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Yamaha TMAX 2020, Руководство по обслуживанию

Новый Yamaha TMAX 2020 - это современный макси-скейтер, способный удовлетворить требования даже самых взыскательных райдеров. Для тех, кто ищет Service Manual или инструкцию по эксплуатации, можно бесплатно скачать их с manualshive.com. Получите все необходимые руководства для вашего Yamaha TMAX 2020 прямо сейчас.

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V-BELT AUTOMATIC TRANSMISSION ....................................................... 5-39

REMOVING THE PRIMARY SHEAVE AND SECONDARY 

SHEAVE ................................................................................................. 5-43

DISASSEMBLY THE SECONDARY SHEAVE........................................ 5-43
CHECKING THE V-BELT........................................................................ 5-44
CHECKING THE PRIMARY SHEAVE .................................................... 5-44
CHECKING THE V-BELT CASE AIR DUCT ........................................... 5-44
CHECKING THE PRIMARY SHEAVE WEIGHTS................................... 5-44
CHECKING THE SLIDERS ..................................................................... 5-44
CHECKING THE SECONDARY SHEAVE .............................................. 5-44
ASSEMBLING THE PRIMARY SHEAVE ................................................ 5-45
ASSEMBLING THE SECONDARY SHEAVE.......................................... 5-45
INSTALLING THE PRIMARY SHEAVE ASSEMBLY, 

SECONDARY SHEAVE ASSEMBLY AND V-BELT............................... 5-47

INSTALLING THE V-BELT CASE ........................................................... 5-48

GENERATOR AND STARTER CLUTCH...................................................... 5-49

REMOVING THE GENERATOR ............................................................. 5-52
REMOVING THE STARTER CLUTCH ................................................... 5-52
CHECKING THE STARTER CLUTCH .................................................... 5-53
CHECKING THE OIL STRAINER ........................................................... 5-53
ASSEMBLING THE OIL TANK................................................................ 5-53
INSTALLING THE STARTER CLUTCH .................................................. 5-53
INSTALLING THE GENERATOR............................................................ 5-53

CLUTCH ........................................................................................................ 5-55

REMOVING THE CLUTCH ..................................................................... 5-58
DISASSEMBLING THE CLUTCH ........................................................... 5-58
CHECKING THE FRICTION PLATES..................................................... 5-59
CHECKING THE CLUTCH PLATES ....................................................... 5-59
CHECKING THE CLUTCH DAMPER SPRINGS .................................... 5-59
CHECKING THE CLUTCH SPRING PLATE........................................... 5-60
CHECKING THE CLUTCH SPRINGS..................................................... 5-60
CHECKING THE CLUTCH HOUSING .................................................... 5-60
CHECKING THE CLUTCH BOSS........................................................... 5-60
CHECKING THE PRESSURE PLATE AND THRUST PLATE................ 5-60
ASSEMBLING THE CLUTCH ................................................................. 5-60
INSTALLING THE CLUTCH.................................................................... 5-61

OIL PUMP...................................................................................................... 5-63

CHECKING THE OIL PUMP ................................................................... 5-65
CHECKING THE RELIEF VALVE ........................................................... 5-65
CHECKING THE OIL PIPES ................................................................... 5-65
CHECKING THE OIL PUMP DRIVE CHAIN ........................................... 5-65
ASSEMBLING THE OIL PUMP............................................................... 5-65
INSTALLING THE OIL PUMP ................................................................. 5-65

Содержание TMAX 2020

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

Страница 2: ......

Страница 3: ...ill appear in future editions of this manual where applicable TIP If the contents of the manual are revised the last digit of the manual number will be increased by one Designs and specifications are...

Страница 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...

Страница 5: ...TION 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 clea...

Страница 6: ......

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

Страница 8: ......

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

Страница 10: ...AS30002 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped onto the right side of the frame EAS30003 MODEL LABEL The model label 1 is affixed to the storage box This informat...

Страница 11: ...is detected in the fuel meter electri cal circuit the fuel meter will flash repeatedly Check the vehicle Coolant temperature meter The coolant temperature varies with changes in the weather and engine...

Страница 12: ...before the V belt re placement indicator flashes the indicator must be reset in order for the next periodic V belt change to be indicated at the correct time Oil change indicator This indicator flashe...

Страница 13: ...the handlebar grip or throttle grip be comes worn or damaged stop using the grip warmers and replace the grips Adjusting the seat heater This vehicle can be equipped with a seat heater which can only...

Страница 14: ...traveled from that point In this case push the select switch to switch the display in the following order F TRIP Display 1 Display 2 Dis play 3 F TRIP If you do not reset the fuel reserve tripmeter ma...

Страница 15: ...ttings 1 Use the select switch to highlight Grip Warmer 1 Setting mode display 1 Display Description Grip Warmer This function allows you to set the low middle and high settings to 10 temperature leve...

Страница 16: ...o return to the menu screen Seat heater settings 1 Use the select switch to highlight Seat Heat er 2 Push the MENU switch The seat heater setting display will be shown 3 Push the MENU switch The tempe...

Страница 17: ...hen you finished changing the settings push the MENU switch to return to the menu screen Resetting the maintenance counters 1 Use the select switch to highlight Mainte nance 2 Push the MENU switch and...

Страница 18: ...e display to change and then push the MENU switch again 3 Use the select switch to highlight the item to change and then push the MENU switch TIP Display item order is as follows 4 Use the select swit...

Страница 19: ...he clock TIP The clock uses a 12 hour time system 1 Use the select switch to highlight Clock 2 Push the MENU switch 3 When the hour digits are highlighted use the select switch to set the hours 4 Push...

Страница 20: ...e will stop and the beeper will sound to prevent you from forgetting to turn off the vehicle power The sidestand alarm beeper can be set to not activate Setting procedure 1 Set the engine stop switch...

Страница 21: ...provided below to avoid any mistakes TIP For U S A and Canada use part numbers starting with YM YU or ACC For others use part numbers starting with 90890 Tool name Tool No Illustration Reference page...

Страница 22: ...90890 01426 Oil filter wrench YU 38411 3 27 6 8 Oil pressure gauge set 90890 03120 3 29 Oil pressure adapter B 90890 03124 3 29 Pressure gauge 90890 03153 Pressure gauge YU 03153 3 29 7 12 7 13 Fork...

Страница 23: ...90890 01437 Universal damping rod bleeding tool set YM A8703 4 87 Rod puller attachment M10 90890 01436 Universal damping rod bleeding tool set YM A8703 4 87 Compression gauge 90890 03081 Engine compr...

Страница 24: ...guide installer 4 0 mm YM 04112 5 25 Valve guide reamer 4 90890 04113 Valve guide reamer 4 0 mm YM 04113 5 25 Piston pin puller set 90890 01304 Piston pin puller YU 01304 5 31 Digital circuit tester...

Страница 25: ...ve spring compressor 90890 04134 Sheave spring compressor YM 04134 5 43 5 46 Sheave fixed block 90890 04135 Sheave fixed bracket YM 04135 5 43 5 46 Yamaha bond No 1215 90890 85505 Three bond No 1215 5...

Страница 26: ...holder YU 01235 5 58 5 61 Clutch spring compressor 90890 01482 5 58 5 61 Universal clutch holder 90890 04086 Universal clutch holder YM 91042 5 58 5 60 Plane bearing installer 90890 04139 5 75 5 79 Ra...

Страница 27: ...6 14 Fuel injector pressure adapter 90890 03210 Fuel injector pressure adapter YU 03210 7 12 Fuel pressure adapter 90890 03186 Fuel pressure adapter YM 03186 7 13 Ignition checker 90890 06754 Oppama p...

Страница 28: ...stic tool A I 90890 03264 This special tool includes the YDT sub harness 6P 90890 03266 TIP YDT sub harness 6P 90890 03266 If you already have Yamaha diagnostic tool A I 90890 03262 YDT sub harness 6P...

Страница 29: ...GENERAL SPECIFICATIONS 2 1 ENGINE SPECIFICATIONS 2 2 CHASSIS SPECIFICATIONS 2 7 ELECTRICAL SPECIFICATIONS 2 9 TIGHTENING TORQUES 2 11 ENGINE TIGHTENING TORQUES 2 11 CHASSIS TIGHTENING TORQUES 2 11 CA...

Страница 30: ...n Overall width 765 mm 30 1 in Overall height 1420 1475 mm 55 9 58 1 in XP560E 1420 1555 mm 55 9 61 2 in XP560D Wheelbase 1575 mm 62 0 in Ground clearance 125 mm 4 92 in Minimum turning radius 2 8 m 9...

Страница 31: ...gal Engine oil Recommended brand YAMALUBE SAE viscosity grades 10W 40 Recommended engine oil grade API service SG type or higher JASO standard MA Lubrication system Dry sump Engine oil quantity Oil ch...

Страница 32: ...intake 0 90 1 10 mm 0 0354 0 0433 in Limit 1 6 mm 0 06 in Valve seat contact width exhaust 0 90 1 10 mm 0 0354 0 0433 in Limit 1 6 mm 0 06 in Valve stem diameter intake 3 975 3 990 mm 0 1565 0 1571 i...

Страница 33: ...0 0026 in Side clearance limit 0 115 mm 0 0045 in 2nd ring End gap limit 0 85 mm 0 0335 in Ring side clearance 0 020 0 055 mm 0 0008 0 0022 in Side clearance limit 0 115 mm 0 0045 in Connecting rod Oi...

Страница 34: ...ity 7 pcs Clutch spring plate height 4 70 mm 0 19 in Minimum height 4 40 mm 0 17 in Spring quantity 1 pcs Clutch in revolution 1650 2250 r min Clutch stall revolution 3500 4500 r min V belt V belt wid...

Страница 35: ...2 feedback control Active Coolant temperature 85 105 C 185 221 F Intake vacuum 34 0 kPa 255 mmHg 10 0 inHg Difference in vacuum pressure between the cylinders 0 kPa 1 3 kPa 0 mmHg 10 mmHg 0 inHg 0 4 i...

Страница 36: ...TLAX SCF Rear tire Type Tubeless Size 160 60R15M C 67H Manufacturer model BRIDGESTONE BATTLAX SCR Tire air pressure measured on cold tires 1 person Front 225 kPa 2 25 kgf cm 33 psi Rear 250 kPa 2 50 k...

Страница 37: ...2 mm 0 01 in Recommended oil Yamaha Suspension Oil 01 Quantity left 444 0 cm 15 01 US oz Quantity right 434 0 cm 14 67 US oz Level left 114 mm 4 5 in Level right 118 mm 4 6 in Rear suspension Type Swi...

Страница 38: ...ge up to operating angle 0 4 1 4 V Output voltage over operating angle 3 7 4 4 V Charging system Charging system AC magneto Standard output 14 0 V 25 0 A at 5000 r min Stator coil resistance 0 224 0 3...

Страница 39: ...air temperature sensor resistance 5400 6600 at 0 C 5400 6600 at 32 F Intake air temperature sensor resistance 290 390 at 80 C 290 390 at 176 F Atmospheric pressure sensor output voltage 3 59 3 67 V a...

Страница 40: ...kgf m 30 lb ft Coolant drain bolt M12 1 1 6 N m 0 16 kgf m 1 2 lb ft Engine oil drain bolt M14 1 43 N m 4 3 kgf m 32 lb ft Item Thread size Q ty Tightening torque Remarks Front wheel axle M14 1 91 N m...

Страница 41: ...h a soft hammer until its end is flush with the front fork However if the surface of the front axle end is not parallel to the surface of the front fork align a point on the outer edge of the axle wit...

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

Страница 43: ...te handle bar switch coupler 3 left white rear brake light switch coupler white for XP560D front brake light switch cou pler black for XP560D handlebar switch coupler 3 right black for XP560E han dleb...

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

Страница 45: ...lamp does not matter D Route the headlight sub wire harness going to the right turn signal light in front of the headlight assembly lead E Fully push in the blue tape section of the headlight sub wire...

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

Страница 47: ...cooling sys tem air bleed hose G Insert the injector couplers separately into 1 and 2 H Route the radiator fan motor lead on the inside of the radiator inlet hose I Fasten the radiator fan motor lead...

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

Страница 49: ...ck cylinder E To seat heater for XP560D F Fasten the storage box light switch lead with the clamp G It does not matter whether the storage box light leads are installed on the left or right of the sto...

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

Страница 51: ...ead cou pler D Pass it outside the starter motor lead E Make sure the spark plug leads after this clamp are not twisted F Make sure there is no slack in the spark plug lead when installed within this...

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

Страница 53: ...he illustration Point the end of the plastic locking tie rearward and place it inside of the footboard I Assemble the wire harness clamp to the round area of the rib J Install the plastic locking tie...

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

Страница 55: ...P560D B The order of arrangement of the lead does not matter as long as it is installed within this range C Install the plastic locking tie within this range D Fasten the tape portion of each lead wit...

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

Страница 57: ...ront brake hose hydraulic unit to front brake caliper 16 Windshield drive unit cable for XP560D A After connecting the coupler to the meter insert it until the coupler cover contacts the bottom of the...

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

Страница 59: ...relay control for XP560D 11 Seat heater relay power for XP560D 12 Radiator fan motor relay 13 Turn signal hazard relay 14 Wire harness 15 Storage box light switch lead A Route the lead along the edge...

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

Страница 61: ...e hose holder A Route the rear brake lock cable through the hole in the handlebar cover B Route through the cable guide in the order of the throttle cable decelerator cable fol lowed by throttle cable...

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

Страница 63: ...ront brake hose with the white paint mark on the metal part facing the front L Route the metal part of the rear brake hose between the guides of the rear brake mas ter cylinder M Attach the rear brake...

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

Страница 65: ...y throttle cable accelerator cable C Install the grip warmer lead left into the slot in the handlebar switch left D Turn the rear brake lock lever up to the position shown in the illustration before i...

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

Страница 67: ...right to assemble it N The metal part of the front brake hose should come into contact with the guide section of the front brake master cylinder O Install the front brake hose with the white paint mar...

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

Страница 69: ...tic locking tie The plastic locking tie should face downward with the end cut to 5 mm 0 2 in or less J Install the bracket with the identification mark facing the front K Install the front brake hose...

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

Страница 71: ...ke lock cable in front of the section where the electrical compo nents tray and frame are fastened D Route the rear brake hose along the guide of the electrical components tray E Make sure there is no...

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

Страница 73: ...ation stopper against the rear frame C Install the clamp with the clamp in contact with the protector end of the rear wheel sensor lead D Install the rear brake hose with the rear brake hose in contac...

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

Страница 75: ...nd fuel tank breather hose with the clamp Install the clamp with the longer side of the fixed sec tion facing downward and adjust the posi tion so that the intersection of the rear brake hose and fuel...

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

Страница 77: ...all the fuel tank overflow hose with the mark facing the outside B Route the fuel tank overflow hose between the sidestand bracket and the frame C Align the mark on the fuel tank with the mark on the...

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

Страница 79: ...he hose mounting area G Insert the canister purge hose until it butts against the throttle body assembly H Do not allow the bolt head of the clamp that is holding the throttle body joint to touch the...

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

Страница 81: ...ntil it butts against the throttle body assembly E Do not allow the intake air pressure sensor hose to be twisted F Pass the intake air pressure sensor hose under the brim of the air filter case duct...

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

Страница 83: ...lant reservoir hose to the bottom of the radiator filler hose O 2 mm 0 08 in or more P Insert the oil cooler inlet hose all the way to the paint mark on the end Q Make sure the clamp does not ride on...

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

Страница 85: ...contact with it 0 10 mm 0 0 39 in J Align the clamp with the paint mark on the coolant reservoir hose K Make sure the clamp does not ride on top of the bulge in the hose installing area L Make sure t...

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

Страница 87: ...e clamp does not ride on top of the bulge in the hose mounting area C Install the clip with its end facing the down D Insert the coolant reservoir hose until it comes into contact with the rib of the...

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

Страница 89: ...front brake hose 3 with the L shaped pin in contact with the side of the hydraulic unit The installation order of rear brake hose 1 and front brake hose 3 does not matter 2 Install the front brake ho...

Страница 90: ...2 61 CABLE ROUTING...

Страница 91: ...NT AND CLEANING THE CHECK HOSE 3 12 CLEANING THE V BELT CASE AIR FILTER ELEMENT 3 13 CHECKING THE BRAKE OPERATION 3 14 CHECKING THE BRAKE FLUID LEVEL 3 14 ADJUSTING THE FRONT DISC BRAKE 3 14 CHECKING...

Страница 92: ...SHOCK ABSORBER ASSEMBLY for XP560D 3 25 CHECKING THE CONNECTING ARM AND RELAY ARM 3 26 CHECKING THE ENGINE OIL LEVEL 3 27 CHANGING THE ENGINE OIL 3 27 MEASURING THE ENGINE OIL PRESSURE 3 29 CHECKING T...

Страница 93: ...ISSION CONTROL SYSTEM EAS30615 GENERAL MAINTENANCE AND LUBRICATION CHART No ITEM CHECK OR MAINTENANCE JOB ODOMETER READINGS ANNUAL CHECK 1000 km 600 mi 10000 km 6000 mi 20000 km 12000 mi 30000 km 1800...

Страница 94: ...es for looseness Moderately repack with lithi um soap based grease 17 Chassis fasteners Make sure that all nuts bolts and screws are properly tight ened 18 Front and rear brake lever pivot shaft Lubri...

Страница 95: ...ternal components of the brake master cylinders and calipers and change the brake fluid every 2 years Replace the brake hoses every 4 years or sooner if cracked or damaged 28 Front and rear brake swit...

Страница 96: ...AND DIAGNOSTIC CODE TABLE on page 9 38 4 Perform Dynamic inspection TIP Use the Dynamic inspection function of the YDT version 3 0 and after to perform the dynam ic inspection For information about u...

Страница 97: ...plug Insulator 2 Abnormal color Replace the spark plug Normal color is medium to light tan 6 Clean Spark plug with a spark plug cleaner or wire brush 7 Measure Spark plug gap a with a wire thickness...

Страница 98: ...e generator rotor with the mark b on the generator cover TIP TDC on the compression stroke can be found when the cylinder 1 camshaft lobes are turned away from each other In order to be sure that the...

Страница 99: ...valve clearance Example Specified valve clearance 0 15 0 22 mm 0 0059 0 0087 in Measured valve clearance 0 25 mm 0 0098 in 0 25 mm 0 0098 in 0 22 mm 0 0087 in 0 03 mm 0 001 in c Check the thickness o...

Страница 100: ...e specified clearance is obtained 8 Install All removed part TIP For installation reverse the removal procedure 9 Adjust Throttle grip free play Refer to CHECKING THE THROTTLE GRIP on page 3 33 EAS310...

Страница 101: ...Footboard Refer to GENERAL CHASSIS 2 on page 4 11 Fuel tank Refer to FUEL TANK on page 7 1 3 Remove Intake air pressure sensor hose 1 Cap 2 4 Install Hose 1 Parts No 5JW 24311 00 3 way joint 2 Parts N...

Страница 102: ...ace the throttle bodies The difference in vacuum pressure between the throttle bodies should not exceed 1 33 kPa 10 mmHg 2 Stop the engine and remove the measuring equipment 3 Install Intake air press...

Страница 103: ...r 5 4 Install Footboard right Rear side cowling assembly right Side cover right Fuel tank cover assembly Center cover Refer to GENERAL CHASSIS 2 on page 4 11 Bottom center cowling Side panel Bottom si...

Страница 104: ...olume use the CO adjustment mode of the YDT For more infor mation refer to the operation manual of the YDT 1 Remove the protective cap and then connect the YDT to coupler Refer to YDT on page 9 3 TIP...

Страница 105: ...HE V BELT CASE AIR FILTER ELEMENT 1 Remove Bottom side cowling Side panel Bottom center cowling Refer to GENERAL CHASSIS 1 on page 4 1 Center cover Fuel tank cover assembly Side cover Rear side cowlin...

Страница 106: ...e causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake...

Страница 107: ...the brake pads as a set Refer to FRONT BRAKE on page 4 38 EAS30631 ADJUSTING THE REAR DISC BRAKE 1 Adjust Rear brake lever position distance a from the left side grip to the brake lever a Push the bra...

Страница 108: ...AR BRAKE on page 4 50 EAS30893 BLEEDING THE HYDRAULIC BRAKE SYSTEM WARNING EWA14000 Always bleed the brake system when the brake related parts are removed NOTICE ECA18050 Bleed the brake system in the...

Страница 109: ...ir to the proper level with the speci fied brake fluid l Tighten the bleed screw to specification m Fill the brake master cylinder reservoir to the proper level with the specified brake flu id Refer t...

Страница 110: ...1 Check Rear brake lock operation Apply the rear brake lock and then pushing the vehicle for properly locks the rear brake lock Rear brake lock not working properly Check the rear brake lock cable an...

Страница 111: ...ires listed below have been approved by Yamaha Motor Co Ltd for this model The front and rear tires should always be by the same manufacturer and of the same design No guarantee con cerning handling c...

Страница 112: ...on page 4 94 2 Clean Drive belt a Wipe the drive belt with a clean cloth b Put the drive belt in a mixture of mild deter gent and water Then remove any dirt from the drive belt c Remove the drive bel...

Страница 113: ...t room temperature and when the drive belt is dry 1 Stand the vehicle on a level surface TIP Place the vehicle on the centerstand 2 Remove the drive belt upper guard Refer to REAR WHEEL on page 4 30 3...

Страница 114: ...tween the left and right sides is within 0 8 mm 0 03 in 7 Use the tension meter and measure the drive belt tension again 8 Measure and adjust until proper drive belt tension within specification value...

Страница 115: ...ou put in too much grease the grease will come out of the holder which could cause grease to get on the drive belt TIP Use a scale to weigh the grease and inject 38 g into the drive pulley assembly in...

Страница 116: ...turning the front fork all the way in both directions If any binding is felt re move the lower bracket and check the up per and lower bearings Refer to STEERING HEAD on page 4 90 e Install the rubber...

Страница 117: ...ace WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over 2 Check Inner tube Damage scratches Replace Front fork leg Oil leaks between inner tube and outer tube R...

Страница 118: ...is ad justment range may not exactly match the spec ifications listed due to small differences in production EAS30809 CHECKING THE CONNECTING ARM AND RELAY ARM 1 Check Rear shock absorber assembly ope...

Страница 119: ...ankcase TIP Before checking the engine oil level wait a few minutes until the oil has settled 4 Start the engine warm it up for several min utes and then turn it off 5 Check the engine oil level again...

Страница 120: ...g and bot tom center cowling Refer to GENERAL CHASSIS 1 on page 4 1 b Slightly loosen the engine oil check bolt 1 c Start the engine and keep it idling until en gine oil starts to seep from the oil ch...

Страница 121: ...point plug TIP Lubricate the O ring of the engine oil pressure check point plug with a thin coat of lithium soap based grease EAS30811 CHECKING THE COOLANT LEVEL 1 Stand the vehicle on a level surface...

Страница 122: ...CKING THE COOLING SYSTEM 1 Remove Bottom side cowling Side panel Radiator cover Bottom center cowling Refer to GENERAL CHASSIS 1 on page 4 1 Center cover Fuel tank cover assembly Side cover Rear side...

Страница 123: ...team 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...

Страница 124: ...lant to the maxi mum level mark a 12 Install Coolant reservoir cap 13 Start the engine warm it up for one minute and then stop it TIP Place the vehicle on the centerstand 14 Check Coolant level Refer...

Страница 125: ...all of the in ner and outer cables WARNING EWA13270 Damaged outer cable may cause the cable to corrode and interfere with its movement Re place damaged outer cable and inner cables as soon as possibl...

Страница 126: ...CHARGING THE BATTERY Refer to CHECKING AND CHARGING THE BATTERY on page 8 94 EAS30662 CHECKING THE FUSES Refer to CHECKING THE FUSES on page 8 93 EAS30664 ADJUSTING THE HEADLIGHT BEAMS 1 Adjust Headli...

Страница 127: ...EL 4 22 REMOVING THE FRONT WHEEL 4 24 DISASSEMBLING THE FRONT WHEEL 4 24 CHECKING THE FRONT WHEEL 4 24 ASSEMBLING THE FRONT WHEEL 4 25 MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR 4 26 ADJUS...

Страница 128: ...ALIPER 4 60 ASSEMBLING THE REAR BRAKE CALIPER 4 60 INSTALLING THE REAR BRAKE CALIPER 4 60 REMOVING THE REAR BRAKE MASTER CYLINDER 4 61 CHECKING THE REAR BRAKE MASTER CYLINDER 4 61 ASSEMBLING THE REAR...

Страница 129: ...THE DRIVE BELT 4 95 INSTALLING THE DRIVE BELT AND DRIVE PULLEY 4 95 REAR SHOCK ABSORBER ASSEMBLY 4 96 HANDLING THE REAR SHOCK ABSORBER 4 97 DISPOSING OF A REAR SHOCK ABSORBER 4 97 REMOVING THE REAR S...

Страница 130: ...r 1 6 Rearview mirror 2 7 Windshield inner panel 1 8 Meter assembly coupler 1 Disconnect 9 Meter assembly 1 10 Meter panel assembly 1 3 1 1 3 4 5 7 8 10 9 6 6 2 2 1 6 N m 0 16 kgf m 1 2 lb ft 1 5 N m...

Страница 131: ...6 Windshield inner panel 1 7 Meter assembly coupler 1 Disconnect 8 Meter assembly 1 9 Meter panel assembly 1 3 1 1 3 4 6 7 9 8 5 5 2 2 1 6 N m 0 16 kgf m 1 2 lb ft 1 5 N m 0 15 kgf m 1 1 lb ft 1 5 N...

Страница 132: ...ct 2 Front turn signal light 2 3 Headlight assembly coupler 2 Disconnect 4 Front cowling assembly 1 5 Side cowling 2 6 Front turn signal light bracket 2 7 Headlight under panel 1 8 Headlight sub wire...

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

Страница 134: ...SIS 2 on page 4 11 1 Battery cover 1 2 Negative battery lead 1 Disconnect 3 Positive battery lead 1 Disconnect 4 Battery band 1 5 Battery 1 6 Storage compartment lid lock solenoid coupler 1 Disconnect...

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

Страница 136: ...shield by removing the screws 3 d Install the windshield to the desired position by installing the screws 3 e Tighten the screws to the specified torque f Install the caps 1 g Place the windshield cov...

Страница 137: ...ts b EAS30821 REMOVING THE SIDE PANEL The following procedure applies to both of the side panels 1 Remove Bottom side cowling 2 Remove Side panel 1 a Remove the side panel screws 2 b Remove the quick...

Страница 138: ...ners 3 c Install the side panel screws 4 2 Install Bottom side cowling EAS30819 REMOVING THE INNER PANEL The following procedure applies to both of the in ner panels 1 Remove Inner panel 1 a Remove th...

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

Страница 140: ...1 2 Fuel tank cover assembly 1 3 Seat fuel lid lock solenoid coupler 1 Disconnect 4 Seat lock cable 1 Disconnect 5 Side cover 2 6 Footboard 4 7 Seat fuel button cover 1 8 Cover 2 9 Seat fuel lid lock...

Страница 141: ...sembly Side cover Refer to GENERAL CHASSIS 2 on page 4 11 1 Grab bar 2 2 Rubber cover 1 3 Rear side cowling assembly 2 4 Rear side cowling 2 5 Inner panel 2 6 Rear turn signal light coupler 2 Disconne...

Страница 142: ...n page 4 11 1 Rear cover 1 2 Tail brake light coupler 1 Disconnect 3 Seat lock cable 1 Disconnect 4 Rear cowling assembly 1 5 Lid 1 6 Tail brake light 1 7 Seat lock key cylinder 1 8 Tail brake light c...

Страница 143: ...Refer to GENERAL CHASSIS 2 on page 4 11 1 Storage box inner mat 1 2 Storage box light switch connector 2 Disconnect 3 Wire harness 1 Disconnect 4 Storage box 1 5 Rear panel 2 6 Storage box light 1 7...

Страница 144: ...Remove Side cover Rear cover Grab bar Refer to GENERAL CHASSIS 2 on page 4 11 2 Remove Rear side cowling assembly 1 a Remove the rear side cowling assembly screw bolt and quick fastener EAS31523 REMOV...

Страница 145: ...liding it to the upper side EAS31193 REMOVING THE REAR COVER 1 Remove Rubber cover 1 2 Remove Grab bar Rear side cowling assembly GENERAL CHASSIS 2 on page 4 11 3 Remove Tail brake light cover 1 a Rem...

Страница 146: ...el tank cover assembly Side cover Rear side cowling assembly Footboard Refer to GENERAL CHASSIS 2 on page 4 11 1 Ignition coil connector 2 Disconnect 2 Ignition coil 1 3 Buzzer coupler 1 Disconnect 4...

Страница 147: ...r cover Fuel tank cover assembly Side cover Rear side cowling assembly Footboard Refer to GENERAL CHASSIS 2 on page 4 11 1 Handlebar switch coupler 2 2 Rectifier regulator coupler 1 Disconnect 3 Recti...

Страница 148: ...ssembly Footboard Refer to GENERAL CHASSIS 2 on page 4 11 Brake hose holder Refer to HANDLEBAR on page 4 74 1 Handlebar switch coupler 2 2 Rectifier regulator coupler 1 Disconnect 3 Rectifier regulato...

Страница 149: ...ly Footboard Refer to GENERAL CHASSIS 2 on page 4 11 Battery box Electrical components tray Meter bracket Windshield bracket XP560E Wind shield drive unit XP560D Refer to GENERAL CHASSIS 3 on page 4 1...

Страница 150: ...drive unit coupler to the wire harness b Adjust the distances at the top a and bot tom b of the rails so they are the same TIP Refer to the illustration below for the positions to measure c c After i...

Страница 151: ...heel axle bolt 1 8 Front wheel axle 1 9 Front wheel 1 10 Collar 1 Length 22 mm 0 87 in 11 Collar 1 Length 18 mm 0 71 in 12 Front brake disc 2 LT LT 1 2 3 3 3 3 4 5 5 6 6 7 8 9 10 11 12 12 1 2 2 5 N m...

Страница 152: ...ng the front wheel Order Job Parts to remove Q ty Remarks 1 Front wheel sensor rotor 1 2 Oil seal 2 3 Wheel bearing 2 4 Collar 1 LT 8 N m 0 8 kgf m 5 9 lb ft 2 0 N m 0 20 kgf m 1 5 lb ft 3 0 N m 0 30...

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

Страница 154: ...4 that matches the diameter of the wheel bearing outer race b Install the spacer c Install the new wheel bearing left side TIP Place a suitable washer 1 between the socket 2 and the bearing so that bo...

Страница 155: ...e they have been accurately adjusted Keep them away from dirt and do not sub ject them to shocks The front wheel sensor cannot be disas sembled Do not attempt to disassemble it If faulty replace with...

Страница 156: ...NT WHEEL STATIC BALANCE TIP After replacing the tire wheel or both the front wheel static balance should be adjusted Adjust the front wheel static balance with the brake disc installed Refer to ADJUST...

Страница 157: ...sensor rotor and front wheel sensor TIP When installing the front wheel sensor check the front wheel sensor lead for twists To route the front wheel sensor lead refer to CABLE ROUTING on page 2 13 7...

Страница 158: ...holder WARNING EWA13500 Make sure the brake hose is routed properly Front brake caliper bolt 35 N m 3 5 kgf m 26 lb ft Front brake hose holder bolt left 9 N m 0 9 kgf m 6 6 lb ft Front brake hose hol...

Страница 159: ...Loosen 6 Adjusting bolt 2 Loosen 7 Rear wheel axle nut 1 8 Washer 1 9 Rear wheel axle 1 10 Adjusting block left 1 11 Adjusting block right 1 12 Rear wheel 1 13 Rear wheel sensor housing 1 14 Brake ca...

Страница 160: ...der Job Parts to remove Q ty Remarks 1 Rear brake disc 1 2 Rear wheel sensor rotor 1 3 Drive belt guide 1 4 Rear wheel pulley 1 5 Rear wheel 1 1 2 3 4 5 LT LT LT LT 8 N m 0 8 kgf m 5 9 lb ft 10 N m 1...

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

Страница 162: ...wheel axle Rear wheel Rear brake caliper bracket Rear wheel sensor housing Collar NOTICE ECA21400 Be sure to remove the rear wheel sensor be fore removing the brake caliper bracket oth erwise the sens...

Страница 163: ...h care since they have been accurately adjusted Keep them away from dirt and do not sub ject them to shocks The rear wheel sensor cannot be disassem bled Do not attempt to disassemble it If faulty rep...

Страница 164: ...ousing Rear brake caliper bracket Rear wheel Adjusting block Rear wheel axle Washer Wheel axle nut TIP Do not install the brake caliper and brake lock caliper Fit the brake torque stop pin a on the sw...

Страница 165: ...1 and adjusting bolt 2 9 Install Rear wheel sensor 1 NOTICE ECA21080 Make sure there are no foreign materials in the rear wheel sensor rotor and rear wheel sensor Foreign materials cause damage to the...

Страница 166: ...ct 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...

Страница 167: ...rake pad 2 5 Front brake hose holder bolt 1 The tightening torque of the front brake hose holder bolt on the right side is 7 N m 0 7 kgf m 5 2 lb ft 6 Front brake hose holder 1 7 Front reflector 1 8 F...

Страница 168: ...servoir diaphragm holder 1 3 Brake master cylinder reservoir diaphragm 1 4 Front brake lever 1 5 Front brake light switch connector 2 Disconnect For XP560E 6 Brake hose union bolt 1 7 Brake hose gaske...

Страница 169: ...4 40 FRONT BRAKE Disassembling the front brake master cylinder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder kit 1 2 Brake master cylinder body 1 1 2...

Страница 170: ...brake hose holder bolt 1 The tightening torque of the front brake hose holder bolt on the right side is 7 N m 0 7 kgf m 5 2 lb ft 2 Front brake hose holder 1 3 Front reflector 1 4 Brake hose union bol...

Страница 171: ...lipers 1 Brake pad clip 2 2 Brake pad pin 1 3 Brake pad spring 1 4 Front brake pad 2 5 Brake caliper piston 4 6 Brake caliper piston dust seal 4 7 Brake caliper piston seal 4 8 Bleed screw 1 Left brak...

Страница 172: ...ace the brake disc a Place the vehicle on the centerstand so that the front wheel is elevated b Remove the brake caliper c Hold the dial gauge at a right angle against the brake disc surface d Measure...

Страница 173: ...the bleed screw and push the brake caliper pistons into the brake caliper with your finger c Tighten the bleed screw d Install the brake pads and brake pad spring TIP The arrow mark a on the brake pa...

Страница 174: ...the brake caliper WARNING EWA17060 Never try to pry out the brake caliper pis tons Do not loosen the bolts 4 c Remove the brake caliper piston dust seals and brake caliper piston seals d Repeat the pr...

Страница 175: ...Brake hose gasket Brake hose 2 Brake hose union bolt 3 WARNING EWA13531 Proper brake hose routing is essential to in sure safe vehicle operation NOTICE ECA21410 When installing the brake hose onto the...

Страница 176: ...master cylinder drain the brake fluid from the entire brake sys tem 1 Disconnect Brake light switch connector from the front brake light switch 2 Remove Brake hose union bolt Brake hose gasket Brake h...

Страница 177: ...ter cylinder reservoir with the specified amount of the specified brake fluid WARNING EWA13540 Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing...

Страница 178: ...nimum level mark Add the specified brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 14 6 Check Brake lever operation Soft or spongy feeling Bleed the brake sys tem Ref...

Страница 179: ...the rear brake pads Order Job Parts to remove Q ty Remarks 1 Rear brake caliper bolt 2 2 Rear brake caliper 1 3 Rear brake pad 2 4 Brake pad support 2 5 Bleed screw 1 S 3 4 3 4 2 5 1 1 FWD FWD 27 N m...

Страница 180: ...der reservoir diaphragm holder 1 3 Brake master cylinder reservoir diaphragm 1 4 Rear brake lever 1 5 Rear brake light switch connector 2 Disconnect For XP560E 6 Brake hose union bolt 1 7 Brake hose g...

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

Страница 182: ...EEDING THE HYDRAULIC BRAKE SYSTEM on page 3 16 1 Brake hose union bolt 1 2 Brake hose gasket 2 3 Rear brake hose 1 4 Rear brake caliper bolt 2 5 Rear brake caliper 1 6 Rear brake pad 2 7 Brake pad sup...

Страница 183: ...ear brake caliper Order Job Parts to remove Q ty Remarks 1 Brake caliper piston 1 2 Brake caliper piston dust seal 1 3 Brake caliper piston seal 1 4 Bleed screw 1 5 Brake caliper body 1 6 N m 0 6 kgf...

Страница 184: ...ear brake lock pads Order Job Parts to remove Q ty Remarks 1 Rear brake lock cable adjusting nut 1 2 Pin 1 3 Rear brake lock spring 1 4 Rear brake lock caliper 1 5 Rear brake lock pad 2 5 3 2 1 4 FWD...

Страница 185: ...moving the rear brake lock caliper Order Job Parts to remove Q ty Remarks 1 Rear brake lock cable adjusting nut 1 2 Pin 1 3 Rear brake lock spring 1 4 Rear brake lock caliper 1 3 2 1 4 FWD FWD 23 N m...

Страница 186: ...r brake lock pad 2 6 Caliper piston assembly 1 Locknut Left hand thread 7 Rear brake lock caliper bracket bolt 1 8 Rear brake lock caliper bracket 1 9 Sleeve 1 10 Boot 2 11 Boot 1 12 Slide pin bolt 1...

Страница 187: ...ng Replace 3 Measure Brake disc runout Out of specification Correct the brake disc deflection or replace the brake disc Refer to CHECKING THE FRONT BRAKE DISCS on page 4 43 4 Measure Brake disc thickn...

Страница 188: ...EM on page 3 16 EAS30186 REMOVING THE REAR BRAKE CALIPER TIP Before removing the brake caliper drain the brake fluid from the entire brake system 1 Remove Brake hose union bolt Brake hose gasket Rear...

Страница 189: ...ake caliper is disassembled replace the brake caliper piston dust seal and brake caliper piston seal EAS30190 INSTALLING THE REAR BRAKE CALIPER 1 Install Rear brake caliper 1 temporarily Brake hose ga...

Страница 190: ...AKE SYSTEM on page 3 16 EAS30193 REMOVING THE REAR BRAKE MASTER CYLINDER TIP Before removing the rear brake master cylinder drain the brake fluid from the entire brake sys tem 1 Remove Brake hose unio...

Страница 191: ...brake hose does not touch other parts e g wire harness cables leads Correct if necessary 3 Fill Brake master cylinder reservoir with the specified amount of the specified brake fluid WARNING EWA13540...

Страница 192: ...RAKE LOCK PADS 1 Remove Rear brake lock cable adjusting nut Pin Rear brake lock spring 2 Remove Rear brake lock caliper bolt Rear brake lock caliper 3 Remove Rear brake lock pad left side 1 TIP Push o...

Страница 193: ...able 3 Install Rear brake lock cable WARNING EWA13490 Make sure the brake cable is routed properly 4 Adjust Rear brake lock cable length a Adjust the clearance for the rear brake lock pad Refer to ADJ...

Страница 194: ...es the locknut b With shaft L fastened turn and adjust the piston adjusting bolt so that the length a between the end of shaft L and the end of the piston adjusting bolt is changed to 19 mm 0 75 in Re...

Страница 195: ...ter installing the rear brake lock pad to the caliper check that the pad rotates smoothly EAS31422 INSTALLING THE REAR BRAKE LOCK CALIPER 1 Install Rear brake lock caliper Rear brake lock caliper bolt...

Страница 196: ...YSTEM on page 3 16 1 ABS ECU coupler 1 Disconnect 2 Brake hose union bolt 4 3 Brake hose gasket 8 4 Rear brake hose rear brake master cylinder to hydraulic unit 1 Disconnect 5 Front brake hose hydraul...

Страница 197: ...cou plers and cause bad contacts If the union bolts for the hydraulic unit as sembly have been removed be sure to tighten them to the specified torque and bleed the brake system 1 Disconnect ABS ECU c...

Страница 198: ...draulic unit 4 Gasket Brake hose union bolt NOTICE ECA21121 If the brake hose union bolt does not turn easily replace the hydraulic unit assembly brake hoses and related parts as a set TIP To route th...

Страница 199: ...ine routing confirmation use the diagnosis of function of the YDT Before performing the brake line routing confir mation make sure that no malfunctions have been detected in the ABS ECU and that the w...

Страница 200: ...o danger of it falling over TIP For the ABS reaction force confirmation use the diagnosis of function of the YDT For more information refer to the operation manual of the YDT Before performing the ABS...

Страница 201: ...IP The reaction force pulsating action consists of quick pulses Be sure to continue operating the front brake lever and rear brake lever even after the pul sating action has stopped ON and OFF on the...

Страница 202: ...it brake pipes and related parts as a set 17 If the operation of the hydraulic unit is normal delete all of the DTC EAS30202 CHECKING THE ABS WARNING LIGHT After all checks and servicing are completed...

Страница 203: ...er front 1 3 Parking Unlock switch coupler 1 Disconnect 4 OFF LOCK switch coupler 1 Disconnect 5 Lower handlebar cover 1 6 Accelerator position sensor coupler 1 Disconnect 7 Handlebar cover rear 1 8 P...

Страница 204: ...r Footboard Refer to GENERAL CHASSIS 2 on page 4 11 Handlebar cover Refer to HANDLEBAR on page 4 74 1 Front brake light switch connector 2 Disconnect for XP560E 2 Front brake master cylinder holder 1...

Страница 205: ...ver 1 13 Rear brake lock cable 1 Disconnect 14 Rear brake master cylinder assembly 1 15 Handlebar switch left 1 16 Handlebar switch holder 2 17 Handlebar grip 1 FWD FWD 10 9 11 12 13 14 15 17 16 16 3...

Страница 206: ...board Refer to GENERAL CHASSIS 2 on page 4 11 Handlebar cover Brake master cylinder Handle bar switch Refer to HANDLEBAR on page 4 74 1 Clamp 2 2 Bracket 1 3 Upper handlebar holder 2 4 Handlebar 1 5 L...

Страница 207: ...ehicle so that there is no danger of it falling over 2 Install Brake hose bracket Lower handlebar holder Handlebar 1 Upper handlebar holder 2 Bracket 3 NOTICE ECA18300 First tighten the bolts on the f...

Страница 208: ...efer to INSTALLING THE REAR BRAKE MASTER CYLINDER on page 4 62 9 Install Handlebar grip Grip end 1 a Apply a thin coat of rubber adhesive onto the end of the left handlebar b Slide the handlebar grip...

Страница 209: ...Diagnostic code No 14 is selected g Turn the throttle grip to the fully closed po sition h Adjust the position of the accelerator posi tion sensor angle so that 11 20 can appear in the YDT screen i A...

Страница 210: ...nel Meter assembly Bottom side cowling Side panel Front cowling assembly Refer to GENERAL CHASSIS 1 on page 4 1 Front wheel Refer to FRONT WHEEL on page 4 22 1 Front fender 1 2 Upper bracket pinch bol...

Страница 211: ...Damper rod locknut 1 4 Spacer 1 5 Fork spring 1 6 Damper rod assembly bolt 1 7 Copper washer 1 8 Damper rod assembly 1 9 Dust seal 1 10 Oil seal clip 1 11 Outer tube 1 12 Oil seal 1 13 Washer 1 14 Out...

Страница 212: ...e front fork legs NOTICE ECA22020 Because the left and right damper rod as semblies are different be sure to install them in the correct positions 1 Remove Cap bolt 1 Spacer 2 Damper rod locknut 3 a P...

Страница 213: ...ld the front fork leg horizontally b Securely clamp the brake caliper bracket in a vise with soft jaws c Separate the outer tube from the inner tube by pulling the outer tube forcefully but care fully...

Страница 214: ...he following parts Inner tube bushing Outer tube bushing Oil seal Dust seal Oil seal clip O ring Copper washer Before assembling the front fork leg make sure all of the components are clean 1 Lubricat...

Страница 215: ...t side is used for the rebound operation and left side for the compression Pay attention not to mistake the right and left TIP The left side for the compression damper rod assembly has the holes a of...

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

Страница 217: ...rod puller and install the rod holder 2 between the damper rod locknut 3 and the spacer 4 TIP Use the side of the rod holder that is marked B f Remove the rod puller and the rod puller at tachment g...

Страница 218: ...y tighten the upper and lower bracket pinch bolts TIP Make sure the outer tube is flush with the top of the upper bracket 2 Tighten Lower bracket pinch bolt 1 Cap bolt 2 Upper bracket pinch bolt 3 Low...

Страница 219: ...ENERAL CHASSIS 1 on page 4 1 Center cover Fuel tank cover assembly Rear side cowling assembly Side cover Footboard Refer to GENERAL CHASSIS 2 on page 4 11 Handlebar cover Handlebar Lower handlebar hol...

Страница 220: ...remove Q ty Remarks 8 Lower bracket 1 9 Upper bearing cover 1 10 Upper bearing 1 11 Lower bearing 1 12 Dust seal 1 13 Steering lock unit coupler 1 Disconnect 14 Steering lock unit 1 15 Stay 1 FWD LT L...

Страница 221: ...ve the bearing races from the steer ing head pipe 1 with a long rod 2 and hammer b Remove the bearing race from the lower bracket 3 with a floor chisel 4 and ham mer c Install a new rubber seal and ne...

Страница 222: ...STEERING HEAD on page 3 23 3 Install Upper bracket Washer Steering stem nut TIP Temporarily tighten the steering stem nut 4 Install Front fork leg Refer to FRONT FORK on page 4 81 TIP Temporarily tig...

Страница 223: ...per Rear brake lock caliper Refer to REAR BRAKE on page 4 50 Rear wheel Refer to REAR WHEEL on page 4 30 1 Drive pulley cover 1 2 Dust cover 1 3 Holder 1 4 Collar 2 5 Circlip 1 6 Drive pulley 1 7 O ri...

Страница 224: ...VE BELT AND DRIVE PULLEY 1 Install Drive belt NOTICE ECA22720 Align the mark of the drive belt with the prog ress direction A Do not twist the drive belt when installing it 2 Lubricate Drive pulley as...

Страница 225: ...nut Rear shock absorber assembly lower bolt 1 1 3 Washer 1 4 Collar 1 5 Collar 1 6 Rear shock absorber assembly upper nut Washer Rear shock absorber assembly upper bolt 1 2 1 7 Rear shock absorber as...

Страница 226: ...ORBER 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...

Страница 227: ...Lubricate Collar Oil seal 2 Install Bearing 1 Oil seal 2 TIP When installing the oil seals 2 to the connect ing arms 3 face the character stamp of the oil seals outside Install the bearing to the conn...

Страница 228: ...the rear shock absorber assembly so that the label is facing downward Install the rear shock absorber assembly so that the rebound damping adjusting screw b is facing downward for XP560D EAS30225 INST...

Страница 229: ...R ASSEMBLY on page 4 96 Drive belt Refer to BELT DRIVE on page 4 94 1 Holder 1 2 Holder 1 3 Drive belt inner guard 1 4 Swingarm left 1 5 Swingarm right 1 6 Dowel pin 2 7 Pivot shaft 1 8 Oil seal 1 9 O...

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

Страница 231: ...Refer to BELT DRIVE on page 4 94 4 Remove Drive pulley assembly bolt Swingarm bolt Pivot shaft nut EAS30227 CHECKING THE SWINGARM 1 Check Swingarm left Swingarm right Bends cracks damage Replace 2 Che...

Страница 232: ...uches the collar and then tighten the pivot shaft to the specified torque b Tighten the pivot shaft nut to the specified torque Swingarm bolt 40 N m 4 0 kgf m 30 lb ft Drive pulley assembly bolt 48 N...

Страница 233: ...HEAD 5 20 REMOVING THE CYLINDER HEAD 5 21 CHECKING THE CYLINDER HEAD 5 21 INSTALLING THE CYLINDER HEAD 5 21 VALVES AND VALVE SPRINGS 5 23 REMOVING THE VALVES 5 24 CHECKING THE VALVES AND VALVE GUIDES...

Страница 234: ...STARTER CLUTCH 5 52 CHECKING THE STARTER CLUTCH 5 53 CHECKING THE OIL STRAINER 5 53 ASSEMBLING THE OIL TANK 5 53 INSTALLING THE STARTER CLUTCH 5 53 INSTALLING THE GENERATOR 5 53 CLUTCH 5 55 REMOVING T...

Страница 235: ...MBLING THE CRANKCASE 5 71 CRANKSHAFT 5 73 REMOVING THE CONNECTING RODS 5 75 REMOVING THE CRANKSHAFT JOURNAL BEARINGS 5 75 CHECKING THE CRANKSHAFT AND CONNECTING RODS 5 75 INSTALLING THE CRANKSHAFT JOU...

Страница 236: ...camshaft 2 Exhaust camshaft 3 Timing chain tensioner 4 Connecting rod 5 To piston 6 Starter clutch gear 7 Crankshaft 8 Balancer connecting rod 9 To balancer piston 10 Oil pipe 11 Check valve 12 Relie...

Страница 237: ...LUBRICATION DIAGRAMS 2 8 9 1 3 7 7 6 5 4 7 11 10 12 4 1 Exhaust camshaft 2 Intake camshaft 3 Oil delivery pipe 4 Oil pump assembly 5 Scavenge pump 6 Feed pump 7 Oil pipe 8 Oil cooler 9 Oil filter 10 E...

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

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

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

Страница 241: ...nk the en gine until the reading on the compression gauge stabilizes TIP The difference in compression pressure be tween cylinders should not exceed 100 kPa 1 kgf cm 14 psi c If the compression pressu...

Страница 242: ...ly right Footboard right Refer to GENERAL CHASSIS 2 on page 4 11 1 O2 sensor coupler 1 Disconnect 2 O2 sensor 1 3 Exhaust assembly 1 4 Gasket 2 5 Front muffler protector 1 6 Muffler protector 1 7 Muff...

Страница 243: ...sembly Seat assembly Storage box Refer to GENERAL CHASSIS 2 on page 4 11 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 27 Coolant Drain Refer to CHANGING THE COOLANT on page 3 31 Exhaust...

Страница 244: ...SION on page 5 39 Radiator inlet hose Cooling system air bleed hose Radiator outlet hose Refer to RADIATOR on page 6 3 1 Spark plug cap 2 Disconnect 2 Sidestand switch coupler 1 Disconnect 3 Centerst...

Страница 245: ...Rear frame 2 6 Engine mounting bolt front left lower side 2 7 Sidestand 1 8 Engine mounting bolt front right lower side 1 9 Engine mounting bolt front upper side 2 10 Engine 1 LT LT LT LT LT LT 78 N m...

Страница 246: ...nut rear side 4 Rear frame bolts 5 TIP When tightening the engine mounting nuts and engine mounting bolts do not apply an upward load to the frame such as supporting the area around steering head of t...

Страница 247: ...AL CHASSIS 1 on page 4 1 Center cover Fuel tank cover assembly Side cover Rear side cowling assembly Footboard Refer to GENERAL CHASSIS 2 on page 4 11 Radiator bracket Refer to RADIATOR on page 6 3 1...

Страница 248: ...n page 5 12 1 Timing mark accessing plug 1 2 Timing chain tensioner 1 3 Timing chain tensioner gasket 1 4 Intake camshaft cap 1 5 Exhaust camshaft cap 1 6 Dowel pin 4 TIP During removal the dowel pins...

Страница 249: ...nt marks d on the exhaust camshaft sprocket must align with the cylinder head mating surface as shown in the illustration 2 Remove Timing chain tensioner 1 Timing chain tensioner gasket 3 Remove Intak...

Страница 250: ...he specified torque To prevent the camshaft cap from cracking tighten the camshaft cap carefully by tapping the camshaft using a soft face hammer both for temporary and final tightening Do not turn th...

Страница 251: ...CHAIN TENSIONER 1 Check Timing chain tensioner Cracks damage rough movement Replace a Using the valve spring compressor 1 push and insert timing chain tensioner rod 2 into the timing chain tensioner h...

Страница 252: ...pointer b on the generator cover c Install the timing chain onto both camshaft sprockets and then install the camshafts onto the cylinder head TIP Lubricate the camshaft journal with the molyb denum...

Страница 253: ...vent the camshaft cap from cracking tighten the camshaft cap carefully by tapping the camshaft using a soft face hammer both for temporary and final tightening 4 Install Timing chain tensioner gasket...

Страница 254: ...g surface Out of alignment Correct Refer to the installation steps above 8 Measure Valve clearance Out of specification Adjust Refer to ADJUSTING THE VALVE CLEAR ANCE on page 3 5 9 Install Timing chai...

Страница 255: ...on page 5 12 Thermostat Refer to THERMOSTAT on page 6 9 1 Coolant temperature sensor coupler 1 Disconnect 2 Coolant temperature sensor 1 3 Gasket 1 4 Cylinder head 1 5 Cylinder head gasket 1 6 Dowel p...

Страница 256: ...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 sand...

Страница 257: ...when the cylinder head and cylinder are cold Use four steps to tighten the cylinder head nuts 4 Install Exhaust camshaft Intake camshaft Refer to INSTALLING THE CAMSHAFTS on page 5 17 Cylinder head n...

Страница 258: ...remove Q ty Remarks Cylinder head Refer to CYLINDER HEAD on page 5 20 1 Valve lifter 8 2 Valve pad 8 3 Valve cotter 16 4 Valve spring retainer 8 5 Valve spring 8 6 Intake valve 4 7 Exhaust valve 4 8 V...

Страница 259: ...re should be no leakage at the valve seat 1 3 Remove Valve cotter TIP Remove the valve cotters by compressing the valve spring with the valve spring compressor 1 and the valve spring compressor attach...

Страница 260: ...de 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 cl...

Страница 261: ...seat Pitting wear Replace the cylinder head 3 Measure Valve seat width a Out of specification Replace the cylinder head a Apply blue layout fluid b onto the valve face b Install the valve into the cy...

Страница 262: ...d repeat the above steps f After every lapping procedure be sure to clean off all of the lapping compound from the valve face and valve seat g Apply blue layout fluid b onto the valve face h Install t...

Страница 263: ...r head TIP Make sure each valve is installed in its original place Install the valve springs with the larger pitch a facing up 4 Install Valve cotter TIP Install the valve cotters by compressing the v...

Страница 264: ...OTICE ECA22150 After making sure that the valve pads are ful ly inserted install the valve lifter taking care so that the pads do not fall TIP The valve lifter must move smoothly when ro tated with a...

Страница 265: ...rks Cylinder head Refer to CYLINDER HEAD on page 5 20 1 Coolant hose 1 Disconnect 2 Timing chain guide exhaust side 1 3 Cylinder 1 4 Cylinder gasket 1 5 Dowel pin 2 6 Piston pin clip 4 7 Piston pin 2...

Страница 266: ...ring 2nd ring Oil ring TIP When removing a piston ring open the end gap with your fingers and lift the other side of the ring over the piston crown EAS30291 CHECKING THE CYLINDERS AND PISTONS The fol...

Страница 267: ...of the cylinder where the cylinder wear is lowest 3 Measure Piston ring end gap Out of specification Replace the piston ring set TIP The oil ring expander spacer s end gap cannot be measured If the o...

Страница 268: ...following procedure applies to all of the pis tons and cylinders 1 Install Oil ring expander 1 Lower oil ring rail 2 Upper oil ring rail 3 2nd ring 4 Top ring 5 into the piston TIP Be sure to install...

Страница 269: ...e cutout c in the piston as shown in the illustration 3 Install Dowel pin Cylinder gasket 4 Lubricate Piston Piston ring Cylinder with the recommended lubricant 5 Offset Piston ring end gap 6 Install...

Страница 270: ...r cowling Refer to GENERAL CHASSIS 1 on page 4 1 Center cover Fuel tank cover assembly Side cover Rear side cowling assembly Footboard Refer to GENERAL CHASSIS 2 on page 4 11 Fuel tank Refer to FUEL T...

Страница 271: ...lator and starter motor rear cover replace the starter motor assembly Order Job Parts to remove Q ty Remarks 1 Starter motor front cover 1 2 Armature assembly 1 3 Starter motor yoke 1 4 O ring 2 5 Bru...

Страница 272: ...it tester and check the continuity b If there is no continuity replace the starter motor 4 Measure Brush length a Out of specification Replace the brush holder set 5 Measure Brush spring force Out of...

Страница 273: ...otor front cover 3 TIP Align the match mark a on the starter motor rear cover with the match mark b on the start er motor yoke Align the match mark c on the starter motor yoke with the match mark d on...

Страница 274: ...NERAL CHASSIS 2 on page 4 11 1 Crankshaft end access cover 1 2 Damper 1 3 V belt case air filter case cover 1 4 O2 sensor lead 1 5 V belt case air filter case 1 6 V belt case air filter element right...

Страница 275: ...e nut 1 6 Secondary sheave assembly 1 7 V belt 1 8 Primary fixed sheave 1 9 V belt case air duct joint clamp 1 Loosen 10 V belt case air duct 1 11 Inner V belt case plate 1 12 Inner V belt case 1 13 D...

Страница 276: ...pply YAMAHA GREASE F 2 When replacing the primary sliding sheave or collar replace them as a set Order Job Parts to remove Q ty Remarks 1 Cam 1 2 Slider 8 3 Primary sheave weight 8 4 Primary sliding s...

Страница 277: ...Job Parts to remove Q ty Remarks 1 Secondary sheave spring seat nut 1 2 Upper spring seat 1 3 Secondary sheave compression spring 1 4 Spring seat 1 5 Guide pin 6 6 Secondary sliding sheave 1 7 O ring...

Страница 278: ...with the sheave holder 3 loosen the second ary sheave spring seat nut with the locknut wrench 4 Do not loosen the secondary sheave spring seat nut 1 more than 1 4 turn 2 Remove Secondary sheave spring...

Страница 279: ...e applies to all of the pri mary sheave weights 1 Check Primary sheave weight Cracks damage wear Replace 2 Measure Primary sheave weight outside diameter Out of specification Replace EAS30318 CHECKING...

Страница 280: ...DARY SHEAVE 1 Lubricate Secondary fixed sheave inner surface 1 Secondary sliding sheave inner surface 2 Oil seals with the recommended lubricant 2 Install Guide pin TIP Before installing the guide pin...

Страница 281: ...arily tighten the secondary sheave spring seat nut 5 Tighten Secondary sheave spring seat nut 1 TIP While holding the secondary fixed sheave 2 with the sheave holder 3 tighten the second ary sheave sp...

Страница 282: ...A22160 Do not allow grease to contact the V belt pri mary and secondary sheave TIP When installing the belt screw M6 more than 45 mm 1 77 in bolts 4 to spread apart the secondary sheave and then insta...

Страница 283: ...t EAS31235 INSTALLING THE V BELT CASE 1 Install Oil seal 1 into outer V belt case 2 Fill the space b shown in the illustration with 10 g 0 35 oz or more of lithium soap based grease 3 Install Bearing...

Страница 284: ...assembly Side cover left Rear side cowling assembly left Footboard left Refer to GENERAL CHASSIS 2 on page 4 11 V belt case air filter element left Generator cover protector Water pump inlet pipe Wat...

Страница 285: ...ch idle gear shaft 1 8 Starter clutch idle gear 1 9 Generator rotor nut 1 10 Spacer 1 11 Generator rotor 1 12 Woodruff key 1 13 Washer 1 14 Starter clutch gear 1 15 Starter clutch 1 13 15 5 6 7 8 6 11...

Страница 286: ...15 Three bond No 1215 Order Job Parts to remove Q ty Remarks 1 Oil tank 1 2 Oil tank gasket 1 3 Dowel pin 2 4 Oil strainer 1 5 Crankshaft position sensor 1 6 Stator coil 1 7 Bearing cover 1 8 Oil seal...

Страница 287: ...ion on the generator rotor 3 Remove Generator rotor 1 with the flywheel puller 2 Woodruff key TIP Make sure the flywheel puller is centered over the generator rotor EAS30868 REMOVING THE STARTER CLUTC...

Страница 288: ...n turning the starter clutch gear clock wise B it should turn freely otherwise the starter clutch is faulty and must be re placed EAS31439 CHECKING THE OIL STRAINER 1 Check Oil strainer Damage Replace...

Страница 289: ...t Do not allow the sheave holder to touch the projection on the generator rotor TIP Tighten the nut until it is at the specified angle 3 Apply Sealant onto the crankshaft position sensor stator lead g...

Страница 290: ...Refer to GENERAL CHASSIS 2 on page 4 11 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 27 Coolant Drain Refer to CHANGING THE COOLANT on page 3 31 V belt case air filter element left Gen...

Страница 291: ...e 1 4 Pressure plate 1 5 Clutch plate 2 2 6 Clutch damper spring 7 7 Friction plate 6 8 Clutch plate 1 5 9 Clutch spring 6 10 Thrust plate 1 11 Clutch boss nut 1 12 Primary drive gear 1 13 Bearing 2 1...

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

Страница 293: ...plate 1 TIP To ensure proper balance of the clutch assem bly one to three holes a or no hole at all may have been drilled in the spring stopper plate Be fore removing the spring stopper plate make al...

Страница 294: ...plates as a set Clutch plate thickness Out of specification Replace the clutch plates and friction plates as a set TIP Measure the clutch plate 2 at four places EAS31442 CHECKING THE CLUTCH DAMPER SP...

Страница 295: ...housing dogs will cause er ratic clutch operation EAS30353 CHECKING THE CLUTCH BOSS 1 Check Clutch boss spline Damage pitting wear Replace the clutch boss TIP Pitting on the clutch boss splines will...

Страница 296: ...t plate 1 can be identified by punch mark b on the pressure plate 4 Install Clip 1 TIP While compressing the clutch springs with the clutch spring compressor 2 install the clip EAS30363 INSTALLING THE...

Страница 297: ...5 62 CLUTCH 1 3 2...

Страница 298: ...HASSIS 2 on page 4 11 V belt case air filter element left Generator cover protector Water pump inlet pipe Water pump outlet pipe Water pump assembly Refer to WATER PUMP on page 6 11 Generator cover Ge...

Страница 299: ...Oil pump housing 1 1 2 Dowel pin 2 3 Oil pump outer rotor 1 1 4 Oil pump inner rotor 1 1 5 Pin 1 6 Washer 1 7 Oil pump housing center 1 8 Oil pump outer rotor 2 1 9 Oil pump inner rotor 2 1 10 Pin 1...

Страница 300: ...KING THE OIL PUMP DRIVE CHAIN 1 Check Oil pump drive chain Cracks stiffness Replace the oil pump chain and oil pump assembly as a set EAS30342 ASSEMBLING THE OIL PUMP 1 Lubricate Inner rotor Outer rot...

Страница 301: ...page 6 11 Generator cover Generator rotor Starter clutch gear Refer to GENERATOR AND STARTER CLUTCH on page 5 49 Clutch assembly Refer to CLUTCH on page 5 55 Oil pump assembly Refer to OIL PUMP on pa...

Страница 302: ...1 4 Crankcase left 1 5 Dowel pin 2 6 Oil strainer 1 7 Crankcase right 1 8 Centerstand lock solenoid cover 1 9 Centerstand lock solenoid 1 3 3 6 6 8 5 2 New New 1 2 3 4 5 6 7 8 9 5 LT LT LT LS LS 10 N...

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

Страница 304: ...Order Job Parts to remove Q ty Remarks Crankshaft assembly Refer to CRANKSHAFT on page 5 73 Transmission Refer to TRANSMISSION on page 5 83 1 Bearing retainer 2 2 Oil seal 2 3 Bearing 5 1 2 2 3 3 3 3...

Страница 305: ...t 4 Tighten Centerstand nut 5 Lubricate Centerstand 1 Centerstand bracket 2 TIP Apply grease to the sliding surfaces of the cen terstand and centerstand bracket After applying grease while the centers...

Страница 306: ...a mild solvent 2 Thoroughly clean all the gasket surfaces and crankcase mating surfaces 3 Check Crankcase Cracks damage Replace Oil delivery passage Obstruction Blow out with compressed air EAS31445 C...

Страница 307: ...t a time in stag es and in a crisscross pattern M8 120 mm 4 72 in bolts 1 M8 110 mm 4 33 in bolts 2 M6 50 mm 1 97 in bolts 3 M6 35 mm 1 38 in bolts 4 6 Check Crankshaft and transmission operation Roug...

Страница 308: ...Parts to remove Q ty Remarks Crankcase Separate Refer to CRANKCASE on page 5 66 1 Dowel pin 2 2 Balancer cylinder 1 3 Crankshaft assembly 1 4 Oil seal 1 5 Crankshaft journal bearing 2 3 5 4 2 1 4 5 N...

Страница 309: ...piston pin 1 7 Balancer piston 1 8 Balancer connecting rod cap 1 9 Balancer big end lower bearing 1 10 Balancer connecting rod 1 11 Balancer big end upper bearing 1 1 1 2 2 3 3 4 4 5 5 6 7 8 9 10 11 N...

Страница 310: ...kshaft journal bearings 1 Remove Crankshaft assembly Crankshaft journal bearing 1 TIP Remove the crankshaft journal bearing using the plane bearing installer 2 TIP Identify the position of each cranks...

Страница 311: ...a piece of Plastigauge 1 on the crankshaft pin d Assemble the connecting rod halves TIP Do not move the connecting rod or crankshaft until the clearance measurement has been completed Lubricate the b...

Страница 312: ...the smaller value is used The following procedure applies to all of the crankshaft journal bearings NOTICE ECA13920 Do not interchange the crankshaft journal bearings To obtain the correct crankshaft...

Страница 313: ...arance is If the oil clearance is out of specification select replacement bearings 6 Select Crankshaft journal bearing J1 J2 TIP The numbers A is stamped onto the crank shaft web the number B on the l...

Страница 314: ...e an iron plate 3 beneath the crankcase and press fit until the end of the plain bearing installer touches the iron plate EAS30426 INSTALLING THE CONNECTING RODS 1 Lubricate Bolt thread Nut seat with...

Страница 315: ...rench b Put a mark 1 on the corner of the connect ing rod nut 2 and the connecting rod cap 3 c Tighten the connecting rod nuts further to reach the specified angle 120 WARNING EWA13400 If the connecti...

Страница 316: ...nterrupted between 30 N m 3 0 kgf m 22 lb ft and 60 N m 6 0 kgf m 44 lb ft loosen the nut to less than 30 N m 3 0 kgf m 22 lb ft and start again 7 Install Balancer piston 1 Balancer piston pin Piston...

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

Страница 318: ...rease R0 Order Job Parts to remove Q ty Remarks Crankcase Separate Refer to CRANKCASE on page 5 66 1 Secondary shaft 1 2 Collar 1 3 O ring 1 4 Primary driven gear 1 5 Main axle 1 6 1st pinion gear 1 7...

Страница 319: ...e part s 3 Check Main axle Cracks damage wear Replace the main axle 4 Measure Drive axle runout with a centering device and dial gauge Out of specification Replace the drive axle 5 Measure Secondary s...

Страница 320: ...5 85 TRANSMISSION...

Страница 321: ...OR 6 5 OIL COOLER 6 7 CHECKING THE OIL COOLER 6 8 INSTALLING THE OIL COOLER 6 8 THERMOSTAT 6 9 CHECKING THE THERMOSTAT 6 10 INSTALLING THE THERMOSTAT ASSEMBLY 6 10 WATER PUMP 6 11 DISASSEMBLING THE WA...

Страница 322: ...ller hose 3 Cooling system air bleed hose 4 Coolant reservoir hose 5 Radiator inlet hose 6 Thermostat 7 Oil cooler inlet hose 8 Oil cooler 9 Oil cooler outlet hose 10 Coolant hose 11 Water pump outlet...

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

Страница 324: ...otboard Refer to GENERAL CHASSIS 2 on page 4 11 Coolant Drain Refer to CHANGING THE COOLANT on page 3 31 1 Coolant reservoir hose 1 2 Coolant reservoir 1 3 Coolant reservoir cap 1 4 Coolant reservoir...

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

Страница 326: ...age Replace Malfunction Check and repair Refer to COOLING SYSTEM on page 8 39 EAS30440 INSTALLING THE RADIATOR 1 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHAN...

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

Страница 328: ...sembly Side cover Rear side cowling assembly Footboard Refer to GENERAL CHASSIS 2 on page 4 11 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 27 Coolant Drain Refer to CHANGING THE COOLAN...

Страница 329: ...the slot b in the crankcase 3 Install Oil filter cartridge Refer to CHANGING THE ENGINE OIL on page 3 27 4 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING T...

Страница 330: ...de panel Bottom center cowling Refer to GENERAL CHASSIS 1 on page 4 1 Center cover Fuel tank cover assembly Side cover Rear side cowling assembly Footboard Refer to GENERAL CHASSIS 2 on page 4 11 Cool...

Страница 331: ...ooling 2 Check Thermostat cover Cracks damage Replace EAS30445 INSTALLING THE THERMOSTAT ASSEMBLY 1 Install Thermostat TIP Install the thermostat with its jiggle valve a facing upward 2 Fill Cooling s...

Страница 332: ...lant Drain Refer to CHANGING THE COOLANT on page 3 31 1 V belt case air filter element joint clamp 1 Loosen 2 V belt case air filter element left 1 3 Oil filler cap 1 4 Generator cover protector 1 5 O...

Страница 333: ...ump Order Job Parts to remove Q ty Remarks 1 Water pump housing cover 1 2 Circlip 1 3 Impeller shaft 1 4 Mechanical seal 1 5 Bearing 1 6 Oil seal 1 7 Water pump housing 1 M E New New New New New 1 2 2...

Страница 334: ...k Water pump inlet pipe Water pump outlet pipe Cracks damage wear Replace EAS30448 ASSEMBLING THE WATER PUMP 1 Install Oil seal 1 Bearing 2 into the water pump housing TIP Before installing the oil se...

Страница 335: ...e specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 31 3 Check Cooling system Leaks Repair or replace any faulty part Refer to INSTALLING THE RADIATOR on page 6 5 4...

Страница 336: ...6 15 WATER PUMP...

Страница 337: ...ANK 7 4 THROTTLE BODY 7 5 CHECKING THE INJECTORS BEFORE REMOVING 7 9 REMOVING THE FUEL HOSE FUEL RAIL SIDE 7 9 REMOVING THE INJECTORS 7 9 CHECKING THE INJECTORS 7 9 CHECKING AND CLEANING THE THROTTLE...

Страница 338: ...ing assembly Footboard Refer to GENERAL CHASSIS 2 on page 4 11 1 Fuel tank overflow hose 1 2 Fuel tank breather hose 1 Disconnect 3 Fuel pump coupler 1 Disconnect 4 Fuel hose connector 1 Disconnect 5...

Страница 339: ...cover Rear side cowling assembly Footboard Refer to GENERAL CHASSIS 2 on page 4 11 Fuel tank Refer to FUEL TANK on page 7 1 1 Canister breather hose 1 2 Canister purge hose hose joint to canister 1 3...

Страница 340: ...el pump slide the fuel hose connector cover 1 on the end of the hose in the direction of the arrow shown press the two buttons 2 on the sides of the connector and then remove the hose Before removing...

Страница 341: ...tight ening sequence as shown EAS30457 INSTALLING THE FUEL TANK 1 Connect Fuel hose fuel tank side NOTICE ECA17500 When installing the fuel hose make sure that it is securely connected and that the fu...

Страница 342: ...ootboard Refer to GENERAL CHASSIS 2 on page 4 11 Fuel tank Refer to FUEL TANK on page 7 1 Throttle body assembly Refer to THROTTLE BODY on page 7 5 Cylinder head cover Refer to CAMSHAFTS on page 5 12...

Страница 343: ...on page 7 1 Air filter case Disconnect Refer to THROTTLE BODY on page 7 5 Canister purge hose hose joint to canister Disconnect Refer to FUEL TANK on page 7 1 1 Throttle servo motor coupler 1 Disconn...

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

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

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

Страница 347: ...tion Do not apply cleaning solvent directly to any plastic parts sensors or seals Be careful not to remove the white paint mark that identifies the standard throttle body Do not turn the bypass air sc...

Страница 348: ...e bodies synchronizing Out of specification Replace the throttle bodies Refer to SYNCHRONIZING THE THROT TLE BODIES on page 3 9 EAS31160 REPLACING THE THROTTLE BODIES 1 Remove the throttle bodies from...

Страница 349: ...ure drops Check the pressure gauge and adapter Check the seals and O rings and then rein stall Out of specification Replace the fuel in jectors EAS30482 CHECKING THE FUEL PRESSURE 1 Check Fuel pressur...

Страница 350: ...E POSITION SENSOR NOTICE ECA17540 Handle the throttle position sensor with special care Never subject the throttle position sensor to strong shocks If the throttle position sensor is dropped replace i...

Страница 351: ...ired For information about using the YDT refer to the operation manual that is included with the tool e Diagnostic code number 01 is selected f Adjust the position of the throttle position sensor angl...

Страница 352: ...7 15 THROTTLE BODY...

Страница 353: ...M 8 23 CIRCUIT DIAGRAM 8 23 TROUBLESHOOTING 8 27 SIGNALING SYSTEM 8 29 CIRCUIT DIAGRAM 8 29 TROUBLESHOOTING 8 33 COOLING SYSTEM 8 39 CIRCUIT DIAGRAM 8 39 TROUBLESHOOTING 8 43 FUEL PUMP SYSTEM 8 45 CIR...

Страница 354: ...T POSITION SENSOR 8 104 CHECKING THE LEAN ANGLE SENSOR 8 104 CHECKING THE STARTER MOTOR OPERATION 8 105 CHECKING THE STATOR COIL 8 105 CHECKING THE RECTIFIER REGULATOR 8 105 CHECKING THE FUEL SENDER 8...

Страница 355: ......

Страница 356: ...L Y Y W R R W Y R L Lg L W W R B L B Lg B L B B B B B W B B B W B B B W B W B W B W B B B B B B W B B B Lg B B B B B G B B G B L Y L Y R B R B R B R B R B R W R W B L L L R R L Y L Y B B Br L Br B Br...

Страница 357: ...ion fuse 22 Battery 23 Engine ground 24 Main fuse 27 Diode 1 28 Sidestand relay 29 Diode 2 31 Starting circuit cut off relay 32 Sidestand switch 34 Handlebar switch right 35 Engine stop switch 57 ECU...

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

Страница 359: ...ion fuse 22 Battery 23 Engine ground 24 Main fuse 27 Diode 1 28 Sidestand relay 29 Diode 2 31 Starting circuit cut off relay 32 Sidestand switch 34 Handlebar switch right 35 Engine stop switch 70 ECU...

Страница 360: ...on page 8 94 NG Clean the battery terminals Recharge or replace the battery OK 3 Check the spark plugs Refer to CHECKING THE SPARK PLUGS on page 3 5 NG Re gap or replace the spark plugs OK 4 Check th...

Страница 361: ...on page 8 91 NG Replace the sidestand switch OK 12 Check the engine stop switch Refer to CHECKING THE SWITCHES on page 8 91 NG The engine stop switch is faulty Replace the handlebar switch right OK 13...

Страница 362: ...B W B B B W B B B W B W B W B W B B B B B B W B B B Y W Y Br Y BL B Sb G Y Lg B B B B B G B B G B L Y L Y R B R B R B R W R W B R R L Y L Y B B B Br L Br B Br B Br L Br L Br L B Br Br Br B B Br L W L...

Страница 363: ...4 Main fuse 25 Starter relay 26 Starter motor 28 Sidestand relay 29 Diode 2 31 Starting circuit cut off relay 32 Sidestand switch 33 Diode 4 34 Handlebar switch right 35 Engine stop switch 36 ON start...

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

Страница 365: ...use 25 Starter relay 26 Starter motor 28 Sidestand relay 29 Diode 2 31 Starting circuit cut off relay 32 Sidestand switch 33 Diode 4 34 Handlebar switch right 35 Engine stop switch 36 ON start switch...

Страница 366: ...ed The rear brake lever is pulled to the handlebar the rear brake light switch is closed and the sidestand is up the sidestand switch is closed The starting circuit cut off relay prevents the starter...

Страница 367: ...brake light switch 8 Rear brake light switch 9 Diode 4 10 Starting circuit cut off relay 11 ON start switch 12 ECU Engine Control Unit 13 Fuel injection system relay 14 Engine stop switch 15 Fuel inj...

Страница 368: ...ace the battery OK 3 Check the starter motor operation Refer to CHECKING THE START ER MOTOR OPERATION on page 8 105 OK Starter motor is OK Perform the electric starting system troubleshooting starting...

Страница 369: ...tand switch Refer to CHECKING THE SWITCHES on page 8 91 NG Replace the sidestand switch OK 13 Check the front brake light switch Refer to CHECKING THE SWITCHES on page 8 91 NG Replace the front brake...

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

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

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

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

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

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

Страница 376: ...y Refer to CHECKING AND CHARGING THE BATTERY on page 8 94 NG Clean the battery terminals Recharge or replace the battery OK 3 Check the stator coil Refer to CHECKING THE STA TOR COIL on page 8 105 NG...

Страница 377: ...8 22 CHARGING SYSTEM...

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

Страница 379: ...mmer 41 Smart key system relay unlock 44 Meter assembly 46 Meter light 55 High beam indicator light 56 Multi function display 57 ECU Engine Control Unit 78 YDT coupler 82 Handlebar switch left 84 Dimm...

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

Страница 381: ...r 45 Smart key system relay unlock 55 Meter assembly 57 Meter light 68 High beam indicator light 69 Multi function display 70 ECU Engine Control Unit 91 YDT coupler 95 Handlebar switch left 98 Dimmer...

Страница 382: ...ion signaling system and taillight Refer to CHECKING THE FUS ES on page 8 93 NG Replace the fuse s OK 3 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 94 NG Clean the battery t...

Страница 383: ...K 9 Check the storage box light switch Refer to CHECKING THE SWITCHES on page 8 91 NG Replace the storage box light switch OK 10 Check the entire lighting system s wiring Refer to CIRCUIT DIAGRAM on p...

Страница 384: ...g L Lg L Lg W Lg W R G B B B B B B B B B B B B Br L Br L Br L Br L Br L Br L B W B W Ch Ch Ch Gy W Gy W V V Gy Gy R G R G R G R G R G R G R G R G Br Br Br B B Br Br Br P R B R B R G Br Br R G R G R G...

Страница 385: ...Turn signal indicator light left 52 Turn signal indicator light right 56 Multi function display 57 ECU Engine Control Unit 63 Coolant temperature sensor 64 Intake air temperature sensor 73 Fuel sender...

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

Страница 387: ...dicator light 61 Traction control system indicator light 62 Turn signal indicator light left 63 Turn signal indicator light right 69 Multi function display 70 ECU Engine Control Unit 76 Coolant temper...

Страница 388: ...t s 1 Front cowling assembly 2 Storage box 3 Fuel tank 4 Footboards 5 Rear side cowling assembly right 1 Check the fuses Main signaling system ABS mo tor ABS solenoid ABS ECU brake light and backup Re...

Страница 389: ...ace the front brake light switch OK 2 Check the rear brake light switch Refer to CHECKING THE SWITCHES on page 8 91 NG Replace the rear brake light switch OK 3 Check the entire signaling sys tem s wir...

Страница 390: ...CKING THE FUEL SENDER on page 8 106 NG Replace the fuel pump assembly OK 2 Check the entire signaling sys tem s wiring Refer to CIRCUIT DIAGRAM on page 8 29 NG Properly connect or replace the wire har...

Страница 391: ...sensor OK 2 Check the entire wheel sensor wir ing Refer to TIP NG Properly connect or replace the wire har ness OK Replace the hydraulic unit assembly ECU and or meter assembly The tachometer fails t...

Страница 392: ...r replace the wire har ness OK Replace the meter assembly The oil change indicator fails to come on 1 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 8 29 NG Properly connect...

Страница 393: ...8 38 SIGNALING SYSTEM...

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

Страница 395: ...18 Radiator fan motor fuse 20 Backup fuse 22 Battery 23 Engine ground 24 Main fuse 44 Meter assembly 56 Multi function display 57 ECU Engine Control Unit 63 Coolant temperature sensor 78 YDT coupler...

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

Страница 397: ...18 Radiator fan motor fuse 20 Backup fuse 22 Battery 23 Engine ground 24 Main fuse 55 Meter assembly 69 Multi function display 70 ECU Engine Control Unit 76 Coolant temperature sensor 91 YDT coupler...

Страница 398: ...battery OK 3 Check the ignition system relay Refer to CHECKING THE RE LAYS on page 8 94 NG Replace the ignition system relay OK 4 Check the radiator fan motor Refer to CHECKING THE RADIA TOR FAN MOTO...

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

Страница 400: ...B W B W B W B W B B B B B B W B B B B B G B B G B R B R B R B R B R W R W B R R R R L Y L Y Lg W Lg W Lg L Lg L Lg W Lg W B B B Br L Br L Br L Br L L Y L Y R G R G R G R G R G R G R G R L R L B B R G...

Страница 401: ...6 Ignition fuse 19 Fuel injection system fuse 20 Backup fuse 22 Battery 23 Engine ground 24 Main fuse 30 Fuel injection system relay 34 Handlebar switch right 35 Engine stop switch 57 ECU Engine Contr...

Страница 402: ...B B B B W B B B Br Y R W Br W R B R W Br Y R B Br W B B G B B G B R B R B R B R B R W R W B R R R R L Y L Y Lg W Lg W Lg L Lg L Lg W Lg W B B B Br L Br B Br B Br L Br L Br L L Y L Y R G R G R G R G R...

Страница 403: ...6 Ignition fuse 19 Fuel injection system fuse 20 Backup fuse 22 Battery 23 Engine ground 24 Main fuse 30 Fuel injection system relay 34 Handlebar switch right 35 Engine stop switch 70 ECU Engine Contr...

Страница 404: ...engine stop switch Refer to CHECKING THE SWITCHES on page 8 91 NG The engine stop switch is faulty Replace the handlebar switch right OK 4 Check the ignition system relay Refer to CHECKING THE RE LAY...

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

Страница 406: ...W R W B R R L Y L Y W L W L R W R W R W G W G P B P B Br B Br L Br B Br B Br L Br L Br L B W P W P W R G R G R G R G R G R G R G R G R G R G Br L R B R B R B R B R B R B R B R B B R G R W R W B W B W...

Страница 407: ...ay 16 Ignition fuse 20 Backup fuse 22 Battery 23 Engine ground 24 Main fuse 49 Windshield drive unit relay down 50 Windshield drive unit 51 Windshield drive unit relay up 55 Meter assembly 69 Multi fu...

Страница 408: ...to CHECKING THE FUS ES on page 8 93 NG Replace the fuse s OK 4 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 94 NG Clean the battery terminals Recharge or replace the battery...

Страница 409: ...e unit relay down OK 10 Check the windshield drive motor Refer to CHECKING THE WIND SHIELD DRIVE UNIT for XP560D on page 8 109 NG Replace the windshield drive unit OK 11 Check the entire windshield dr...

Страница 410: ...W G Lg W Lg W Lg L Lg L Lg W Lg W B Br L Br B Br B Br L Br L Br L R G R G R G R G R G R G R G R G R G R G R G R G Br L B B B B B B B Y R Y R R G R W R W B W B W B W B W B W B W Lg L Lg L R G Y R R G R...

Страница 411: ...0 Backup fuse 22 Battery 23 Engine ground 24 Main fuse 55 Meter assembly 69 Multi function display 70 ECU Engine Control Unit 73 Grip warmer connector 74 Grip warmer left 75 Grip warmer right 91 YDT c...

Страница 412: ...grip warmer settings OK 3 Check the fuses Main ignition and backup Refer to CHECKING THE FUS ES on page 8 93 NG Replace the fuse s OK 4 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on...

Страница 413: ...ture level of the high grip warmer setting is set to highest temperature NG Adjust the temperature levels of the grip warmer settings OK 2 Check that the MIL is on and that DTC No P0500 is displayed i...

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

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

Страница 416: ...L W Lg B W B W B W B W B B B B B B W B B B B B G B B G B B R R L Y L Y W L W L W R W R W G W G G B G B Br Y Br Y B W B W B B B Br L Br B Br B Br L Br L Br L R G R G R G R G R G R G R G R G R G R G Br...

Страница 417: ...em fuse 20 Backup fuse 22 Battery 23 Engine ground 24 Main fuse 52 Seat heater relay control 53 Seat heater relay power 54 Seat heater 55 Meter assembly 69 Multi function display 70 ECU Engine Control...

Страница 418: ...that the engine is started NG Start the engine OK 4 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 94 NG Clean the battery terminals Recharge or replace the battery OK 5 Check...

Страница 419: ...to CHECKING THE RE LAYS on page 8 94 NG Replace the seat heater relay power OK 3 Check the seat heater Refer to CHECKING THE SEAT HEATER for XP560D on page 8 110 NG Replace the seat assembly OK Repla...

Страница 420: ...anged 1 Check the menu switch Refer to CHECKING THE SWITCHES on page 8 91 NG The menu switch is faulty Replace the handlebar switch left OK 2 Check the select switch Refer to CHECKING THE SWITCHES on...

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

Страница 422: ...Y W Y L L L G Y G Y L Y L Y L R L R V W V W Br Y Br Y R L R L O L O L Lg L Lg L Lg W Lg W Lg L Lg L Lg L Lg L Lg W Lg W Lg W Lg W L G L G L G L G R G R G R G B B B B B B B B B R L R R R B Br L Br B B...

Страница 423: ...relay unlock 42 Seat fuel lid lock solenoid 43 Smart key system relay lock 44 Meter assembly 45 Smart key system indicator light 51 Turn signal indicator light left 52 Turn signal indicator light rig...

Страница 424: ...B G Y B Br Y R W Br W R B L W B W G B W L W W G B W R W Br Y R B Br W B B B G B B G R Y V Y L Gy Y B R Y Ch Y L Dg Y B B R W R W Dg Dg Br G Dg B R R W Y W Y L L L G Y G Y L Y L Y L R L R V W Br Y Br...

Страница 425: ...lock 46 Storage compartment lid lock solenoid 47 Seat fuel lid lock solenoid 48 Smart key system relay lock 55 Meter assembly 56 Smart key system indicator light 62 Turn signal indicator light left 63...

Страница 426: ...RT KEY BATTERY on page 8 112 NG Replace the button cell battery of the smart key Standard battery CR2025 OK 2 Check the fuses Main backup ignition and signal ing system Refer to CHECKING THE FUS ES on...

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

Страница 428: ...Replace the smart key or remote control unit The vehicle cannot be turned on in the emergency mode but the storage box light comes on when the seat is opened Replace the remote control unit The storag...

Страница 429: ...not flash There are sources of strong electro magnetic waves in the vicinity Move the vehicle Smart key malfunction Register and use a different smart key Remote control unit malfunction Replace the r...

Страница 430: ...ssible Check the wire harness Light green White Light green White and or replace the remote control unit and or meter NO The seat fuel lid cannot be opened Check the mechanical components of the lock...

Страница 431: ...rage compartment lid solenoid for XP560D Refer to CHECKING THE STOR AGE COMPARTMENT LID LOCK SOLENOID for XP560D on page 8 112 Replace the remote control unit and or meter assembly 1 Check the turn si...

Страница 432: ...between the remote con trol unit and centerstand lock unit is not possible Check the wire harness Light green White Light green White and or replace the remote control unit and or cen terstand lock u...

Страница 433: ...67 Vehicle power off ver ification error a LED on b LED off 10 seconds The smart key cannot be recognized Check that there are no sources of strong electromagnetic waves in the vicinity the smart key...

Страница 434: ...g lock unit ECU communica tion error Data error ECU malfunction a LED on b LED off Flashes continuously until the error is re solved flashes 4 times in a repeating cycle Check the wire har ness Check...

Страница 435: ...serting the mechanical key into the lock located right side of body and turn it counter clockwise 3 Open the seat and check that the trunk light comes on 4 Push the ON start switch once 5 Without comp...

Страница 436: ...system indicator light flashes twice The second digit has been set as 2 Repeat the above procedure until all digits of the identification number have been set The smart key system indicator light wil...

Страница 437: ...mote control unit Be sure to register the smart keys one at a time Do not register multiple smart keys at the same time 1 Place the smart key 1 that will be registered within 80 cm 31 5 in a of the re...

Страница 438: ...system indicator light will come on for 3 seconds and then the smart key system will turn off If the smart key was not registered successfully the smart key system indicator light will flash for 3 se...

Страница 439: ...e mode is activat ed 5 Turn on unlocked setting the smart keys that you want to enable and place them within 80 cm 31 5 in of the remote control unit 6 Push the OFF LOCK switch 1 time to start the com...

Страница 440: ...ication number on the smart key with the new number EAS31556 REPLACING THE STEERING LOCK UNIT 1 Replace the steering lock unit and then place the previously used smart key within 80 cm 31 5 in of the...

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

Страница 442: ...d ECU as a set Smart key Remote control unit Steer ing lock unit Replace the smart key remote control unit steering lock unit and ECU as a set Smart key Remote control unit ECU Replace the smart key r...

Страница 443: ...ery 8 Steering lock unit 9 Diode 3 10 Diode 1 11 Injector 12 Coolant temperature sensor 13 Spark plug 14 Spark plug cap 15 Radiator fan motor 16 Throttle position sensor 17 Throttle servo motor 18 Fro...

Страница 444: ...nd relay Turn signal hazard relay Radiator fan motor relay Seat heater relay power for XP560D Seat heater relay control for XP560D Windshield drive unit relay down for XP560D Windshield drive unit rel...

Страница 445: ...rake light switch for XP560E 7 Rear brake light switch for XP560D 8 Starter relay 9 Fuse box 4 Brake light fuse for XP560D Fuse box 5 Cruise control fuse for XP560D 10 Fuse box 1 11 Fuse box 2 12 Fuse...

Страница 446: ...N DOWN B L B B PASS HI LO Br W R W G L B B P Br G Y Dg Ch Br W W L B W L B L B L B L B Br Y R W Br W R B Br G Y L G R R L G L W W G B W B Br P PUSH FREE B R B R W RUN OFF L W B OFF ON Br WBr Y OFF ON...

Страница 447: ...W W G UP N DOWN B B B B B L B B PASS HI LO Br P PUSH FREE B R B R W RUN OFF L W B OFF ON Br WBr Y OFF ON 1 2 3 4 5 6 7 8 9 10 11 12 15 16 18 13 14 17 1 Cruise control power switch 2 Cruise control set...

Страница 448: ...d ignition systems to malfunction and could possibly cause a fire 4 Install Front cover Refer to GENERAL CHASSIS 1 on page 4 1 EAS31006 REPLACING THE ECU Engine Control Unit 1 Push the ON start switch...

Страница 449: ...ery terminal Dirt Clean with a wire brush Loose connection Connect properly 8 Lubricate Battery terminal 9 Install Battery band Battery cover Refer to GENERAL CHASSIS 1 on page 4 1 EAS30553 CHECKING T...

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

Страница 451: ...ve battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 R R L R B L Y G R G Y L Y Lg 1 Positive battery terminal 2 Negative ba...

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

Страница 453: ...en 1 and 3 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe 5 Negative tester probe Result No continuity between 3 and 4 Continuity between 3 and...

Страница 454: ...egative tester probe 3 Negative tester probe A XP560E B XP560D 1 2 3 4 G Y Y Br R B Br R R G O L A 1 2 3 R B R B R G O L 1 2 3 B Result Continuity between 1 and 2 No continuity between 1 and 3 1 Posit...

Страница 455: ...Continuity between 1 and 2 No continuity between 1 and 3 Br B Br R R L R G 1 2 3 A Br B R B R L R G 1 2 3 B 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative t...

Страница 456: ...r probe Brown 2 Negative tester probe Green Red Blue White 1 Diode 2 Continuity Positive tester probe Red Black 3 Negative tester probe Blue Yellow 4 No continuity Positive tester probe Blue Yellow 4...

Страница 457: ...specification Replace a Remove the spark plug cap from the spark plug lead b Connect the digital circuit tester to the spark plug cap as shown c Measure the spark plug cap resistance EAS30558 CHECKIN...

Страница 458: ...sconnect the spark plug cap from the spark plug b Connect the ignition checker 1 as shown c Push the ON start switch and the engine stop switch to d Measure the ignition spark gap a e Crank the engine...

Страница 459: ...ngle sensor and wire harness as shown b Connect the digital circuit tester DC V to the test harness lean angle sensor 6P c Push the ON start switch d When turn the lean angle sensor to 65 e Measure th...

Страница 460: ...Connect the digital circuit tester to the stator coil coupler as shown b Measure the stator coil resistance EAS30680 CHECKING THE RECTIFIER REGULATOR 1 Check Battery charging voltage Out of specifica...

Страница 461: ...detection circuit 1 Check Fuel meter fuel level warning indicator 1 Push the ON start switch Fuel meter fuel level warning indicator comes on for a few seconds then goes off Fuel meter fuel level war...

Страница 462: ...ied temperature e Measure the coolant temperature sensor resistance 3 Install Coolant temperature sensor EAS30581 CHECKING THE THROTTLE POSITION SENSOR 1 Remove Throttle position sensor from the throt...

Страница 463: ...position sensor terminals as shown b Measure the accelerator position sensor maximum resistance 3 Install Accelerator position sensor EAS30592 CHECKING THE THROTTLE SERVO MOTOR 1 Remove Air filter ca...

Страница 464: ...1 Check Grip warmer resistance Out of specification Replace the grip warmer a Disconnect the grip warmer coupler from the wire harness b Connect the digital circuit tester to the grip warmer coupler a...

Страница 465: ...e test harness S pressure sensor 3P coupler a b Connect the digital circuit tester to the test harness S pressure sensor 3P c Push the ON start switch d Measure the intake air pressure sensor out put...

Страница 466: ...l down to the specified temperatures e Measure the intake air temperature sensor resistance 3 Install Intake air temperature sensor EAS30681 CHECKING THE FUEL INJECTOR 1 Check Fuel injector resistance...

Страница 467: ...ce a Disconnect the seat fuel lid lock solenoid from the wire harness b Connect the battery DC 12 V as shown c Check the seat fuel lid lock solenoid move ment EAS32450 CHECKING THE STORAGE COMPARTMENT...

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

Страница 469: ...OPERATION 9 20 BASIC INSTRUCTIONS FOR TROUBLESHOOTING 9 21 BASIC PROCESS FOR TROUBLESHOOTING 9 22 A CHECKING THE CRUISE CONTROL SYSTEM INDICATOR LIGHT 9 23 B 1 DIAGNOSIS USING THE DTC 9 23 B 2 DIAGNOS...

Страница 470: ...BLE FOR ABS Anti lock Brake System 9 53 COMMUNICATION ERROR WITH THE METER 9 58 DIAGNOSTIC CODE SENSOR OPERATION TABLE 9 58 DIAGNOSTIC CODE ACTUATOR OPERATION TABLE 9 62 EVENT CODE TABLE 9 63 30_EVENT...

Страница 471: ...9 112 TROUBLESHOOTING 9 112 P0500 9 115 TROUBLESHOOTING 9 115 P0507 9 119 TROUBLESHOOTING 9 119 P0560 P0563 9 121 TROUBLESHOOTING 9 121 P0564 9 122 TROUBLESHOOTING 9 122 P056C 9 128 TROUBLESHOOTING 9...

Страница 472: ...P2138 9 158 TROUBLESHOOTING 9 158 P2158 9 162 TROUBLESHOOTING 9 162 U0155 or Err 9 166 TROUBLESHOOTING 9 166 11 25_ABS 9 169 TROUBLESHOOTING 9 169 12_ABS 9 170 TROUBLESHOOTING 9 170 13 26_ABS 9 171 TR...

Страница 473: ...9 186 TROUBLESHOOTING 9 186 33_ABS 9 187 TROUBLESHOOTING 9 187 34_ABS 9 189 TROUBLESHOOTING 9 189 41_ABS 9 190 TROUBLESHOOTING 9 190 42 47_ABS 9 191 TROUBLESHOOTING 9 191 43_ABS 9 192 TROUBLESHOOTING...

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

Страница 475: ...TC is a code that is saved within a control unit s memory when the control unit detects an abnormal condition If the abnormal condition continues a malfunction may be determined Driving cycle Driving...

Страница 476: ...cause the occurrence of the warning light coming on without malfunction Reprogramming of the ECU software Using the electrical accessory which may affect the ECU Using the incorrect specification of s...

Страница 477: ...protective cap 1 and then connect the YDT to the coupler EAS32864 PARTS CONNECTED TO THE ECU The following parts are connected to the ECU When checking for a power short circuit the couplers must be...

Страница 478: ...ng for a power short circuit the couplers must be disconnected from all of the following parts beforehand EAS33137 PRECAUTIONS FOR ROAD TEST WARNING EWA20860 When test riding the vehicle always comply...

Страница 479: ...se control power switch 29 Cruise control setting switch RES 28 Cruise control setting switch SET 25 Front brake light switch 26 Rear brake light switch 31 Crankshaft position sensor 32 Intake air pre...

Страница 480: ...celerator position sensor 38 Accelerator position sensor 37 Throttle position sensor 37 Throttle position sensor 50 Headlight control unit 47 Radiator fan motor relay 45 Grip warmer left 1 ECU Engine...

Страница 481: ...24 Brake light fuse 25 Front brake light switch 26 Rear brake light switch 27 Cruise control power switch 28 Cruise control setting switch SET 29 Cruise control setting switch RES 30 Grip cancel switc...

Страница 482: ...16 Injector 1 R B 17 Joint coupler B 18 Electronic throttle valve fuse R L 19 Radiator fan motor relay Y R 20 21 22 23 24 25 Joint coupler B 26 Battery charger ter minal seat heater relay power wind...

Страница 483: ...70 Lean angle sensor Y G 71 72 Joint coupler L 73 74 75 No Connected parts Wireharness color 76 Crankshaft position sensor B Y 77 Joint coupler Lg L 78 79 80 81 82 Handlebar switch left R G 83 Handleb...

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

Страница 485: ...9 11 SYSTEM DIAGRAM...

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

Страница 487: ...57 ECU Engine Control Unit 58 Ignition coil 59 Spark plug 60 Grip warmer connector 61 Grip warmer left OPTION 62 Grip warmer right OPTION 63 Coolant temperature sensor 64 Intake air temperature sensor...

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

Страница 489: ...8 High beam indicator light 69 Multi function display 70 ECU Engine Control Unit 71 Ignition coil 72 Spark plug 73 Grip warmer connector 74 Grip warmer left 75 Grip warmer right 76 Coolant temperature...

Страница 490: ...ck and repair it according to applicable troubleshooting When pushing the ON start switch does the MIL come on Does the MIL LED work properly B Perform the checking with the diagnostic mode Check the...

Страница 491: ...MIL DOES NOT COME ON BUT THE ENGINE OPERATION IS NOT NORMAL 1 Monitor the operation of these sensors and actuators by using the YDT in the diagnostic mode Refer to DIAGNOSTIC CODE SENSOR OPERATION TAB...

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

Страница 493: ...ke light switch 43 Rear brake light switch 44 Grip cancel switch 55 Meter assembly 64 Cruise control system indicator light 65 Cruise control setting indicator light 69 Multi function display 70 ECU E...

Страница 494: ...n meter 14 Grip cancel switch 17 ECU Engine Control Unit 19 Cruise control system indicator light 20 Cruise control setting indicator light 1 Battery 2 Main fuse 3 Ignition system relay 4 Backup fuse...

Страница 495: ...art switch and then check the DTC of mal function is not displayed TIP If another DTC is displayed repeat steps 1 to 3 until no DTC is displayed Push the OFF LOCK switch will not erase the malfunction...

Страница 496: ...control system to the customer Finished Is there automatic deactivation history for the cruise control system Check the malfunction history using the malfunction mode of the YDT Is there any malfuncti...

Страница 497: ...nction mode of the YDT Malfunction history is displayed on the YDT B 1 Malfunction history is not displayed on the YDT B 3 EAS32882 B 3 MALFUNCTION HISTORY IS NOT DISPLAYED Use the YDT to check whethe...

Страница 498: ...may not be able to maintain the set cruising speed When going uphill the actual traveling speed may become lower than the set cruising speed If this occurs accelerate to the desired traveling speed u...

Страница 499: ...e rear brake light switches Refer to CHECKING THE SWITCHES on page 8 91 3 Execute the diagnostic mode DTC No 82 and 83 to check the operation of the front brake light switch rear brake light switch an...

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

Страница 501: ...39 Front brake light switch 40 Headlight relay dimmer 44 Meter assembly 54 ABS warning light 56 Multi function display 57 ECU Engine Control Unit 75 Front wheel sensor 76 Rear wheel sensor 77 ABS ECU...

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

Страница 503: ...mmer 40 Brake light relay 41 Brake light fuse 42 Front brake light switch 43 Rear brake light switch 55 Meter assembly 67 ABS warning light 69 Multi function display 70 ECU Engine Control Unit 88 Fron...

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

Страница 505: ...B WR GR G W B B W G W W Y G R Lg Lg B L B Lg LLg W B B G W B W B Gy W Gy W 5 6 1 2 3 4 R W R L G Y Br W R Lg LB W R GLg W Gy O L R L Br Y Ch Dg R GR W Gy V Gy WV W G RG L G W GW R W L Y B WLg WLg L B...

Страница 506: ...inal check before delivering the vehicle to the customer TIP To final check refer to C 1 FINAL CHECK on page 9 37 ABS operation when the ABS warning light comes on 1 The ABS warning light remains on A...

Страница 507: ...to damage components by subjecting them to shocks or pulling on them with too much force since the ABS components are precisely adjusted The ABS ECU and hydraulic unit are united assemblies and canno...

Страница 508: ...ere 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 connect...

Страница 509: ...start switch for continuity Refer to CHECKING THE SWITCHES on page 8 91 If there is no continuity replace the handlebar switch right 2 Battery Check the condition of the battery Refer to CHECKING AND...

Страница 510: ...y EAS32902 A 5 ABS ECU AND FI ECU FAIL TO COMMUNICATE 1 YDT Check that the YDT is properly connected 2 Wire harness Open circuit in the wire harness between the ABS ECU coupler and the YDT coupler Che...

Страница 511: ...rake master cylinder reservoir Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 14 2 Check the wheel sensors for proper installation Refer to INSTALLING THE FRONT WHEEL DISC BRAKE on page 4 27 and IN...

Страница 512: ...sembly defective sole noid drive circuit 24_ABS Brake light switch or tail brake light 30_EVENT Latch up detected Unable Unable D08 31_ABS Hydraulic unit assembly abnormal ABS solenoid power supply 32...

Страница 513: ...ssure sensor ground short circuit detected P0108 Intake air pressure sensor open or power short circuit detected Able Able P0112 P0113 P0112 Intake air temperature sensor ground short circuit detected...

Страница 514: ...voltage is abnormal P0563 Vehicle system power voltage out of range Able Able P0564 Cruise control setting switch RES open or short circuit is detected Cruise control setting switch SET open or short...

Страница 515: ...or position sensor open or ground short circuit detected P2123 Accelerator position sensor power short circuit detected P2127 Accelerator position sensor ground short circuit detected P2128 Accelerato...

Страница 516: ...ected Open or short cir cuit in wire har ness Disconnected cou pler Defective O2 sen sor heater control ler Malfunction in ECU Broken or discon nected lead in O2 sensor heater When the O2 sen sor does...

Страница 517: ...learning is not carried out Cruise control sys tem cannot be oper ated P0112 P0113 P0112 Intake air temperaturesensor ground short circuit detected P0113 Intake air temperaturesensor open or power sh...

Страница 518: ...short cir cuit in wire har ness between coolant tempera ture sensor and ECU Improperly in stalled coolant temperature sen sor Defective coolant temperature sen sor Malfunction in ECU Engine is diffic...

Страница 519: ...speed is high Engine idling speed is unstable Engine response is poor Loss of engine pow er Deceleration is poor Increased exhaust emissions Vehicle cannot be driven Change in the throt tle opening is...

Страница 520: ...ankshaftposition sensor and ECU Improperly in stalled crankshaft position sensor Malfunction in generator rotor Defective crank shaft position sen sor Malfunction in ECU Engine cannot be started Does...

Страница 521: ...ot displayed on the meter Engine idling speed is unstable Traction control does not work Vehicle speed dis played on the meter 0 km h O2 feedback is not carried out Fuel cut off control when the rear...

Страница 522: ...ss Defective cruise control setting switch Malfunction in ECU Cruise control sys tem cannot be oper ated Cruise control sys tem cannot be oper ated P056C Front brake light switch open or short circuit...

Страница 523: ...t is restricted Cruise control sys tem cannot be oper ated P062F EEPROM DTC an error is detected while reading or writing on EE PROM CO adjustment value is not prop erly written ISC learning value is...

Страница 524: ...it in wire har ness between fuel injection system relay and ECU Open circuit in wire harness between battery and ECU Defective fuel in jection system re lay Malfunction in ECU Engine is difficult to s...

Страница 525: ...s not carried out O2 feedback learn ing value is not writ ten Cruise control sys tem cannot be oper ated P1604 P1605 P1604 Lean angle sensor ground short circuit detect ed P1605 Lean angle sensor open...

Страница 526: ...U Engine response is poor Loss of engine pow er Engine idling speed is unstable No change in accel erator opening transient control is not carried out Accelerator open ing is fixed to 0 O2 feedback is...

Страница 527: ...while the vehicle is traveling Foreign material ad hered around the rear wheel sensor Incorrect installation of the rear wheel Defective sensor rotor or incorrect installation of the rotor Defective...

Страница 528: ...or miss ing pulses Front wheel sensor signal is not received properly Missing pulses are de tected in the signal while the vehicle is traveling Foreign material ad hered around the front wheel sensor...

Страница 529: ...oupler be tween the battery and the hydraulic unit assembly Open or short circuit in the wire harness be tween the battery and the hydraulic unit assembly Defective hydraulic unit assembly 32 Hydrauli...

Страница 530: ...ront wheel sensor miss ing pulses Front wheel sensor signal is not received properly Missing pulses are de tected in the signal while the vehicle is traveling Foreign material ad hered around the fron...

Страница 531: ...ulic unit assembly Defective charging sys tem Defective hydraulic unit assembly 55 Hydraulic unit assembly defective ABS ECU Abnormal data is detected in the hydraulic unit as sembly Defective hydraul...

Страница 532: ...ol sys tem cannot be oper ated Diagnostic code No Item Tool display Procedure D01 Throttle position sensor signal 1 Fully closed position 11 20 Check with throttle valves fully closed Fully open posit...

Страница 533: ...position 93 109 Check with throttle valves fully open D14 Accelerator position sen sor signal 1 Fully closed position 11 20 Check with throttle grip fully closed position Fully open position 95 106 Ch...

Страница 534: ...on display ISC Idle Speed Control learning data erasure 00 ISC Idle Speed Control learning data has been erased 01 It is not necessary to erase the ISC Idle Speed Con trol learning data 02 It is neces...

Страница 535: ...irec tion ON Throttle grip is released OFF D83 Front brake light switch and rear brake light switch Operate the front brake lever and rear brake lever Front brake lever is squeezed ON Front brake leve...

Страница 536: ...el pump coupler before doing this procedure Check that injector 2 is actuated five times by lis tening for the operating sound D50 Fuel injection system relay Actuates the fuel injection system relay...

Страница 537: ...P0118 Perform the inspection items listed for DTC No P0117 and P0118 197 Intake air tem perature sensor Brief abnormality detected in the in takeairtemperature sensor Same as for DTC No P0112 and P01...

Страница 538: ...he sys tem is functioning properly 243 ISC Stuck at the lower limit for adjustment During idling the adjustment is main tained at the lower limit Idling engine speed is fast Poorly adjusted throt tle...

Страница 539: ...n off under the fol lowing conditions Unable to maintain the set cruising speed when traveling up a steep slope Wheel slip detected Engine stalls Sidestand is extend ed Engine stop switch is set to th...

Страница 540: ...of the sensor 3 Defective lean angle sensor Execute the diagnostic mode Code D08 Check the lean angle sensor output voltage Is the MIL on YES Go to step 2 NO Service is completed Is check result OK YE...

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

Страница 542: ...s displayed at the same time check the other error code first and repair it 1 Allow to idle for a long period Push the OFF LOCK switch Check whether it is possible to start the engine 2 Malfunction in...

Страница 543: ...tion of the pins TIP For this check also set the engine stop switch to ON 2 Connection of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broke...

Страница 544: ...d condition YES Go to step 6 and complete the service NO Start the engine and then check the condition of the DTC Is it in the Recovered condition YES Go to step 6 and complete the service NO Go to st...

Страница 545: ...ep 6 and complete the service NO Go to Short circuit check Between O2 sensor coupler 1 and ground red blue ground black green ground O2 sensor coupler 1 red blue any other coupler terminal black green...

Страница 546: ...ntrol Unit on page 8 93 6 Delete the DTC and check that the MIL goes off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC Is it in the Recovered condition YES Go...

Страница 547: ...bent or broken terminals and locking condition of the pins Is check result OK YES Go to step 2 NO a Reinstall or replace the O2 sensor Refer to ENGINE REMOVAL on page 5 7 b Start the engine and let i...

Страница 548: ...DT Is it in the Recovered condition YES Go to step 8 and complete the service NO Go to step 4 Between O2 sensor coupler 1 and ECU cou pler 2 black green black green gray green gray green black blue bl...

Страница 549: ...coupler terminal black blue any other coupler terminal ECU coupler 2 black green any other coupler terminal gray green any other coupler terminal black blue any other coupler terminal Fuel injection...

Страница 550: ...service NO Go to step 5 Is check result OK YES Go to step 6 NO a Replace the fuel pump Refer to REMOVING THE FUEL PUMP on page 7 3 b Start the engine and let it idle for approximately 1 minute c Chec...

Страница 551: ...nt or broken terminals and locking condition of the pins 3 Wire harness continuity Disconnect the intake air pressure sensor coupler and ECU coupler Open circuit check Is the coupler condition normal...

Страница 552: ...resistance 0 YES Go to Short circuit check NO a Replace the wire harness b Push the ON start switch and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovere...

Страница 553: ...Go to step 4 NO a Replace the wire harness b Push the ON start switch and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 a...

Страница 554: ...tion of Recovered using the YDT and then delete the DTC At sea level Approx 101 kPa 757 6 mmHg 29 8 inHg approx 3 64 V 1000 m 3300 ft above sea level Approx 90 kPa 675 1 mmHg 26 6 inHg approx 3 30 V 2...

Страница 555: ...ing 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 coup...

Страница 556: ...L Y G P W G Y L Lg W B L Br W Gy G Lg L W G W Y G R L W Lg B L Br W 1 2 2 XP560D XP560E Is resistance 0 YES Go to Short circuit check NO a Replace the wire harness b Push the ON start switch and then...

Страница 557: ...O W W G Y L Lg W B L Br W Gy G G L R G Lg L W G W Y G R Lg B L W Lg B Y L Y G P W G Y L Lg W B L Br W Gy G Lg L W G W Y G R L W Lg B L Br W B L Br W A B 1 1 2 2 XP560D XP560E Is resistance YES Go to...

Страница 558: ...hat the DTC has a condition of Recovered using the YDT and then delete the DTC Is check result OK YES Go to step 6 NO a Replace the intake air temperature sensor Refer to GENERAL CHASSIS 3 on page 4 1...

Страница 559: ...the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Is the coupler condition normal YES Go to step 2 NO a Connect...

Страница 560: ...Y G P W G Y L Lg W B L Br W Gy G Lg L W G W Y G R L W Lg B L G R 2 2 1 XP560D XP560E Is resistance 0 YES Go to step Short circuit check NO a Replace the wire harness b Push the ON start switch and the...

Страница 561: ...G Y L Lg W B L Br W Gy G G L R G Lg L W G W Y G R Lg B L W Lg B Y L Y G P W G Y L Lg W B L Br W Gy G Lg L W G W Y G R L W Lg B L G R B L G R A B 1 1 2 2 XP560D XP560E Is resistance YES Go to step 4 NO...

Страница 562: ...m that the DTC has a condition of Recovered using the YDT and then delete the DTC Is check result OK YES Go to step 6 NO a Replace the coolant temperature sensor Refer to CYLINDER HEAD on page 5 20 b...

Страница 563: ...oupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins 2 Connection of ECU coupler Check the locking con...

Страница 564: ...222 blue blue P0122 P0123 P0222 P0223 P2135 white white P0123 P0223 black blue black blue P0122 P0123 P0222 P0223 P2135 black black Is resistance 0 YES Go to Short circuit check NO a Replace the wire...

Страница 565: ...2 P0222 blue any other coupler terminal P0122 P0123 P0222 P0223 P2135 white any other coupler terminal P0123 P0223 black blue any other coupler terminal P0122 P0123 P0222 P0223 P2135 black any other c...

Страница 566: ...the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 9 and complete the service NO Go to step 5 Is check result OK YES Go to step 6 NO a Repla...

Страница 567: ...covered using the YDT and then delete the DTC Is it in the Recovered condition YES Go to step 9 and complete the service NO Go to step 7 When the throttle valves are fully closed 9 23 When throttle va...

Страница 568: ...rminals and locking condition of the pins Is check result OK YES Go to step 2 NO a Reinstall or replace the sensor b Push the ON start switch and then check the condition of the DTC using the malfunct...

Страница 569: ...hen check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to step 4 Between O2 sensor coupler 1 and ECU...

Страница 570: ...t circuit check Between O2 sensor coupler 1 and ground gray green ground black blue ground O2 sensor coupler 1 black blue any other coupler terminal gray green any other coupler terminal ECU coupler 2...

Страница 571: ...resistance YES Go to step 5 NO a Replace the wire harness b Push the ON start switch and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES...

Страница 572: ...bent or broken terminals and locking condition of the pins 2 Defective injector 1 Measure the injector resistance Refer to CHECKING THE FUEL INJECTOR on page 8 111 Is the coupler condition normal YES...

Страница 573: ...ct the coupler securely or replace the wire harness b Execute the diagnostic mode Code D36 Is it hear operating sound YES Go to step 6 NO Go to step 4 Between injector 1 coupler 1 and ECU cou pler 2 r...

Страница 574: ...he DTC has a condition of Recovered using the malfunction mode of the YDT and then delete the DTC Between injector 1 coupler 1 and ground red black ground red blue ground Injector 1 coupler 1 red blac...

Страница 575: ...bent or broken terminals and locking condition of the pins 2 Defective injector 2 Measure the injector resistance Refer to CHECKING THE FUEL INJECTOR on page 8 111 Is the coupler condition normal YES...

Страница 576: ...the coupler securely or replace the wire harness b Execute the diagnostic mode Code D37 Is it hear operating sound YES Go to step 6 NO Go to step 4 Between injector 2 coupler 1 and ECU cou pler 2 gree...

Страница 577: ...DTC has a condition of Recovered using the malfunction mode of the YDT and then delete the DTC Between injector 2 coupler 1 and ground green black ground red blue ground Injector 2 coupler 1 green bla...

Страница 578: ...harness continuity Disconnect the crankshaft position sensor coupler and ECU coupler Open circuit check Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace th...

Страница 579: ...resistance 0 YES Go to Short circuit check NO a Replace the wire harness b Crank the engine and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered conditi...

Страница 580: ...B Y B L 2 2 1 1 A B XP560D XP560E Is resistance YES Go to step 4 NO a Replace the wire harness b Crank the engine and then check the condition of the DTC using the malfunction mode of the YDT Is it i...

Страница 581: ...Engine Control Unit on page 8 93 7 Delete the DTC and check that the MIL goes off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC Is check result OK YES Go to...

Страница 582: ...nect the ignition coil coupler and ECU coupler Open circuit check Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Start the engine and...

Страница 583: ...et it idle for approximately 5 seconds c Check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to Short...

Страница 584: ...lete 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...

Страница 585: ...rm that spark plug does not sparking Replace the ECU and complete the service Refer to REPLACING THE ECU Engine Control Unit on page 8 93 7 Delete the DTC and check that the MIL goes off Confirm that...

Страница 586: ...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 Push the ON start sw...

Страница 587: ...and ECU coupler 2 yellow red yellow red Is resistance 0 YES Go to Short circuit check NO a Replace the wire harness b Push the ON start switch and then check the condition of the DTC using the malfun...

Страница 588: ...he MIL goes off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC Is resistance YES Go to step 4 NO a Replace the wire harness b Push the ON start switch and then...

Страница 589: ...of the pins 3 Connection of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Is the coupler...

Страница 590: ...sensor coupler 1 and ABS ECU coupler 2 black black white white Between ABS ECU coupler 2 and ECU cou pler 3 white green white green B Y L Y G P Lg L O W W G Y L Lg W B L Br W Gy G G L R G Lg L W G W...

Страница 591: ...hite any other coupler terminal ABS ECU coupler 2 black any other coupler terminal white any other coupler terminal white green any other coupler terminal ECU coupler 3 white green any other coupler t...

Страница 592: ...tate 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 malf...

Страница 593: ...DIES on page 7 10 Is check result OK YES Go to step 2 NO a Replace the throttle bodies b Start the engine and let it idle for approximately 5 minutes c Push the ON start switch and then check the cond...

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

Страница 595: ...fer to CHARGING SYSTEM on page 8 17 2 Delete the DTC and check that the MIL goes off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC Is check result OK YES Repe...

Страница 596: ...e from step 3 to step 5 and from step 9 to step 10 b Execute the diagnostic mode Code 81 c Confirm that it is defective d Go to step 6 Is the coupler condition normal YES Go to step 2 NO a Connect the...

Страница 597: ...ise control setting switch and then check the condi tion of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 10 and complete the service NO Go to step 4 Be...

Страница 598: ...ed condition YES Go to step 10 and complete the service NO Go to Short circuit check Between ignition system relay coupler 1 and ground brown blue ground Between handlebar switch coupler left 3 and gr...

Страница 599: ...ES side of the cruise control setting switch and then check the condi tion of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 10 and complete the service...

Страница 600: ...andlebar switch coupler left 3 and ECU coupler 4 green blue green blue Is resistance 0 YES Go to Short circuit check NO a Replace the wire harness b Push the ON start switch c Push and SET side of the...

Страница 601: ...any other coupler terminal Handlebar switch coupler left 3 green blue any other coupler terminal yellow black any other coupler terminal ECU coupler 4 green blue any other coupler terminal Is resistan...

Страница 602: ...11 2 Connection of ECU coupler front brake light switch coupler brake light relay coupler and handlebar switch coupler right Check the locking condition of the coupler Disconnect the coupler and chec...

Страница 603: ...ng the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 11 and complete the service NO Go to step 4 Between ignition system relay coupler 1 and signaling system fuse holder...

Страница 604: ...to step 11 and complete the service NO Go to Short circuit check Between ignition system relay coupler 1 and ground brown blue ground Between front brake light switch 3 and ground green white ground...

Страница 605: ...ler and check the pins bent or broken terminals and locking condition of the pins Is resistance YES Go to step 5 NO a Replace the wire harness b Push the ON start switch c Operate the front brake leve...

Страница 606: ...YES Go to step 11 and complete the service NO Go to step 7 Is check result OK YES Go to step 8 NO a Replace the fuse b Push the ON start switch c Operate the rear brake lever and then check the condit...

Страница 607: ...check Between ignition system relay coupler 1 and ground brown blue ground Between rear brake light switch coupler 3 and ground green yellow ground light green black ground Between brake light relay...

Страница 608: ...ered condition YES Go to step 11 and complete the service NO Go to step 9 Is check result OK YES Go to step 10 NO a Push the ON start switch b Operate the rear brake lever and then check the condition...

Страница 609: ...place the ECU and complete the service Refer to REPLACING THE ECU Engine Control Unit on page 8 93 11 Delete the DTC and check that the MIL goes off Confirm that the DTC has a condition of Recovered u...

Страница 610: ...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 REPLACIN...

Страница 611: ...are detected at the same time correct the P0122 P0123 P0222 P0223 and P2135 first Push the ON start switch and then check the condition of the DTC using the malfunction mode of the YDT 2 Malfunction...

Страница 612: ...de push the OFF LOCK switch Push the ON start switch and then check the condition of the DTC using the malfunction mode of the YDT 3 02 is indicated in diagnostic mode code D60 EEPROM data error for a...

Страница 613: ...malfunction mode of the YDT 5 Malfunction in ECU Replace the ECU and complete the service Refer to REPLACING THE ECU Engine Control Unit on page 8 93 6 Delete the DTC and check that the MIL goes off C...

Страница 614: ...pins bent or broken terminals and locking condition of the pins Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Push the ON start switc...

Страница 615: ...using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 8 and complete the service NO Go to step 4 Between throttle servo motor coupler 1 and ECU coupler 2 yellow red yel...

Страница 616: ...r coupler terminal red blue any other coupler terminal Is resistance YES Go to step 5 NO a Replace the wire harness b Push the ON start switch and then check the condition of the DTC using the malfunc...

Страница 617: ...onfirm that the DTC has a condition of Recovered using the YDT and then delete the DTC Is it in the Recovered condition YES Go to step 8 and complete the service NO Go to step 6 Is check result OK YES...

Страница 618: ...ler 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 t...

Страница 619: ...fuel injection system relay coupler 2 red black red black Between fuel injection system relay coupler 2 and ECU coupler 5 red blue red blue blue yellow blue yellow Is resistance 0 YES Go to Short cir...

Страница 620: ...ler terminal blue yellow any other coupler terminal Is resistance YES Go to step 4 NO a Replace the wire harness b Start the engine and let it idle for approximately 5 seconds c Check the condition of...

Страница 621: ...s a condition of Recovered using the YDT and then delete the DTC Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to step 5 Is the fuel system voltage less than 3V YES...

Страница 622: ...he 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 t...

Страница 623: ...4 Between sidestand relay coupler 1 and ECU coupler 2 light green light green Between sidestand relay coupler 1 and side stand switch coupler 3 light green light green B Y L Y G P Lg L O W W G Y L Lg...

Страница 624: ...green any other coupler terminal Sidestand switch coupler 3 light green any other coupler terminal B Y L Y G P Lg L O W W G Y L Lg W B L Br W Gy G G L R G Lg L W G W Y G R Lg B L W Lg B Y L Y G P W G...

Страница 625: ...es off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC Sidestand retracted ON Sidestand extended OFF Is check result OK YES Go to step 6 NO a Replace the sidest...

Страница 626: ...e pins bent or broken terminals and locking condition of the pins Is check result OK YES Go to step 2 NO a Reinstall or replace the battery leads b Push the ON start switch and then check the conditio...

Страница 627: ...condition YES Go to step 6 and complete the service NO Go to step 4 Between battery 1 and starter relay terminal 2 red red Between starter relay coupler 3 and ECU cou pler 4 red red Is resistance 0 YE...

Страница 628: ...TC has a condition of Recovered using the YDT and then delete the DTC Between starter relay coupler 3 and ground red ground Starter relay coupler 3 red any other coupler terminal ECU coupler 4 red any...

Страница 629: ...ondition of the pins 3 Wire harness continuity Disconnect the lean angle sensor coupler and ECU coupler Open circuit check Is the coupler condition normal YES Go to step 2 NO a Connect the coupler sec...

Страница 630: ...Lg W B L Br W Gy G Lg L W G W Y G R L W Lg B L Y G L 2 2 1 XP560D XP560E Is resistance 0 YES Go to Short circuit check NO a Replace the wire harness b Push the ON start switch then to OFF and then ba...

Страница 631: ...g B Y L Y G P W G Y L Lg W B L Br W Gy G Lg L W G W Y G R L W Lg B L Y G L B A 2 2 1 XP560D XP560E Is resistance YES Go to step 4 NO a Replace the wire harness b Push the ON start switch then to OFF a...

Страница 632: ...pler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins 2 Connection of ECU coupler Check the locking condi...

Страница 633: ...122 P2123 P2127 P2128 P2138 white white P2123 P2128 black blue black blue P2122 P2127 blue blue P2122 P2123 P2127 P2128 P2138 red red Is resistance 0 YES Go to Short circuit check NO a Replace the wir...

Страница 634: ...122 P2123 P2127 P2128 P2138 white any other coupler terminal P2123 P2128 black blue any other coupler terminal P2122 P2127 blue any other coupler terminal P2122 P2123 P2127 P2128 P2138 red any other c...

Страница 635: ...page 8 93 6 Delete the DTC and check that the MIL goes off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC Is check result OK YES Go to step 5 NO Replace the ac...

Страница 636: ...check the pins bent or broken terminals and locking condition of the pins Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Execute the d...

Страница 637: ...at the indicated value increases Is that value increased YES Go to step 8 and complete the service NO Go to step 4 Between front wheel sensor coupler 1 and ABS ECU coupler 2 black black white white Be...

Страница 638: ...ground white yellow ground Front wheel sensor coupler 1 black any other coupler terminal white any other coupler terminal ABS ECU coupler 2 black any other coupler terminal white any other coupler ter...

Страница 639: ...irm that the DTC has a condition of Recovered using the malfunction mode of the YDT and then delete the DTC Delete this DTC even if it has a condition of Detected Is resistance YES Go to step 5 NO a R...

Страница 640: ...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...

Страница 641: ...y G Lg L W G W Y G R L W Lg G B P WP B O L R LB W Br Y L R Br YChDgR GR W Gy V Gy WV WG RG L G W GW RW L Y B WLg WLg LB WR GR G 2 2 1 XP560D XP560E Is resistance 0 YES Go to Short circuit check NO a R...

Страница 642: ...Y L Lg W B L Br W Gy G G L R G Lg L W G W Y G R Lg B L W Lg B Y L Y G P W G Y L Lg W B L Br W Gy G Lg L W G W Y G R L W Lg G B P WP B O L R LB W Br Y L R Br YChDgR GR W Gy V Gy WV WG RG L G W GW RW L...

Страница 643: ...4 24 3 Defective sensor rotor or incorrect installation of the rotor Check the surface of the sensor rotor for damage Refer to MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR on page 4 26 4 Def...

Страница 644: ...e surface of the sensor rotor for damage Refer to MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR on page 4 34 4 Defective rear wheel sensor or incorrect installation of the sensor Check the whe...

Страница 645: ...r to CHECKING THE FRONT WHEEL on page 4 24 3 Defective sensor rotor or incorrect installation of the rotor Check the surface of the sensor rotor for damage Refer to MAINTENANCE OF THE FRONT WHEEL SENS...

Страница 646: ...r to CHECKING THE REAR WHEEL on page 4 33 3 Defective sensor rotor or incorrect installation of the rotor Check the surface of the sensor rotor for damage Refer to MAINTENANCE OF THE REAR WHEEL SENSOR...

Страница 647: ...pler and front wheel sensor coupler Open circuit check Short circuit check TIP Disconnect the ABS ECU related connectors before checking Refer to PARTS CONNECTED TO THE ABS ECU on page 9 4 Ground shor...

Страница 648: ...nit assembly Refer to FRONT WHEEL on page 4 22 and ABS Anti lock Brake System on page 4 67 ABS ECU coupler 1 white any other coupler terminal black any other coupler terminal Front wheel sensor 2 whit...

Страница 649: ...pler and rear wheel sensor coupler Open circuit check Short circuit check TIP Disconnect the ABS ECU related connectors before checking Refer to PARTS CONNECTED TO THE ABS ECU on page 9 4 Ground short...

Страница 650: ...nit assembly Refer to REAR WHEEL on page 4 30 and ABS Anti lock Brake System on page 4 67 ABS ECU coupler 1 white any other coupler terminal black any other coupler terminal Rear wheel sensor 2 white...

Страница 651: ...ortion and bends Refer to CHECKING THE FRONT WHEEL on page 4 24 3 Defective sensor rotor or incorrect installation of the rotor Check the surface of the sensor rotor for damage Refer to MAINTENANCE OF...

Страница 652: ...tortion and bends Refer to CHECKING THE REAR WHEEL on page 4 33 3 Defective sensor rotor or incorrect installation of the rotor Check the surface of the sensor rotor for damage Refer to MAINTENANCE OF...

Страница 653: ...1_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 Br...

Страница 654: ...OFF LOCK switch before disconnecting or connecting a coupler 3 Wire harness continuity XP560E Disconnect the handlebar switch coupler right handlebar switch coupler left and ABS ECU cou pler Open circ...

Страница 655: ...1 green yellow any other coupler terminal Handlebar switch coupler left 2 green yellow any other coupler terminal ABS ECU coupler 3 green yellow any other coupler terminal Is resistance YES Go to step...

Страница 656: ...coupler 2 green yellow any other coupler terminal Rear brake light switch coupler 3 green yellow any other coupler terminal light green black any other coupler terminal Brake light relay coupler 4 bro...

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

Страница 658: ...sh the OFF LOCK switch before disconnecting or connecting a coupler 3 Wire harness continuity Disconnect the ABS solenoid fuse and ABS ECU coupler Open circuit check Short circuit check Is check resul...

Страница 659: ...ic unit assembly Replace the hydraulic unit assembly Refer to ABS Anti lock Brake System on page 4 67 Between ABS ECU coupler 2 and ground red white ground ABS ECU coupler 2 red white any other couple...

Страница 660: ...33376 TROUBLESHOOTING Item Hydraulic unit assembly short circuit in ABS solenoid power supply circuit Procedure 1 Defective hydraulic unit assembly Replace the hydraulic unit assembly Refer to ABS Ant...

Страница 661: ...pler TIP Push the OFF LOCK switch before disconnecting or connecting a coupler 3 Wire harness continuity Disconnect the ABS motor fuse and ABS ECU coupler Open circuit check Is check result OK YES Go...

Страница 662: ...ssembly Replace the hydraulic unit assembly Refer to ABS Anti lock Brake System on page 4 67 Between ABS ECU coupler 2 and ground red blue ground ABS ECU coupler 2 red blue any other coupler terminal...

Страница 663: ...S33323 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...

Страница 664: ...G THE FRONT WHEEL on page 4 24 and CHECKING THE FRONT BRAKE DISCS on page 4 43 3 Front brake dragging Check that the brake fluid pressure is correctly transmitted to the brake caliper when the brake l...

Страница 665: ...o CHECKING THE REAR WHEEL on page 4 33 and CHECKING THE REAR BRAKE DISC on page 4 58 3 Rear brake dragging Check that the brake fluid pressure is correctly transmitted to the brake caliper when the br...

Страница 666: ...of the sensor rotor for damage Refer to MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR on page 4 26 4 Defective front wheel sensor or incorrect installation of the sensor Check the wheel sens...

Страница 667: ...of the sensor rotor for damage Refer to MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR on page 4 34 4 Defective rear wheel sensor or incorrect installation of the sensor Check the wheel sensor...

Страница 668: ...Recharge or replace the battery and check again Refer to CHECKING AND CHARGING THE BATTERY on page 8 94 2 Disconnected battery terminal Check the connection 3 Defective charging system Check the char...

Страница 669: ...disconnecting or connecting a coupler 3 Wire harness continuity Disconnect the ABS ECU fuse and ABS ECU coupler Open circuit check Short circuit check TIP Disconnect the ABS ECU related connectors be...

Страница 670: ...hite any other coupler terminal Is resistance YES Go to step 4 NO Replace the wire harness Is check result OK YES Replace the hydraulic unit assembly ABS ECU NO Confirm the cause of the problem and re...

Страница 671: ...before disconnecting or connecting a coupler 3 Wire harness continuity Disconnect the ABS ECU fuse ABS motor fuse and ABS ECU coupler Open circuit check Short circuit check TIP Disconnect the ABS ECU...

Страница 672: ...n page 9 26 Between ABS ECU coupler 3 and ground brown white ground red blue ground ABS ECU coupler 3 brown white any other coupler terminal red blue any other coupler terminal Is resistance YES Go to...

Страница 673: ...20700 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 Syst...

Страница 674: ...56_ABS EAS33329 TROUBLESHOOTING Item Hydraulic unit assembly abnormal internal power supply Procedure 1 Defective hydraulic unit assembly Replace the hydraulic unit assembly Refer to ABS Anti lock Bra...

Страница 675: ...check A Lines short circuit check B Between front wheel sensor coupler 1 and ground white ground black ground Front wheel sensor coupler 1 white any other coupler terminal black any other coupler ter...

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

Страница 677: ...A Lines short circuit check B Between rear wheel sensor coupler 1 and ground white ground black ground Rear wheel sensor coupler 1 white any other coupler terminal black any other coupler terminal ABS...

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

Страница 679: ...mper and suspen sion warning light 54 ABS warning light 55 High beam indicator light 56 Multi function display 57 ECU Engine Control Unit 58 Ignition coil 59 Spark plug 60 Grip warmer connector 61 Gri...

Страница 680: ...cator light left 63 Turn signal indicator light right 64 Cruise control system indicator light 65 Cruise control setting indicator light 66 Steering damper and suspen sion warning light 67 ABS warning...

Страница 681: ...L Green Blue G R Green Red G W Green White G Y Green Yellow Gy G Gray Green Gy W Gray White L B Blue Black L G Blue Green L R Blue Red L W Blue White L Y Blue Yellow Lg B Light green Black Lg L Light...

Страница 682: ......

Страница 683: ......

Страница 684: ......

Страница 685: ...B L B L R L R V W V W W L W G W R W L Br Y Br Y Y B R Y W R W G R L R L O L O L L L P Lg L Lg L Lg W Lg W Lg W Lg W Lg W Lg W Lg L Lg L Lg W Lg W Lg L Lg L Lg L Lg L Lg W Lg W Lg W Lg W L G L G L G L...

Страница 686: ...0 14 22 25 31 33 32 27 28 29 30 41 42 43 58 10 59 60 61 62 63 57 45 44 46 48 47 49 50 51 52 53 54 68 10 10 71 72 73 74 75 10 77 10 80 79 78 76 69 70 64 65 66 10 67 23 26 24 11 10 12 13 9 N HI FREE PAS...

Страница 687: ...Y V Y L Gy Y B R Y Ch Y L B B Dg Y B W W W B L Y L Y R B R B R B R B R B R B R B R W R W R W R W Dg Br G Dg L L Br B Br B Br Y B R R W W W B B B B L L L L B G Y Y Y B Y B B B W W R R R R Y B Y B W Y...

Страница 688: ...41 43 42 44 45 46 47 48 49 51 50 53 52 71 10 72 73 74 75 76 70 56 55 57 59 58 60 61 62 63 64 65 66 67 81 10 10 84 85 86 87 88 10 90 10 93 92 91 89 82 83 77 78 79 10 80 54 23 26 24 11 10 12 13 9 RES N...

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