto the damper rod assembly d Install the rod puller and rod puller attach ment e Install the spacer and guide f Install the fork spring compressor g Press down on the spacer with the fork spring compressor 1 h Pull up the rod puller and install the rod holder 2 between the locknut 3 and the guide 4 TIP Use the side of the ...

Page 247: ...lling the front fork leg to the vehicle and tightening the lower bracket pinch bolts EAS30210 INSTALLING THE FRONT FORK LEGS for YZF R1 The following procedure applies to both of the front fork legs 1 Install Front fork leg Temporarily tighten the upper and lower bracket pinch bolts WARNING EWA13680 Make sure the brake hoses are routed prop erly TIP Align the outer tube with the position a as show...

Page 248: ...Cable routing TIP Make sure the brake hose throttle cables clutch cable and handlebar switch leads are routed properly Refer to CABLE ROUTING on page 2 17 5 Adjust Spring preload Rebound damping Compression damping Refer to ADJUSTING THE FRONT FORK LEGS for YZF R1 on page 3 21 T R Handlebar bolt 7 N m 0 7 kgf m 5 2 lb ft T R Handlebar pinch bolt 32 N m 3 2 kgf m 24 lb ft T R Upper bracket pinch bo...

Page 249: ...er to GENERAL CHASSIS 2 on page 4 7 1 Front fender 1 2 Upper bracket pinch bolt 1 Loosen 3 Handlebar pinch bolt 1 Loosen 4 Handlebar bolt 1 Loosen 5 Front fork stepping motor coupler 1 Disconnect 6 Cap bolt with front fork stepping motor 1 Loosen 7 Lower bracket pinch bolt 2 Loosen 8 Front fork leg 1 7 N m 0 7 kgf m 5 2 lb ft 32 N m 3 2 kgf m 24 lb ft 26 N m 2 6 kgf m 19 lb ft 20 N m 2 0 kgf m 15 ...

Page 250: ... the front fork legs 1 Cap bolt with front fork stepping motor 1 2 O ring 1 3 Damper adjusting rod 1 4 Locknut 1 5 Upper spring seat 1 6 Fork spring 1 7 Spacer 1 8 Outer tube 1 9 Dust seal 1 10 Oil seal clip 1 11 Oil seal 1 12 Washer 1 13 Inner tube 1 21 N m 2 1 kgf m 15 lb ft 20 N m 2 0 kgf m 15 lb ft 19 N m 1 9 kgf m 14 lb ft 9 8 11 10 12 13 ...

Page 251: ...ase the gas pressure drill a 2 3 mm 0 08 0 12 in hole through the rear shock absorber as shown WARNING EWA13760 Wear eye protection to prevent eye damage from released gas or metal chips EAS31648 REMOVING THE FRONT FORK LEGS for YZF R1M The following procedure applies to both of the front fork legs 1 Stand the vehicle on a level surface WARNING EWA13120 Securely support the vehicle so that there i...

Page 252: ...osen the cap bolt 1 using the front fork cap bolt wrench 4 and then remove it from the outer tube b Hold the spring preload adjusting bolt 5 and loosen the locknut c Remove the cap bolt damper adjusting rod upper spring seat and fork spring 3 Drain Fork oil TIP Separately from the fork oil in the inner tube fork oil is in the inside cartridge of the lower part of the inner tube The fork oil of the...

Page 253: ...lity TIP When assembling the front fork leg be sure to replace the following parts Oil seal Dust seal O ring Before assembling the front fork leg make sure all of the components are clean 1 Lubricate Inner tube s outer surface 2 Install Dust seal 1 Oil seal clip 2 Oil seal 3 Washer 4 NOTICE ECA19170 Make sure the numbered side of the oil seal faces bottom side TIP Before installing the oil seal lu...

Page 254: ...ring the fork oil level wait ten minutes until the oil has settled and the air bubbles have dispersed 9 Measure Front fork leg oil level a from the top of the outer tube with the outer tube fully compressed and without the fork spring Out of specification Correct 10 Install Spacer Fork spring Upper spring seat Locknut Damper adjusting rod Fork seal driver 90890 01442 Adjustable fork seal driver 36...

Page 255: ...of the inner tube d Hold the spring preload adjusting bolt 3 and tighten the locknut 4 to specification 11 Install Cap bolt to the outer tube TIP Temporarily tighten the cap bolt When to tighten the cap bolt to the specified torque is after installing the front fork leg to the vehicle and tightening the lower bracket pinch bolts EAS31652 INSTALLING THE FRONT FORK LEGS The following procedure appli...

Page 256: ... sure the brake hose throttle cables clutch cable and handlebar switch leads are routed properly Refer to CABLE ROUTING on page 2 17 5 Adjust Spring preload Rebound damping Compression damping Refer to ADJUSTING THE PRELOAD OF THE FRONT FORK LEGS for YZF R1M on page 3 23 and ADJUSTING THE DAMP ING FORCE OF THE FRONT FORK LEGS AND REAR SHOCK ABSORBER ASSEM BLY for YZF R1M on page 3 23 T R Lower bra...

Page 257: ...fer to GENERAL CHASSIS 5 on page 4 16 Front cowling assembly Refer to GENERAL CHASSIS 6 on page 4 23 Air intake duct Refer to GENERAL CHASSIS 7 on page 4 28 Front wheel Refer to FRONT WHEEL on page 4 35 Upper bracket Handlebars Refer to HANDLEBARS on page 4 83 Front fork legs Refer to FRONT FORK for YZF R1 on page 4 89 or refer to FRONT FORK for YZF R1M on page 4 100 LT LT 7 N m 0 7 kgf m 5 2 lb f...

Page 258: ...eering damper solenoid coupler 1 Disconnect 5 Steering damper solenoid 1 6 Lock washer 1 7 Upper ring nut 1 8 Rubber washer 1 9 Lower ring nut 1 10 Lower bracket 1 11 Bearing cover 1 12 Lower bearing dust seal 1 13 Upper bearing 1 14 Lower bearing 1 LT LT 7 N m 0 7 kgf m 5 2 lb ft 11 N m 1 1 kgf m 8 1 lb ft 1st 2nd 52 N m 5 2 kgf m 38 lb ft 14 N m 1 4 kgf m 10 lb ft 23 N m 2 3 kgf m 17 lb ft 1 2 3...

Page 259: ...mage pitting Replace the bearings and bearing races as a set 3 Replace Bearing Bearing race a Remove the bearing races from the steer ing head pipe 1 with a long rod 2 and hammer b Remove the bearing race 3 from the 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 co...

Page 260: ...orarily tighten the steering stem nut 4 Install Front fork legs Refer to FRONT FORK for YZF R1 on page 4 89 or FRONT FORK for YZF R1M on page 4 100 TIP Temporarily tighten the upper and lower bracket pinch bolts EAS30215 CHECKING THE STEERING DAMPER 1 Check Steering damper body Damage oil leaks Replace the steering damper assembly Steering damper rod Bends scratch Replace the steering damper assem...

Page 261: ... brake caliper Refer to REAR BRAKE on page 4 63 Rear wheel Refer to REAR WHEEL on page 4 43 Exhaust chamber Refer to ENGINE REMOVAL on page 5 11 1 Connecting arm upper nut Washer Bolt 1 1 1 2 Rear shock absorber assembly lower nut Bolt 1 1 3 Connecting arm lower nut Washer Bolt 1 1 1 4 Connecting arm 2 5 Rear shock absorber assembly upper nut Col lar Bolt 1 1 1 5 2 4 1 4 5 1 2 3 3 40 N m 4 0 kgf m...

Page 262: ...t 1 1 7 Collar 1 8 Relay arm 1 9 Rear shock absorber assembly 1 10 Oil seal Bearing 2 1 11 Collar Oil seal Bearing 1 2 2 12 Collar Oil seal Bearing 1 2 1 13 Collar Dust seal Circlip Bushing 2 2 1 1 14 Collar Oil seal Bearing 1 2 2 13 13 14 14 11 12 11 10 10 12 40 N m 4 0 kgf m 30 lb ft 40 N m 4 0 kgf m 30 lb ft 40 N m 4 0 kgf m 30 lb ft 6 9 6 8 7 ...

Page 263: ...heel Refer to REAR WHEEL on page 4 43 Exhaust chamber Refer to ENGINE REMOVAL on page 5 11 1 Rear shock absorber assembly stepping motor coupler 2 Disconnect 2 Connecting arm upper nut Washer Bolt 1 1 1 3 Rear shock absorber assembly lower nut Bolt 1 1 4 Connecting arm lower nut Washer Bolt 1 1 1 5 Connecting arm 2 6 Rear shock absorber assembly upper nut Col lar Bolt 1 1 1 6 6 1 1 4 2 5 5 2 4 3 3...

Page 264: ... 1 1 8 Collar 1 9 Relay arm 1 10 Rear shock absorber assembly 1 11 Oil seal Bearing 2 1 12 Collar Oil seal Bearing 1 2 2 13 Collar Oil seal Bearing 1 2 1 14 Collar Dust seal Circlip Bushing 2 2 2 1 15 Collar Oil seal Bearing 1 2 2 14 14 15 15 13 12 12 13 40 N m 4 0 kgf m 30 lb ft 40 N m 4 0 kgf m 30 lb ft 40 N m 4 0 kgf m 30 lb ft 10 9 7 11 8 11 7 ...

Page 265: ...SORBER 1 Gas pressure must be released before dis posing of a rear shock absorber To release the gas pressure drill a 2 3 mm 0 08 0 12 in hole through the rear shock absorber as shown WARNING EWA13760 Wear eye protection to prevent eye damage from released gas or metal chips EAS30219 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 1 Stand the vehicle on a level surface WARNING EWA13120 Securely support ...

Page 266: ...tside diameter 4 Remove Oil seal Bearing 1 TIP Remove the bearing with a socket 2 that matches its outside diameter EAS30220 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 1 Check Rear shock absorber rod Bends damage Replace the rear shock absorber assembly Rear shock absorber assembly Gas leaks oil leaks Replace the rear shock absorber assembly Spring Bushings Damage wear Replace the bushings Bolts Be...

Page 267: ...RM 1 Lubricate Collars Oil seals 2 Install Bearings 1 to the relay arm Oil seals 2 to the relay arm TIP When installing the oil seals 2 to the relay arm face the character stamp of the oil seals outside Press in the oil seal so it does not protrude from the end surface of the relay arm Installed depth a 4 0 mm 0 16 in Installed depth a YZF R1 6 0 mm 0 24 in YZF R1M 3 0 mm 0 12 in New 2 1 a New New...

Page 268: ...en installing the rear shock absorber as sembly lift up the swingarm 2 Tighten Relay arm nut Rear shock absorber assembly upper nut Connecting arm lower nut Rear shock absorber assembly lower nut Connecting arm upper nut T R Relay arm nut 40 N m 4 0 kgf m 30 lb ft Rear shock absorber assembly upper nut 40 N m 4 0 kgf m 30 lb ft Connecting arm lower nut 40 N m 4 0 kgf m 30 lb ft Rear shock absorber...

Page 269: ...ER AS SEMBLY on page 4 112 Drive sprocket Refer to CHAIN DRIVE on page 4 125 1 Drive chain guard 1 2 Rear fender 1 3 Drive chain guide 1 4 Rear wheel sensor lead cover 1 5 Pivot shaft nut Washer 1 1 6 Pivot shaft ring nut Washer 1 1 7 Pivot shaft 1 1 2 3 4 5 6 7 7 N m 0 7 kgf m 5 2 lb ft 7 N m 0 7 kgf m 5 2 lb ft 7 N m 0 7 kgf m 5 2 lb ft 7 N m 0 7 kgf m 5 2 lb ft 16 N m 1 6 kgf m 12 lb ft 65 N m ...

Page 270: ...d hook 1 9 Swingarm 1 10 Drive chain 1 11 Dust cover 2 12 Washer 1 13 Bushing 1 14 Bearing 2 8 9 10 11 11 12 13 14 14 7 N m 0 7 kgf m 5 2 lb ft 7 N m 0 7 kgf m 5 2 lb ft 7 N m 0 7 kgf m 5 2 lb ft 7 N m 0 7 kgf m 5 2 lb ft 16 N m 1 6 kgf m 12 lb ft 65 N m 6 5 kgf m 48 lb ft 105 N m 10 5 kgf m 77 lb ft ...

Page 271: ...vertical movement B by moving the swingarm up and down If the swingarm vertical movement is not smooth or if there is binding check the piv ot shaft collars bearings and dust cov ers 4 Remove Drive chain Refer to REMOVING THE DRIVE CHAIN on page 4 126 5 Remove Pivot shaft nut Pivot shaft ring nut 1 TIP Loosen the pivot shaft ring nut with the ring nut wrench 2 6 Remove Pivot shaft 1 TIP Loosen the...

Page 272: ...t Oil seals Collar Bushing 2 Install Bearings 1 to the swingarm Oil seals 2 to the swingarm TIP When installing the oil seals to the swingarm face the character stamp of the oil seals out side Press in the oil seal so it does not protrude from the end surface of the swingarm 3 Install Swingarm Pivot shaft 1 Recommended cleaning solvent Kerosene 3 4 2 5 4 1 2 4 1 4 Recommended lubricant Lithium soa...

Page 273: ...Refer to REAR SHOCK ABSORBER AS SEMBLY on page 4 112 Rear wheel Refer to REAR WHEEL on page 4 43 7 Adjust Drive chain slack Refer to Adjusting the drive chain slack on page 3 19 Damper rod holder ø22 90890 01365 T R Pivot shaft ring nut 65 N m 6 5 kgf m 48 lb ft Ring nut wrench 90890 01507 Ring nut wrench YM 01507 T R Pivot shaft nut 105 N m 10 5 kgf m 77 lb ft 1 2 1 2 Drive chain slack 25 0 35 0 ...

Page 274: ...rod 1 5 Shift arm 1 6 Shift rod joint 2 7 Shift pedal 1 8 Drive sprocket cover 1 9 Drive chain guide 1 10 Drive sprocket nut 1 11 Washer 1 12 Drive sprocket 1 13 Drive chain 1 E LT LT M LT 1 2 3 4 5 6 6 7 8 10 11 9 12 13 2 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 7 N m 0 7 kgf m 5 2 lb ft T R 28 N m 2 8 kgf m 21 lb ft T R 140 N m 14 kgf m 103 lb ft T R ...

Page 275: ... b be tween the outer sides of the pins on a 15 link section of the drive chain as shown in the illustration b Calculate the 15 link section length c of the drive chain using the following formula Drive chain 15 link section length c length a between pin inner sides length b between pin outer sides 2 TIP When measuring a 15 link section of the drive chain make sure that the drive chain is taut Per...

Page 276: ...in Drive chain rollers 2 Damage wear Replace the drive chain Drive chain side plates 3 Damage wear cracks Replace the drive chain 5 Lubricate Drive chain EAS30231 CHECKING THE DRIVE SPROCKET 1 Check Drive sprocket More than 1 4 tooth a wear Replace the drive sprocket the rear wheel sprocket and the drive chain as a set Bent teeth Replace the drive sprocket the rear wheel sprocket and the drive cha...

Page 277: ... inside of the connecting link 3 and inside of the connecting plate 1 is 15 10 15 30 mm 0 594 0 602 in 2 Lubricate Drive chain 3 Install Drive sprocket Washer 1 Drive sprocket nut 2 TIP While applying the rear brake tighten the drive sprocket nut Install washer 1 with the OUT mark a fac ing out Stake the drive sprocket nut 2 at cutouts b in the drive axle 4 Install Shift arm 1 TIP Before installin...

Page 278: ...ne 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 EAS31729 ADJUSTING THE SHIFT PEDAL TIP The shift pedal position is determined by the in stalled shift rod length 1 Measure Installed shift rod length a Incorrect Adjust 2 Adjust Installed shift rod length a Loosen both locknuts 1 b Turn the shift rod until t...

Page 279: ... TIP Be sure to place the shift rod joints in parallel The allowable twist of the shift rod joints is 5 d Make sure the installed shift rod length is within specification T R Shift rod locknut 7 N m 0 7 kgf m 5 2 lb ft ...

Page 280: ...CHAIN DRIVE 4 131 ...

Page 281: ...DES 5 26 CHECKING THE TIMING CHAIN TENSIONER 5 27 ASSEMBLING THE TIMING CHAIN COVER 5 27 INSTALLING THE ROCKER ARMS AND ROCKER ARM SHAFTS 5 27 INSTALLING THE TIMING CHAIN COVER 5 28 INSTALLING THE CAMSHAFTS 5 29 CYLINDER HEAD 5 33 REMOVING THE CYLINDER HEAD 5 34 CHECKING THE CYLINDER HEAD 5 34 INSTALLING THE CYLINDER HEAD 5 34 VALVES AND VALVE SPRINGS 5 36 REMOVING THE VALVES 5 38 CHECKING THE VAL...

Page 282: ...ECKING THE PRESSURE PLATE 5 66 CHECKING THE PRIMARY DRIVE GEAR 5 66 CHECKING THE PRIMARY DRIVEN GEAR 5 66 CHECKING THE PULL LEVER SHAFT AND PULL ROD 5 66 INSTALLING THE CLUTCH 5 66 SHIFT SHAFT 5 69 CHECKING THE SHIFT SHAFT 5 70 CHECKING THE STOPPER LEVER 5 70 INSTALLING THE SHIFT SHAFT 5 70 CRANKCASE 5 71 DISASSEMBLING THE CRANKCASE 5 74 CHECKING THE CRANKCASE 5 74 ASSEMBLING THE CRANKCASE 5 74 IN...

Page 283: ... BALANCER SHAFT 5 94 INSTALLING THE CRANKSHAFT 5 95 INSTALLING THE THRUST BEARING 5 96 INSTALLING THE BALANCER ASSEMBLY 5 96 TRANSMISSION 5 98 REMOVING THE TRANSMISSION 5 102 CHECKING THE SHIFT FORKS 5 102 CHECKING THE SHIFT DRUM ASSEMBLY 5 102 CHECKING THE TRANSMISSION 5 103 ASSEMBLING THE MAIN AXLE AND DRIVE AXLE 5 103 INSTALLING THE TRANSMISSION 5 104 ...

Page 284: ...mp 3 Relief valve 4 Oil cooler 5 Oil filter cartridge 6 Main gallery 7 Oil pressure switch 8 Crankshaft 9 Generator rotor 10 Balancer shaft 11 Oil nozzle 12 Sub gallery 13 Timing chain tensioner 14 Intake rocker arm 15 Intake camshaft 16 Exhaust rocker arm 17 Exhaust camshaft 18 Shift fork guide bar upper 19 Main axle 20 Drive axle 21 Mission shower ...

Page 285: ...RT AND DIAGRAMS 5 2 EAS32363 LUBRICATION DIAGRAMS Crankcase cylinder and cylinder head left side view 1 Intake camshaft 2 Oil nozzle 3 Oil delivery pipe 2 4 Oil filter cartridge 5 Crankshaft 6 Exhaust camshaft 7 Sub gallery ...

Page 286: ...case and cylinder right side view 1 Timing chain tensioner 2 Intake camshaft 3 Exhaust camshaft 4 Crankshaft 5 Relief valve 6 Oil pipe 1 7 Oil delivery pipe 1 8 Oil pan 9 Oil strainer 10 Oil pump 11 Shift fork guide bar 12 Shift fork C 13 Drive axle ...

Page 287: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 5 4 Timing chain cover and oil pipe right side view 1 Timing chain cover 2 Oil pipe 3 3 Oil pipe 2 4 Crankshaft 5 Crankcase ...

Page 288: ...er bottom view 1 Oil cooler 2 Oil delivery pipe 1 3 Oil cooler outlet hose 4 Oil filter cartridge 5 Oil pressure switch 6 Oil delivery pipe 2 7 Oil strainer 8 Oil pump 9 Oil pipe 1 10 Main gallery 11 Relief valve 12 Oil pipe 2 13 Oil pipe 3 14 Oil cooler inlet hose ...

Page 289: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 5 6 Camshaft and balancer shaft top view 1 Cylinder head 2 Exhaust camshaft 3 Intake camshaft 4 Balancer shaft ...

Page 290: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 5 7 Crankshaft rear view 1 Oil nozzle 2 Oil pipe 3 3 Timing chain cover 4 Crankshaft 5 Oil pipe 2 6 Oil pressure switch 7 Generator rotor 8 Shaft ...

Page 291: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 5 8 Crankshaft and transmission top view 1 Oil pump 2 Main axle 3 Clutch housing 4 Drive axle 5 Oil delivery pipe 3 ...

Page 292: ...cification Refer to steps c and d a Set the main switch to ON b With the throttle wide open crank the en gine until the reading on the compression gauge stabilizes WARNING EWA17100 To prevent sparking the plug remove all ig nition coil couplers and fuel injector cou plers before cranking the engine TIP The difference in compression pressure be tween cylinders should not exceed 100 kPa 1 kgf cm 15 ...

Page 293: ...8 N m 1 8 kgf m 13 lb ft 7 Install Ignition coils Refer to CAMSHAFTS on page 5 18 Air cut off valve Refer to AIR INDUCTION SYSTEM on page 7 20 Air filter case Refer to AIR FILTER CASE on page 7 5 Fuel tank Refer to FUEL TANK on page 7 1 Rider seat Refer to GENERAL CHASSIS 1 on page 4 1 T R Spark plug 13 N m 1 3 kgf m 9 6 lb ft Spark plug new 18 N m 1 8 kgf m 13 lb ft ...

Page 294: ... page 4 23 Side cover bracket Refer to GENERAL CHASSIS 8 on page 4 32 Electrical components tray Refer to GENERAL CHASSIS 9 on page 4 34 Fuel tank Refer to FUEL TANK on page 7 1 Radiator Refer to RADIATOR on page 6 3 Oil cooler Refer to OIL COOLER on page 6 7 1 Muffler protector 1 2 Muffler joint 1 3 Muffler 1 FWD FWD 6 N m 0 6 kgf m 4 4 lb ft 20 N m 2 0 kgf m 15 lb ft 6 N m 0 6 kgf m 4 4 lb ft 10...

Page 295: ...ket 4 13 Gasket 2 14 EXUP servo motor coupler 1 Disconnect 15 EXUP servo motor bracket 1 16 EXUP servo motor 1 17 EXUP servo motor cover 1 FWD FWD 6 N m 0 6 kgf m 4 4 lb ft 20 N m 2 0 kgf m 15 lb ft 6 N m 0 6 kgf m 4 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft 20 N m 2 0 kgf m 15 lb ft 20 N m 2 0 kgf m 15 lb ft 2 0 N m 0 20 kgf m 1 5 lb ft 4 5 6 11 12 7...

Page 296: ...le bodies Refer to THROTTLE BODIES on page 7 11 Thermostat assembly Refer to THERMOSTAT on page 6 9 Shift rod Drive sprocket Refer to CHAIN DRIVE on page 4 125 1 Clutch cable 1 Disconnect 2 Starter motor lead 1 Disconnect 3 Cylinder identification sensor coupler 1 Disconnect 4 Ignition coil coupler 4 Disconnect 5 Coolant temperature sensor coupler sub wire harness 1 Disconnect 6 Neutral switch con...

Page 297: ...ts to remove Q ty Remarks 7 Stator coil coupler 1 Disconnect 8 Crankshaft position sensor coupler 1 Disconnect 9 Oil pressure switch connector 1 Disconnect 10 Gear position sensor coupler 1 Disconnect FWD FWD 7 N m 0 7 kgf m 5 2 lb ft 6 N m 0 6 kgf m 4 4 lb ft 7 8 9 10 ...

Page 298: ...front side 1 5 Engine mounting bolt rear upper side Engine mounting nut rear upper side 1 1 6 Engine mounting bolt rear lower side Engine mounting nut rear lower side 1 1 7 Engine 1 8 Engine mounting adjust bolt 2 FWD FWD 8 N m 0 8 kgf m 5 9 lb ft 56 N m 5 6 kgf m 41 lb ft 56 N m 5 6 kgf m 41 lb ft 70 N m 7 0 kgf m 52 lb ft 70 N m 7 0 kgf m 52 lb ft 4 5 6 1 2 3 7 5 6 8 8 ...

Page 299: ...specification with the pivot shaft wrench Make sure that the flange on the engine mounting adjust bolt contacts the engine 7 Install Engine mounting nut rear lower side 8 Engine mounting nut rear upper side 9 8 Tighten Engine mounting nut rear lower side 8 9 Tighten Engine mounting nut rear upper side 9 10 Tighten Engine mounting bolt left front side 4 11 Tighten Engine mounting bolt right front s...

Page 300: ...Install Exhaust pipe Gasket 1 to exhaust chamber Muffler TIP When installing the gasket install it so that the chamfered side a of the gasket faces the ex haust pipe side as shown in the illustration Installed depth of gasket b 5 0 mm 0 20 in 1 1 2 3 4 5 6 7 8 9 New 1 a b ...

Page 301: ... Front side cowling inner panel Refer to GENERAL CHASSIS 6 on page 4 23 Side cover bracket Refer to GENERAL CHASSIS 8 on page 4 32 Electrical components tray Refer to GENERAL CHASSIS 9 on page 4 34 Fuel tank Refer to FUEL TANK on page 7 1 Air filter case Refer to AIR FILTER CASE on page 7 5 Radiator Refer to RADIATOR on page 6 3 Air cut off valve Refer to AIR INDUCTION SYSTEM on page 7 20 FWD FWD ...

Page 302: ...g is a new one tighten it to 18 N m 1 8 kgf m 13 lb ft 4 Cylinder identification sensor coupler 1 Disconnect 5 Cylinder identification sensor 1 6 Cylinder head cover 1 7 Cylinder head cover gasket 1 8 Cylinder head cover gasket 1 9 Timing chain guide top side 1 FWD FWD LT 8 N m 0 8 kgf m 5 9 lb ft 10 N m 1 0 kgf m 7 4 lb ft 13 N m 1 3 kgf m 9 6 lb ft 1 2 3 4 5 6 7 8 9 1 6 ...

Page 303: ... onto the mating surface and threads of the bolt If the camshaft cap bolt is a new one tight en it to 10 N m 1 0 kgf m 7 4 lb ft 4 Camshaft cap 2 1 If the camshaft cap bolt is a new one it is not necessary to apply engine oil onto the mating surface and threads of the bolt If the camshaft cap bolt is a new one tight en it to 10 N m 1 0 kgf m 7 4 lb ft 5 Intake camshaft 1 6 Exhaust camshaft 1 FWD F...

Page 304: ...em to the crankcase 2 Timing chain cover 1 Install the oil pipe to the timing chain cover and then install them to the crankcase 3 Timing chain cover gasket 1 4 Dowel pin 2 5 Timing chain guide intake side 1 6 Timing chain guide exhaust side 1 7 Timing chain 1 8 Timing chain sprocket bolt 1 9 Timing chain sprocket 1 FWD FWD LT E LT 5 4 7 6 9 8 3 1 2 5 10 N m 1 0 kgf m 7 4 lb ft 72 N m 7 2 kgf m 53...

Page 305: ... Job Parts to remove Q ty Remarks 10 Straight key 1 11 Circlip 1 12 Washer 1 13 Oil seal 1 14 Oil pipe 2 1 When removing the oil pipe 2 also remove the water pump inlet pipe Refer to WATER PUMP on page 6 13 FWD FWD LT E LT 10 11 12 13 14 5 10 N m 1 0 kgf m 7 4 lb ft 72 N m 7 2 kgf m 53 lb ft 1st 2nd 3 0 N m 0 30 kgf m 2 2 lb ft Specified angle 90 6 N m 0 6 kgf m 4 4 lb ft ...

Page 306: ...REMOVAL on page 5 11 Intake camshaft Exhaust camshaft Refer to CAMSHAFTS on page 5 18 1 Rocker arm shaft bolt 4 2 Straight plug rocker arm shaft 3 3 Rocker arm shaft 4 4 Rocker arm 16 FWD FWD E E LT E LT E LT 6 N m 0 6 kgf m 4 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft 4 1 3 2 4 3 2 3 ...

Page 307: ... 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 Exhaust camshaft TIP To prevent the timing chain from falling into the crankcase fasten it with a wire 1 EAS31655 REMOVING THE ROCKER ARMS AND ROCKER ARM SHAFTS 1 Remove Rocker arm shaft bolt Straight plug Rocker arm shaft Rocker arm EAS30257 CH...

Page 308: ...1 0 kgf m 7 4 lb ft 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 mea sure the width of the Plastigauge 1 5 Measure Camshaft journal diameter a Out of specification Replace the camshaft Within specific...

Page 309: ...Damage stiffness Replace the timing chain and camshaft and camshaft sprocket as a set 2 Check Camshaft sprocket More than 1 4 tooth wear a Replace the camshaft sprockets and the timing chain as a set EAS30265 CHECKING THE TIMING CHAIN GUIDES The following procedure applies to all of the camshaft sprockets and timing chain guides 1 Check Timing chain guide exhaust side Timing chain guide intake sid...

Page 310: ... d Make sure that the timing chain tensioner rod can smoothly move out from the timing chain tensioner housing in direction d If not smooth replace the timing chain ten sioner assembly EAS31744 ASSEMBLING THE TIMING CHAIN COVER 1 Install Oil seal 1 TIP Install the oil seal with a socket 2 that matches its outside diameter 2 Install Washer Circlip EAS31657 INSTALLING THE ROCKER ARMS AND ROCKER ARM ...

Page 311: ...t a timing chain cover to oil pipe and b oil pipe to oil pipe bolt TIP Apply locking agent LOCTITE onto the oil pipe bolt d Install the timing chain cover assembly and a new timing chain cover gasket e Install new timing chain cover bolts and tighten them Following the tightening order loosen the bolt one by one and then retighten it to the specific torque and the specific angle TIP Tighten the ti...

Page 312: ...tall Exhaust camshaft 1 Intake camshaft 2 TIP Hang the timing chain on the sprocket from the exhaust camshaft to the intake camshaft The intake camshaft sprocket timing mark a and exhaust camshaft sprocket timing mark b should align with the cylinder head surface c Check the timing mark position of the camshaft sprocket using a mirror The timing chain exhaust side should be stretched and the timin...

Page 313: ... to avoid damage or improper valve timing NOTICE ECA23010 There are two kinds of camshaft cap bolts with different lengths Be sure to install each bolt onto the correct position 6 Install Timing chain tensioner Timing chain tensioner gasket a Using the valve spring compressor 1 push and insert timing chain tensioner rod 2 into the timing chain tensioner housing TIP Push the timing chain tensioner ...

Page 314: ...Out of alignment Adjust Refer to the installation steps above TIP Check the timing mark position of the camshaft sprocket using a mirror 9 Measure Valve clearance Out of specification Adjust Refer to ADJUSTING THE VALVE CLEAR ANCE on page 3 6 10 Install Timing mark accessing bolt Crankshaft end cover Refer to GENERATOR on page 5 44 11 Install Timing chain guide top side Cylinder head cover gasket ...

Page 315: ...lugs Ignition coils 1 TIP Before installing the spark plug clean the spark plug and gasket surface If the spark plug is a new one tighten it to 18 N m 1 8 kgf m 13 lb ft Install the ignition coils 1 in the direction shown in the illustration T R Spark plug 13 N m 1 3 kgf m 9 6 lb ft Spark plug new 18 N m 1 8 kgf m 13 lb ft 1 a a 2 1 ...

Page 316: ...to ENGINE REMOVAL on page 5 11 Intake camshaft Exhaust camshaft Refer to CAMSHAFTS on page 5 18 1 Coolant temperature sensor 1 2 Cylinder head 1 3 Cylinder head gasket 1 4 Dowel pin 2 5 Oil delivery pipe 1 FWD FWD 10 N m 1 0 kgf m 7 4 lb ft 45 N m 4 5 kgf m 33 lb ft 1st 3rd 4th 25 N m 2 5 kgf m 18 lb ft 2nd Specified angle 160 15 N m 1 5 kgf m 11 lb ft E 1 2 4 5 3 9 N m 0 9 kgf m 6 6 lb ft T R 16 ...

Page 317: ...Mineral deposits rust Eliminate 3 Measure Cylinder head warpage Out of specification Resurface the cylinder head a Place a straightedge 1 and a thickness gauge 2 across the cylinder head b Measure the warpage c If the limit is exceeded resurface the cylin der head as follows d Place a 400 600 grit wet sandpaper on the surface plate and resurface the cylin der head using a figure eight sanding pat ...

Page 318: ...d the specific angle TIP Tighten the cylinder head bolts in the tightening sequence as shown and torque them in 4 stag es 4 Install Exhaust camshaft Intake camshaft Refer to INSTALLING THE CAMSHAFTS on page 5 29 T R Cylinder head bolt 1 10 1st 10 N m 1 0 kgf m 7 4 lb ft 2nd 25 N m 2 5 kgf m 18 lb ft 3rd 45 N m 4 5 kgf m 33 lb ft 4th 15 N m 1 5 kgf m 11 lb ft Specified angle 160 Cylinder head bolt ...

Page 319: ...to CYLINDER HEAD on page 5 33 1 Exhaust valve pad 8 2 Exhaust valve cotter 16 3 Exhaust valve spring retainer 8 4 Exhaust valve spring outer 8 5 Exhaust valve spring inner 8 6 Exhaust valve 8 7 Exhaust valve stem seal 8 8 Exhaust valve spring seat 8 9 Exhaust valve guide 8 10 Intake valve pad 8 11 Intake valve cotter 16 FWD FWD M M M M M 1 2 3 4 7 8 5 6 9 10 11 ...

Page 320: ...Parts to remove Q ty Remarks 12 Intake valve spring retainer 8 13 Intake valve spring outer 8 14 Intake valve spring inner 8 15 Intake valve 8 16 Intake valve stem seal 8 17 Intake valve spring seat 8 18 Circlip 8 19 Intake valve guide 8 FWD FWD M M M M M 15 19 18 12 13 16 17 14 ...

Page 321: ...e 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 outer Valve spring inner 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 EAS302...

Page 322: ...valve guide bore the valve guide with the valve guide reamer 3 to obtain the proper valve stem to valve guide clearance TIP After replacing the valve guide reface the valve seat Valve stem to valve guide clear ance intake 0 010 0 037 mm 0 0004 0 0015 in Limit 0 080 mm 0 0032 in Valve stem to valve guide clear ance exhaust 0 025 0 052 mm 0 0010 0 0020 in Limit 0 100 mm 0 0039 in G088960 G088961 G08...

Page 323: ...at Pitting wear Replace the cylinder head 3 Measure Valve seat contact width a Out of specification Replace the cylinder head a Apply blue layout fluid b onto the valve face Valve guide remover ø4 5 90890 04116 Valve guide remover 4 5 mm YM 04116 Valve guide remover ø5 90890 04097 Valve guide remover 5 0 mm YM 04097 Valve guide installer ø4 5 90890 04117 Valve guide installer 4 5 mm YM 04117 Valve...

Page 324: ... valve guides use new valves to lap the valve seats and then replace them with new intake valves a Apply a coarse lapping compound a to the valve face NOTICE ECA13790 Do not let the lapping compound enter the gap between the valve stem and the valve guide b Apply molybdenum disulfide oil onto the valve stem c Install the valve into the cylinder head d Turn the valve until the valve face and valve ...

Page 325: ...pplies to all of the valves and related components 1 Deburr Valve stem end with an oil stone 2 Lubricate Valve stem Valve stem seal with the recommended lubricant 3 Install Valve spring seat 1 Valve stem seal 2 Valve 3 Valve spring inner 4 Valve spring outer 5 Valve spring retainer 6 into the cylinder head TIP Make sure each valve is installed in its original place Install the valve springs with t...

Page 326: ...ace hammer NOTICE ECA13800 Hitting the valve tip with excessive force could damage the valve 6 Lubricate Valve pad with the recommended lubricant 7 Install Valve pad TIP Each valve pad must be reinstalled in its original position b Smaller pitch Valve spring compressor 90890 04019 Valve spring compressor YM 04019 Valve spring compressor attach ment ø26 90890 01243 Valve spring compressor adapt er ...

Page 327: ...oupler 1 Disconnect 2 Crankshaft position sensor coupler 1 Disconnect 3 Generator cover 1 4 Generator cover gasket 1 5 Dowel pin 2 6 Stator coil lead holder 1 7 Stator coil assembly stator coil crankshaft posi tion sensor 1 FWD FWD E LT LT LT 6 N m 0 6 kgf m 4 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft 15 N m 1 5 kgf m 11 lb ft 15 N m 1 5 kgf m 11 lb ft 85 N m 8 5 kgf m 63 lb ft...

Page 328: ... ty Remarks 8 Shaft 1 9 Generator rotor 1 10 Woodruff key 1 11 Crankshaft end cover 1 12 Timing mark accessing bolt 1 FWD FWD E LT LT LT 6 N m 0 6 kgf m 4 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft 15 N m 1 5 kgf m 11 lb ft 15 N m 1 5 kgf m 11 lb ft 85 N m 8 5 kgf m 63 lb ft 1st 2nd 6 N m 0 6 kgf m 4 4 lb ft 3 0 N m 0 30 kgf m 2 2 lb ft Specified angle 90 8 9 10 11 12 8 ...

Page 329: ...or Washer 1 Shaft 2 Generator rotor bolt 3 TIP Clean the tapered portion of the crankshaft and the generator rotor hub When installing the generator rotor make sure the woodruff key is properly seated in the key way of the crankshaft Lubricate the washer with engine oil Install the shaft to the hole of the generator ro tor bolt Lubricate the generator rotor bolt threads and washer mating surfaces ...

Page 330: ... then retighten it to the specific torque and the specific angle TIP Tighten the generator cover bolts in the tighten ing sequence as shown 5 Connect Stator coil coupler Crankshaft position sensor coupler TIP To route the stator coil lead refer to CABLE ROUTING on page 2 17 15mm pin type rotor holding tool 90890 04171 YM 04171 Yamaha bond No 1215 90890 85505 Three bond No 1215 T R Generator cover ...

Page 331: ...ter clutch Order Job Parts to remove Q ty Remarks Clutch housing assembly Refer to CLUTCH on page 5 60 1 Starter clutch gear 1 2 Bearing 1 3 Starter clutch assembly 1 4 Circlip 1 5 Starter clutch idle gear 1 FWD FWD E E E LT E 14 N m 1 4 kgf m 10 lb ft 1 2 3 4 5 ...

Page 332: ...ly b When turning the starter clutch gear clock wise A the starter clutch and the starter clutch gear should engage otherwise the starter clutch is faulty and must be re placed c When turning the starter clutch gear coun terclockwise B it should turn freely oth erwise the starter clutch is faulty and must be replaced EAS30309 INSTALLING THE STARTER CLUTCH 1 Install Starter clutch TIP Install the s...

Page 333: ... cover Refer to GENERAL CHASSIS 3 on page 4 9 Fuel tank Refer to FUEL TANK on page 7 1 Air filter case Refer to AIR FILTER CASE on page 7 5 Canister Refer to FUEL TANK on page 7 1 For California only Throttle bodies Refer to THROTTLE BODIES on page 7 11 1 Starter motor lead 1 Disconnect 2 Starter motor 1 F W D F W D 1 2 6 N m 0 6 kgf m 4 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft ...

Page 334: ...er motor Order Job Parts to remove Q ty Remarks 1 O ring 1 2 Starter motor front cover 1 3 Starter motor yoke 1 4 Armature assembly 1 5 Gasket 2 6 Brush holder set 1 7 Starter motor rear cover 1 FWD FWD 4 5 N m 0 45 kgf m 3 3 lb ft 1 2 3 4 5 5 6 7 ...

Page 335: ...ut 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 Starter motor rear cover 1 Starter motor yoke 2 Starter motor front cover 3 TIP Align the ma...

Page 336: ...ELECTRIC STARTER 5 53 1 2 3 a b ...

Page 337: ...page 3 29 Fuel tank Refer to FUEL TANK on page 7 1 Radiator Refer to RADIATOR on page 6 3 Oil cooler Refer to OIL COOLER on page 6 7 Exhaust pipe Muffler Refer to ENGINE REMOVAL on page 5 11 1 Oil pan 1 2 Oil pan gasket 1 3 Oil strainer 1 4 Oil delivery pipe 1 1 5 Oil pipe 1 1 6 Relief valve assembly 1 FWD FWD LT LT LT LT LT LT E E 1 2 3 4 5 6 10 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ...

Page 338: ...Oil pump drive sprocket 1 11 Washer 1 12 Oil pump drive chain 1 13 Oil pump 1 14 Dowel pin 2 15 Baffle plate 1 FWD FWD 9 10 11 8 12 15 7 13 14 LT LT LT LT LT LT E E 10 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft 23 N m 2 3 kgf m 17 lb ft 10 N m 1 0 kgf m 7 4 lb ft LT ...

Page 339: ... pump Order Job Parts to remove Q ty Remarks 1 Oil pump cover 1 2 Dowel pin 2 3 Oil pump outer rotor 1 4 Oil pump inner rotor 1 5 Pin 1 6 Oil pump housing 1 7 Oil pump driven sprocket 1 FWD FWD 1 2 3 4 5 6 7 E 10 N m 1 0 kgf m 7 4 lb ft ...

Page 340: ...Rough movement Repeat steps 1 and 2 or replace the oil pump assembly EAS30338 CHECKING THE RELIEF VALVE 1 Check Relief valve body 1 Relief valve 2 Spring 3 Damage wear Replace the defective part s EAS30339 CHECKING THE OIL DELIVERY PIPES The following procedure applies to all of the oil delivery pipes 1 Check Oil delivery pipe 1 Oil delivery pipe 2 Oil pipe 1 Damage Replace Obstruction Wash and bl...

Page 341: ...rocket make sure the oil pump turns smoothly 3 Install Oil pump drive chain guide 4 Install O ring Oil pipe 1 O ring Oil delivery pipe 1 Oil strainer O ring Relief valve assembly 5 Install O ring Oil delivery pipe 2 EAS30345 INSTALLING THE OIL PAN 1 Install Oil pan gasket Oil pan Oil pan bolt 12 T R Oil pump bolt 10 N m 1 0 kgf m 7 4 lb ft 1 2 3 4 5 1 2 2 T R Oil pump drive chain guide bolt 10 N m...

Page 342: ...ts 1 6 9 12 M6 30 mm 1 18 in bolts 7 8 2 Tighten Oil pan bolt 3 Install Engine oil drain bolt Gasket T R Oil pan bolt 10 N m 1 0 kgf m 7 4 lb ft LOCTITE T R Engine oil drain bolt 23 N m 2 3 kgf m 17 lb ft 7 8 2 1 3 4 5 6 9 10 11 12 New ...

Page 343: ...remove Q ty Remarks Front side cowling right Refer to GENERAL CHASSIS 3 on page 4 9 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 29 1 Clutch cable 1 Disconnect 2 Clutch cover 1 3 Clutch cover gasket 1 4 Dowel pin 2 5 Oil filler cap 1 FWD FWD 7 N m 0 7 kgf m 5 2 lb ft 1st 2nd 6 N m 0 6 kgf m 4 4 lb ft 3 0 N m 0 30 kgf m 2 2 lb ft Specified angle 180 1 2 3 4 5 10 ...

Page 344: ...to remove Q ty Remarks 1 Circlip 1 2 Pull lever 1 3 Pull lever spring 1 4 Circlip 1 5 Pull lever shaft 1 6 Oil seal 1 7 Bearing 1 8 Bearing 1 9 Clutch cover damper plate 1 10 Clutch cover damper 1 FWD FWD LT LT E 10 N m 1 0 kgf m 7 4 lb ft 9 1 2 3 4 5 6 7 8 10 ...

Page 345: ... 1 4 Pull rod 1 5 Bearing 1 Press the bearing into pressure plate 2 6 Friction plate 1 3 Blackish shoe 7 Clutch plate 1 1 Inside diameter 110 2 mm 4 34 in 8 Clutch plate 2 8 Inside diameter 103 5 mm 4 07 in 9 Friction plate 2 7 Whitish shoe FWD FWD E E E E E E 10 N m 1 0 kgf m 7 4 lb ft 125 N m 12 5 kgf m 92 lb ft 1 2 3 4 5 6 7 9 6 8 ...

Page 346: ...er spring 1 11 Clutch damper spring seat 1 12 Clutch boss nut 1 13 Conical spring washer 1 14 Clutch boss 1 15 Thrust plate 1 16 Clutch housing assembly 1 17 Bearing 1 18 Washer 1 FWD FWD E E E E E E 10 N m 1 0 kgf m 7 4 lb ft 125 N m 12 5 kgf m 92 lb ft 10 11 12 13 14 15 16 17 18 10 11 ...

Page 347: ...use an impact wrench for removing the clutch boss nut 6 Remove Clutch boss nut Conical spring washer Clutch boss Thrust plate Clutch housing assembly Bearing Washer EAS30348 CHECKING THE FRICTION PLATES The following procedure applies to all of the fric tion plates 1 Check Friction plate 1 blackish shoe Friction plate 2 whitish shoe Damage wear Replace the friction plates as a set 2 Measure Fricti...

Page 348: ...pplies to all of the clutch springs 1 Check Clutch spring Damage Replace the clutch springs as a set 2 Measure Clutch spring free length Out of specification Replace the clutch springs as a set EAS30352 CHECKING THE CLUTCH HOUSING 1 Check Clutch housing dogs Damage pitting wear Deburr the clutch housing dogs or replace the clutch housing TIP Pitting on the clutch housing dogs will cause er ratic c...

Page 349: ...ECKING THE PULL LEVER SHAFT AND PULL ROD 1 Check Pull lever shaft pinion gear teeth Pull rod teeth Damage wear Replace the pull rod and pull lever shaft as a set 2 Check Pull rod bearing Damage wear Replace EAS30363 INSTALLING THE CLUTCH TIP After assembling the clutch assembly the noise like a dry type clutch might occur with the gear position in neutral and half clutch This is due to the clutch ...

Page 350: ... plates Clutch plates with the recommended lubricant 4 Install Clutch damper spring seat Clutch damper spring Friction plates 1 Clutch plates 2 Friction plates 2 Clutch plate 1 TIP First install a friction plate and then alternate between a clutch plate and a friction plate Install the last friction plate 1 offset from the other friction plates 2 making sure to align a projection on the friction p...

Page 351: ...to the specific torque and the specific angle TIP Tighten the clutch cover bolts in the tightening sequence as shown 8 Install Pull lever spring 1 Pull lever 2 Washer Circlip TIP The end of the pull lever should be closest to the clutch cover match mark a when there is no free play of the pull lever Make sure that the pull rod teeth and pull lever shaft pinion gear are engaged 9 Adjust Clutch leve...

Page 352: ... page 5 60 Shift arm Refer to CHAIN DRIVE on page 4 125 1 Circlip 1 2 Washer 1 3 Shift shaft 1 4 Washer 1 5 Circlip 1 6 Washer 1 7 Stopper lever 1 8 Stopper lever spring 1 9 Collar 1 10 Shift shaft spring 1 11 Shift shaft spring stopper 1 12 Bearing 1 13 Oil seal 1 14 Bearing 1 FWD FWD LT E E E E 22 N m 2 2 kgf m 16 lb ft 1 2 13 14 3 4 5 6 7 8 9 10 11 12 ...

Page 353: ... Install Shift shaft spring stopper 1 Shift shaft assembly Stopper lever spring 2 TIP Hook the end of the shift shaft spring 3 onto the shift shaft spring stopper 1 Hook the ends of the stopper lever spring 2 onto the stopper lever 4 and the crankcase boss 5 Mesh the stopper lever with the shift drum seg ment assembly 2 Install Bearing Oil seal Washer Circlip TIP Lubricate the oil seal lips with l...

Page 354: ... 5 33 Generator rotor Refer to GENERATOR on page 5 44 Starter motor Refer to ELECTRIC STARTER on page 5 50 Water pump Refer to WATER PUMP on page 6 13 Clutch housing assembly Refer to CLUTCH on page 5 60 Oil strainer Oil pump Relief valve assembly Refer to OIL PUMP on page 5 54 FWD FWD 70 N m 7 0 kgf m 52 lb ft LT LT LT LT 4 0 N m 0 40 kgf m 3 0 lb ft 1 8 N m 0 18 kgf m 1 3 lb ft 10 N m 1 0 kgf m ...

Page 355: ...er cartridge union bolt 1 6 Crankcase breather cover 1 7 Crankcase breather cover gasket 1 8 Damper plate upper crankcase 1 9 Clutch cable holder 1 10 Neutral switch 1 11 Gasket 1 FWD 70 N m 7 0 kgf m 52 lb ft LT LT LT LT 4 0 N m 0 40 kgf m 3 0 lb ft 1 8 N m 0 18 kgf m 1 3 lb ft 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft 12 N m 1 2 kgf m 8 9 lb ft 13 N m 1 3 kgf m 9 6 lb ft 17 N m 1 7 k...

Page 356: ... gallery 2 2 Plug balancer shaft end 2 3 Lower crankcase 1 4 Dowel pin 4 FWD FWD E E E E LT E 8 N m 0 8 kgf m 5 9 lb ft 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft 24 N m 2 4 kgf m 18 lb ft 24 N m 2 4 kgf m 18 lb ft 1st 3rd 2nd 20 N m 2 0 kgf m 15 lb ft 15 N m 1 5 kgf m 11 lb ft Specified angle 75 2 4 2 2 10 6 4 4 2 5 4 1 8 3 2 ...

Page 357: ...of each part very carefully so that it can be reinstalled in its original place EAS30390 CHECKING THE CRANKCASE 1 Thoroughly wash the crankcase halves in a mild solvent 2 Thoroughly clean all the gasket surfaces and crankcase mating surfaces 3 Check Crankcase Cracks damage Replace Oil delivery passages Obstruction Blow out with compressed air EAS30397 ASSEMBLING THE CRANKCASE 1 Lubricate Crankshaf...

Page 358: ...Lubricate the bolts 28 40 mating surfaces with engine oil Apply the bolts 28 40 thread with LOC TITE M9 100 mm 3 94 in bolts with washers 1 10 M8 58 mm 2 28 in bolts with new O rings 11 18 M8 60 mm 2 36 in bolts 19 20 M6 65 mm 2 56 in bolts 21 22 M6 70 mm 2 76 in bolt 23 M6 60 mm 2 36 in bolts 24 27 35 38 M6 50 mm 1 97 in bolts 31 34 M6 50 mm 1 97 in bolts LOCTITE 28 40 M6 40 mm 1 57 in bolts 29 3...

Page 359: ...HE CRANKCASE BREATHER COVER 1 Install Crankcase breather cover Crankcase breather cover bolt 2 Tighten Crankcase breather cover bolt Following the tightening order loosen the bolt one by one and then retighten it to the specific torque and the specific angle TIP Tighten the crankcase breather cover bolts in the tightening sequence as shown T R Crankcase bolts 11 20 24 N m 2 4 kgf m 18 lb ft Crankc...

Page 360: ...LLING THE GEAR POSITION SENSOR NOTICE ECA22630 To prevent damage to the gear position sen sor keep magnets including any pickup tool with a magnet magnetized screwdrivers etc away from the gear position sensor 1 Install O ring Gear position sensor 1 TIP Lubricate the O ring with lithium soap based grease Fit the end a of the shift drum assembly into the opening b in the gear position sensor 1 T R ...

Page 361: ...fer to CRANKCASE on page 5 71 1 Connecting rod cap 4 2 Big end lower bearing 4 3 Big end upper bearing 4 4 Connecting rod 4 5 Piston pin clip 8 6 Piston pin 4 7 Piston 4 8 Top ring 4 9 2nd ring 4 10 Oil ring 4 11 Cylinder 1 12 Cylinder gasket 1 13 Dowel pin 2 FWD FWD E E E E E E 1st 2nd 25 N m 2 5 kgf m 18 lb ft Specified angle 180 1 2 8 3 4 12 13 13 8 9 10 11 5 6 7 5 ...

Page 362: ... either the a or b position in relation to the cutout c TIP If the piston pin clip ends are not positioned at a or b adjust the piston pin clip ends position by following steps b to c b Install the piston pin clip rotation tool 2 to the piston pin clip TIP When installing the piston pin clip rotation tool align the projection d on the piston pin clip ro tation tool with the clip ends e c Turn the ...

Page 363: ... side of the ring over the piston crown EAS30747 CHECKING THE CYLINDER AND PISTON 1 Check Piston wall Cylinder wall Vertical scratches Replace the cylinder block and replace the pistons and piston rings as a set 2 Measure Piston to cylinder clearance a Measure cylinder bore C with the cylin der bore gauge TIP Measure cylinder bore C by taking side to side and front to back measurements of the cyli...

Page 364: ... piston ring near bottom of cylinder a where 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 Piston Diameter 78 961 78 994 mm 3 1087 3 1100 in a 8 0 mm 0 31 in from the bottom edge of the piston Piston to cylinder c...

Page 365: ...hange 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 connecting rods with oil cleaner TIP When cleaning the connecting rod clean the bearing surface a of the connecting rod bolt and threads b ...

Page 366: ...h the big end bearing 2 down and install it to the connecting rod and connecting rod cap d Put a piece of Plastigauge 1 on the crankshaft pin e Assemble the connecting rod halves NOTICE ECA18390 Tighten the connecting rod bolts using the plastic region tightening angle method Al ways install new bolts TIP Install the new connecting rod bolt without cleaning and without any oil Make sure that the p...

Page 367: ...urement has been completed Make sure that the projection a on the con necting rod cap faces the same direction as the mark b on the connecting rod Make sure the marks b on the connecting rods face towards the left side of the crank shaft Install the connecting rod so that the Plasti gauge is in position c or d h Tighten the connecting rod bolts with a torque wrench i Put a mark 1 on the corner of ...

Page 368: ...crankshaft pin If the crank shaft pin to big end bearing clearance is out of specification select replacement big end bearings 2 Select Big end bearings P1 P4 TIP The numbers A stamped into the crankshaft web and the numbers 1 on the connecting rods are used to determine the replacement big end bearings sizes P1 P4 refer to the bearings shown in the crankshaft illustration For example if the conne...

Page 369: ...e sure to reinstall each big end bearing in its original place From the 3 types choose the connecting rod big end metal installer 1 that fits exactly and install it to the connecting rod and connecting rod cap as shown in the illustration Align the projections c on the big end bear ings with the notches d in the connecting rods and connecting rod caps Push the big end bearing 2 down and install it...

Page 370: ...nment d Loosen the connecting rod bolt remove the connecting rod and connecting rod cap and install these parts to the crank shaft with the big end bearing kept in the current condition 3 Install Top ring 1 into the piston 2nd ring 2 Upper oil ring rail 3 Oil ring expander 4 Lower oil ring rail 5 TIP Be sure to install the piston rings so that the manufacturer s marks or numbers a face up 4 Instal...

Page 371: ...Install the piston pin clip to the piston by pressing the portion b on the piston pin clip insertion tool 3 in the direction shown in the illustration d Make sure the piston pin clip 1 is posi tioned as shown in the illustration e Install the piston pin clip installer tool 4 onto the piston f While holding the piston clip installer tool turn it counterclockwise c to completely install the piston p...

Page 372: ... assembly into the cylinder so that the piston ring end gap is aligned with the cylinder skirt a 10 Install Cylinder gasket Dowel pins Cylinder assembly Connecting rod caps Connecting rod bolts TIP Make sure the marks a on the connecting rods face towards the left side of the crank shaft Make sure that the projection b on the con necting rod cap faces the same direction as the mark a on the connec...

Page 373: ...e is out of range re place the connecting rod bolt to new one and repeat from step a WARNING EWA16610 If the bolt is tightened more than the speci fied angle do not loosen the bolt and then re tighten it Instead replace the bolt with a new one and perform the procedure again d After the installation check that the sec tion shown a is flush with each other by touching the surface WARNING EWA17120 I...

Page 374: ... rod Refer to REMOVING THE CONNECTING RODS AND PISTONS on page 5 79 1 Balancer shaft 1 2 Balancer shaft journal lower bearing 4 3 Balancer shaft journal upper bearing 4 4 Crankshaft 1 5 Crankshaft journal lower bearing 5 6 Crankshaft journal upper bearing 5 7 Thrust bearing 2 8 Oil nozzle 1 4 9 Oil nozzle 2 5 FWD FWD E E LT LT E E 10 N m 1 0 kgf m 7 4 lb ft 3 0 N m 0 30 kgf m 2 2 lb ft E E 5 9 9 1...

Page 375: ...ankshaft journal bearing 3 Measure Crankshaft journal to crankshaft journal bearing clearance Out of specification Replace the crank shaft journal bearings NOTICE ECA13920 Do not interchange the crankshaft journal bearings To obtain the correct crankshaft journal to crankshaft journal bearing clear ance and prevent engine damage the crank shaft journal bearings must be installed in their original ...

Page 376: ...ft journal If the crankshaft journal to crankshaft journal bearing clearance is out of specifi cation select replacement crankshaft journal bearings 4 Select Crankshaft journal bearings J1 J5 TIP The numbers A stamped into the crankshaft web and the numbers B stamped into the lower crankcase are used to determine the re placement crankshaft journal bearing sizes J1 J5 refer to the bearings shown i...

Page 377: ...arings balancer shaft journals and bearing por tions of the crankcase b Place the upper crankcase upside down on a bench c Install the balancer shaft journal upper bearings 1 and the balancer shaft into the upper crankcase TIP Align the projections a on the balancer shaft journal upper bearings with the notches b in the upper crankcase d Put a piece of Plastigauge 1 on each balancer shaft journal ...

Page 378: ...numbers A stamped into the balancer shaft web and the numbers B stamped into the lower crankcase are used to determine the replacement balancer shaft journal bearing siz es J1 J4 refer to the bearings shown in the bal ancer shaft and lower crankcase illustration For example if the crankcase J1 and bal ancer shaft web J1 numbers are 6 and 2 re spectively then the bearing size for J1 is EAS31077 INS...

Page 379: ...nkshaft Apply engine oil on the grooves a side of the thrust bearing a Insert the thrust bearing 1 into the slot of the upper crankcase as shown in the illus tration and slide it in the direction of the ar row TIP When installing the thrust bearing shift the crankshaft to the left to widen the gap between the crankshaft and the crankcase b Insert the thrust bearing 2 into the slot of the upper cra...

Page 380: ...n the projections a on the balancer shaft journal bearings 1 with the notches b in the crankcases Be sure to install each balancer shaft journal bearing in its original place 2 Install Balancer shaft TIP Install by aligning the crankshaft match mark a and the balancer shaft match marks b 1 a b G089019 a b b ...

Page 381: ... axle assembly 1 2 Shift drum retainer 2 3 Spring 2 4 Shift fork guide bar 2 5 Shift fork L 1 6 Shift fork R 1 7 Shift drum assembly 1 8 Shift fork C 1 9 Main axle assembly 1 10 Oil delivery pipe 3 1 11 O ring 3 12 Oil baffle plate 1 13 Bearing 2 FWD FWD LT E E E E LT LT LT LT E 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft 12 N m 1 2 kgf m 8 9 lb ft 1 2 3 3 4 4 5 6 7 8 9 10 11 12 13 13 ...

Page 382: ...ed side of the pinion gear faces to the left 2 Toothed lock washer 1 3 Toothed lock washer retainer 1 4 6th pinion gear 1 5 Collar 1 6 Washer 1 7 Circlip 1 8 3rd pinion gear 1 9 Circlip 1 10 Washer 1 11 5th pinion gear 1 12 Collar 1 13 Bearing housing 1 14 Bearing 1 15 Main axle 1 M M M M E M 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 FWD FWD ...

Page 383: ... to remove Q ty Remarks 1 Circlip 1 2 Bearing 1 3 Washer 1 4 1st wheel gear 1 5 Collar 1 6 5th wheel gear 1 7 Circlip 1 8 Washer 1 9 3rd wheel gear 1 10 Collar 1 11 Toothed lock washer 1 12 Toothed lock washer retainer 1 FWD FWD M M M M M M M E E 1 2 3 4 5 6 7 8 9 10 11 12 ...

Page 384: ... Q ty Remarks 13 4th wheel gear 1 14 Collar 1 15 Washer 1 16 Circlip 1 17 6th wheel gear 1 18 Circlip 1 19 Washer 1 20 2nd wheel gear 1 21 Collar 1 22 Collar 1 23 Oil seal 1 24 Circlip 1 25 Bearing 1 26 Drive axle 1 FWD FWD M M M M M M M E E 19 20 21 22 23 24 25 26 13 14 15 16 17 18 ...

Page 385: ...ECKING THE SHIFT FORKS The following procedure applies to all of the shift forks 1 Check Shift fork cam follower 1 Shift fork pawl 2 Bends damage scoring wear Replace the shift fork 2 Check Shift fork guide bar Roll the shift fork guide bar on a flat surface Bends Replace WARNING EWA12840 Do not attempt to straighten a bent shift fork guide bar 3 Check Shift fork movement along the shift fork guid...

Page 386: ...gs Cracks damage rounded edges Replace the defective gear s 4 Check Transmission gear engagement each pinion gear to its respective wheel gear Incorrect Reassemble the transmission axle assemblies 5 Check Transmission gear movement Rough movement 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 ...

Page 387: ...he toothed lock washer that is between the alignment marks b with the alignment mark c on the re tainer EAS30438 INSTALLING THE TRANSMISSION 1 Install Bearings 1 Oil delivery pipe 3 2 TIP Face the seal side of bearing to the outside 2 Install Main axle assembly 1 Bearing housing 2 b c 1 2 a A 2 1 c b b A Main axle B Drive axle T R Oil delivery pipe 3 bolt 10 N m 1 0 kgf m 7 4 lb ft LOCTITE T R Mai...

Page 388: ...Shift fork R 1 Shift fork L 2 Shift fork guide bar Shift drum retainers 3 Bearing Oil seal Circlip 4 Drive axle assembly 5 TIP Install shift fork R into the groove a in the 5th wheel gear and shift fork L into the groove b in the 6th wheel gear on the drive axle Install the shift drum retainer with its OUT mark c facing outward Make sure that the projection d on the drive axle assembly is inserted...

Page 389: ...CKING THE OIL COOLER 6 8 INSTALLING THE OIL COOLER 6 8 THERMOSTAT 6 9 REMOVING THE THERMOSTAT ASSEMBLY 6 11 CHECKING THE THERMOSTAT 6 11 ASSEMBLING THE THERMOSTAT ASSEMBLY 6 11 INSTALLING THE THERMOSTAT ASSEMBLY 6 11 WATER PUMP 6 13 DISASSEMBLING THE WATER PUMP 6 15 CHECKING THE WATER PUMP 6 15 ASSEMBLING THE WATER PUMP 6 15 INSTALLING THE WATER PUMP 6 16 ...

Page 390: ...DIAGRAMS 6 1 EAS20299 COOLING SYSTEM DIAGRAMS 1 Radiator outlet hose 2 Cooling system air bleed hose 3 Thermostat assembly 4 Radiator inlet hose 5 Radiator 6 Water pump outlet pipe 7 Water pump 8 Water pump inlet pipe ...

Page 391: ...COOLING SYSTEM DIAGRAMS 6 2 1 Cooling system air bleed hose 2 Radiator 3 Radiator outlet hose 4 Radiator inlet hose 5 Water pump inlet pipe 6 Water pump outlet pipe 7 Water pump 8 Thermostat assembly ...

Page 392: ... 5 on page 4 16 Side cover Front side cowling inner panel Refer to GENERAL CHASSIS 6 on page 4 23 Side cover bracket Refer to GENERAL CHASSIS 8 on page 4 32 Electrical components tray Refer to GENERAL CHASSIS 9 on page 4 34 Coolant Drain Refer to CHANGING THE COOLANT on page 3 32 FWD FWD 8 N m 0 8 kgf m 5 9 lb ft 7 N m 0 7 kgf m 5 2 lb ft 8 N m 0 8 kgf m 5 9 lb ft 10 N m 1 0 kgf m 7 4 lb ft ...

Page 393: ...oir cap 1 4 Radiator cap 1 5 Radiator fan motor coupler 2 Disconnect 6 Cooling system air bleed hose 1 Disconnect 7 Radiator outlet hose 1 Disconnect 8 Radiator inlet hose 1 Disconnect 9 Radiator 1 10 Radiator fan 2 FWD FWD 8 N m 0 8 kgf m 5 9 lb ft 7 N m 0 7 kgf m 5 2 lb ft 8 N m 0 8 kgf m 5 9 lb ft 10 N m 1 0 kgf m 7 4 lb ft 1 2 3 4 5 6 7 8 9 10 10 ...

Page 394: ... opening pressure Below the specified pressure Replace the radiator cap a Install the radiator cap tester 1 and radi ator cap tester adapter 2 to the radiator cap 3 b Apply the specified pressure for ten sec 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 Install...

Page 395: ...ng system Leaks Repair or replace any faulty part a Attach the radiator cap tester 1 and radi ator cap tester adapter 2 to the radiator b Apply 137 3 kPa 1 37 kgf cm 19 9 psi of pressure c Measure the indicated pressure with the gauge 6 Measure Radiator cap valve opening pressure Below the specified pressure Replace the radiator cap Refer to CHECKING THE RADIATOR on page 6 5 Radiator cap tester 90...

Page 396: ...G THE ENGINE OIL on page 3 29 1 Oil cooler cover 1 2 Damper 2 3 Oil cooler inlet hose 1 Disconnect When removing the oil cooler inlet hose also remove the water pump inlet pipe Refer to WATER PUMP on page 6 13 4 Oil cooler outlet hose 1 5 Oil cooler 1 FWD FWD 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft LT LT LT 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft LT 3 5 2 1 2 4 ...

Page 397: ...Oil cooler 1 O ring Oil cooler bolt upper 2 Oil cooler bolt lower 3 Radiator bolt 4 TIP Apply lithium soap based grease to the O ring 2 Tighten Oil cooler bolt upper 2 3 Tighten Oil cooler bolt lower 3 4 Tighten Radiator bolt 4 5 Fill Crankcase with the specified amount of the recom mended engine oil Refer to CHANGING THE ENGINE OIL on page 3 29 6 Measure Engine oil pressure Refer to MEASURING THE...

Page 398: ...e cowling inner panel Refer to GENERAL CHASSIS 6 on page 4 23 Side cover bracket Refer to GENERAL CHASSIS 8 on page 4 32 Fuel tank Refer to FUEL TANK on page 7 1 Canister Refer to FUEL TANK on page 7 1 For California only Air filter case Refer to AIR FILTER CASE on page 7 5 Throttle bodies Refer to THROTTLE BODIES on page 7 11 Coolant Drain Refer to CHANGING THE COOLANT on page 3 32 FWD FWD 10 N m...

Page 399: ...rks 1 Cooling system air bleed hose 1 Disconnect 2 Radiator inlet hose 1 3 Thermostat housing cover 1 4 O ring 1 5 Thermostat 1 6 Thermostat housing 1 7 O ring 1 FWD FWD 1 2 3 4 5 6 7 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 ...

Page 400: ...Thermostat housing cover Cracks damage Replace EAS30444 ASSEMBLING THE THERMOSTAT ASSEMBLY 1 Install Thermostat housing 1 Thermostat 2 O ring 3 Thermostat housing cover 4 TIP Install the thermostat with its breather hole a facing up EAS30445 INSTALLING THE THERMOSTAT ASSEMBLY 1 Install Thermostat assembly 2 Install Radiator inlet hose Hose clamp Clic R Refer to INSTALLING THE RADIATOR on page 6 5 ...

Page 401: ...HERMOSTAT 6 12 Refer to INSTALLING THE RADIATOR on page 6 5 5 Measure Radiator cap valve opening pressure Below the specified pressure Replace the radiator cap Refer to CHECKING THE RADIATOR on page 6 5 ...

Page 402: ...on page 4 23 Side cover bracket Refer to GENERAL CHASSIS 8 on page 4 32 Fuel tank Refer to FUEL TANK on page 7 1 Radiator Refer to RADIATOR on page 6 3 Oil cooler Refer to OIL COOLER on page 6 7 Muffler Exhaust pipe Refer to ENGINE REMOVAL on page 5 11 1 Water pump inlet pipe 1 2 Water pump outlet pipe 1 3 Water pump assembly 1 4 Oil cooler stay 3 FWD FWD 10 N m 1 0 kgf m 7 4 lb ft LT 10 N m 1 0 k...

Page 403: ...ater pump Order Job Parts to remove Q ty Remarks 1 Water pump housing cover 1 2 O ring 1 3 Circlip 1 4 Impeller shaft 1 5 Mechanical seal 1 6 Bearing 1 7 Oil seal 1 FWD 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft 1 2 3 4 5 6 7 ...

Page 404: ... wear Replace Water pump housing Cracks damage wear Replace the water pump assembly 2 Check Bearing Rough movement Replace 3 Check Water pump inlet pipe Water pump outlet pipe Cracks damage wear Replace EAS30448 ASSEMBLING THE WATER PUMP 1 Install Oil seal 1 Bearing 2 into the water pump housing 3 TIP Install the oil seal with a socket 4 that matches its outside diameter 2 Install Mechanical seal ...

Page 405: ...m with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 32 3 Check Cooling system Leaks Repair or replace the faulty part 4 Measure Radiator cap valve opening pressure Below the specified pressure Replace the radiator cap Refer to CHECKING THE RADIATOR on page 6 5 Mechanical seal installer ø33 90890 04132 Water pump seal installer ø33 YM 33221 A Middle drive...

Page 406: ...WATER PUMP 6 17 ...

Page 407: ...E INTAKE FUNNEL 7 8 INSTALLING THE INTAKE FUNNEL AND AIR FILTER CASE 7 8 CHECKING THE INTAKE FUNNEL OPERATION 7 9 INSTALLING THE SECONDARY INJECTORS 7 9 INSTALLING THE UPPER AIR FILTER CASE 7 9 INSTALLING THE FUEL HOSE PRIMARY INJECTOR JOINT SIDE AND SECONDARY INJECTOR JOINT SIDE 7 10 THROTTLE BODIES 7 11 CHECKING THE PRIMARY INJECTORS BEFORE REMOVING 7 15 REMOVING THE PRIMARY INJECTORS 7 15 CHECK...

Page 408: ...sconnect 6 Fuel tank drain hose 1 Disconnect 7 Fuel tank 1 8 Fuel tank top cover rear 1 9 Fuel tank top cover front 1 10 Fuel pump bracket 1 11 Fuel pump 1 12 Fuel tank cap 1 13 Fuel tank protector 1 9 11 3 10 4 4 5 6 8 7 2 12 13 1 New 0 4 N m 0 04 kgf m 0 30 lb ft T R 0 4 N m 0 04 kgf m 0 30 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...

Page 409: ...ove Q ty Remarks Rider seat Refer to GENERAL CHASSIS 1 on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 1 Canister purge hose hose joint to canister 1 2 Fuel tank breather hose fuel tank to canister 1 3 Canister holder 1 4 Canister 1 5 Canister bracket 1 1 3 4 2 5 10 N m 1 0 kgf m 7 4 lb ft T R ...

Page 410: ...ver 1 in direction b slide the fuel hose connector cover in direction c and then remove the hose from the fuel pump Before removing the hose place a few rags in the area under where it will be removed It is prohibited to wear the cotton work gloves or equivalent coverings 4 Remove Fuel tank TIP Do not set the fuel tank down so that the instal lation surface of the fuel pump is directly under the t...

Page 411: ... Temporarily tighten the rear fuel tank bolt 2 Connect Fuel hose fuel tank side NOTICE ECA17500 When installing the fuel hose make sure that it is securely connected and that the fuel hose connector cover on the fuel hose is in the correct position otherwise the fuel hose will not be properly installed TIP Install the fuel hose onto the fuel pump secure ly and slide the fuel hose connector cover 1...

Page 412: ...uel hose 1 fuel tank to fuel hose 2 1 4 Fuel hose 3 fuel hose 2 to throttle body 1 Disconnect 5 Secondary injector coupler 4 Disconnect 6 Fuel rail Secondary injector joint 2 1 7 Secondary injector 4 8 Upper air filter case 1 9 Air filter element 1 10 Crankcase breather hose 1 Disconnect LT 4 10 6 2 5 1 6 7 8 9 10 4 3 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 7 N m 0 7 kgf ...

Page 413: ...e funnel servo motor rod assembly 1 16 Intake funnel assembly 1 17 Intake funnel servo motor 1 18 Rear shock absorber assembly stepping motor lead 1 for YZF R1M 19 Coolant temperature sensor lead 1 20 Throttle servo motor lead 1 21 Cross bar 1 LT 4 10 6 15 16 11 17 21 20 18 19 14 12 13 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 7 N m 0 7 kgf m 5 2 lb ft T R 8 N m 0 8 kgf m 5...

Page 414: ...emove the hose from the fuel pump Before removing the hose place a few rags in the area under where it will be removed It is prohibited to wear the cotton work gloves or equivalent coverings EAS30460 REMOVING THE SECONDARY INJECTORS WARNING EWA17330 Check the injectors in a well ventilated area free of combustible materials Make sure that there is no smoking or use of electric tools in the vicinit...

Page 415: ...place Damage Replace 2 Check Injector resistance Refer to CHECKING THE FUEL INJEC TORS on page 8 51 EAS31664 CHECKING THE AIR FILTER CASE SEAL 1 Check Air filter case seal Damage Replace EAS30463 CHECKING THE INTAKE FUNNEL 1 Check Intake funnel servo motor rod assembly Damage scratches Replace Intake funnel assembly Cracks damage Replace 2 Check Intake funnel movement Sticks Replace the intake fun...

Page 416: ...not to twist or pinch the O rings when installing the injectors When installing the injector install it at the same position as the removed cylinder If an injector is subject to strong shocks or excessive force replace it If installing the original fuel rail and bolts remove the white paint marks using a cleaning solvent Otherwise paint chips on the bolt seats could prevent the bolts from being ti...

Page 417: ...nector cover on the fuel hose is in the correct position otherwise the fuel hose will not be properly installed TIP While pushing the ends a of the fuel hose connector cover 1 in direction b slide the fuel hose connector cover in direction c and then remove the hose from the fuel pump Before removing the hose place a few rags in the area under where it will be removed It is prohibited to wear the ...

Page 418: ...er to GENERAL CHASSIS 6 on page 4 23 Side cover bracket Refer to GENERAL CHASSIS 8 on page 4 32 Fuel tank Refer to FUEL TANK on page 7 1 Air filter case Refer to AIR FILTER CASE on page 7 5 Canister Refer to FUEL TANK on page 7 1 For California only 1 Throttle position sensor coupler 1 Disconnect 2 Intake air pressure sensor coupler 1 Disconnect 3 Coupler holder 1 3 2 1 LT 10 N m 1 0 kgf m 7 4 lb ...

Page 419: ...ector coupler 4 Disconnect 7 Intake solenoid vacuum hose 1 Disconnect 8 Coolant temperature sensor coupler sub wire harness 1 Disconnect 9 Throttle body joint clamp screw 4 Loosen 10 Throttle body assembly 1 11 Neutral switch connector 1 Disconnect 12 Heat protector 1 13 Throttle body joint 2 LT 11 13 12 13 6 6 6 6 10 5 8 4 9 7 10 N m 1 0 kgf m 7 4 lb ft T R 3 0 N m 0 30 kgf m 2 2 lb ft T R ...

Page 420: ...essure hose 5 2 Hose joint 2 3 Service hose 1 4 Intake air pressure sensor 1 5 Throttle position sensor 1 6 Fuel rail 2 7 Primary injector joint 1 8 Primary injector 4 6 6 7 4 1 1 3 1 2 1 1 5 2 8 8 8 8 New New 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 3 5 N m 0 35 kgf m 2 6 lb ft T R ...

Page 421: ...e pressure hose 5 4 Hose joint 2 5 Service hose 1 6 Intake air pressure sensor 1 7 Throttle position sensor 1 8 Fuel rail 2 9 Primary injector joint 1 10 Primary injector 4 8 8 9 6 3 3 5 3 4 3 3 7 1 1 1 1 2 1 1 2 2 4 10 10 10 10 New New 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 3 5 N m 0 35 kgf m 2 6 lb ft T R ...

Page 422: ...51 EAS30769 CHECKING AND CLEANING THE THROTTLE BODIES TIP Clean the throttle bodies only if they cannot be synchronized using the bypass air screws Be fore cleaning the throttle bodies check the fol lowing items Valve clearance Spark plugs Air filter element Throttle body joints Fuel hoses Air induction system Exhaust system Crankcase breather hose Vacuum hose WARNING EWA17340 If the throttle bodi...

Page 423: ...n from the air filter case side of the throttle body to the engine side NOTICE ECA17590 Do not use a tool such as a wire brush to remove the carbon deposits otherwise the inside of the throttle bodies may be dam aged Do not allow carbon deposits or other for eign materials to enter any of the passages in each throttle body or in the space be tween the throttle valve shaft and the throt tle body f ...

Page 424: ...r adhere to the injectors fuel rails or O rings Be careful not to twist or pinch the O rings when installing the injectors When installing the injector install it at the same position as the removed cylinder If an injector is subject to strong shocks or excessive force replace it If installing the original fuel rail and bolts remove the white paint marks using a cleaning solvent Otherwise paint ch...

Page 425: ...1 on page 4 1 Fuel tank cover Refer to FUEL TANK on page 7 1 2 Check Fuel pressure a Remove the fuel tank bolts and hold up the fuel tank b Disconnect the fuel hose 1 from the fuel pump Refer to FUEL TANK on page 7 1 WARNING EWA17320 Cover fuel hose connections with a cloth when disconnecting them Residual pres sure in the fuel lines could cause fuel to spurt out when removing the hose NOTICE ECA1...

Page 426: ...emoved a Temporary tighten the throttle position sensor screws b Check that the throttle valves are fully closed c Connect the throttle 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 SELF DIAGNOST...

Page 427: ... 20 EAS20071 AIR INDUCTION SYSTEM 1 Air filter case 2 Air cut off valve 3 Air induction system hose air filter case to air cut off valve 4 Cylinder head cover 5 Air induction system hose air cut off valve to reed valve cover ...

Page 428: ... 1 Atmospheric pressure sensor coupler 1 Disconnect 2 Intake air temperature sensor coupler 1 Disconnect 3 Air filter case duct 1 4 Atmospheric pressure sensor hose 1 5 Atmospheric pressure sensor 1 6 Damper 1 7 Intake air temperature sensor holder 1 8 Intake air temperature sensor 1 3 6 5 1 2 7 8 4 LT LT 10 N m 1 0 kgf m 7 4 lb ft T R 10 N m 1 0 kgf m 7 4 lb ft T R 2 5 N m 0 25 kgf m 1 8 lb ft T ...

Page 429: ...r 1 11 Air induction system hose air filter case to air cut off valve 1 12 Air induction system hose air cut off valve to reed valve cover 1 13 Air cut off valve 1 14 Reed valve cover 2 15 Reed valve assembly 2 16 Reed valve plate 4 13 14 15 16 14 15 16 11 10 9 12 LT LT 10 N m 1 0 kgf m 7 4 lb ft T R 10 N m 1 0 kgf m 7 4 lb ft T R 2 5 N m 0 25 kgf m 1 8 lb ft T R 0 3 N m 0 03 kgf m 0 22 lb ft T R ...

Page 430: ...ECU in accordance with the combus tion conditions Ordinarily the air cut off valve opens to allow the air to flow during idle and closes to cut off the flow when the vehicle is be ing driven However if the coolant temperature is below the specified value the air cut off valve remains open and allows the air to flow into the exhaust pipe until the temperature becomes higher than the specified value...

Page 431: ... THE AIR INDUCTION SYSTEM 1 Install Reed valve plate TIP Align the projection a on the cylinder head cov er 1 with the hole b in the reed valve plate 2 Install Reed valve assembly TIP Install the reed valve assembly so that the open side turns to the exhaust side of the engine 3 Install Reed valve cover A Exhaust side G089044 A G089045 T R Reed valve cover bolt 10 N m 1 0 kgf m 7 4 lb ft LOCTITE ...

Page 432: ...AIR INDUCTION SYSTEM 7 25 ...

Page 433: ...TROUBLESHOOTING 8 10 CHARGING SYSTEM 8 12 CIRCUIT DIAGRAM 8 12 TROUBLESHOOTING 8 13 LIGHTING SYSTEM 8 15 CIRCUIT DIAGRAM 8 15 TROUBLESHOOTING 8 17 SIGNALING SYSTEM 8 19 CIRCUIT DIAGRAM 8 19 TROUBLESHOOTING 8 21 COOLING SYSTEM 8 27 CIRCUIT DIAGRAM 8 27 TROUBLESHOOTING 8 29 FUEL PUMP SYSTEM 8 31 CIRCUIT DIAGRAM 8 31 TROUBLESHOOTING 8 33 COMMUNICATION CONTROL SYSTEM for YZF R1M 8 35 CIRCUIT DIAGRAM 8...

Page 434: ...MOTOR OPERATION 8 46 CHECKING THE STATOR COIL 8 46 CHECKING THE RECTIFIER REGULATOR 8 46 CHECKING THE HORN 8 47 CHECKING THE FUEL SENDER 8 47 CHECKING THE FUEL LEVEL WARNING LIGHT 8 48 CHECKING THE RADIATOR FAN MOTORS 8 48 CHECKING THE COOLANT TEMPERATURE SENSOR 8 48 CHECKING THE THROTTLE SERVO MOTOR 8 49 CHECKING THE AIR INDUCTION SYSTEM SOLENOID 8 49 CHECKING THE CYLINDER IDENTIFICATION SENSOR 8...

Page 435: ......

Page 436: ... R Br L R W R W R W R W R W R W L W L L W L R R L R B L R L W R W L B L Y B Y Sb W Sb L W Br W L R L R W L B B B B B B O R W B Gy R R W B O G R W B Gy G R W B B L R Gy L B L P W P V W W B L W B Y B L Gy G Br W Gy B W L L W L Y Gy Y G W G L W L W L W L W L W L W L B L B L B L B L B L B B R W L B L W B W L W L W L W L W L W L W L W L B L B L B L B L B L B L B B Gy B L Gy B Y R Lg R R L R G Y L Y B B...

Page 437: ...ht 27 Start engine stop switch 29 Relay unit 32 Neutral switch 33 Sidestand switch 43 Cylinder identification sensor 45 Crankshaft position sensor 48 ECU Engine Control Unit 49 Spark plug 50 Ignition coil 1 51 Ignition coil 2 52 Ignition coil 3 53 Ignition coil 4 70 IMU Inertial Measurement Unit Joint coupler for YZF R1 Joint coupler for YZF R1M ...

Page 438: ... is open However the engine continues to run under the following conditions The transmission is in gear the neutral switch is open and the sidestand is up the sidestand switch circuit is closed The transmission is in neutral the neutral switch is closed and the sidestand is down the sidestand switch circuit is open 10 11 9 1 4 5 7 2 6 3 8 1 Battery 2 Main fuse 3 Main switch 4 Ignition fuse 5 Start...

Page 439: ... page 8 42 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 SPARK PLUGS on page 3 5 Ignition system is OK 5 Check the ignition coils Refer to CHECKING THE IGNI TION COILS on page 8 44 Replace the ignition coil s 6 Check the cranksh...

Page 440: ...r to CHECKING THE SWITCHES on page 8 40 Replace the neutral switch 11 Check the sidestand switch Refer to CHECKING THE SWITCHES on page 8 40 Replace the sidestand switch 12 Check the relay unit diode Refer to CHECKING THE RELAY UNIT DIODE on page 8 43 Replace the relay unit 13 Check the entire ignition system s wiring Refer to CIRCUIT DIAGRAM on page 8 1 Properly connect or repair the ignition sys...

Page 441: ...IGNITION SYSTEM 8 6 ...

Page 442: ... R L W Sb L B Br L B W B W L Y L Y B B B B B B R R R Br L R Br L L W B R W R W R W R W R W R W R W R W L W L L W L R R L R B L R L W R W L B L Y B Y Sb W Sb L W Br W L R L R W L B B B B B B B Y B L R Gy L B L P W P V W W B L W B Y B L Gy G Br W Gy B W L L W L Y Gy Y G W G B Y L R B L W L W B Y B W L Y B Y R Lg R R L R G Y L Y B B W R L B W Sb G Y W L Br R Br Y L W Br B Sb W B Gy R P W O G O B R B ...

Page 443: ...18 Engine ground 19 Battery 20 Starter relay 22 Starter motor 23 Joint coupler 25 Handlebar switch right 27 Start engine stop switch 29 Relay unit 30 Starting circuit cut off relay 32 Neutral switch 33 Sidestand switch 48 ECU Engine Control Unit 89 Handlebar switch left 97 Clutch switch ...

Page 444: ...perating when neither of these condi tions has been met In this instance the starting circuit cut off relay is open so current cannot reach the starter motor When at least one of the above conditions has been met the starting circuit cut off relay is closed and the engine can be started by pressing the side of the start engine stop switch 12 1 11 4 6 6 6 6 a b 8 6 9 7 5 2 3 10 10 a WHEN THE TRANSM...

Page 445: ... 42 Clean the battery terminals Recharge or replace the battery 3 Check the starter motor operation Refer to CHECKING THE START ER MOTOR OPERATION on page 8 46 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 52 Repair or replace the starter motor 5 Check the relay unit starting ci...

Page 446: ...o CHECKING THE SWITCHES on page 8 40 Replace the sidestand switch 11 Check the clutch switch Refer to CHECKING THE SWITCHES on page 8 40 Replace the clutch switch 12 Check the start engine stop switch Refer to CHECKING THE SWITCHES on page 8 40 Replace the handlebar switch right 13 Check the entire starting system s wiring Refer to CIRCUIT DIAGRAM on page 8 7 Properly connect or repair the startin...

Page 447: ...STEM 8 12 EAS20074 CHARGING SYSTEM EAS30496 CIRCUIT DIAGRAM W W W R R R R B R R B B R R R R R B R R W W W W W W Dgy W B W W R 1 2 4 18 19 1 AC magneto 2 Rectifier regulator 4 Main fuse 18 Engine ground 19 Battery ...

Page 448: ...use 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 42 Clean the battery terminals Recharge or replace the battery 3 Check the stator coil Refer to CHECKING THE STATOR COIL on page 8 46 Replace the stator coil assembly 4 Check the rectifier regulator Refer to CHECKING THE RECTI FIER REGULATOR on page 8 46 Replace the rectifier regulator 5 Check the entire charging system s...

Page 449: ...CHARGING SYSTEM 8 14 ...

Page 450: ...R W R W L R B B L R Gy L B L P W P V W W B L W B Y B L Gy G Br W Gy B W L L W L Y Gy Y G W G B R G B L R B Y B R B B L R B Y B L R B R Y B Y Y B B R Y B W R W Br W Br B Br Y L W L B G W Dg Ch W L W Y R GR G Sb W G L G Y W G O Y G G B W B W G Gy G G Y G B L Y W Y W L B Y B Br Y B Y B G G Y G B L Y Y W Y W B B Y B B G B Y R Lg R R L R G Y L Y B B W R L B W Sb G Y W L Br R Br Y L W Br B Sb W B Gy R P...

Page 451: ...ontrol Unit 71 Meter assembly 76 Multi function meter 82 Meter light 84 High beam indicator light 89 Handlebar switch left 91 Pass LAP switch 92 Dimmer switch 100 Front turn signal position light right 101 Front turn signal position light left 102 Headlight control unit 103 Headlight high beam 104 Headlight low beam 106 Tail brake light 107 License plate light 108 Auxiliary light ...

Page 452: ...HE BATTERY on page 8 42 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 40 Replace the main switch 4 Check the dimmer switch Refer to CHECKING THE SWITCHES on page 8 40 The dimmer switch is faulty Replace the handlebar switch left 5 Check the Pass LAP switch Refer to CHECKING THE SWITCHES on page 8 40 The Pass LAP switch ...

Page 453: ...LIGHTING SYSTEM 8 18 ...

Page 454: ... B L R L W R W L B L Y B Y Sb W Sb L W Br W L R L R W Y L R Br Y B R L B G W B Dl L R G W B Y B Y B L R Gy L B L P W P V W W B L W B Y B L Gy G Br W Gy B W L L W L Y Gy Y G W G G B B Dg Br B B B B Ch B W W B B R W L W B B W Gy B L Y G R B B L W G O W L L B W W L B L W L W L W L W L W L W L B L B L B L B L B L B B B L V L R B W B B Y B L R B Br L R Gy Gy B Br B L W B G L R B B B Br W L W B W R W Br...

Page 455: ... warning light 74 Neutral indicator light 75 Shift indicator light 76 Multi function meter 78 Oil pressure and coolant temperature warning light 80 Turn signal indicator light right 81 Turn signal indicator light left 88 Oil pressure switch 89 Handlebar switch left 93 Horn switch 94 Turn signal switch 95 Hazard switch 96 Horn 98 Rear turn signal light right 99 Rear turn signal light left 100 Front...

Page 456: ... 1 Check the fuses Main ignition signaling system backup ABS ECU and hazard light ing Refer to CHECKING THE FUS ES on page 8 41 Replace the fuse s 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 42 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 40 Replace the main switch 4 Check the entire signal...

Page 457: ...heck the front brake light switch Refer to CHECKING THE SWITCHES on page 8 40 Replace the front brake light switch 2 Check the rear brake light switch Refer to CHECKING THE SWITCHES on page 8 40 Replace the rear brake light switch 3 Check the entire signaling sys tem s wiring Refer to CIRCUIT DIAGRAM on page 8 19 Properly connect or repair the signaling system s wiring Replace the tail brake light...

Page 458: ... THE SWITCHES on page 8 40 Replace the neutral switch 2 Check the relay unit diode Refer to CHECKING THE RELAY UNIT DIODE on page 8 43 Replace the relay unit 3 Check the entire signaling sys tem s wiring Refer to CIRCUIT DIAGRAM on page 8 19 Properly connect or repair the signaling system s wiring Replace the meter assembly 1 Check the entire signaling sys tem s wiring Refer to CIRCUIT DIAGRAM on ...

Page 459: ...age oil viscosity oil seal oil filter or oil pump Replace the oil pressure switch 1 Check the fuel sender Refer to CHECKING THE FUEL SENDER on page 8 47 Replace the fuel pump assembly 2 Check the entire signaling sys tem s wiring Refer to CIRCUIT DIAGRAM on page 8 19 Properly connect or repair the signaling system s wiring Replace the meter assembly 1 Check the coolant temperature sen sor Refer to...

Page 460: ...QS icon is lit Operate while the QS icon is lit 5 Is the transmission gear display normal Repair the gear position sensor 6 Check the connection of the cou pler between the gear position sen sor and the ECU Connect the gear position sensor coupler 7 Are the clutch and neutral switches normal Repair the switch if it is not normal 8 Check the shift sensor value in the DIAG mode 2 5 V when the shift ...

Page 461: ... and ECU coupler blue white blue white blue black blue black Between joint coupler and meter assembly coupler blue white blue white blue black blue black 1 Check the rear wheel sensor Refer to MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR on page 4 49 Replace the rear wheel sensor 2 Check the entire wheel sensor wir ing Refer to TIP Properly connect or repair the wheel sen sor wiring Repla...

Page 462: ... G W B L R R R R B B L B Br L G W B L B W B W R R R Br L R Br L R B R G Y R W B L R Gy L B L P W P V W W B L W B Y B L Gy G Br W Gy B W L L W L Y Gy Y G W G B L B L B B L W B L B B L G W B Y R Lg R R L R G Y L Y B B W R L B W Sb G Y W L Br R Br Y L W Br B Sb W B Gy R P W O G O B R B Gy G G B L B L R B P B O B B L B Y W Y B G B B B G L Y L Y B L G W B R W R W B L G W G W B L B 3 4 5 9 10 11 12 18 1...

Page 463: ...use 10 Sub radiator fan motor fuse 11 Radiator fan motor fuse 12 Ignition fuse 18 Engine ground 19 Battery 46 Coolant temperature sensor 48 ECU Engine Control Unit 110 Sub radiator fan motor right 111 Radiator fan motor left A Wire harness C Sub wire harness coolant temperature sensor ...

Page 464: ...Replace the fuse s 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 42 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 40 Replace the main switch 4 Check the radiator fan motor Refer to CHECKING THE RADIA TOR FAN MOTORS on page 8 48 Replace the radiator fan motor 5 Check the radiator fan motor rela...

Page 465: ... NG OK 7 Check the entire cooling system s wiring Refer to CIRCUIT DIAGRAM on page 8 27 Properly connect or repair the cooling sys tem s wiring Replace the ECU Refer to REPLACING THE ECU En gine Control Unit on page 8 41 ...

Page 466: ... R R R R B B Br L B W B W R L R R R Br L R Br L R W R W R W R W R W R W L W L L W L R R L R B L R L W R W L B L Y B Y Sb W Sb L W Br W L R L R W B R L B G W B B L R Gy L B L P W P V W W B L W B Y B L Gy G Br W Gy B W L L W L Y Gy Y G W G B Y R Lg R R L R G Y L Y B B W R L B W Sb G Y W L Br R Br Y L W Br B Sb W B Gy R P W O G O B R B Gy G G B L B L R B P B O B B L B Y W Y B G B B B G L Y L Y B L G ...

Page 467: ...ain fuse 7 Fuel injection system fuse 9 Backup fuse 12 Ignition fuse 18 Engine ground 19 Battery 23 Joint coupler 25 Handlebar switch right 27 Start engine stop switch 29 Relay unit 31 Fuel pump relay 35 Fuel pump 48 ECU Engine Control Unit ...

Page 468: ...ace the fuse s 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 42 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 40 Replace the main switch 4 Check the start engine stop switch Refer to CHECKING THE SWITCHES on page 8 40 Replace the handlebar switch right 5 Check the relay unit fuel pump re lay R...

Page 469: ...NG OK 7 Check the entire fuel pump sys tem s wiring Refer to CIRCUIT DIAGRAM on page 8 31 Properly connect or repair the fuel pump system s wiring Replace the ECU Refer to REPLACING THE ECU En gine Control Unit on page 8 41 ...

Page 470: ...L B R R R Br L R Br L R W R W R W R W G W R B W B Y O B L R Gy L B L P W P V W W B L W B Y B L Gy G Br W Gy B W L L W L Y Gy Y G W G L W L W L W L W L W L W L B L B L B L B L B L B B R W L B L W B W B W R W Br W Br B Br Y L W L B G W Dg Ch W L W Y R GR G Sb W G L G Y W G O Y G G B W B W G Gy L W B W R R G L B L W L W L W L W L W L W L W L B L B L B L B L B L B L B B L W L B B W R G B Y W O B Y R L...

Page 471: ...9 Backup fuse 12 Ignition fuse 18 Engine ground 19 Battery 23 Joint coupler 48 ECU Engine Control Unit 70 IMU Inertial Measurement Unit 71 Meter assembly 76 Multi function meter 85 YDT coupler 86 CCU Communication Control Unit 87 GPS unit A Wire harness E Sub wire harness CCU Communication Control Unit ...

Page 472: ...ECKING THE FUS ES on page 8 41 Replace the fuse s 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 42 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 40 Replace the main switch 4 Check the entire communication control system s wiring Refer to CIRCUIT DIAGRAM on page 8 35 Properly connect or repair ...

Page 473: ...otor 7 Secondary injector 8 Fuel pump 9 Battery 10 GPS unit for YZF R1M 11 CCU Communication Control Unit for YZF R1M 12 EXUP servo motor 13 IMU Inertial Measurement Unit 14 Hydraulic unit assembly ABS ECU 15 Shift sensor 16 Stator coil 17 Crankshaft position sensor 18 ECU Engine Control Unit 19 Radiator fan motor 20 Horn 21 Headlight control unit 22 Steering damper solenoid 23 SCU Suspension Cont...

Page 474: ...ensor 7 Neutral switch 8 Rear shock absorber assembly stepping motor for YZF R1M 9 Main fuse 10 Starter relay 11 Relay unit 12 Fuse box 1 13 Radiator fan motor relay 14 Rear wheel sensor 15 Rear brake light switch 16 Gear position sensor 17 Sidestand switch 18 O2 sensor 19 Oil pressure switch 20 Front wheel sensor 21 Cylinder identification sensor 22 Fuse box 3 SCU fuse for YZF R1M 23 Rectifier re...

Page 475: ...ck the wiring connections and if necessary replace the switch 1 L B L B L Y L Y 2 1 3 4 6 5 7 8 9 12 3 10 11 MODE DOWN 1 Start engine stop switch 2 Mode switch 3 Pass LAP switch 4 Dimmer switch 5 Horn switch 6 Turn signal switch 7 Hazard switch 8 Main switch 9 Sidestand switch 10 Clutch switch 11 Front brake light switch 12 Neutral switch 13 Rear brake light switch ...

Page 476: ...ge to the electri cal system cause the lighting and ignition systems to malfunction and could possibly cause a fire 4 Install Rider seat Passenger seat Refer to GENERAL CHASSIS 1 on page 4 1 Front panel left Refer to GENERAL CHASSIS 3 on page 4 9 EAS31006 REPLACING THE ECU Engine Control Unit 1 Turn the main switch to OFF 2 Replace the ECU Engine Control Unit 3 Clean the throttle bodies and reset ...

Page 477: ...nect Battery leads to the battery terminals NOTICE ECA13630 First connect the positive battery lead 1 and then the negative battery lead 2 TIP Route the positive battery lead 1 to the outside of the EXUP servo motor lead 3 and starter re lay lead 4 8 Check Battery terminals Dirt Clean with a wire brush Loose connection Connect properly 9 Lubricate Battery terminals 10 Install Battery cover Rider s...

Page 478: ...tive tester probe Relay operation 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 L W R W R W 1 2 3 4 Br W L W R W L R L L R L WR W L B L Y Sb B Y Sb W 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3...

Page 479: ... shown Continuity Positive tester probe sky blue 1 Negative tester probe black yellow 2 No continuity Positive tester probe black yellow 2 Negative tester probe sky blue 1 Continuity Positive tester probe sky blue 1 Negative tester probe blue yellow 3 No continuity Positive tester probe blue yellow 3 Negative tester probe sky blue 1 Continuity Positive tester probe sky blue 1 Negative tester probe...

Page 480: ...misfire occurs EAS30560 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 Ω to the crankshaft position sensor coupler as shown Digital circuit tester CD732 90890 03243 Model 88 Multimeter with ta ...

Page 481: ...L 1 Disconnect Stator coil coupler from the wire harness 2 Check Stator coil resistance Out of specification Replace the stator coil a Connect the digital circuit tester to the sta tor coil coupler as shown b Measure the stator coil resistance EAS30680 CHECKING THE RECTIFIER REGULATOR 1 Check Rectifier regulator input voltage Out of specification Correct the stator coil condition Refer to CHECKING...

Page 482: ...page 7 1 3 Remove Fuel pump from the fuel tank 4 Connect Fuel pump coupler Fuel hose 5 Turn the main switch to ON 6 Check Fuel level warning light Out of specification Replace the fuel pump 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 Pos...

Page 483: ...30578 CHECKING THE COOLANT TEMPERATURE SENSOR 1 Remove Coolant temperature sensor Refer to CYLINDER HEAD on page 5 33 WARNING EWA14130 Handle the coolant temperature sensor with special care Never subject the coolant temperature sen sor to strong shocks If the coolant tem perature sensor is dropped replace it 2 Check Coolant temperature sensor resistance Out of specification Replace a Connect the ...

Page 484: ...ervo motor TIP Do not use old batteries to operate the throttle servo motor EAS30587 CHECKING THE AIR INDUCTION SYSTEM SOLENOID 1 Check Air induction system solenoid resistance Out of specification Replace a Remove the air induction system solenoid coupler from the air induction system sole noid b Connect the digital circuit tester Ω to the air induction system solenoid terminal as shown T R Coola...

Page 485: ... THE INTAKE AIR TEMPERATURE SENSOR 1 Remove Intake air temperature sensor WARNING EWA14110 Handle the intake air temperature sensor with special care Never subject the intake air temperature sensor to strong shocks If the intake air temperature sensor is dropped replace it 2 Check Intake air temperature sensor resistance Out of specification Replace a Connect the digital circuit tester Ω to the in...

Page 486: ...er c Measure the steering damper solenoid re sistance EAS30681 CHECKING THE FUEL INJECTORS The following procedure applies to all of the fuel injectors 1 Remove Fuel injector Refer to THROTTLE BODIES on page 7 11 or AIR FILTER CASE on page 7 5 2 Check Fuel injector resistance Out of specification Replace the fuel injec tor a Disconnect the fuel injector coupler from the fuel injector b Connect the...

Page 487: ... e When turning the wheel switch in direction a check that the output voltage is within the specified values f When turning the wheel switch in direction b check that the output voltage is within the specified values Digital circuit tester CD732 90890 03243 Model 88 Multimeter with ta chometer YU A1927 Positive tester probe white green 2 Negative tester probe black yellow 3 Output voltage reading ...

Page 488: ...ELECTRICAL COMPONENTS 8 53 ...

Page 489: ... NOT NORMAL 9 14 ABS Anti lock Brake System 9 15 CIRCUIT DIAGRAM 9 15 ABS COMPONENTS CHART 9 17 ABS COUPLER LOCATION CHART 9 18 MAINTENANCE OF THE ABS ECU 9 19 ABS TROUBLESHOOTING OUTLINE 9 19 BASIC INSTRUCTIONS FOR TROUBLESHOOTING 9 20 A CHECKING THE ABS WARNING LIGHT 9 22 A 1 ONLY THE ABS WARNING LIGHT FAILS TO COME ON 9 22 A 2 ALL INDICATOR LIGHTS FAIL TO COME ON 9 22 A 3 THE ABS WARNING LIGHT ...

Page 490: ...ION TABLE FOR STEERING DAMPER SYSTEM 9 56 SELF DIAGNOSTIC FUNCTION TABLE FOR ELECTRONICALLY ADJUSTABLE SUSPENSION SYSTEM for YZF R1M 9 56 COMMUNICATION ERROR WITH THE METER 9 59 DIAGNOSTIC CODE SENSOR OPERATION TABLE 9 59 DIAGNOSTIC CODE ACTUATOR OPERATION TABLE 9 62 DIAGNOSTIC CODE TABLE SCU for YZF R1M 9 64 EVENT CODE TABLE 9 65 30_EVENT 9 67 TROUBLESHOOTING 9 67 70_EVENT 9 69 TROUBLESHOOTING 9 ...

Page 491: ...7 9 101 TROUBLESHOOTING 9 101 P0107 P0108 9 105 TROUBLESHOOTING 9 105 P0112 P0113 9 109 TROUBLESHOOTING 9 109 P0117 P0118 9 113 TROUBLESHOOTING 9 113 P0122 P0123 P0222 P0223 P2135 9 117 TROUBLESHOOTING 9 117 P0132 9 121 TROUBLESHOOTING 9 121 P0152 9 124 TROUBLESHOOTING 9 124 P0201 9 127 TROUBLESHOOTING 9 127 P0202 9 130 TROUBLESHOOTING 9 130 P0203 9 133 TROUBLESHOOTING 9 133 ...

Page 492: ...9 153 TROUBLESHOOTING 9 153 P0354 9 157 TROUBLESHOOTING 9 157 P0475 P0476 P048B 9 161 TROUBLESHOOTING 9 161 P0480 9 165 TROUBLESHOOTING 9 165 P048D P048E 9 168 TROUBLESHOOTING 9 168 P0500 FI P1500 9 171 TROUBLESHOOTING 9 171 P0500 SCU 9 183 TROUBLESHOOTING 9 183 P0560 FI P0563 9 184 TROUBLESHOOTING 9 184 P0560 SCU 9 185 TROUBLESHOOTING 9 185 P0601 9 186 TROUBLESHOOTING 9 186 ...

Page 493: ... P1400 9 201 TROUBLESHOOTING 9 201 P1600 9 205 TROUBLESHOOTING 9 205 P1601 9 209 TROUBLESHOOTING 9 209 P1602 9 213 TROUBLESHOOTING 9 213 P1806 P1807 9 217 TROUBLESHOOTING 9 217 P2122 P2123 P2127 P2128 P2138 9 221 TROUBLESHOOTING 9 221 P2158 FI 9 225 TROUBLESHOOTING 9 225 P2158 SCU 9 229 TROUBLESHOOTING 9 229 P21CF 9 230 TROUBLESHOOTING 9 230 P21D0 9 233 TROUBLESHOOTING 9 233 ...

Page 494: ...0125 FI 9 252 TROUBLESHOOTING 9 252 U0125 SCU 9 256 TROUBLESHOOTING 9 256 U0155 or Err FI 9 259 TROUBLESHOOTING 9 259 U0155 or Err SCU 9 263 TROUBLESHOOTING 9 263 11_ABS 9 266 TROUBLESHOOTING 9 266 12_ABS 9 267 TROUBLESHOOTING 9 267 13 26_ABS 9 268 TROUBLESHOOTING 9 268 14 27_ABS 9 269 TROUBLESHOOTING 9 269 15_ABS 9 270 TROUBLESHOOTING 9 270 16_ABS 9 272 TROUBLESHOOTING 9 272 ...

Page 495: ...TING 9 280 42_ABS 9 281 TROUBLESHOOTING 9 281 43 45_ABS 9 282 TROUBLESHOOTING 9 282 44 46_ABS 9 283 TROUBLESHOOTING 9 283 51_ABS 9 284 TROUBLESHOOTING 9 284 53_ABS 9 285 TROUBLESHOOTING 9 285 55_ABS 9 287 TROUBLESHOOTING 9 287 56_ABS 9 288 TROUBLESHOOTING 9 288 57_ABS 9 289 TROUBLESHOOTING 9 289 62_ABS 9 293 TROUBLESHOOTING 9 293 68_ABS 9 294 TROUBLESHOOTING 9 294 ...

Page 496: ...89_ABS 9 295 TROUBLESHOOTING 9 295 90_ABS 9 298 TROUBLESHOOTING 9 298 91_ABS 9 301 TROUBLESHOOTING 9 301 ...

Page 497: ......

Page 498: ...e of the warning light coming on without malfunction Reprogramming of the ECU software Using the electrical accessory which may affect the ECU Using the incorrect specification of spark plug and fuel injector Using the third party accessories such as suspension and exhaust system Change of specifications of drive chain sprocket wheel and tire Removing or modifying the O2 sensor the air induction s...

Page 499: ...l A I 90890 03262 YDT sub harness 6P 90890 03266 is separately required A GST can also be used to identify malfunctions Connecting the YDT Remove the protective cap 1 and then connect the YDT to the coupler System Lighting up warning light Lighting time FUEL INJECTION SYSTEM MIL 2 2 0 seconds ABS Anti lock Brake System ABS warning light 1 STEERING DAMPER SYS TEM Auxiliary system warning light 3 2 ...

Page 500: ...solenoid Secondary injector 2 Throttle servo motor Secondary injector 3 Relay unit Secondary injector 4 Starter relay Ignition coil 1 Radiator fan motor relay Ignition coil 2 Meter assembly Ignition coil 3 Steering damper solenoid Ignition coil 4 EXUP servo motor Throttle position sensor Cylinder identification sensor Accelerator position sensor Intake funnel servo motor Intake air pressure sensor...

Page 501: ...ping motor re bound damping Fuel sender Steering damper solenoid OPTION Fuel pump ECU Engine Control Unit Handlebar switch left Hydraulic unit assembly ABS ECU Headlight control unit Meter assembly Auxiliary light IMU Inertial Measurement Unit Front turn signal position light right and left CCU Communication Control Unit Steering damper solenoid Radiator fan motor SCU Suspension Control Unit YZF R...

Page 502: ...or 20 Cylinder identification sensor 21 Crankshaft position sensor 22 EXUP servo motor 23 Atmospheric pressure sensor 24 Intake air pressure sensor 25 Coolant temperature sensor 26 Intake air temperature sensor 27 Shift sensor 11 Fuel pump 13 Neutral indicator light 42 Throttle servo motor 10 Fuel pump relay 7 Main fuse 8 Battery 25 23 24 21 22 14 18 1 10 7 6 9 8 17 A B a A B 29 26 32 41 96 95 80 ...

Page 503: ...or position sensor 31 Throttle position sensor 29 O2 sensor 1 left side 30 O2 sensor 2 right side 47 Intake funnel servo motor 22 EXUP servo motor 48 Steering damper solenoid 49 Intake solenoid 50 Air induction system solenoid 52 Dimmer switch 53 Pass LAP switch 55 Meter assembly 56 CAN communication circuit 33 Hydraulic unit assembly ABS ECU a 11 19 51 Radiator fan motor relay 54 Headlight contro...

Page 504: ...mperature sensor 26 Intake air temperature sensor 27 Shift sensor 28 Gear position sensor 29 O2 sensor 1 left side 30 O2 sensor 2 right side 31 Throttle position sensor 32 Accelerator position sensor 33 Hydraulic unit assembly ABS ECU 34 Primary injector 1 35 Primary injector 2 36 Primary injector 3 37 Primary injector 4 38 Secondary injector 1 39 Secondary injector 2 40 Secondary injector 3 41 Se...

Page 505: ... Primary injector 1 R B 16 Primary injector 2 G B 17 Ground B 18 Electronic throttle valve fuse R L 19 Radiator fan motor re lay G Y 20 Air induction system solenoid Br R 21 Secondary injector 3 Br Y 22 Secondary injector 4 Br B 23 Secondary injector 1 W L 24 Secondary injector 2 Sb W 25 Ground B 26 Backup fuse R G 27 28 Pass LAP switch dim mer switch headlight control unit Y B 29 Fuel pump relay ...

Page 506: ...lay clutch switch B Y 81 82 No Connected parts Wire harness color 83 84 O2 sensor 1 left side Gy G 85 86 Intake air tempera ture sensor Br W 87 88 Cylinder identification sensor crankshaft po sition sensor EXUP servo motor atmo spheric pressure sen sor intake air pressure sensor cool ant temperature sen sor intake air temperature sensor shift sensor O2 sen sor 1 left side O2 sensor 2 right side B ...

Page 507: ...SYSTEM DIAGRAM 9 10 ...

Page 508: ...B L B B B W B W L Y L Y R R R Br L R Br L R B R G Y R W R W R W R W R W Y G Y R W B W G B W R Y B L Y B B Y B W B L L G R W P B Gy G B L B R W R W L W L L W L R R L R B L R L W R W L B L Y B Y Sb W Sb L W Br W L R L R W L B B B B B B B B Y B B R B Sb Y L B R L B G W B L R R W B Dl L R G W O R W B Gy R R W B O G R W B Gy G R W B Lg R Y R B R W Br R G O R LR B R L G B R L L B R L O B B L R Gy L B L ...

Page 509: ...ensor 48 ECU Engine Control Unit 49 Spark plug 50 Ignition coil 1 51 Ignition coil 2 52 Ignition coil 3 53 Ignition coil 4 54 Air induction system solenoid 55 Primary injector 1 56 Primary injector 2 57 Primary injector 3 58 Primary injector 4 59 Secondary injector 1 60 Secondary injector 2 61 Secondary injector 3 62 Secondary injector 4 63 Intake funnel servo motor 64 Throttle servo motor 65 Stee...

Page 510: ...ck and repair it according to applicable troubleshooting When turning the main switch to ON does the MIL come on Does the MIL LED work properly B Perform the checking with the diagnostic mode Check the MIL LED The MIL goes off after 2 seconds Still on flash A Check the DTC Do the troubleshooting according to the DTCs of malfunction Check the DTCs of malfunction are not displayed on the screen Fini...

Page 511: ...Refer to DIAGNOSTIC CODE SENSOR OPERATION TABLE on page 9 59 and DIAGNOSTIC CODE ACTUATOR OPERATION TABLE on page 9 62 If a malfunction is detected in the sensors or actuators repair or replace all faulty parts If no malfunction is detected in the sensors and actuators check and repair the inner parts of the engine D01 Throttle position sensor signal 1 throttle angle D13 Throttle position sensor s...

Page 512: ...R W R W R W R W L W L W L W R W R W L W L L W L R R L R B Y L R Br Y B Y B Y B L R Gy L B L P W P V W W B L W B Y B L Gy G Br W Gy B W L L W L Y Gy Y G W G B W W B B W W B B R W L W B B W Gy B L Y G R B B L W G O W L L B W W L B L W L W L W L W L W L W L B L B L B L B L B L B B R W L B L W B W B Y B L R B W R W Br W Br B Br Y L W L B G W Dg Ch W L W Y R GR G Sb W G L G Y W G O Y G G B W B W G Gy L...

Page 513: ...y 21 ABS motor fuse 23 Joint coupler 24 Front brake light switch 25 Handlebar switch right 48 ECU Engine Control Unit 66 Hydraulic unit assembly ABS ECU 67 Front wheel sensor 68 Rear wheel sensor 70 IMU Inertial Measurement Unit 71 Meter assembly 76 Multi function meter 83 ABS warning light 85 YDT coupler 105 Rear brake light switch 106 Tail brake light Joint coupler for YZF R1 Joint coupler for Y...

Page 514: ...draulic unit assembly ABS ECU 3 Fuse box 1 4 ABS solenoid fuse 5 YDT coupler 6 Starter relay 7 ABS motor fuse 8 Rear brake caliper 9 Rear wheel sensor rotor 10 Rear wheel sensor 11 Front brake caliper left 12 Front wheel sensor 13 Front wheel sensor rotor 14 Front brake caliper right 15 Fuse box 2 16 Signaling system fuse ...

Page 515: ...r Y L W Lg L B G W Dg Ch W L W Y R GR GSb WG L G Y W G O Y G G B W B W G Gy L WB W R R GL B B R W L W B B W Gy B L Y G R B B L W G O W L L B W W L B B W W B B W W B 5 4 2 1 3 1 Meter assembly coupler 2 YDT coupler 3 ABS ECU coupler 4 Rear wheel sensor coupler 5 Front wheel sensor coupler ...

Page 516: ... 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 main switch is turned to ON and finishes when the vehicle has traveled at a speed of approximately 10 km h 6 mi h 2 The ABS warning light comes on after the engine starts and then goes off when the ve...

Page 517: ...emblies and cannot be disassembled The malfunction history is stored in the memory of the ABS ECU Delete the DTC when the service is finished This is because the past DTC will be displayed again if another malfunction occurs EAS32895 BASIC INSTRUCTIONS FOR TROUBLESHOOTING 1 Check the DTC of malfunction using the YDT 2 Check and repair the malfunction according to applicable DTC troubleshooting 3 T...

Page 518: ...ks Were all of the final checks completed normally The reaction force generated during brake line routing confirmation is incorrect Refer to C 1 FINAL CHECK The brake hoses and brake pipes are not connected correctly The ABS warning light does not go off when the light is checked Refer to C 1 FINAL CHECK The malfunction is not corrected There is a break in the wire harness between the ABS ECU and ...

Page 519: ...the main switch for continuity Refer to CHECKING THE SWITCHES on page 8 40 If there is no continuity replace the main switch unit 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 42 If the battery is defective clean the battery terminals and recharge it or replace the battery 3 Main fuse Check the fuse for continuity Refer to CHECKING THE FUSES on p...

Page 520: ...T is properly connected 2 Wire harness Open circuit in the wire harness between the ABS ECU coupler and the YDT coupler Check for continuity between blue white terminal of the ABS ECU coupler and blue white terminal of the YDT coupler CANH Check for continuity between blue black terminal of the ABS ECU coupler and blue black terminal of the YDT coupler CANL EAS32903 B 1 MALFUNCTION ARE CURRENTLY D...

Page 521: ...E FLUID LEVEL on page 3 13 2 Check the wheel sensors for proper installation Refer to INSTALLING THE FRONT WHEEL DISC BRAKE on page 4 40 and INSTALLING THE REAR WHEEL DISC BRAKE on page 4 49 3 Perform brake line routing confirmation Refer to HYDRAULIC UNIT OPERATION TEST on page 4 79 If it does not have reaction force properly the brake hose is not properly routed or connected 4 Delete the DTCs Re...

Page 522: ... W R W B B Y B B B L R Gy L B L P W P V W W B L W B Y B L Gy G Br W Gy B W L L W L Y Gy Y G W G L W L W L W L W L W L W L B L B L B L B L B L B B W R W Br W Br B Br Y L W L B G W Dg Ch W L W Y R GR G Sb W G L G Y W G O Y G G B W B W G Gy L W B W R R G L B L W L W L W L W L W L W L W L B L B L B L B L B L B L B B Y R Lg R R L R G Y L Y B B W R L B W Sb G Y W L Br R Br Y L W Br B Sb W B Gy R P W O G...

Page 523: ... fuse 9 Backup fuse 12 Ignition fuse 18 Engine ground 19 Battery 23 Joint coupler 48 ECU Engine Control Unit 65 Steering damper solenoid 71 Meter assembly 76 Multi function meter 79 Auxiliary system warning light 85 YDT coupler Joint coupler for YZF R1 Joint coupler for YZF R1M ...

Page 524: ...lfunction using the YDT 2 Check and repair the malfunction according to applicable DTC troubleshooting 3 Turn the main switch from OFF to ON and then check the DTC of malfunction is not displayed TIP If another DTC is displayed repeat steps 1 to 3 until no DTC is displayed Turning the main switch to OFF will not erase the malfunction history ...

Page 525: ...STEERING DAMPER SYSTEM 9 28 ...

Page 526: ... L W B Y B L Gy G Br W Gy B W L L W L Y Gy Y G W G B L B L W Y B P B W G W R W B W Gy B P L G B G L Y G Gy R Br W P W Y Y R Gy G P Gy G B G R L W L W L W L W L W L W L B L B L B L B L B L B G R G B G G L P W P B P P L W R W B W W G Y R Y B Y Y G Gy G Gy B Gy Gy R B R W L B L W B W B W R W Br W Br B Br Y L W L B G W Dg Ch W L W Y R GR G Sb W G L G Y W G O Y G G B W B W G Gy L W B W R R G L B L W L ...

Page 527: ...iliary system warning light 85 YDT coupler 112 SCU fuse 113 SCU Suspension Control Unit 114 Front fork stepping motor left 115 Front fork stepping motor right 116 Rear shock absorber assembly stepping motor compression damping 117 Rear shock absorber assembly stepping motor rebound damping 118 Steering damper solenoid OPTION A Wire harness G Sub wire harness SCU steering damper solenoid sub wire h...

Page 528: ...or clean TIP If the SCU couplers are clogged with mud or dirt clean with compressed air EAS32916 BASIC INSTRUCTIONS FOR TROUBLESHOOTING 1 Check the DTC of malfunction using the YDT 2 Check and repair the malfunction according to applicable DTC troubleshooting 3 Turn the main switch from OFF to ON and then check the DTC of malfunction is not displayed TIP If another DTC is displayed repeat steps 1 ...

Page 529: ...nit assembly abnormal ABS mo tor power supply 34_ABS Hydraulic unit assembly short circuit in ABS motor power supply circuit 41_ABS Front wheel ABS intermittent wheel speed pulses or incorrect depressurization 42_ABS Rear wheel ABS intermittent wheel speed pulses or incorrect depressurization 43 45_ABS Front wheel sensor missing pulses 44 46_ABS Rear wheel sensor missing pulses 51_ABS Vehicle syst...

Page 530: ... or atmospheric pressure sensor when the main switch is turned to ON the intake air pressure sen sor voltage and atmospheric pressure sen sor voltage differ greatly Able Able D02 D03 P00D1 P2195 P00D1 O2 sensor 1 heater performance deterioration P2195 O2 sensor 1 open circuit detected Able Able P00D3 P2197 P00D3 O2 sensor 2 heater performance deterioration P2197 O2 sensor 2 open circuit detected A...

Page 531: ...ylin ders D37 P0203 Primary injector 3 malfunction in primary injector 3 Able dependingon the number of faulty cylin ders Able dependingon the number of faulty cylin ders D38 P0204 Primary injector 4 malfunction in primary injector 4 Able dependingon the number of faulty cylin ders Able dependingon the number of faulty cylin ders D39 P0335 Crankshaft position sensor no normal sig nals are received...

Page 532: ...om the rear wheel sensor P1500 Neutral switch open or short circuit is detected Clutch switch open or short circuit is detect ed Able Able D07 D21 P0500 SCU Abnormal rear wheel sensor Able Able P0560 FI P0563 P0560 FI Charging voltage is abnormal P0563 Vehicle system power voltage out of range Able Able P0560 SCU Abnormal SCU power supply voltage Able Able D09 P0601 Internal malfunction in ECU Whe...

Page 533: ... no normal signals are received from the front wheel sensor Able Able D16 P2158 SCU Front wheel sensor no normal signals are received from the front wheel sensor Able Able P21CF Secondary injector 1 malfunction in sec ondary injector 1 Able dependingon the number of faulty cylin ders Able dependingon the number of faulty cylin ders D40 P21D0 Secondary injector 2 malfunction in sec ondary injector ...

Page 534: ...he IMU Unable Able Unable U0125 SCU Abnormal CAN communication between IMU and SCU Able Able U0155 or Err FI Multi function meter signals cannot be transmitted between the ECU and the multi function meter Able Able U0155 or Err SCU Abnormal CAN communication between meter assembly and SCU Able Able DTC Symptom Fail safe system Diagnostic code Starting the engine Driving the vehicle ...

Page 535: ...tances Engine cannot be started depending on the circumstances P0030 O2 sensor 1 heater defective heater con troller detected Open or short cir cuit in wire harness Disconnected cou pler Defective O2 sensor 1 heater controller Malfunction in ECU Broken or discon nected lead in O2 sensor 1 heater When the O2 sensor 1 does not operate because the exhaust temperature is low Increased exhaust emission...

Page 536: ...C learning is not carried out QSS is not carried out P00D1 O2 sensor 1 heater performance deterio ration Improperly installed O2 sensor 1 Defective coupler between O2 sensor 1 and ECU Open or short cir cuit in wire harness between O2 sensor 1 and ECU Incorrect fuel pres sure Defective O2 sensor 1 Malfunction in ECU Increased exhaust emissions O2 feedback is not carried out O2 learning is not car r...

Page 537: ...to 101 3 kPa O2 feedback is not carried out ISC feedback is not carried out ISC learning is not carried out QSS is not carried out P0112 P0113 P0112 Intake air temperature sensor ground short circuit detected P0113 Intake air temperature sensor open or power short circuit detected P0112 Low voltage of the intake air tem perature sensor circuit 0 1 V or less P0113 High voltage of the intake air tem...

Page 538: ... short circuit detected P0223 Throttle posi tion sensor power short circuit detected P2135 Throttle posi tion sensor output voltage deviation er ror P0122 P0222 Low voltage of the throttle position sensor circuit 0 25 V or less P0123 P0223 High voltage of the throttle position sensor circuit 4 75 V or more P2135 Difference in output voltage 1 and output voltage 2 of the throttle position sen sor D...

Page 539: ... is not carried out O2 feedback learning is not carried out Air induction system solenoid is turned on all the time air induc tion system air cut off QSS is not carried out P0201 P0202 P0203 P0204 P0201 Primary injec tor 1 malfunction in primary injector 1 P0202 Primary injec tor 2 malfunction in primary injector 2 P0203 Primary injec tor 3 malfunction in primary injector 3 P0204 Primary injec tor...

Page 540: ...d out ISC learning is not carried out P0340 Cylinder identification sensor no normal signals are received from the cylinder iden tification sensor Defective coupler between cylinder identification sensor and ECU Open or short cir cuit in wire harness between cylinder identification sensor and ECU Improperly installed cylinder identifica tion sensor Defective pickup ro tor Defective cylinder identi...

Page 541: ...m solenoid is turned on all the time air induc tion system air cut off O2 feedback is not carried out ISC feedback is not carried out ISC learning is not carried out QSS is not carried out P0475 EXUP servo motor performance deterio ration Defective coupler between EXUP ser vo motor and ECU Open or short cir cuit in wire harness between EXUP ser vo motor and ECU Improperly installed EXUP servo moto...

Page 542: ...een EXUP ser vo motor and ECU Improperly installed EXUP servo motor and cables Defective EXUP ser vo motor Stuck EXUP servo motor mechanism or motor Malfunction in ECU Loss of engine power Learning values for fully closed EXUP are fixed Learning values for fully open EXUP are fixed O2 feedback is not carried out P048D P048E P048D EXUP servo motor open or ground short circuit detected P048E EXUP se...

Page 543: ...f control when the rear wheel sensor or neutral switch malfunctions is carried out ISC feedback is not carried out ISC learning is not carried out Traction control does not work QSS is not carried out P0560 Charging voltage is abnormal Battery over dis charging broken or disconnected lead in charging system Battery over dis charging defective rectifier regulator Engine is difficult to start Increa...

Page 544: ...t correct CO adjustment value for the faulty cylinder 0 default value ISC learning values Default values OBD memory value is initialized Initialization of O2 feedback learning val ue P0638 YCC T drive system malfunction detected Defective coupler between throttle ser vo motor and ECU Open or short cir cuit in wire harness between throttle ser vo motor and ECU Defective throttle servo motor Throttl...

Page 545: ...en or short cir cuit in wire harness Disconnected cou pler Defective air induc tion system sole noid Defective air induc tion system sole noid controller malfunction in ECU Increased exhaust emissions Electric current in air induction system so lenoid is prohibited air induction system air in O2 feedback is not carried out P1600 Lean angle sensor open or short circuit detected Open or short cir cu...

Page 546: ...n or ground short cir cuit detected P2123 Accelerator position sensor pow er short circuit detect ed P2127 Accelerator position sensor open or ground short cir cuit detected P2128 Accelerator position sensor pow er short circuit detect ed P2138 Deviation er ror P2122 P2127 Low voltage of the acceler ator position sensor circuit 0 25 V or less P2123 P2128 High voltage of the acceler ator position s...

Page 547: ... Open or short cir cuit in wire harness between O2 sensor 1 and ECU Incorrect fuel pres sure Defective O2 sensor 1 Malfunction in ECU Increased exhaust emissions O2 feedback is not carried out O2 feedback learning is not carried out Air induction system solenoid is turned on all the time air induc tion system air cut off QSS is not carried out P2197 O2 sensor 2 open cir cuit detected Signal voltag...

Page 548: ...ted P2228 Low voltage of the atmospheric pressure sensor cir cuit 0 5 V or less P2229 High voltage of the atmospheric pressure sensor cir cuit 4 8 V or more Defective coupler between atmospher ic pressure sensor and ECU Open or short cir cuit in wire harness between atmospher ic pressure sensor and ECU Improperly installed atmospheric pres sure sensor Defective atmo spheric pressure sensor Malfunc...

Page 549: ... 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 13 26 Front wheel sensor abnor mal pulse period Front wheel sensor signal is not received properly The pulse period is abnormal while the veh...

Page 550: ...lown ABS solenoid fuse Defective coupler between the battery and the hydrau lic unit assembly Open or short circuit in the wire harness between the battery and the 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 betw...

Page 551: ...y 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 Vehicle system power supply voltage of ABS ECU power supply is high Power voltage supplied to ...

Page 552: ...trical interlock ing brake Defective front brake line Defective hydraulic unit as sembly 89 CAN communication be tween meter assembly and hydraulic unit assembly Transmitted data from the meter cannot be normally re ceived Defective coupler between meter assembly and hy draulic unit assembly Harness is broken or short circuit between meter as sembly and hydraulic unit assembly Defective meter asse...

Page 553: ...en steering damper solenoid and ECU Defective steering damper solenoid Malfunction in ECU Steering damper does not work Solenoid fixed at OFF DTC Item Probable cause of malfunction Vehicle symptom Fail safe system operation C0044 Abnormal ABS Defective front and rear brake line Defective hydraulic unit assembly ERS adjustments can not be performed The damping preset value is fixed at the prescribe...

Page 554: ...n automatic setting modes P0560 Abnormal SCU power supply volt age Battery overcharg ing defective rectifi er regulator Battery overcharg ing broken or dis connected lead in rectifier regulator wire harness Battery over dis charging broken or disconnected lead in charging system Battery over dis charging defective rectifier regulator ERS adjustments can not be performed P2158 Front wheel sen sor n...

Page 555: ...sembly and SCU couplers Wire harness conti nuity Malfunction in SCU Malfunction in meter assembly ERS adjustments can not be performed The damping preset value is fixed at the prescribed position automatic setting modes Abnormality in side SCU Malfunction in SCU ERS adjustments can not be performed The Err and ERS icons are displayed on the meter display Steering damper stepping motor manufactured...

Page 556: ...sed Fully open position 96 107 Check with throttle valves ful ly open D02 Atmospheric pressure Displays the atmospheric pressure Compare the actually mea sured atmospheric pressure with the tool display value D03 Intake air pressure Displays the intake air pres sure Operate the throttle while pushing the side of the start engine stop switch If the display value changes the performance is OK D05 In...

Page 557: ...he front wheel is rotated The number is cu mulative and does not reset each time the wheel is stopped D17 Bank angle display Displays the bank angle in in crements of 5 0 5 vehicle is vertical Less than 30 when the sidestand is used Check that 0 5 is displayed when the vehicle is vertical and that the displayed value increases as the vehicle con tinues to incline D20 Sidestand switch Extend and re...

Page 558: ...earning data has been erased 01 It is not necessary to erase the ISC Idle Speed Control learning data 02 It is necessary to erase the ISC Idle Speed Control learning data To erase the ISC Idle Speed Control learning data push the Operation button 3 times in 5 seconds D70 Control number 0 254 D87 O2 feedback learning data erasure 00 O2 feedback learning data has been erased 01 O2 feedback learning ...

Page 559: ...ch time the ignition coil is actu ated Check that a spark is gener ated five times Connect an ignition check er D34 Intake funnel servo motor Actuates the intake funnels up position down position for each six seconds Illuminates the check indi cator Check the operating of the intake funnel servo motor D36 Primary injector 1 Actuates the primary injec tor 1 five times at one sec ond intervals The c...

Page 560: ...n jector 3 five times at one second intervals The check indicator on the YDT screen come on each time the fuel injector is actu ated Disconnect the fuel pump coupler before doing this procedure Check that secondary injec tor 3 is actuated five times by listening for the operating sound D43 Secondary injector 4 Actuates the secondary in jector 4 five times at one second intervals The check indicato...

Page 561: ...ve times at five seconds intervals The check indicator on the YDT screen come on each time the relay is actuated Check that the radiator fan motor relay is actuated five times by listening for the op erating sound D52 Headlight relay Actuates the headlight five times at five seconds inter vals The check indicator on the YDT screen come on each time the headlight is actuat ed Check that the headlig...

Page 562: ...118 Perform the inspection items listed for DTC num ber P0117 and P0118 197 Intake air tem perature sensor Brief abnormality de tected in the intake air temperature sensor Same as for DTC num ber P0112 and P0113 Perform the inspection items listed for DTC num ber P0112 and P0113 198 Atmospheric pressure sensor Brief abnormality de tected in atmospher ic pressure sensor Same as for DTC num ber P222...

Page 563: ...ent During idling the ad justment is main tained at the lower limit Idling engine speed is fast Poorly adjusted clutch cable Malfunction in the fuel injection system Dirty or worn spark plug Malfunction in the bat tery Malfunction in ECU If a DTC is occurring re spond to that first Rarely Code 243 occurs even when the system is functioning properly 244 Poor starting in ability to start Poor starti...

Page 564: ...Defective IMU Execute the diagnostic mode Code D17 Check that 0 5 is displayed when the vehicle is vertical and that the displayed value increases as the vehicle continues to incline Is the MIL on YES Go to step 2 NO Service is completed Is check result OK YES Go to step 3 NO a Fix the IMU installation condition b Turn the main switch to ON then to OFF and then back to ON Is the MIL on YES Go to s...

Page 565: ...30_EVENT 9 68 4 Malfunction in ECU Replace the ECU and complete the service Refer to REPLACING THE ECU Engine Control Unit on page 8 41 NO Service is completed ...

Page 566: ...s displayed at the same time check the other error code first and repair it 1 Allow to idle for a long period Turn the main switch to OFF Check whether it is possible to start the engine 2 Malfunction in ECU Replace the ECU and complete the service Refer to REPLACING THE ECU Engine Control Unit on page 8 41 Can the engine starting YES Service is completed NO Go to step 2 ...

Page 567: ...re 1 Abnormal ABS Check the items of DTCs 62 and 68 for the ABS Refer to B 2 DIAGNOSIS USING THE DTC on page 9 23 Turn the main switch to OFF and back to ON and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Service is completed NO Refer to the item corresponding to the DTC ...

Page 568: ...t coupler 2 IMU coupler 3 and ignition fuse 4 Open circuit check Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Turn the main switch to ON and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to step 2 Is the coupler condition n...

Page 569: ...G Br W Gy B W L L W L Y Gy Y G W G Y R Lg R R L R G Y L Y B B W R L B W Sb G Y W L Br R Br Y L W Br B Sb W B Gy R P W O G O B R B Gy G G B L B L R B P B O 1 2 4 3 1 Joint coupler for YZF R1 Joint coupler for YZF R1M Is resistance 0 Ω YES Go to Short circuit check NO a Replace the wire harness b Turn the main switch to ON and then check the condition of the DTC using the malfunction mode of the YDT...

Page 570: ...B L B L B L B L WL WL WL WL WL W L W L B L B L B L B L B L B L B L R Gy L B L P W P V W W B L W B Y B L Gy G Br W Gy B W L L W L Y Gy Y G W G L R Gy L B L P W P V W W B L W B Y B L Gy G Br W Gy B W L L W L Y Gy Y G W G B A 1 2 3 1 3 Joint coupler for YZF R1 Joint coupler for YZF R1M Is resistance Ω YES Go to step 4 NO a Replace the wire harness b Turn the main switch to ON and then check the condi...

Page 571: ...Control Unit on page 8 41 7 Delete the DTC and check that the MIL goes off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC a Fix the IMU installation condition b Turn the main switch to ON and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to step 5 Is...

Page 572: ...rmal front wheel sensor Check the item of DTC C0520 for the ECU Refer to SELF DIAGNOSTIC FUNCTION TABLE FOR FUEL INJECTION SYSTEM on page 9 38 Turn the main switch to OFF and back to ON and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Service is completed NO Refer to the item corresponding to DTC ...

Page 573: ...nect the ECU coupler 1 and steering damper solenoid coupler 2 Open circuit check Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Turn the main switch to ON and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 6 and complete the service NO Go to step 2 Is the cou...

Page 574: ...h to ON and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 6 and complete the service NO Go to Short circuit check Between ECU coupler 1 and ground yellow black ground ECU coupler yellow black any other coupler terminal Steering damper solenoid coupler 2 yellow black any other coupler terminal Is resistance Ω YES Go to step...

Page 575: ...fer to REPLACING THE ECU Engine Control Unit on page 8 41 6 Delete the DTC and check that the MIL goes off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC NO a Replace the wire harness b Turn the main switch to ON and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 6 and complete the s...

Page 576: ...and back to ON Check the condition of the DTC using the malfunction mode of the YDT 2 Malfunction in SCU Replace the SCU Refer to GENERAL CHASSIS 6 on page 4 23 Turn the main switch to OFF and back to ON and then check the condition of the DTC using the malfunction mode of the YDT Make sure confirm the Recovered condition and complete the service Is it in the Recovered condition YES Service is com...

Page 577: ...als and locking condition of the pins 3 Connection of front fork stepping motor sub wire harness coupler Check the locking condition of the coupler Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness and or sub wire harness b Turn the main switch to OFF and back to ON and then check the condition of the DTC using the malfunction mode of th...

Page 578: ...the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Service is completed NO Go to step 4 Between SCU coupler 1 and front fork stepping motor left 2 green green green black green black green red green red green blue green blue Between SCU coupler 1 and front fork stepping motor right 2 pink pink pink black pink black pink white pink white pink blue pink blue Between S...

Page 579: ...ES Go to Short circuit check NO a Replace the wire harness and or sub wire harness b Turn the main switch to OFF and back to ON and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Service is completed NO Go to Short circuit check Between front fork stepping motor left 1 and pow er ground 2 green black green black black green red black ...

Page 580: ... 3 and power battery 6 pink brown white pink black brown white pink white brown white pink blue brown white Between rear shock absorber assembly stepping motor compression damping 4 and power battery 6 white brown white white black brown white white red brown white white green brown white Between rear shock absorber assembly stepping motor rebound damping 5 and power battery 6 yellow brown white y...

Page 581: ... NO a Replace the stepping motor Refer to FRONT FORK for YZF R1M on page 4 100 and REAR SHOCK ABSORBER ASSEM BLY on page 4 112 b Turn the main switch to ON Check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Service is completed NO Go to step c 14 8 18 2 Ω When the motor is cold at 20 C 68 F YES Go to step 6 NO a Replace the stepping motor Refe...

Page 582: ... the main switch to OFF and back to ON and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Service is completed NO Refer to the item corresponding to DTC ...

Page 583: ...art engine Able to drive vehicle Procedure 1 Malfunction in SCU Replace the SCU Refer to GENERAL CHASSIS 6 on page 4 23 Turn the main switch to OFF and back to ON and then check the condition of the DTC using the malfunction mode of the YDT Make sure confirm the Recovered condition and complete the service ...

Page 584: ...is check also set the start engine stop switch to ON 2 Connection of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Turn the main switch to ON and then check the condition of the...

Page 585: ...ed condition YES Go to step 6 and complete the service NO Go to step 3 Between O2 sensor 1 coupler and ECU coupler pink black pink black Between O2 sensor 1 coupler and ignition fuse hold er red white red white Between main switch coupler and ignition fuse hold er brown blue brown blue Is resistance 0 Ω YES Go to Short circuit check NO a Replace the wire harness b Turn the main switch to ON and th...

Page 586: ...coupler red white any other coupler terminal pink black any other coupler terminal ECU coupler 2 pink black any other coupler terminal Main switch coupler brown blue any other coupler terminal Is resistance Ω YES Go to step 4 NO a Replace the wire harness b Turn the main switch to ON and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES ...

Page 587: ...op switch to ON 5 Malfunction in ECU Replace the ECU and complete the service Refer to REPLACING THE ECU Engine Control Unit on page 8 41 6 Delete the DTC and check that the MIL goes off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC Go to step 4 Is it in the Recovered condition YES Go to step 6 and complete the service NO Start the engine and then check th...

Page 588: ...is check also set the start engine stop switch to ON 2 Connection of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Turn the main switch to ON and then check the condition of the...

Page 589: ...tion YES Go to step 6 and complete the service NO Go to step 3 Between O2 sensor 2 coupler and ECU coupler pink white pink white Between O2 sensor 2 coupler and ignition fuse hold er red white red white Between main switch coupler and ignition fuse hold er brown blue brown blue Is resistance 0 Ω YES Go to Short circuit check NO a Replace the wire harness b Turn the main switch to ON and then check...

Page 590: ...e any other coupler terminal pink white any other coupler terminal ECU coupler 2 pink white any other coupler terminal Main switch coupler brown blue any other coupler terminal Is resistance Ω YES Go to step 4 NO a Replace the wire harness b Turn the main switch to ON and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 6 and...

Page 591: ...op switch to ON 5 Malfunction in ECU Replace the ECU and complete the service Refer to REPLACING THE ECU Engine Control Unit on page 8 41 6 Delete the DTC and check that the MIL goes off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC Go to step 4 Is it in the Recovered condition YES Go to step 6 and complete the service NO Start the engine and then check th...

Page 592: ... conditions is in dicated 2 Defective atmospheric pressure sensor Execute the diagnostic mode Code D02 When engine is stopped Atmospheric pressure at the current altitude and weather conditions is in dicated 0 m above sea level Approx 101 kPa 757 6 mmHg 29 8 inHg 3000 m 9800 ft above sea level Approx 70 kPa 525 0 mmHg 20 7 inHg Is check result OK YES Go to step 2 NO a Replace the intake air pressu...

Page 593: ...es off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC a Replace the atmospheric pressure sensor Refer to AIR INDUCTION SYSTEM on page 7 20 b Turn the main switch to ON and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 4 and complete the service NO Go to step 3 ...

Page 594: ...ent or broken terminals and locking condition of the pins Is check result OK YES Go to step 2 NO a Reinstall or replace the O2 sensor 1 Refer to ENGINE REMOVAL on page 5 11 b Start the engine and let it idle for approximately 1 minute c Check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 8 and complete the service NO Go to step 2 Is ...

Page 595: ... Recovered condition YES Go to step 8 and complete the service NO Go to step 4 Between O2 sensor 1 coupler and ECU coupler gray green gray green pink black pink black black blue black blue Between O2 sensor 1 coupler and ignition fuse hold er red white red white Is resistance 0 Ω YES Go to Short circuit check NO a Replace the wire harness b Start the engine and let it idle for approximately 1 minu...

Page 596: ...ler terminal red white any other coupler terminal ECU coupler 2 gray green any other coupler terminal pink black any other coupler terminal black blue any other coupler terminal Is resistance Ω YES Go to step 5 NO a Replace the wire harness b Start the engine and let it idle for approximately 1 minute c Check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered con...

Page 597: ...fer to REMOVING THE FUEL PUMP on page 7 3 b Start the engine and let it idle for approximately 1 minute c Check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 8 and complete the service NO Go to step 6 Is check result OK YES Go to step 7 NO a Replace the O2 sensor 1 Refer to ENGINE REMOVAL on page 5 11 b Start the engine and let it id...

Page 598: ...bent or broken terminals and locking condition of the pins Is check result OK YES Go to step 2 NO a Reinstall or replace the O2 sensor 2 Refer to ENGINE REMOVAL on page 5 11 b Start the engine and let it idle for approximately 1 minute c Check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 8 and complete the service NO Go to step 2 Is...

Page 599: ...ed condition YES Go to step 8 and complete the service NO Go to step 4 Between O2 sensor 2 coupler and ECU coupler gray yellow gray yellow pink white pink white black blue black blue Between O2 sensor 2 coupler and ignition fuse hold er red white red white Is resistance 0 Ω YES Go to Short circuit check NO a Replace the wire harness b Start the engine and let it idle for approximately 1 minute c C...

Page 600: ...d white any other coupler terminal ECU coupler 2 gray yellow any other coupler terminal pink white any other coupler terminal black blue any other coupler terminal Is resistance Ω YES Go to step 5 NO a Replace the wire harness b Start the engine and let it idle for approximately 1 minute c Check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go ...

Page 601: ...fer to REMOVING THE FUEL PUMP on page 7 3 b Start the engine and let it idle for approximately 1 minute c Check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 8 and complete the service NO Go to step 6 Is check result OK YES Go to step 7 NO a Replace the O2 sensor 2 Refer to ENGINE REMOVAL on page 5 11 b Start the engine and let it id...

Page 602: ...or broken terminals and locking condition of the pins 3 Wire harness continuity Disconnect the intake air pressure sensor coupler 1 and ECU coupler 2 Open circuit check Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Turn the main switch to ON and then check the condition of the DTC using the malfunction mode of the YDT Is it in the ...

Page 603: ... malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to Short circuit check Between intake air pressure sensor coupler 1 and ground blue ground pink white ground Intake air pressure sensor coupler blue any other coupler terminal pink white any other coupler terminal black blue any other coupler terminal ECU coupler 2 blue any other coupler t...

Page 604: ... step 4 Is check result OK YES Go to step 5 NO a Reinstall or replace the sensor b Turn the main switch to ON and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to step 5 At sea level Approx 101 kPa 757 6 mmHg 29 8 inHg approx 3 64 V 1000 m 3300 ft above sea level Approx 90 kPa 675 1 mmHg 26...

Page 605: ...er to REPLACING THE ECU Engine Control Unit on page 8 41 7 Delete the DTC and check that the MIL goes off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to step 6 ...

Page 606: ...Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins 3 Connection of ECU coupler Check the locking condition of the coupler Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness and or sub wire harness b Turn the main switch to ON and then check the condition of the DTC using the malfunction mo...

Page 607: ... malfunction mode of the YDT Is it in the Recovered condition YES Go to step 8 and complete the service NO Go to step 4 Between intake air temperature sensor coupler and sub wire harness coupler wire harness side brown white brown white black blue black blue Between wire harness coupler sub wire harness side and ECU coupler brown white brown white black blue black blue Is resistance 0 Ω YES Go to ...

Page 608: ...ck blue any other coupler terminal Wire harness coupler sub wire harness side brown white any other coupler terminal black blue any other coupler terminal ECU coupler 4 brown white any other coupler terminal black blue any other coupler terminal Is resistance Ω YES Go to step 5 NO a Replace the wire harness and or sub wire harness b Turn the main switch to ON and then check the condition of the DT...

Page 609: ...ete the DTC and check that the MIL goes off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC a Reinstall the sensor b Turn the main switch to ON and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 8 and complete the service NO Go to step 6 Is check result OK YES Go to step 7 NO a Replac...

Page 610: ...onnect the coupler and check the pins bent or broken terminals and locking condition of the pins 3 Connection of ECU coupler Check the locking condition of the coupler Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness and or sub wire harness b Turn the main switch to ON and then check the condition of the DTC using the malfunction mode o...

Page 611: ...function mode of the YDT Is it in the Recovered condition YES Go to step 8 and complete the service NO Go to step 4 Between coolant temperature sensor coupler and sub wire harness coupler wire harness side green white green white black blue black blue Between wire harness coupler sub wire harness side and ECU coupler green white green white black blue black blue Is resistance 0 Ω YES Go to step Sh...

Page 612: ...e any other coupler terminal Wire harness coupler sub wire harness side green white any other coupler terminal black blue any other coupler terminal ECU coupler 4 green white any other coupler terminal black blue any other coupler terminal Is resistance Ω YES Go to step 5 NO a Replace the wire harness and or sub wire harness b Turn the main switch to ON and then check the condition of the DTC usin...

Page 613: ...ete the DTC and check that the MIL goes off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC a Reinstall the sensor b Turn the main switch to ON and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 8 and complete the service NO Go to step 6 Is check result OK YES Go to step 7 NO a Replac...

Page 614: ...he coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins 2 Connection of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Tur...

Page 615: ... Replace the wire harness b Turn the main switch to ON and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 8 and complete the service NO Go to Short circuit check Between throttle position sensor coupler 1 and ground white ground blue ground black ground Throttle position sensor coupler white any other coupler terminal black...

Page 616: ... the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 8 and complete the service NO Go to step 4 Is check result OK YES Go to step 5 NO a Reinstall or adjust the sensor b Turn the main switch to ON and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 8 and complete the service NO Go to...

Page 617: ... THE THROTTLE POSITION SENSOR on page 7 19 b Turn the main switch to ON and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 8 and complete the service NO Go to step 6 When the throttle valves are fully closed 9 23 When throttle valves are fully open 93 109 Is check result OK YES Go to step 7 NO a Replace the throttle positio...

Page 618: ...f the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Is check result OK YES Go to step 2 NO a Reinstall or replace the sensor b Turn the main switch to ON and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to step 2 Is the coupler...

Page 619: ...he Recovered condition YES Go to step 7 and complete the service NO Go to step 4 Between O2 sensor 1 coupler and ECU coupler black blue black blue gray green gray green Is resistance 0 Ω YES Go to Short circuit check NO a Replace the wire harness b Turn the main switch to ON and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to ste...

Page 620: ...s resistance Ω YES Go to step 5 NO a Replace the wire harness b Turn the main switch to ON and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to step 5 Is check result OK YES Go to step 6 NO a Replace the O2 sensor 1 Refer to ENGINE REMOVAL on page 5 11 b Turn the main switch to ON and then ...

Page 621: ...f the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Is check result OK YES Go to step 2 NO a Reinstall or replace the sensor b Turn the main switch to ON and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to step 2 Is the coupler...

Page 622: ... Recovered condition YES Go to step 7 and complete the service NO Go to step 4 Between O2 sensor 2 coupler and ECU coupler black blue black blue gray yellow gray yellow Is resistance 0 Ω YES Go to Short circuit check NO a Replace the wire harness b Turn the main switch to ON and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to ste...

Page 623: ...Is resistance Ω YES Go to step 5 NO a Replace the wire harness b Turn the main switch to ON and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to step 5 Is check result OK YES Go to step 6 NO a Replace the O2 sensor 2 Refer to ENGINE REMOVAL on page 5 11 b Turn the main switch to ON and then...

Page 624: ...imary injector resistance Refer to CHECKING THE FUEL INJECTORS on page 8 51 3 Connection of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Execute the diagnostic mode Code D36 Is...

Page 625: ...tween primary injector 1 coupler and ECU cou pler red black red black Between primary injector 1 coupler and relay unit coupler red blue red blue Is resistance 0 Ω YES Go to Short circuit check NO a Replace the wire harness b Execute the diagnostic mode Code D36 Is it hear operating sound YES Go to step 6 NO Go to Short circuit check Between primary injector 1 coupler 1 and ground red black ground...

Page 626: ...ction mode of the YDT and then delete the DTC ECU coupler 2 red black any other coupler terminal Relay unit coupler 3 red blue any other coupler terminal Is resistance Ω YES Go to step 5 NO a Replace the wire harness b Execute the diagnostic mode Code D36 Is it hear operating sound YES Go to step 6 NO Go to step 5 L R L W R W L B L Y B Y Sb W Sb L W Br W L R L R W R LR B R LR B Y R Lg R R L R G Y ...

Page 627: ...imary injector resistance Refer to CHECKING THE FUEL INJECTORS on page 8 51 3 Connection of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Execute the diagnostic mode Code D37 Is...

Page 628: ...n primary injector 2 coupler and ECU cou pler green black green black Between primary injector 2 coupler and relay unit coupler red blue red blue Is resistance 0 Ω YES Go to Short circuit check NO a Replace the wire harness b Execute the diagnostic mode Code D37 Is it hear operating sound YES Go to step 6 NO Go to Short circuit check Between primary injector 2 coupler 1 and ground green black grou...

Page 629: ...tion mode of the YDT and then delete the DTC ECU coupler 2 green black any other coupler terminal Relay unit coupler 3 red blue any other coupler terminal Is resistance Ω YES Go to step 5 NO a Replace the wire harness b Execute the diagnostic mode Code D37 Is it hear operating sound YES Go to step 6 NO Go to step 5 L R L W R W L B L Y B Y Sb W Sb L W Br W L R L R W R LG B R LG B Y R Lg R R L R G Y...

Page 630: ...imary injector resistance Refer to CHECKING THE FUEL INJECTORS on page 8 51 3 Connection of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Execute the diagnostic mode Code D38 Is...

Page 631: ...een primary injector 3 coupler and ECU cou pler blue black blue black Between primary injector 3 coupler and relay unit coupler red blue red blue Is resistance 0 Ω YES Go to Short circuit check NO a Replace the wire harness b Execute the diagnostic mode Code D38 Is it hear operating sound YES Go to step 6 NO Go to Short circuit check Between primary injector 3 coupler 1 and ground blue black groun...

Page 632: ...ion mode of the YDT and then delete the DTC ECU coupler 2 blue black any other coupler terminal Relay unit coupler 3 red blue any other coupler terminal Is resistance Ω YES Go to step 5 NO a Replace the wire harness b Execute the diagnostic mode Code D38 Is it hear operating sound YES Go to step 6 NO Go to step 5 L R L W R W L B L Y B Y Sb W Sb L W Br W L R L R W R L L B R L L B Y R Lg R R L R G Y...

Page 633: ...imary injector resistance Refer to CHECKING THE FUEL INJECTORS on page 8 51 3 Connection of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Execute the diagnostic mode Code D39 Is...

Page 634: ...primary injector 4 coupler and ECU cou pler orange black orange black Between primary injector 4 coupler and relay unit coupler red blue red blue Is resistance 0 Ω YES Go to Short circuit check NO a Replace the wire harness b Execute the diagnostic mode Code D39 Is it hear operating sound YES Go to step 6 NO Go to Short circuit check Between primary injector 4 coupler 1 and ground orange black gro...

Page 635: ...ion mode of the YDT and then delete the DTC ECU coupler 2 orange black any other coupler terminal Relay unit coupler 3 red blue any other coupler terminal Is resistance Ω YES Go to step 5 NO a Replace the wire harness b Execute the diagnostic mode Code D39 Is it hear operating sound YES Go to step 6 NO Go to step 5 L R L W R W L B L Y B Y Sb W Sb L W Br W L R L R W R LO B R LO B Y R Lg R R L R G Y...

Page 636: ...s 3 Wire harness continuity Disconnect the crankshaft position sensor coupler 1 and ECU coupler 2 Open circuit check Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Crank the engine and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service ...

Page 637: ...n the Recovered condition YES Go to step 7 and complete the service NO Go to Short circuit check Between crankshaft position sensor coupler 1 and ground gray ground Crankshaft position sensor coupler black blue any other coupler terminal gray any other coupler terminal ECU coupler 2 black blue any other coupler terminal gray any other coupler terminal Is resistance Ω YES Go to step 4 NO B L Gy L R...

Page 638: ...d then delete the DTC a Replace the wire harness b Crank the engine and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to step 4 Is check result OK YES Go to step 5 NO a Reinstall or replace the sensor b Crank the engine and then check the condition of the DTC using the malfunction mode of t...

Page 639: ...sconnect the coupler and check the pins bent or broken terminals and locking condition of the pins 3 Wire harness continuity Disconnect the cylinder identification sensor coupler 1 and ECU coupler 2 Open circuit check Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Crank the engine and then check the condition of the DTC using the ma...

Page 640: ...de of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to Short circuit check Between cylinder identification sensor coupler 1 and ground white black ground blue ground Cylinder identification sensor coupler white black any other coupler terminal blue any other coupler terminal black blue any other coupler terminal ECU coupler 2 white black any other coupler...

Page 641: ... a condition of Recovered using the YDT and then delete the DTC Is resistance Ω YES Go to step 4 NO a Replace the wire harness b Crank the engine and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to step 4 Is check result OK YES Go to step 5 NO a Replace the cylinder identification sensor b...

Page 642: ...s and locking condition of the pins 3 Wire harness continuity Disconnect the cylinder 1 ignition coil coupler 1 ECU coupler 2 and handlebar switch right coupler 3 Open circuit check Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Start the engine and let it idle for approximately 5 seconds c Check the condition of the DTC using the m...

Page 643: ...ition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to Short circuit check Between cylinder 1 ignition coil coupler 1 and ground orange ground red white ground Cylinder 1 ignition coil coupler orange any other coupler terminal red white any other coupler terminal ECU coupler 2 orange any other coupler terminal Hand...

Page 644: ... the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to step 4 Is check result OK YES Go to step 5 NO a Reinstall or replace the ignition coil b Start the engine and let it idle for approximately 5 seconds c Check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to st...

Page 645: ...ECU and complete the service Refer to REPLACING THE ECU Engine Control Unit on page 8 41 7 Delete the DTC and check that the MIL goes off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC ...

Page 646: ...s and locking condition of the pins 3 Wire harness continuity Disconnect the cylinder 2 ignition coil coupler 1 ECU coupler 2 and handlebar switch right coupler 3 Open circuit check Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Start the engine and let it idle for approximately 5 seconds c Check the condition of the DTC using the m...

Page 647: ...the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to Short circuit check Between cylinder 2 ignition coil coupler 1 and ground gray red ground red white ground Cylinder 2 ignition coil coupler gray red any other coupler terminal red white any other coupler terminal ECU coupler 2 gray red any other coupler terminal Handleb...

Page 648: ... the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to step 4 Is check result OK YES Go to step 5 NO a Reinstall or replace the ignition coil b Start the engine and let it idle for approximately 5 seconds c Check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to st...

Page 649: ...ECU and complete the service Refer to REPLACING THE ECU Engine Control Unit on page 8 41 7 Delete the DTC and check that the MIL goes off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC ...

Page 650: ...s and locking condition of the pins 3 Wire harness continuity Disconnect the cylinder 3 ignition coil coupler 1 ECU coupler 2 and handlebar switch right coupler 3 Open circuit check Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Start the engine and let it idle for approximately 5 seconds c Check the condition of the DTC using the m...

Page 651: ...he DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to Short circuit check Between cylinder 3 ignition coil coupler 1 and ground orange green ground red white ground Cylinder 3 ignition coil coupler orange green any other coupler terminal red white any other coupler terminal ECU coupler 2 orange green any other coupler termi...

Page 652: ... the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to step 4 Is check result OK YES Go to step 5 NO a Reinstall or replace the ignition coil b Start the engine and let it idle for approximately 5 seconds c Check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to st...

Page 653: ...ECU and complete the service Refer to REPLACING THE ECU Engine Control Unit on page 8 41 7 Delete the DTC and check that the MIL goes off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC ...

Page 654: ...s and locking condition of the pins 3 Wire harness continuity Disconnect the cylinder 4 ignition coil coupler 1 ECU coupler 2 and handlebar switch right coupler 3 Open circuit check Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Start the engine and let it idle for approximately 5 seconds c Check the condition of the DTC using the m...

Page 655: ...he DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to Short circuit check Between cylinder 4 ignition coil coupler 1 and ground gray green ground red white ground Cylinder 4 ignition coil coupler gray green any other coupler terminal red white any other coupler terminal ECU coupler 2 gray green any other coupler terminal Ha...

Page 656: ... the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to step 4 Is check result OK YES Go to step 5 NO a Reinstall or replace the ignition coil b Start the engine and let it idle for approximately 5 seconds c Check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to st...

Page 657: ...ECU and complete the service Refer to REPLACING THE ECU Engine Control Unit on page 8 41 7 Delete the DTC and check that the MIL goes off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC ...

Page 658: ...ins 2 Connection of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Turn the main switch to ON and then check the condition of the DTC using the malfunction mode of the YDT Is it ...

Page 659: ...0 Ω YES Go to Short circuit check NO a Replace the wire harness b Turn the main switch to ON and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to Short circuit check Between EXUP servo motor coupler 1 and ground black green ground black red ground EXUP servo motor coupler black green any ot...

Page 660: ...lfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to step 4 Is check result OK YES Go to step 5 NO a Replace the EXUP servo motor Refer to ENGINE REMOVAL on page 5 11 b Turn the main switch to ON and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the se...

Page 661: ...n delete the DTC a Replace the cables b Turn the main switch to ON and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to step 6 NO a Replace the EXUP servo motor b Turn the main switch to ON and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered ...

Page 662: ...ect the radiator fan motor relay 1 ECU coupler 2 and ignition fuse 3 Open circuit check Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Turn the main switch to ON and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 6 and complete the service NO Go to step 2 Is ...

Page 663: ... the Recovered condition YES Go to step 6 and complete the service NO Go to Short circuit check Between radiator fan motor relay 1 and ground green yellow ground red white ground Radiator fan motor relay green yellow any other coupler terminal red white any other coupler terminal ECU coupler 2 green yellow any other coupler terminal Is resistance Ω YES Go to step 4 R B R G Y R W Y R Lg R R L R G Y...

Page 664: ...ine Control Unit on page 8 41 6 Delete the DTC and check that the MIL goes off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC NO a Replace the wire harness b Turn the main switch to ON and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 6 and complete the service NO Go to step 4 Is it...

Page 665: ... Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins 3 Wire harness continuity Disconnect the EXUP servo motor coupler 1 and ECU coupler 2 Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Turn the main switch to ON and then check the condition of the DTC using the malfunction mode of th...

Page 666: ...e condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 6 and complete the service NO Go to Short circuit check Between EXUP servo motor coupler 1 and ground white yellow ground blue ground EXUP servo motor coupler white yellow any other coupler terminal blue any other coupler terminal black blue any other coupler terminal ECU coupler 2 white ye...

Page 667: ...he DTC has a condition of Recovered using the YDT and then delete the DTC Is resistance Ω YES Go to step 4 NO a Replace the wire harness b Turn the main switch to ON and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 6 and complete the service NO Go to step 4 Is it in the Recovered condition YES Go to step 6 and complete th...

Page 668: ... 1 Locate the malfunction DTCs P0500 or P0500 and P1500 detected a Execute the diagnostic mode Code D07 b Rotate the rear wheel by hand and check that the indicated value increases TIP Perform the procedure from step 2 to step 7 and step 21 DTC P1500 detected a Execute the diagnostic mode Code D21 TIP Perform the procedure from step 8 to step 14 and step 21 b Execute the diagnostic mode Code D21 I...

Page 669: ...he pins bent or broken terminals and locking condition of the pins Is check result OK YES Go to step 21 NO Go to step 15 Is the coupler condition normal YES Go to step 3 NO a Connect the coupler securely or replace the wire harness b Execute the diagnostic mode Code D07 c Rotate the rear wheel by hand and check that the indicated value increases Is that value increased YES Go to step 21 NO Go to s...

Page 670: ...that value increased YES Go to step 21 NO Go to step 5 Between rear wheel sensor coupler and ABS ECU coupler black black white white Between ABS ECU coupler and ECU coupler white blue white blue Is resistance 0 Ω YES Go to Short circuit check NO a Replace the wire harness b Execute the diagnostic mode Code D07 c Rotate the rear wheel by hand and check that the indicated value increases Is that val...

Page 671: ...minal white any other coupler terminal white blue any other coupler terminal ECU coupler 3 white blue any other coupler terminal Is resistance Ω YES Go to step 6 NO a Replace the wire harness b Execute the diagnostic mode Code D07 c Rotate the rear wheel by hand and check that the indicated value increases Is that value increased YES Go to step 21 NO Go to step 6 Is that value increased YES L R Gy...

Page 672: ...en circuit check Go to step 21 NO Go to step 7 Is the coupler condition normal YES Go to step 9 NO a Connect the coupler securely or replace the wire harness b Execute the diagnostic mode Code D21 When the transmission is in neutral ON When the transmission is in gear with the clutch lever released OFF Is it correct indication YES Go to step 21 NO Go to step 9 Is the coupler condition normal YES G...

Page 673: ...hen the transmission is in neutral ON When the transmission is in gear with the clutch lever released OFF Is it correct indication YES Go to step 21 NO Go to Short circuit check Between relay unit coupler 1 and ground black yellow ground sky blue ground Relay unit coupler black yellow any other coupler terminal sky blue any other coupler terminal ECU coupler 2 black yellow any other coupler termin...

Page 674: ... the clutch lever released OFF Is it correct indication YES Go to step 21 NO Go to step 11 Is check result OK YES Go to step 12 NO a Replace the relay unit b Execute the diagnostic mode Code D21 When the transmission is in neutral ON When the transmission is in gear with the clutch lever released OFF Is it correct indication YES Go to step 21 NO Go to step 12 L R L W R W L B L Y B Y Sb W Sb L W Br...

Page 675: ...pins bent or broken terminals and locking condition of the pins Is check result OK YES Go to step 13 NO a Replace the neutral switch Refer to CRANKCASE on page 5 71 b Execute the diagnostic mode Code D21 When the transmission is in neutral ON When the transmission is in gear with the clutch lever released OFF Is it correct indication YES Go to step 21 NO Go to step 13 Is check result OK YES Go to ...

Page 676: ...racted OFF When the clutch lever is squeezed with the transmission in gear and when the sidestand is retracted ON Is it correct indication YES Go to step 21 NO Go to step 17 Is the coupler condition normal YES Go to step 18 NO a Connect the coupler securely or replace the wire harness b Execute the diagnostic mode Code D21 When the clutch lever is released with the transmission in gear and when th...

Page 677: ...lever is squeezed with the transmission in gear and when the sidestand is retracted ON Is it correct indication YES Go to step 21 NO Go to Short circuit check Between relay unit coupler 1 and ground black yellow ground blue yellow ground Relay unit coupler black yellow any other coupler terminal blue yellow any other coupler terminal ECU coupler 2 black yellow any other coupler terminal Clutch swi...

Page 678: ...indication YES Go to step 21 NO Go to step 19 Is check result OK YES Go to step 20 NO a Replace the clutch switch Refer to HANDLEBARS on page 4 83 b Execute the diagnostic mode Code D21 When the clutch lever is released with the transmission in gear and when the sidestand is retracted OFF When the clutch lever is squeezed with the transmission in gear and when the sidestand is retracted ON Is it c...

Page 679: ...t the MIL goes off Turn the main switch to ON and then rotate the rear wheel by hand Start the engine and input the vehicle speed signals by operating the vehicle at 20 to 30 km h 12 to 19 mph Confirm that the DTC has a condition of Recovered using the malfunction mode of the YDT and then delete the DTC Delete this DTC even if it has a condition of Detected NO Go to step 20 ...

Page 680: ...Abnormal rear wheel sensor Check the item of DTC P0500 for the ECU Refer to SELF DIAGNOSTIC FUNCTION TABLE FOR FUEL INJECTION SYSTEM on page 9 38 Turn the main switch to OFF and back to ON and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Service is completed NO Refer to the item corresponding to DTC ...

Page 681: ...tem Refer to CHARGING SYSTEM on page 8 12 2 Delete the DTC and check that the MIL goes off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC Is check result OK YES Repeat step 1 NO a Defective rectifier regulator or AC magneto Replace b Defective connection in the charging system circuit Properly connect or replace the wire har ness c Start the engine and let ...

Page 682: ...RGING SYSTEM on page 8 12 Is check result OK YES Repeat step 1 NO a Defective rectifier regulator or AC magneto Replace b Defective connection in the charging system circuit Properly connect or replace the wire har ness c Start the engine and let it idle for approximately 5 seconds d Check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Service i...

Page 683: ...ion is detected in the ECU the DTC might not appear on the tool display Fail safe system Unable to start engine Unable to drive vehicle Procedure 1 Malfunction in ECU Replace the ECU Refer to REPLACING THE ECU Engine Control Unit on page 8 41 Turn the main switch to ON Check that the MIL does not come on ...

Page 684: ...are detected at the same time correct the P0122 P0123 P0222 P0223 and P2135 first Turn the main switch to ON and then check the condition of the DTC using the malfunction mode of the YDT 2 Malfunction in ECU Replace the ECU Refer to REPLACING THE ECU Engine Control Unit on page 8 41 Turn the main switch to ON Check that the MIL does not come on 3 Delete the DTC and check that the MIL goes off Conf...

Page 685: ...ngine Able Unable to drive vehicle Procedure 1 Locate the malfunction Execute the diagnostic mode Code D60 2 Malfunction in ECU Replace the ECU and complete the service Refer to REPLACING THE ECU Engine Control Unit on page 8 41 3 Delete the DTC and check that the MIL goes off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC ...

Page 686: ...g condition of the pins 3 Check the electronic throttle valve fuse Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Turn the main switch to ON and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 8 and complete the service NO Go to step 2 Is the coupler condition...

Page 687: ...the service NO Go to step 4 Between throttle servo motor coupler and ECU cou pler yellow red yellow red light green red light green red Between ECU coupler and electronic throttle valve fuse holder red blue red blue Is resistance 0 Ω YES Go to Short circuit check NO a Replace the wire harness b Turn the main switch to ON and then check the condition of the DTC using the malfunction mode of the YDT...

Page 688: ...b Turn the main switch to ON and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 8 and complete the service NO Go to step 5 Is check result OK YES Go to step 6 NO a Replace the throttle bodies Refer to REPLACING THE THROTTLE BODIES on page 7 17 b Turn the main switch to ON and then check the condition of the DTC using the ma...

Page 689: ...t the DTC has a condition of Recovered using the YDT and then delete the DTC Is check result OK YES Go to step 7 NO a Replace the throttle bodies Refer to REPLACING THE THROTTLE BODIES on page 7 17 b Turn the main switch to ON and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 8 and complete the service NO Go to step 7 ...

Page 690: ...check the pins bent or broken terminals and locking condition of the pins 3 Connection of ECU coupler Check the locking condition of the coupler Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Start the engine and let it idle for approximately 5 seconds c Check the condition of the DTC using the malfunction mode of the YDT Is it in t...

Page 691: ...ween fuel injection system fuse holder and relay unit coupler brown white brown white Between ignition fuse holder and handlebar switch right coupler red white red white Between handlebar switch right coupler and relay unit coupler red white red white Between relay unit coupler and ECU coupler red blue red blue blue white blue white Is resistance 0 Ω YES Go to Short circuit check NO a Replace the ...

Page 692: ...terminal red white any other coupler terminal red blue any other coupler terminal Handlebar switch right coupler red white any other coupler terminal ECU coupler 5 red blue any other coupler terminal blue white any other coupler terminal Is resistance Ω YES Go to step 5 NO a Replace the wire harness b Start the engine and let it idle for approximately 5 seconds c Check the condition of the DTC usi...

Page 693: ... 6 NO a Replace the relay unit b Start the engine and let it idle for approximately 5 seconds c Check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 8 and complete the service NO Go to step 6 Is the Fuel system voltage less than 3V YES a Replace the relay unit b Start the engine and let it idle for approximately 5 seconds c Check the ...

Page 694: ...ken terminals and locking condition of the pins 3 Wire harness continuity Disconnect the gear position sensor coupler 1 and ECU coupler 2 Open circuit check Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Turn the main switch to ON and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered co...

Page 695: ...he malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to Short circuit check Between gear position sensor coupler 1 and ground green ground blue red ground Gear position sensor coupler white any other coupler terminal green any other coupler terminal blue red any other coupler terminal ECU coupler 2 white any other coupler terminal green an...

Page 696: ... Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to step 4 Is check result OK YES Go to step 5 NO a Reinstall or replace the sensor Refer to CRANKCASE on page 5 71 b Turn the main switch to ON and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to step 5 Is ch...

Page 697: ...P0916 P0917 9 200 7 Delete the DTC and check that the MIL goes off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC ...

Page 698: ...he pins bent or broken terminals and locking condition of the pins Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Turn the main switch to ON and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 6 and complete the service NO Start the engine and check the status...

Page 699: ...enoid coupler and ECU coupler brown red brown red Between air induction system solenoid coupler and ignition fuse holder red white red white Is resistance 0 Ω YES Go to Short circuit check NO a Replace the wire harness b Turn the main switch to ON and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 6 and complete the service...

Page 700: ...oupler 1 and ground brown red ground red white ground Air induction system solenoid coupler brown red any other coupler terminal red white any other coupler terminal ECU coupler 2 brown red any other coupler terminal Is resistance Ω YES Go to step 4 NO a Replace the wire harness b Turn the main switch to ON and then check the condition of the DTC using the malfunction mode of the YDT Is it in the ...

Page 701: ...trol Unit on page 8 41 6 Delete the DTC and check that the MIL goes off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC Is it in the Recovered condition YES Go to step 6 and complete the service NO Start the engine and check the status of the DTC Is it in the Recovered condition YES Go to step 6 and complete the service NO Go to step 5 ...

Page 702: ...ls and locking condition of the pins 3 Wire harness continuity Disconnect the ECU coupler 1 joint coupler 2 IMU coupler 3 and ignition fuse 4 Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Turn the main switch to ON then to OFF and back to ON c Check the condition of the DTC using the malfunction mode of the YDT Is it in the Recover...

Page 703: ... W L B L B L B L B L B L B L B L R Gy L B L P W P V W W B L W B Y B L Gy G Br W Gy B W L L W L Y Gy Y G W G Y R Lg R R L R G Y L Y B B W R L B W Sb G Y W L Br R Br Y L W Br B Sb W B Gy R P W O G O B R B Gy G G B L B L R B P B O 1 2 4 3 1 Joint coupler for YZF R1 Joint coupler for YZF R1M Is resistance 0 Ω YES Go to Short circuit check NO a Replace the wire harness b Turn the main switch to ON then...

Page 704: ... other coupler terminal L R Gy L B L P W P V W W B L W B Y B L Gy G Br W Gy B W L L W L Y Gy Y G W G L R Gy L B L P W P V W W B L W B Y B L Gy G Br W Gy B W L L W L Y Gy Y G W G L W L W L W L W L W L W L B L B L B L B L B L B L WL WL WL WL WL W L W L B L B L B L B L B L B L B B A 1 2 3 1 3 Joint coupler for YZF R1 Joint coupler for YZF R1M Is resistance Ω YES Go to step 4 NO a Replace the wire har...

Page 705: ... on page 8 41 7 Delete the DTC and check that the MIL goes off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC YES Go to step 5 NO a Fix the IMU installation condition b Turn the main switch to ON then to OFF and back to ON c Check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete th...

Page 706: ...locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Turn the main switch to ON and then extend and retract the sidestand c Check the condition of the DTC using the malfunction mode of the YDT Is it in the ...

Page 707: ... condition YES Go to step 7 and complete the service NO Go to step 4 Between main switch coupler and ECU coupler blue yellow blue yellow Between main switch coupler and relay unit coupler blue black blue yellow Between relay unit coupler and sidestand switch coupler blue black blue black Is resistance 0 Ω YES Go to Short circuit check NO a Replace the wire harness b Turn the main switch to ON and ...

Page 708: ... coupler terminal blue black any other coupler terminal Sidestand switch coupler 4 blue black any other coupler terminal Is resistance Ω YES Go to step 5 NO a Replace the wire harness b Turn the main switch to ON and then extend and retract the sidestand c Check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service...

Page 709: ...the MIL goes off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC a Replace the sidestand switch b Turn the main switch to ON and then extend and retract the sidestand c Check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to step 6 ...

Page 710: ...he locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Is check result OK YES Go to step 2 NO a Reinstall or replace the battery leads b Turn the main switch to ON and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service N...

Page 711: ... step 5 NO a Replace the fuse b Turn the main switch to ON and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to step 5 Between battery and backup fuse holder red red Between backup fuse holder and ECU coupler red green red green Between main switch coupler and ignition fuse hold er brown bl...

Page 712: ...itch coupler 4 and ground brown blue ground ECU coupler red green any other coupler terminal red white any other coupler terminal Main switch coupler brown blue any other coupler terminal Is resistance Ω YES Go to step 6 NO a Replace the wire harness b Turn the main switch to ON and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to...

Page 713: ...he ECU and complete the service Refer to REPLACING THE ECU Engine Control Unit on page 8 41 7 Delete the DTC and check that the MIL goes off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC NO Go to step 6 ...

Page 714: ...inals and locking condition of the pins 3 Wire harness continuity Disconnect the shift sensor coupler 1 and ECU coupler 2 Open circuit check Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Turn the main switch to ON and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go t...

Page 715: ...ing the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to Short circuit check Between shift sensor coupler 1 and ground violet ground blue ground Shift sensor coupler black blue any other coupler terminal violet any other coupler terminal blue any other coupler terminal ECU coupler 2 black blue any other coupler terminal violet any othe...

Page 716: ... to CHAIN DRIVE on page 4 125 b Turn the main switch to ON and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to step 5 Shift sensor output voltage display 0 2 4 8 V With no shift weighting input Approx 2 5 V Shift up weighting Changes to the low side Shift down weighting Changes to the high...

Page 717: ...ce the ECU and complete the service Refer to REPLACING THE ECU Engine Control Unit on page 8 41 7 Delete the DTC and check that the MIL goes off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC Go to step 6 ...

Page 718: ...Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins 2 Connection of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Turn the main ...

Page 719: ...lue yellow white white black blue black blue blue green blue green black black black yellow black yellow Is resistance 0 Ω YES Go to Short circuit check NO a Replace the wire harness b Turn the main switch to ON and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 6 and complete the service NO Go to Short circuit check Betwee...

Page 720: ...ck blue any other coupler terminal blue green any other coupler terminal black any other coupler terminal black yellow any other coupler terminal Is resistance Ω YES Go to step 4 NO a Replace the wire harness b Turn the main switch to ON and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 6 and complete the service NO Go to ...

Page 721: ...rvice Refer to REPLACING THE ECU Engine Control Unit on page 8 41 6 Delete the DTC and check that the MIL goes off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC Is it in the Recovered condition YES Go to step 6 and complete the service NO Go to step 5 ...

Page 722: ...bent or broken terminals and locking condition of the pins 4 Connection of ABS ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Is the ABS warning light on YES Refer to BASIC INSTRUCTIONS FOR TROUBLESHOOTING on page 9 20 NO Go to step 2 Is that value increased YES Go to step 10 and complete t...

Page 723: ...reases Is that value increased YES Go to step 10 and complete the service NO Go to step 5 Is the coupler condition normal YES Go to step 6 NO a Connect the coupler securely or replace the wire harness b Execute the diagnostic mode Code D16 c Rotate the front wheel by hand and check that the indicated value increases Is that value increased YES Go to step 10 and complete the service NO Go to step 6...

Page 724: ...o step 10 and complete the service NO Go to Short circuit check Between ABS ECU coupler 2 and ground black ground white ground gray black ground Front wheel sensor coupler 1 black any other coupler terminal white any other coupler terminal ABS ECU coupler black any other coupler terminal white any other coupler terminal gray black any other coupler terminal ECU coupler 3 gray black any other coupl...

Page 725: ...19 mph Confirm that the DTC has a condition of Recovered using the malfunction mode of the YDT and then delete the DTC Delete this DTC even if it has a condition of Detected Go to step 7 NO a Replace the wire harness b Execute the diagnostic mode Code D16 c Rotate the front wheel by hand and check that the indicated value increases Is that value increased YES Go to step 10 and complete the service...

Page 726: ...rive vehicle Procedure 1 Abnormal front wheel sensor Check the item of DTC P2158 for the ECU Refer to SELF DIAGNOSTIC FUNCTION TABLE FOR FUEL INJECTION SYSTEM on page 9 38 Turn the main switch to OFF and back to ON and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Service is completed NO Refer to the item corresponding to DTC ...

Page 727: ...secondary injector resistance Refer to CHECKING THE FUEL INJECTORS on page 8 51 3 Connection of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Execute the diagnostic mode Code D4...

Page 728: ... secondary injector 1 coupler and ECU coupler white blue white blue Between secondary injector 1 coupler and relay unit coupler red blue red blue Is resistance 0 Ω YES Go to Short circuit check NO a Replace the wire harness b Execute the diagnostic mode Code D40 Is it hear operating sound YES Go to step 6 NO Go to Short circuit check Between secondary injector 1 coupler 1 and ground white blue gro...

Page 729: ...ion mode of the YDT and then delete the DTC ECU coupler 2 white blue any other coupler terminal Relay unit coupler 3 red blue any other coupler terminal Is resistance Ω YES Go to step 5 NO a Replace the wire harness b Execute the diagnostic mode Code D40 Is it hear operating sound YES Go to step 6 NO Go to step 5 L R L W R W L B L Y B Y Sb W Sb L W Br W L R L R W W L R L W L R L Y R Lg R R L R G Y...

Page 730: ...secondary injector resistance Refer to CHECKING THE FUEL INJECTORS on page 8 51 3 Connection of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Execute the diagnostic mode Code D4...

Page 731: ...ry injector 2 coupler and ECU coupler sky blue white sky blue white Between secondary injector 2 coupler and relay unit coupler red blue red blue Is resistance 0 Ω YES Go to Short circuit check NO a Replace the wire harness b Execute the diagnostic mode Code D41 Is it hear operating sound YES Go to step 6 NO Go to Short circuit check Between secondary injector 2 coupler 1 and ground sky blue white...

Page 732: ...n mode of the YDT and then delete the DTC ECU coupler 2 sky blue white any other coupler terminal Relay unit coupler 3 red blue any other coupler terminal Is resistance Ω YES Go to step 5 NO a Replace the wire harness b Execute the diagnostic mode Code D41 Is it hear operating sound YES Go to step 6 NO Go to step 5 L R L W R W L B L Y B Y Sb W Sb L W Br W L R L R W Sb WR L Sb WR L Y R Lg R R L R G...

Page 733: ...secondary injector resistance Refer to CHECKING THE FUEL INJECTORS on page 8 51 3 Connection of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Execute the diagnostic mode Code D4...

Page 734: ...ondary injector 3 coupler and ECU coupler brown yellow brown yellow Between secondary injector 3 coupler and relay unit coupler red blue red blue Is resistance 0 Ω YES Go to Short circuit check NO a Replace the wire harness b Execute the diagnostic mode Code D42 Is it hear operating sound YES Go to step 6 NO Go to Short circuit check Between secondary injector 3 coupler 1 and ground brown yellow g...

Page 735: ...n mode of the YDT and then delete the DTC ECU coupler 2 brown yellow any other coupler terminal Relay unit coupler 3 red blue any other coupler terminal Is resistance Ω YES Go to step 5 NO a Replace the wire harness b Execute the diagnostic mode Code D42 Is it hear operating sound YES Go to step 6 NO Go to step 5 L R L W R W L B L Y B Y Sb W Sb L W Br W L R L R W Br Y R L Br Y R L Y R Lg R R L R G...

Page 736: ...secondary injector resistance Refer to CHECKING THE FUEL INJECTORS on page 8 51 3 Connection of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Execute the diagnostic mode Code D4...

Page 737: ...econdary injector 4 coupler and ECU coupler brown black brown black Between secondary injector 4 coupler and relay unit coupler red blue red blue Is resistance 0 Ω YES Go to Short circuit check NO a Replace the wire harness b Execute the diagnostic mode Code D43 Is it hear operating sound YES Go to step 6 NO Go to Short circuit check Between secondary injector 4 coupler 1 and ground brown black gr...

Page 738: ...on mode of the YDT and then delete the DTC ECU coupler 2 brown black any other coupler terminal Relay unit coupler 3 red blue any other coupler terminal Is resistance Ω YES Go to step 5 NO a Replace the wire harness b Execute the diagnostic mode Code D43 Is it hear operating sound YES Go to step 6 NO Go to step 5 L R L W R W L B L Y B Y Sb W Sb L W Br W L R L R W Br B R L Br B R L Y R Lg R R L R G...

Page 739: ... or broken terminals and locking condition of the pins 3 Wire harness continuity Disconnect the atmospheric pressure sensor coupler 1 and ECU coupler 2 Open circuit check Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Turn the main switch to ON and then check the condition of the DTC using the malfunction mode of the YDT Is it in th...

Page 740: ...e malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to Short circuit check Between atmospheric pressure sensor coupler 1 and ground blue ground pink ground Atmospheric pressure sensor coupler blue any other coupler terminal pink any other coupler terminal black blue any other coupler terminal ECU coupler 2 blue any other coupler terminal p...

Page 741: ...Go to step 5 NO a Reinstall the sensor b Turn the main switch to ON and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to step 5 At sea level Approx 101 kPa 757 6 mmHg 29 8 inHg approx 3 64 V 1000 m 3300 ft above sea level Approx 90 kPa 675 1 mmHg 26 6 inHg approx 3 30 V 2000 m 6700 ft above...

Page 742: ...er to REPLACING THE ECU Engine Control Unit on page 8 41 7 Delete the DTC and check that the MIL goes off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to step 6 ...

Page 743: ...tinuity Disconnect the SCU coupler 1 joint coupler 2 and ECU coupler 3 Open circuit check Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Turn the main switch to OFF and back to ON and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Service is completed NO Go to step 2 Be...

Page 744: ...oupler for YZF R1 Joint coupler for YZF R1M Is resistance 0 Ω YES Go to Short circuit check NO a Replace the wire harness b Turn the main switch to OFF and back to ON and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Service is completed NO Go to Short circuit check Between SCU coupler 1 and ground blue white ground blue black ground...

Page 745: ...WL WL WL W L W L B L B L B L B L B L B L B L B L W Y B P B W G W R W B W Gy B P L G B G L Y G Gy R Br W P W Y Y R Gy G P Gy G B G R L B L W Y B P B W G W R W B W Gy B P L G B G L Y G Gy R Br W P W Y Y R Gy G P Gy G B G R B A 3 1 2 3 1 Joint coupler for YZF R1 Joint coupler for YZF R1M Is resistance Ω YES Go to step 3 NO a Replace the wire harness b Turn the main switch to OFF and back to ON and th...

Page 746: ...tinuity Disconnect the SCU coupler 1 joint coupler 2 and ABS ECU coupler 3 Open circuit check Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Turn the main switch to OFF and back to ON and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Service is completed NO Go to step ...

Page 747: ...YZF R1 Joint coupler for YZF R1M Is resistance 0 Ω YES Go to Short circuit check NO a Replace the wire harness b Turn the main switch to OFF and back to ON and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Service is completed NO Go to Short circuit check Between SCU coupler 1 and ground blue white ground blue black ground Between AB...

Page 748: ...G R L B L W Y B P B W G W R W B W Gy B P L G B G L Y G Gy R Br W P W Y Y R Gy G P Gy G B G R R W L W B B W Gy B L Y G R B B L W G O W L L B W W L B R W L W B B W Gy B L Y G R B B L W G O W L L B W W L B B A 1 2 1 3 3 Joint coupler for YZF R1 Joint coupler for YZF R1M Is resistance Ω YES Go to step 3 NO a Replace the wire harness b Turn the main switch to OFF and back to ON and then check the condi...

Page 749: ...broken terminals and locking condition of the pins 3 Wire harness continuity Disconnect the ECU coupler 1 joint coupler 2 IMU coupler 3 and ignition fuse 4 Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Turn the main switch to OFF and back to ON and then check the condition of the DTC using the malfunction mode of the YDT Is it in t...

Page 750: ... W L W L B L B L B L B L B L B L B L R Gy L B L P W P V W W B L W B Y B L Gy G Br W Gy B W L L W L Y Gy Y G W G Y R Lg R R L R G Y L Y B B W R L B W Sb G Y W L Br R Br Y L W Br B Sb W B Gy R P W O G O B R B Gy G G B L B L R B P B O 1 2 4 3 1 Joint coupler for YZF R1 Joint coupler for YZF R1M Is resistance 0 Ω YES Go to Short circuit check NO a Replace the wire harness b Turn the main switch to OFF...

Page 751: ... blue black any other coupler terminal red white any other coupler terminal L R Gy L B L P W P V W W B L W B Y B L Gy G Br W Gy B W L L W L Y Gy Y G W G L R Gy L B L P W P V W W B L W B Y B L Gy G Br W Gy B W L L W L Y Gy Y G W G L W L W L W L W L W L W L B L B L B L B L B L B L WL WL WL WL WL W L W L B L B L B L B L B L B L B B A 1 2 3 1 3 Joint coupler for YZF R1 Joint coupler for YZF R1M Is res...

Page 752: ...r to REPLACING THE ECU Engine Control Unit on page 8 41 6 Delete the DTC and check that the MIL goes off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC Is it in the Recovered condition YES Go to step 6 and complete the service NO Go to step 5 ...

Page 753: ... continuity Disconnect the SCU coupler 1 joint coupler 2 and IMU coupler 3 Open circuit check Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Turn the main switch to OFF and back to ON and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Service is completed NO Go to step ...

Page 754: ...0 Ω YES Go to Short circuit check NO a Replace the wire harness b Turn the main switch to OFF and back to ON and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Service is completed NO Go to Short circuit check Between SCU coupler 1 and ground blue white ground blue black ground Between IMU coupler 3 and ground blue white ground blue b...

Page 755: ... L Y G Gy R Br W P W Y Y R Gy G P Gy G B G R L B L W Y B P B W G W R W B W Gy B P L G B G L Y G Gy R Br W P W Y Y R Gy G P Gy G B G R B A 2 3 3 1 1 Joint coupler for YZF R1 Joint coupler for YZF R1M Is resistance Ω YES Go to step 3 NO a Replace the wire harness b Turn the main switch to OFF and back to ON and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Re...

Page 756: ...er and check the pins bent or broken terminals and locking condition of the pins 3 Wire harness continuity Disconnect the meter assembly coupler 1 joint coupler 2 and ECU coupler 3 Open circuit check Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Turn the main switch to ON and then check the condition of the DTC using the malfunctio...

Page 757: ... W Br B Br Y L W Lg L B G W Dg Ch W L W Y R GR GSb WG L G Y W G O Y G G B W B W G 3 2 1 Joint coupler for YZF R1 Joint coupler for YZF R1M Is resistance 0 Ω YES Go to Short circuit check NO a Replace the wire harness b Turn the main switch to ON and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 6 and complete the service N...

Page 758: ... W L W L B L B L B L B L B L B L WL WL WL WL WL W L W L B L B L B L B L B L B L B B W R W Br W Br B Br Y L W Lg L B G W Dg Ch W L W Y R GR GSb WG L G Y W G O Y G G B W B W G B W R W Br W Br B Br Y L W Lg L B G W Dg Ch W L W Y R GR GSb WG L G Y W G O Y G G B W B W G B A 3 1 1 2 3 Joint coupler for YZF R1 Joint coupler for YZF R1M Is resistance Ω YES Go to step 4 NO a Replace the wire harness b Turn...

Page 759: ...ECU Replace the ECU and complete the service Refer to REPLACING THE ECU Engine Control Unit on page 8 41 6 Delete the DTC and check that the MIL goes off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC ...

Page 760: ...harness continuity Disconnect the SCU coupler 1 joint coupler 2 and meter assembly coupler 3 Open circuit check Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Turn the main switch to OFF and back to ON and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Service is comple...

Page 761: ... coupler for YZF R1M Is resistance 0 Ω YES Go to Short circuit check NO a Replace the wire harness b Turn the main switch to OFF and back to ON and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Service is completed NO Go to Short circuit check Between SCU coupler 1 and ground blue white ground blue black ground Between meter assembly...

Page 762: ...B P L G B G L Y G Gy R Br W P W Y Y R Gy G P Gy G B G R B W R W Br W Br B Br Y L W Lg L B G W Dg Ch W L W Y R GR GSb WG L G Y W G O Y G G B W B W G B W R W Br W Br B Br Y L W Lg L B G W Dg Ch W L W Y R GR GSb WG L G Y W G O Y G G B W B W G B A 1 2 1 3 3 Joint coupler for YZF R1 Joint coupler for YZF R1M Is resistance Ω YES Go to step 3 NO a Replace the wire harness b Turn the main switch to OFF an...

Page 763: ...e sensor rotor or incorrect installation of the rotor Check the surface of the sensor rotor for damage Refer to MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR on page 4 40 4 Defective front wheel sensor or incorrect installation of the sensor Check the wheel sensor for damage and the installed condition of the sensor Refer to MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR on page 4...

Page 764: ...he surface of the sensor rotor for damage Refer to MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR on page 4 49 4 Defective rear wheel sensor or incorrect installation of the sensor Check the wheel sensor for damage and the installed condition of the sensor Refer to MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR on page 4 49 Is check result OK YES Go to step 2 NO Clean the sensor roto...

Page 765: ...er to CHECKING THE FRONT WHEEL on page 4 38 3 Defective sensor rotor or incorrect installation of the rotor Check the surface of the sensor rotor for damage Refer to MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR on page 4 40 4 Defective front wheel sensor or incorrect installation of the sensor Check the wheel sensor for damage and the installed condition of the sensor Refer to MAINTENANC...

Page 766: ...er to CHECKING THE REAR WHEEL on page 4 47 3 Defective sensor rotor or incorrect installation of the rotor Check the surface of the sensor rotor for damage Refer to MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR on page 4 49 4 Defective rear wheel sensor or incorrect installation of the sensor Check the wheel sensor for damage and the installed condition of the sensor Refer to MAINTENANCE O...

Page 767: ...U coupler 1 and front wheel sensor coupler 2 Open circuit check Short circuit check TIP Disconnect the ABS ECU related connectors before checking Refer to PARTS CONNECTED TO THE ABS ECU on page 9 4 Ground short circuit check A Is check result OK YES Go to step 2 NO If there is a malfunction repair it and connect the coupler securely Between ABS ECU coupler and front wheel sensor coupler white whit...

Page 768: ...ly is defective Replace the wheel sensor or hydraulic unit assembly Refer to FRONT WHEEL on page 4 35 and ABS Anti lock Brake System on page 4 74 ABS ECU coupler white any other coupler terminal black any other coupler terminal Is resistance Ω YES Go to step 3 NO Replace the wire harness R W L W B B W Gy B L Y G R B B L W G O W L L B W W L B R W L W B B W Gy B L Y G R B B L W G O W L L B W W L B B...

Page 769: ...U coupler 1 and rear wheel sensor coupler 2 Open circuit check Short circuit check TIP Disconnect the ABS ECU related connectors before checking Refer to PARTS CONNECTED TO THE ABS ECU on page 9 4 Ground short circuit check A Is check result OK YES Go to step 2 NO If there is a malfunction repair it and connect the coupler securely Between ABS ECU coupler and rear wheel sensor coupler white white ...

Page 770: ...ly is defective Replace the wheel sensor or hydraulic unit assembly Refer to REAR WHEEL on page 4 43 and ABS Anti lock Brake System on page 4 74 ABS ECU coupler white any other coupler terminal black any other coupler terminal Is resistance Ω YES Go to step 3 NO Replace the wire harness R W L W B B W Gy B L Y G R B B L W G O W L L B W W L B R W L W B B W Gy B L Y G R B B L W G O W L L B W W L B B ...

Page 771: ...21_ABS EAS33320 TROUBLESHOOTING Item Hydraulic unit assembly defective solenoid drive circuit Procedure 1 Defective hydraulic unit assembly Replace the hydraulic unit assembly Refer to ABS Anti lock Brake System on page 4 74 ...

Page 772: ...Turn the main switch to OFF before disconnecting or connecting a coupler 3 Wire harness continuity Disconnect the ABS solenoid fuse 1 and ABS ECU coupler 2 Open circuit check Short circuit check Is check result OK YES Go to step 2 NO Replace the fuse and check the wire harness Is check result OK YES Go to step 3 NO If there is a malfunction repair it and connect the coupler securely Between ABS so...

Page 773: ... hydraulic unit assembly Replace the hydraulic unit assembly Refer to ABS Anti lock Brake System on page 4 74 Between ABS ECU coupler 1 and ground blue white ground ABS ECU coupler blue white any other coupler terminal Is resistance Ω YES Go to step 4 NO Replace the wire harness R W L W B B W Gy B L Y G R B B L W G O W L L B W W L B R W L W B B W Gy B L Y G R B B L W G O W L L B W W L B B A 1 1 ...

Page 774: ...OFF before disconnecting or connecting a coupler 3 Wire harness continuity Disconnect the starter relay coupler ABS motor fuse 1 and ABS ECU coupler 2 Open circuit check Short circuit check Is check result OK YES Go to step 2 NO Replace the fuse and check the wire harness Is check result OK YES Go to step 3 NO If there is a malfunction repair it and connect the coupler securely Between starter rel...

Page 775: ...e hydraulic unit assembly Replace the hydraulic unit assembly Refer to ABS Anti lock Brake System on page 4 74 Between ABS ECU coupler 1 and ground red white ground ABS ECU coupler red white any other coupler terminal Is resistance Ω YES Go to step 4 NO Replace the wire harness R W L W B B W Gy B L Y G R B B L W G O W L L B W W L B R W L W B B W Gy B L Y G R B B L W G O W L L B W W L B B A 1 1 ...

Page 776: ...AS33323 TROUBLESHOOTING Item Hydraulic unit assembly short circuit in ABS motor power supply circuit Procedure 1 Defective hydraulic unit assembly Replace the hydraulic unit assembly Refer to ABS Anti lock Brake System on page 4 74 ...

Page 777: ...NG THE FRONT WHEEL on page 4 38 and CHECKING THE FRONT BRAKE DISCS on page 4 57 3 Front brake dragging Check that the brake fluid pressure is correctly transmitted to the brake caliper when the brake lever is operated and that the pressure decreases when the lever is released Refer to CHECKING THE FRONT BRAKE DISCS on page 4 57 4 Defective hydraulic unit assembly Replace the hydraulic unit assembl...

Page 778: ...ING THE REAR WHEEL on page 4 47 and CHECKING THE REAR BRAKE DISC on page 4 68 3 Rear brake dragging Check that the brake fluid pressure is correctly transmitted to the brake caliper when the brake pedal is operated and that the pressure decreases when the pedal is released Refer to CHECKING THE REAR BRAKE DISC on page 4 68 4 Defective hydraulic unit assembly Replace the hydraulic unit assembly Ref...

Page 779: ...incorrect installation of the rotor Check the surface of the sensor rotor for damage Refer to MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR on page 4 40 4 Defective front wheel sensor or incorrect installation of the sensor Check the wheel sensor for damage and the installed condition of the sensor Refer to MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR on page 4 40 Is check resul...

Page 780: ...incorrect installation of the rotor Check the surface of the sensor rotor for damage Refer to MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR on page 4 49 4 Defective rear wheel sensor or incorrect installation of the sensor Check the wheel sensor for damage and the installed condition of the sensor Refer to MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR on page 4 49 Is check result O...

Page 781: ...Refer to CHECKING AND CHARGING THE BATTERY on page 8 42 2 Disconnected battery terminal Check the connection 3 Defective charging system Check the charging system Refer to CHARGING SYSTEM on page 8 12 Is check result OK YES Go to step 3 NO Replace or reconnect the terminal Is check result OK YES Replace the hydraulic unit assembly ABS ECU NO Confirm the cause of the problem and repair it and check...

Page 782: ...re disconnecting or connecting a coupler 3 Wire harness continuity Disconnect the ABS ECU fuse 1 and ABS ECU coupler 2 Open circuit check Short circuit check TIP Disconnect the ABS ECU related connectors before checking Refer to PARTS CONNECTED TO THE ABS ECU on page 9 4 Ground short circuit check A Is check result OK YES Go to step 3 NO If there is a malfunction repair it and connect the coupler ...

Page 783: ... red black any other coupler terminal Is resistance Ω YES Go to step 4 NO Replace the wire harness Is check result OK YES Replace the hydraulic unit assembly ABS ECU NO Confirm the cause of the problem and repair it and check again R W L W B B W Gy B L Y G R B B L W G O W L L B W W L B R W L W B B W Gy B L Y G R B B L W G O W L L B W W L B B A 1 1 ...

Page 784: ...S20700 55_ABS EAS33328 TROUBLESHOOTING Item Hydraulic unit assembly defective ABS ECU Procedure 1 Defective hydraulic unit assembly Replace the hydraulic unit assembly Refer to ABS Anti lock Brake System on page 4 74 ...

Page 785: ...01 56_ABS EAS33329 TROUBLESHOOTING Item Hydraulic unit assembly abnormal internal circuit Procedure 1 Defective hydraulic unit assembly Replace the hydraulic unit assembly Refer to ABS Anti lock Brake System on page 4 74 ...

Page 786: ...Ground short circuit check A Between ECU coupler and joint coupler blue white blue white blue black blue black Between the joint coupler and ABS ECU coupler blue white blue white blue black blue black L W L W L W L W L W L W L B L B L B L B L B L B L WL WL WL WL WL W L W L B L B L B L B L B L B L B R W L W B B W Gy B L Y G R B B L W G O W L L B W W L B L R Gy L B L P W P V W W B L W B Y B L Gy G B...

Page 787: ... blue black any other coupler terminal Joint coupler 2 blue white any other coupler terminal blue black any other coupler terminal ABS ECU coupler blue white any other coupler terminal blue black any other coupler terminal L W L W L W L W L W L W L B L B L B L B L B L B L WL WL WL WL WL W L W L B L B L B L B L B L B L B R W L W B B W Gy B L Y G R B B L W G O W L L B W W L B R W L W B B W Gy B L Y ...

Page 788: ...ler securely Between ABS ECU fuse holder and ABS ECU cou pler red black red black Between ABS solenoid fuse holder and ABS ECU coupler blue white blue white Is resistance 0 Ω YES Go to Short circuit check NO Replace the wire harness Between ABS ECU coupler 1 and ground red black ground blue white ground ABS ECU coupler red black any other coupler terminal blue white any other coupler terminal Is r...

Page 789: ...tem Check the charging system Refer to CHARGING SYSTEM on page 8 12 Go to step 5 NO Replace the wire harness Is resistance Ω YES Replace the hydraulic unit assembly ABS ECU NO Confirm the cause of the problem and repair it and check again ...

Page 790: ...702 62_ABS EAS33333 TROUBLESHOOTING Item Power supply voltage failure in pressure sensor Procedure 1 Defective hydraulic unit assembly Replace the hydraulic unit assembly Refer to ABS Anti lock Brake System on page 4 74 ...

Page 791: ...ont pressure sensor Procedure 1 Defective front brake line Check the front brake line 2 Defective hydraulic unit assembly Replace the hydraulic unit assembly Refer to ABS Anti lock Brake System on page 4 74 Is check result OK YES Go to step 2 NO If there is bending or blocking replace the front brake line ...

Page 792: ...ler 3 Open circuit check Is check result OK YES Go to step 2 NO If there is a malfunction repair it and connect the coupler securely Between meter assembly coupler and joint coupler blue white blue white blue black blue black Between joint coupler and ABS ECU coupler blue white blue white blue black blue black L W L W L W L W L W L W L B L B L B L B L B L B L WL WL WL WL WL W L W L B L B L B L B L...

Page 793: ...hite any other coupler terminal blue black any other coupler terminal ABS ECU coupler blue white any other coupler terminal blue black any other coupler terminal L W L W L W L W L W L W L B L B L B L B L B L B L WL WL WL WL WL W L W L B L B L B L B L B L B L B B W R W Br W Br B Br Y L W Lg L B G W Dg Ch W L W Y R GR GSb WG L G Y W G O Y G G B W B W G B W R W Br W Br B Br Y L W Lg L B G W Dg Ch W L...

Page 794: ...89_ABS 9 297 3 Defective meter assembly Replace the meter assembly and check again 4 Defective hydraulic unit assembly Replace the hydraulic unit assembly ...

Page 795: ...BS ECU coupler 3 Open circuit check Is check result OK YES Go to step 2 NO If there is a malfunction repair it and connect the coupler securely Between ECU coupler and joint coupler blue white blue white blue black blue black Between joint coupler and ABS ECU coupler blue white blue white blue black blue black L W L W L W L W L W L W L B L B L B L B L B L B L WL WL WL WL WL W L W L B L B L B L B L...

Page 796: ...her coupler terminal Joint coupler 2 blue white any other coupler terminal blue black any other coupler terminal ABS ECU coupler blue white any other coupler terminal blue black any other coupler terminal L W L W L W L W L W L W L B L B L B L B L B L B L WL WL WL WL WL W L W L B L B L B L B L B L B L B R W L W B B W Gy B L Y G R B B L W G O W L L B W W L B R W L W B B W Gy B L Y G R B B L W G O W ...

Page 797: ...90_ABS 9 300 3 Defective ECU Replace the ECU and check again 4 Defective hydraulic unit assembly Replace the hydraulic unit assembly ...

Page 798: ... 1 joint coupler 2 and ABS ECU coupler 3 Open circuit check Is check result OK YES Go to step 2 NO If there is a malfunction repair it and connect the coupler securely Between IMU coupler and joint coupler blue white blue white blue black blue black Between joint coupler and ABS ECU coupler blue white blue white blue black blue black L W L W L W L W L W L W L B L B L B L B L B L B L WL WL WL WL WL...

Page 799: ...oupler blue white any other coupler terminal blue black any other coupler terminal Joint coupler 2 blue white any other coupler terminal blue black any other coupler terminal ABS ECU coupler blue white any other coupler terminal blue black any other coupler terminal L W L W L W L W L W L W L B L B L B L B L B L B L WL WL WL WL WL W L W L B L B L B L B L B L B L B R W L W B B W Gy B L Y G R B B L W...

Page 800: ...91_ABS 9 303 4 Defective hydraulic unit assembly Replace the hydraulic unit assembly ...

Page 801: ...91_ABS 9 304 ...

Page 802: ...IL Malfunction indicator light 74 Neutral indicator light 75 Shift indicator light 76 Multi function meter 77 Stability control indicator light 78 Oil pressure and coolant tem perature warning light 79 Auxiliary system warning light 80 Turn signal indicator light right 81 Turn signal indicator light left 82 Meter light 83 ABS warning light 84 High beam indicator light 85 YDT coupler 86 CCU Communi...

Page 803: ...ck G L Green Blue G O Green Orange G R Green Red G W Green White G Y Green Yellow Gy B Gray Black Gy G Gray Green Gy R Gray Red Gy Y Gray Yellow L B Blue Black L G Blue Green L R Blue Red L W Blue White L Y Blue Yellow Lg R Light green Red O B Orange Black O G Orange Green P B Pink Black P L Pink Blue P W Pink White R B Red Black R G Red Green R L Red Blue R W Red White R Y Red Yellow Sb W Sky blu...

Page 804: ......

Page 805: ......

Page 806: ......

Page 807: ...L W L Y L Y R R R Br L R Br L W W W W W W Dgy W B W W R R B R G Y R W L W B R W R W R W R W R W R W L W L W L W Y G Y R W B W G B W R Y B L Y B B Y B W B L L G R B Y B W B W G W B W G B W W B G W R B W B Y O R W P B Gy G B L B R W R W L W L L W L R R L R B L R L W R W L B L Y B Y Sb W Sb L W Br W L R L R W L B B B B B B Y L R Br Y B Br Y Gy B B Y B B R B Sb Y L B R L B G W B L R R W B Dl L R G W B...

Page 808: ...B B B B B G L G L B B B B B 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 23 23 25 24 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 49 49 49 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 96 97 94 95 98 99 100 101 108 107 106 105 102 104 103 109 110 111 114 115 116 117 11...

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