Yamaha XSR700 2018 Скачать руководство пользователя страница 27 | Manualshive

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CABLE ROUTING

– 20 –

1. Brake hose (hydraulic unit to left front brake

caliper)

2. Front wheel sensor lead
3. Brake hose (left front brake caliper to right front

brake caliper)

4. Brake hose (front brake master cylinder to

hydraulic unit)

A. Make sure that there is no slack in the front wheel

sensor lead and that the lead is not pinched
between the headlight bracket and the brake hose
(hydraulic unit to left front brake caliper) in the area
shown in the illustration.

B. Fasten the front wheel sensor lead and brake hose

(hydraulic unit to left front brake caliper) with the
holder as shown in the illustration. Position the
holder 80

–

100 mm (3.15

–

3.94 in) from the

grommet on the hose and route the lead over the
hose.

C. Face the catch of the holder forward, and then

close the holder until three clicks or more are
heard.

D. Make sure that the holder contacts the end of the

hose protector on the brake hose.

E. Fasten the front wheel sensor lead and brake hose

(hydraulic unit to left front brake caliper) with the
holder as shown in the illustration. Position the
holder 30

–

50 mm (1.18

–

1.97 in) from the grommet

on the hose and route the lead to the rear of the
hose.

F. To front brake master cylinder
G. To hydraulic unit
H. Fasten the front wheel sensor lead and brake hose

(hydraulic unit to left front brake caliper) with the
holder as shown in the illustration. Position the
holder 15 mm (0.59 in) or less from the grommet
on the hose and route the lead to the outside of the
hose. Face the catch of the holder inward, and
then close the holder until three clicks or more are
heard.

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Содержание XSR700 2018

Страница 1: ...2018 SUPPLEMENTARY SERVICE MANUAL XSR700 MTM690 MTM690 U BU3 F8197 E0...

Страница 2: ...s it is necessary to use this Supplementary Service Manual together with the following manual MTM690 MTM690 U 2018 SERVICE MANUAL B34 F8197 E2 EAS20002 MTM690 MTM690 U SUPPLEMENTARY SERVICE MANUAL 201...

Страница 3: ...nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable TIP Designs and specifications ar...

Страница 4: ...n title To help identify parts and clarify procedure steps there are exploded diagrams 3 at the start of each removal and disassembly section Numbers 4 are given in the order of the jobs in the explod...

Страница 5: ...viceable with engine mounted Gear oil Filling fluid Molybdenum disulfide oil Lubricant Brake fluid Special tool Wheel bearing grease Tightening torque Lithium soap based grease Wear limit clearance Mo...

Страница 6: ...ENANCE AND LUBRICATION CHART 21 CHECKING THE VEHICLE USING THE YAMAHA DIAGNOSTIC TOOL 24 CHECKING THE EXHAUST SYSTEM 24 GENERAL CHASSIS 3 25 GENERAL CHASSIS 5 26 REMOVING THE ECU engine control unit 2...

Страница 7: ...BLESHOOTING 59 FUEL INJECTION SYSTEM 61 CIRCUIT DIAGRAM 61 TROUBLESHOOTING DETAILS FAULT CODE 63 TROUBLESHOOTING DETAILS EVENT CODE 69 ABS ANTI LOCK BRAKE SYSTEM 71 CIRCUIT DIAGRAM 71 ABS COUPLER LOCA...

Страница 8: ...tools part numbers or both may differ depending on the country When placing an order refer to the list provided below to avoid any mistakes TIP For U S A and Canada use part number starting with YM YU...

Страница 9: ...GENERAL SPECIFICATIONS 2 EAS20013 GENERAL SPECIFICATIONS Model Model BU31 MTM690 B9J1 MTM690 U...

Страница 10: ...ELECTRICAL SPECIFICATIONS 3 EAS20016 ELECTRICAL SPECIFICATIONS Fuse Backup fuse 2 10 0 A...

Страница 11: ...ELECTRICAL SPECIFICATIONS 4...

Страница 12: ...CABLE ROUTING 5 EAS20021 CABLE ROUTING Handlebar front view A B D C E F 4 8 9 10 11 12 12 13 14 14 G 1 1 1 2 2 2 3 3 5 5 6 6 7 7 12 15 16 17 18 12 1 3 5 5 H I J K H I J K L...

Страница 13: ...r Align the holder with the blue tape on the handlebar switch lead B Route the throttle cables through the guide Be sure to route the throttle cable decelerator cable over the throttle cable accelerat...

Страница 14: ...CABLE ROUTING 7 ECU and clutch cable right side view 19 20 F A D 1 2 3 4 5 6 7 8 9 10 11 11 11 12 12 12 13 13 14 15 G H B E C G H I J 16 18 17 K 21...

Страница 15: ...er 16 Wire harness to ECU 17 Damper 18 Frame 19 Cylinder head breather hose 20 Sub wire harness gear position switch coolant temperature sensor fuel injector 21 Meter assembly coupler cover A Position...

Страница 16: ...CABLE ROUTING 9 Engine right side view E A B C D 1 1 2 3 4 5 6 7 12 13 B F G H I L Q K J 8 9 11 10 10 M N O P 1 12 M N O P 3 6 7 14...

Страница 17: ...light switch lead and O2 sensor lead with the holder E To rear brake caliper bracket F Connect the O2 sensor coupler and then insert the projection on the coupler into the hole in the bracket G Route...

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

Страница 19: ...gneto lead horn lead and coolant reservoir hose with the holder Make sure that the coolant reservoir hose and leads do not cross between the oil cooler inlet hose and this holder I Fasten the AC magne...

Страница 20: ...l components tray top view 27 27 27 27 N 26 P Q I J I J H F 27 28 O 1 2 4 5 E G H F 20 E G H F 20 I J H F K H F A B 1 2 3 4 5 6 7 9 10 11 12 13 16 17 18 18 18 19 19 19 20 20 20 21 24 24 25 25 26 22 23...

Страница 21: ...in switch lead 29 Electrical components tray 1 A Insert the projection on the bracket into the hole in the sub wire harness coupler B White paint mark C Insert the projection on the wire harness holde...

Страница 22: ...CABLE ROUTING 15 Battery and rear fender top view 8 9 10 15 16 16 17 17 A B C D 1 2 2 3 3 4 5 6 7 8 9 10 11 11 11 12 12 13 14 14 14 15 18 18 19 20 21 21 22 23 F G H I J K L 14 21 G H G H E...

Страница 23: ...gnostic tool lead and coupler above fuse boxes 1 and 2 as shown in the illustration C Connect all of the couplers near fuse box 2 and then install fuse box 2 to the battery box D Fasten the license pl...

Страница 24: ...CABLE ROUTING 17 Rear brake hose right side view I N 1 E J K L G M 1 1 5 5 5 4 5 2 2 2 2 2 2 6 7 E H 5 2 A B C F D D D 1 2 3 8 8 5 4 4 4 2 6 7...

Страница 25: ...inward with the end pointing downward G Position the end of the plastic locking tie to the inside of the brake hoses H Route the brake hoses on top of the frame I Point the end of the plastic locking...

Страница 26: ...CABLE ROUTING 19 Front brake hose left and right side view A B C D E D F G G H 1 1 2 2 2 3 2 3 4 1...

Страница 27: ...e the lead over the hose C Face the catch of the holder forward and then close the holder until three clicks or more are heard D Make sure that the holder contacts the end of the hose protector on the...

Страница 28: ...formed by your Yamaha dealer because these items re quire special tools data and technical skills From 50000 km 30000 mi repeat the maintenance intervals starting from 10000 km 6000 mi The annual chec...

Страница 29: ...and after washing the motorcycle riding in the rain or riding in wet areas 14 Steering bearings Check bearing assemblies for looseness Moderately repack with lithi um soap based grease 15 Chassis fas...

Страница 30: ...our years and if cracked or damaged 25 Engine oil Change warm engine before draining Check oil level and vehicle for oil leakage 26 Engine oil filter cartridge Replace 27 Cooling system Check coolant...

Страница 31: ...FAULT CODE on page 63 and B 2 DI AGNOSIS USING THE FAULT CODES on page 75 4 Perform Dynamic inspection TIP Use the Dynamic inspection function of the Yamaha diagnostic tool version 3 0 and after to p...

Страница 32: ...center cover 1 5 Air scoop left 1 6 Air scoop right 1 7 Outer side cover left 1 8 Inner side cover left 1 9 Outer side cover right 1 10 Inner side cover right 1 4 3 3 4 4 6 1 2 3 4 5 6 8 10 9 7 8 1 5...

Страница 33: ...age 25 Fuel tank Refer to FUEL TANK on page 38 Hydraulic unit assembly Refer to ABS ANTI LOCK BRAKE SYS TEM in chapter 4 Manual No B34 F8197 E2 1 Stator coil coupler 1 Disconnect 2 Rectifier regulator...

Страница 34: ...motor coupler 1 12 Crankshaft position sensor coupler 1 13 Electrical components tray 1 1 14 ECU coupler 1 Disconnect 15 ECU Engine Control Unit 1 16 Band 1 17 Sub wire harness coupler 1 18 Electrica...

Страница 35: ...the portion a of the ECU cou pler move the lock lever b in the direction of the arrow shown to disconnect the coupler EAS31109 INSTALLING THE ECU engine control unit 1 Connect ECU coupler 1 TIP Conne...

Страница 36: ...1 9 Throttle cable housing 1 10 Throttle cable 2 Disconnect LT LS LS LS LS 1 5 7 3 2 4 9 9 10 10 1 8 6 8 10 N m 1 0 kgf m 7 4 lb ft T R 1 8 N m 0 18 kgf m 1 3 lb ft T R 1 8 N m 0 18 kgf m 1 3 lb ft T...

Страница 37: ...ower handlebar holder 1 LT LS LS LS LS 18 21 20 20 11 12 11 16 13 19 22 14 15 14 17 10 N m 1 0 kgf m 7 4 lb ft T R 1 8 N m 0 18 kgf m 1 3 lb ft T R 1 8 N m 0 18 kgf m 1 3 lb ft T R 2 0 N m 0 20 kgf m...

Страница 38: ...Fuel tank Refer to FUEL TANK on page 38 Front wheel Refer to FRONT WHEEL in chapter 4 Manual No B34 F8197 E2 1 Front brake hose lead holder 2 2 Front fender 1 3 Front fender bracket 1 4 Front fork cap...

Страница 39: ...ler 2 Disconnect 8 Immobilizer unit coupler 1 Disconnect 9 Upper bracket 1 10 Lower bracket pinch bolt 2 Loosen 11 Front fork leg 1 7 N m 0 7 kgf m 5 2 lb ft T R 7 N m 0 7 kgf m 5 2 lb ft T R 7 N m 0...

Страница 40: ...AL CHASSIS 2 in chap ter 4 Manual No B34 F8197 E2 Handlebar Refer to HANDLEBAR on page 29 Front fork legs Refer to FRONT FORK on page 31 1 Front brake hose lower holder 1 2 Front brake hose upper hold...

Страница 41: ...b Parts to remove Q ty Remarks 5 Cap nut 1 6 Lower bracket 1 7 Lower bracket cap 1 8 Bearing cover 1 9 Lower bearing dust seal 1 10 Upper bearing 1 11 Lower bearing 1 5 8 10 6 7 9 11 LS LS LS 1st 52 N...

Страница 42: ...n chapter 4 Manual No B34 F8197 E2 Drive sprocket cover Refer to CHAIN DRIVE in chapter 4 Man ual No B34 F8197 E2 1 Pivot shaft protector left 1 2 Pivot shaft protector right 1 3 Sidestand switch coup...

Страница 43: ...e 1 12 Dust cover 2 13 Oil seal 2 14 Collar 2 15 Oil seal 2 16 Bearing 3 16 15 14 14 10 13 12 13 9 11 16 12 8 5 7 6 LT LT LT LT LS LS LS LS LS New New New New LS New 10 N m 1 0 kgf m 7 4 lb ft T R 7 N...

Страница 44: ...Oil seal 2 21 Bearing 2 22 Washer 1 17 19 18 20 20 21 17 22 LT LT LT LT LS LS LS LS LS New New New New LS New 10 N m 1 0 kgf m 7 4 lb ft T R 7 N m 0 7 kgf m 5 2 lb ft T R 7 N m 0 7 kgf m 5 2 lb ft T R...

Страница 45: ...AL CHASSIS 3 on page 25 1 Intake air temperature sensor coupler 1 Disconnect 2 Fuel tank overflow hose 1 Disconnect 3 Fuel tank breather hose 1 Disconnect 4 Fuel pump coupler 1 Disconnect 5 Fuel hose...

Страница 46: ...ir temperature sensor 1 10 Fuel pump 1 11 Front fuel tank bracket 1 12 Rear fuel tank bracket 1 8 4 New 7 6 8 12 9 10 11 10 N m 1 0 kgf m 7 4 lb ft T R 10 N m 1 0 kgf m 7 4 lb ft T R 3 8 N m 0 38 kgf...

Страница 47: ...FUEL TANK 40...

Страница 48: ...Dg B B Y Y G G L R L R Ch Ch B Dg B Ch L R G Y B B B B B B B B L R L L L R L R L B L B L R L R L B L B R Br L R W Br L Br R Br R B W R G Y L G B R W W W W B R B R R L W R W B Br Y B B Y L R R W L W R...

Страница 49: ...nt coupler 26 Sidestand switch 27 Crankshaft position sensor 30 Ignition coil 1 31 Ignition coil 2 32 Spark plug 36 ECU Engine Control Unit 40 Lean angle sensor 62 Gear position switch 63 Handlebar sw...

Страница 50: ...G THE BATTERY in chapter 8 Manual No B34 F8197 E2 Clean the battery terminals Recharge or replace the battery 3 Check the spark plugs Refer to CHECKING THE SPARK PLUGS in chapter 3 Manual No B34 F8197...

Страница 51: ...No B34 F8197 E2 Replace the gear position switch 10 Check the sidestand switch Refer to CHECKING THE SWITCHES in chapter 8 Manual No B34 F8197 E2 Replace the sidestand switch 11 Check the relay unit d...

Страница 52: ...Dg B B Y Y G G L R L R Ch Ch B Dg B Ch L R G Y B B B B B B B B L R L L L R L R L B L B L R L R L B L B R Br L R W Br L Br R Br R B W R G Y L G B R W W W W B R B R R L W R W B Br Y B B Y L R R W L W R...

Страница 53: ...25 Joint coupler 36 ECU Engine Control Unit 48 Meter assembly 51 Meter light 57 High beam indicator light 68 Handlebar switch left 70 Dimmer switch 71 Pass switch 77 Headlight assembly 78 Auxiliary li...

Страница 54: ...fuses Ignition signaling system head light backup 2 and main Refer to CHECKING THE FUS ES on page 81 Replace the fuse s 3 Check the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 8 Manu...

Страница 55: ...al No B34 F8197 E2 Replace the headlight relay 8 Check the entire lighting system wiring Refer to CIRCUIT DIAGRAM on page 45 Properly connect or replace the wiring har ness Replace the ECU meter assem...

Страница 56: ...g Dg B B Y Y G G L R L R Ch Ch B Dg B Ch L R G Y B B B B B B B B L R L L L R L R L B L B L R L R L B L B R Br L R W Br L Br R Br R B W R G Y L G B R W W W W B R B R R L W R W B Br Y B B Y L R R W L W...

Страница 57: ...light 52 Tachometer 53 Multi function meter 54 Oil pressure warning light 56 Coolant temperature warning light 58 Turn signal indicator light left 59 Turn signal indicator light right 61 Horn 62 Gear...

Страница 58: ...trol unit ignition signaling system backup 2 backup and main Refer to CHECKING THE FUS ES on page 81 Replace the fuse s 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 8 Manu...

Страница 59: ...switch Refer to CHECKING THE SWITCHES in chapter 8 Manual No B34 F8197 E2 Replace the front brake light switch 2 Check the rear brake light switch Refer to CHECKING THE SWITCHES in chapter 8 Manual N...

Страница 60: ...entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 49 Properly connect or replace the wiring har ness Replace the meter assembly 1 Check the gear position switch Refer to CHECKING THE GE...

Страница 61: ...IRCUIT DIAGRAM on page 49 Properly connect or replace the wiring har ness 2 Measure the engine oil pressure Refer to MEASURING THE EN GINE OIL PRESSURE in chapter 3 Manual No B34 F8197 E2 Check the en...

Страница 62: ...RAM on page 49 Properly connect or replace the wiring har ness Replace the ECU or meter assembly Refer to REPLACING THE ECU en gine control unit in chapter 8 Manu al No B34 F8197 E2 1 Check the rear w...

Страница 63: ...SIGNALING SYSTEM 56...

Страница 64: ...Dg B B Y Y G G L R L R Ch Ch B Dg B Ch L R G Y B B B B B B B B L R L L L R L R L B L B L R L R L B L B R Br L R W Br L Br R Br R B W R G Y L G B R W W W W B R B R R L W R W B Br Y B B Y L R R W L W R...

Страница 65: ...ator fan motor fuse 15 Battery 16 Engine ground 18 Main fuse 25 Joint coupler 36 ECU Engine Control Unit 38 Coolant temperature sensor 83 Radiator fan motor 84 Radiator fan motor relay A Wire harness...

Страница 66: ...4 F8197 E2 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES in chapter 8 Manual No B34 F8197 E2 Replace the main switch immobilizer un...

Страница 67: ...7 Check the entire cooling system wiring Refer to CIRCUIT DIAGRAM on page 57 Properly connect or replace the wiring har ness Replace the ECU Refer to REPLAC ING THE ECU engine control unit in chapter...

Страница 68: ...Y L Dg Dg B B Y Y G G L R L R Ch Ch B Dg B Ch L R G Y B B B B B B B B L R L L L R L R L B L B L R L R L B L B R Br L R W Br L Br R Br R B W R G Y L G B R W W W W B R B R R L W R W B Br Y B B Y L R R W...

Страница 69: ...ector 2 35 ISC Idle Speed Control unit 36 ECU Engine Control Unit 37 Intake air temperature sensor 38 Coolant temperature sensor 39 Intake air pressure sensor 40 Lean angle sensor 42 Rear wheel sensor...

Страница 70: ...oupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or bro ken terminals and locking condition of the pins Improperly connected Connect the coupler securel...

Страница 71: ...the malfunction mode of the Yamaha diagnostic tool Condition is Recover Go to item 7 and finish the ser vice Condition is Malfunction Go to item 6 6 Malfunction in ECU Replace the ECU Refer to REPLACI...

Страница 72: ...and ECU coupler gray gray black blue black blue Crank the engine and then check the condition of the fault code using the malfunc tion mode of the Yamaha di agnostic tool Condition is Recover Go to i...

Страница 73: ...mal signals are received from the crankshaft position sensor Fault code No P2195 Item O2 sensor Open circuit detected Fail safe system Able to start engine Able to drive vehicle Diagnostic code No Too...

Страница 74: ...eplace the wire harness Start the engine and let it idle for approximately 10 sec onds Check the condition of the fault code using the malfunc tion mode of the Yamaha di agnostic tool Condition is Rec...

Страница 75: ...Manual No B34 F8197 E2 Start the engine and let it idle for approximately 10 sec onds Check the condition of the fault code using the malfunc tion mode of the Yamaha di agnostic tool Condition is Rec...

Страница 76: ...Connection of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or bro ken terminals and locking condition of the pins Improperly connected Connect...

Страница 77: ...ervice is finished 6 Delete the fault code and check that the engine trouble warning light goes off Confirm that the fault code has a condition of Recover using the Yamaha diagnostic tool and then del...

Страница 78: ...R G Y L Dg Dg B B Y Y G G L R L R Ch Ch B Dg B Ch L R G Y B B B B B B B B L R L L L R L R L B L B L R L R L B L B R Br L R W Br L Br R Br R B W R G Y L G B R W W W W B R B R R L W R W B Br Y B B Y L...

Страница 79: ...em 15 Battery 16 Engine ground 18 Main fuse 21 Rear brake light switch 25 Joint coupler 36 ECU Engine Control Unit 41 Front wheel sensor 42 Rear wheel sensor 43 ABS ECU electronic control unit 44 Yama...

Страница 80: ...KE SYSTEM 73 EAS30990 ABS COUPLER LOCATION CHART 2 5 3 1 4 W B Gy W Gy W W B L R L B R W B G R G W L R L B Sb W Y Dg Ch G R Gy O W R Y W P W R W R G G B B W Gy B W B W Y W G G R Y G G B L Br W B L R L...

Страница 81: ...ABS ANTI LOCK BRAKE SYSTEM 74 1 ABS ECU coupler 2 Rear wheel sensor coupler 3 Yamaha diagnostic tool coupler 4 Meter assembly coupler 5 Front wheel sensor coupler...

Страница 82: ...ar ness between the front wheel sensor and the hydraulic unit assembly Check for continuity between the black terminal 1 and the black terminal 4 and between the white terminal 2 and the white termina...

Страница 83: ...use Check or maintenance job Fault code No 63 Item Front wheel sensor power supply voltage of power supply is low Symptom Power voltage supplied from the ABS ECU to the front wheel sensor is too low O...

Страница 84: ...eel sensor 3 Defective hydraulic unit assembly Replace the hydraulic unit assembly Refer to ABS ANTI LOCK BRAKE SYSTEM in chapter 4 Manual No B34 F8197 E2 Fault code No 63 Item Front wheel sensor powe...

Страница 85: ...ABS ANTI LOCK BRAKE SYSTEM 78...

Страница 86: ...ELECTRICAL COMPONENTS 79 EAS20089 ELECTRICAL COMPONENTS 1 2 3 4 5 5 6 7 8 9 11 12 13 14 10 15 16 17 18...

Страница 87: ...switch 4 Rectifier regulator 5 Ignition coil 6 Battery 7 Fuse box 1 8 Fuse box 2 9 Main fuse 10 Starter relay 11 Rear brake light switch 12 Sidestand switch 13 O2 sensor 14 Gear position switch 15 Oi...

Страница 88: ...eck the electrical circuit WARNING EWA13310 Never use a fuse with an amperage rating other than that specified Improvising or us ing a fuse with the wrong amperage rating may cause extensive damage to...

Страница 89: ...ELECTRICAL COMPONENTS 82...

Страница 90: ...cator light right 60 ABS warning light 61 Horn 62 Gear position switch 63 Handlebar switch right 64 Front brake light switch 65 Hazard switch 66 Start engine stop switch 67 Turn signal hazard relay 68...

Страница 91: ......

Страница 92: ......

Страница 93: ...R R R R R R Lg R W G B R G Y L Dg Dg B B Y Y G G L R L R Ch Ch B Dg B Ch L R G Y B B B B B B B B L R L L L R L R L B L B L R L R L B L B R Br L R W Br L Br R Br R B W R G Y L G B R W W W W B R B R R...

Страница 94: ...D D D D D D A E B B B B B B L B B B B B B B B Gy Gy B B B B B B B B B Gy Gy B B B O B B Gy B B B B B B Gy Gy Gy Gy B B B Y Y B B B 1 2 3 6 5 4 7 8 9 17 13 14 15 16 18 19 20 21 22 23 24 25 25 26 25 27...

Страница 95: ...L W L R R R R R R R Lg R W G B R G Y L Dg Dg B B Y Y G G L R L R Ch Ch B Dg B Ch L R G Y B B B B B B B B L R L L L R L R L B L B L R L R L B L B R Br L R W Br L Br R Br R B W R G Y L G B R W W W W B R...

Страница 96: ...A A B A D D D D D D A E B B B B B B L B B B B B B B B Gy Gy B B B B B B B B B Gy Gy B B B O B B Gy B B B B B B Gy Gy Gy Gy B B B Y Y B B B 1 2 3 6 5 4 7 8 9 17 13 14 15 16 18 19 20 21 22 23 24 25 25...

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