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Yamaha 2SCL Service Manual

Summary of 2SCL

  • Page 1

    2017 service manual mt09tra mt09trah 2sc-28197-e0

  • Page 3

    Eas20002 mt09tra/mt09trah service manual ©2016 by yamaha motor co., ltd. First edition, november 2016 all rights reserved. Any reproduction or unauthorized use without the written permission of yamaha motor co., ltd. Is expressly prohibited..

  • Page 4: Important

    Eas20003 important this manual was produced by the yamaha motor company, ltd. Primarily for use by yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one man- ual. Therefore, anyone who uses this book to perform maintenance and repairs on y...

  • Page 5: How to Use This Manual

    Eas20004 how to use this manual this manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. • the manual is di...

  • Page 6: Symbols

    Eas20005 symbols the following symbols are used in this manual for easier understanding. Tip the following symbols are not relevant to every vehicle. Symbol definition symbol definition serviceable with engine mounted gear oil filling fluid molybdenum disulfide oil lubricant brake fluid special tool...

  • Page 7: General Information

    General information 1 specifications 2 periodic checks and adjustments 3 chassis 4 engine 5 cooling system 6 fuel system 7 electrical system 8 troubleshooting 9 eas10003 table of contents.

  • Page 9: General Information

    1 2 3 4 5 6 7 8 9 general information identification..............................................................................................1-1 vehicle identification number ......................................................1-1 model label......................................................

  • Page 10: Identification

    Identification 1-1 eas20007 identification eas30002 vehicle identification number the vehicle identification number “1” is stamped into the right side of the steering head pipe. Eas30003 model label the model label “1” is affixed to the battery box under the passenger seat. This information will be ...

  • Page 11: Features

    Features 1-2 eas20008 features eas30852 ycc-t (yamaha chip controlled throttle) mechanism characteristics yamaha developed the ycc-t system employing the most advanced electronic control technologies. Electronic control throttle systems have been used on automobiles, but yamaha has developed a fast-...

  • Page 12: Features

    Features 1-3 ycc-t system outline 5 6 7 8 9 3 2 1 4 1. Throttle position sensor 2. Throttle servo motor 3. Accelerator position sensor 4. Ecu (engine control unit) 5. Sensor input 6. Gear position switch 7. Crankshaft position sensor 8. Rear wheel sensor 9. Coolant temperature sensor.

  • Page 13: Features

    Features 1-4 eas30855 outline of the tcs (traction control system) the traction control system controls excessive spinning (slipping) of the rear wheel when accelerating on slippery surfaces, such as unpaved or wet roads. The ecu monitors the front and rear wheel speeds using the signals from the fr...

  • Page 14: Features

    Features 1-5 tcs (traction control system) block diagram the signals from the front and rear wheel sensors are sent to the ecu through the abs ecu, and the ecu calculates the amount of slip according to the difference between the detected front and rear wheel speeds. If the amount of slip exceeds th...

  • Page 15: Features

    Features 1-6 traction control system the traction control system (tcs) helps maintain traction when accelerating on slippery surfaces, such as unpaved or wet roads. If sensors detect that the rear wheel is starting to slip (uncontrolled spinning), the traction control system assists by regulating en...

  • Page 16: Features

    Features 1-7 tcs settings can be changed only when the vehicle is stopped and the throttle closed. • push the “tcs” button to change between tcs settings “1” and “2”. • push the button for two seconds to turn the traction control system off. • push the button again to turn traction control back on (...

  • Page 17: Features

    Features 1-8 eas30682 instrument functions multi-function meter unit the multi-function meter unit is equipped with the following: • a speedometer • a tachometer • a clock • a fuel meter • an eco indicator • a transmission gear display • a drive mode display • a tcs display • an information display ...

  • Page 18: Features

    Features 1-9 notice eca20410 do not operate the engine in the tachometer high-rpm zone. Clock the clock displays time in 12-hour format. To set the clock, refer to “setting the clock”. Fuel meter the fuel meter indicates the amount of fuel in the fuel tank. The display segments of the fuel meter dis...

  • Page 19: Features

    Features 1-10 drive mode display the drive mode display indicates which drive mode has been selected: “std”, “a” or “b”. For more details on the modes and on how to select them, refer to “d-mode (drive mode)” on page 1-16. Tcs display this display indicates which traction control sys- tem setting ha...

  • Page 20: Features

    Features 1-11 to reset a tripmeter, use the select switch to dis- play the tripmeter you want to reset. Then push the “reset” button briefly so that the tripmeter flashes, and then push the “reset” button again for two seconds. Tip • the odometer will lock at 999999. • the tripmeters will reset and ...

  • Page 21: Features

    Features 1-12 tip the selected information display cannot be switched while the message “hi” is flashing. Notice eca10022 do not continue to operate the engine if it is overheating. Average fuel consumption this function calculates the average fuel con- sumption (fuel economy) of the vehicle since i...

  • Page 22: Features

    Features 1-13 resetting the maintenance counters 1. Use the select switch to highlight “mainte- nance”. 2. Push the menu switch, and then push the “reset” button to select the item to reset. 3. While the selected item is flashing, push the “reset” button for 2 seconds. 4. Push the menu switch to ret...

  • Page 23: Features

    Features 1-14 2. Push the menu switch. The unit setting dis- play will be shown. Tip • when kilometers are already selected, “km/l or l/100km” will flash in the display. • when miles are already selected, “km or mile” will flash in the display. Tip • keep kilometers selected: skip to step 5. • selec...

  • Page 24: Features

    Features 1-15 4. Use the select switch to select the item you want to display, and then push the menu switch. 5. When you are finished changing the settings, use the select switch to highlight “ ”, and then push the menu switch to return to the previ- ous display. 6. Use the select switch to highlig...

  • Page 25: Features

    Features 1-16 4. Push the menu switch, and the minute digits start flashing. 5. Use the select switch to set the minutes. 6. Push the menu switch to return to the setting mode menu. Resetting all of the display items 1. Use the select switch to highlight “all reset”. 2. Push the menu switch. 3. Use ...

  • Page 26: Important Information

    Important information 1-17 eas20009 important information eas30006 preparation for removal and disassembly 1. Before removal and disassembly, remove all dirt, mud, dust and foreign material. 2. Use only the proper tools and cleaning equip- ment. Refer to “special tools” on page 1-24. 3. When disasse...

  • Page 27: Important Information

    Important information 1-18 when installing oil seals, lubricate the oil seal lips with a light coat of lithium-soap-based grease. Oil bearings liberally when installing, if appropriate. Notice eca13300 do not spin the bearing with compressed air because this will damage the bearing surfac- es. Eas30...

  • Page 28: Basic Service Information

    Basic service information 1-19 eas20010 basic service information eas30013 quick fasteners rivet type 1. Remove: • quick fastener tip to remove the quick fastener, push its pin with a screwdriver, then pull the fastener out. 2. Install: • quick fastener tip to install the quick fastener, push its pi...

  • Page 29: Basic Service Information

    Basic service information 1-20 eas30014 electrical system electrical parts handling notice eca16600 never disconnect a battery lead while the en- gine is running; otherwise, the electrical components could be damaged. Notice eca16751 when disconnecting the battery leads from the battery, be sure to ...

  • Page 30: Basic Service Information

    Basic service information 1-21 notice eca16610 turn the main switch to “off” before dis- connecting or connecting an electrical com- ponent. Notice eca16620 handle electrical components with special care, and do not subject them to strong shocks. Notice eca16630 electrical components are very sensit...

  • Page 31: Basic Service Information

    Basic service information 1-22 notice eca16640 for waterproof couplers, never insert the tester probes directly into the coupler. When performing any checks using a waterproof coupler, use the specified test harness or a suitable commercially available test har- ness. Checking the connections check ...

  • Page 32: Basic Service Information

    Basic service information 1-23 • make sure all connections are tight. 4. Check: • continuity (with the digital circuit tester) tip • if there is no continuity, clean the terminals. • when checking the wire harness, perform steps (1) to (3). • as a quick remedy, use a contact revitalizer available at...

  • Page 33: Special Tools

    Special tools 1-24 eas20012 special tools the following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools, part numbers o...

  • Page 34: Special Tools

    Special tools 1-25 vacuum gauge 90890-03094 vacuummate yu-44456 3-9 carburetor angle driver 2 90890-03173 3-10 steering nut wrench 90890-01403 exhaust flange nut wrench yu-a9472 3-20, 4-89 oil filter wrench 90890-01426 oil filter wrench yu-38411 3-25 pressure gauge 90890-03153 pressure gauge yu-0315...

  • Page 35: Special Tools

    Special tools 1-26 rod holder 90890-01434 damper rod holder double ended ym-01434 4-79, 4-84, 4-85 damper rod holder (ø27) 90890-01582 damper rod holder ym-01582 4-80, 4-82 fork seal driver 90890-01442 adjustable fork seal driver (36–46 mm) ym-01442 4-82, 4-83 rod puller 90890-01437 universal dampin...

  • Page 36: Special Tools

    Special tools 1-27 drive chain cut & rivet tool 90890-01550 drive chain cut & rivet tool ym-01550 4-99, 4-101 compression gauge 90890-03081 engine compression tester yu-33223 5-1 extension 90890-04136 5-1 pivot shaft wrench 90890-01485 frame mount insert wrench ym-01485 5-7 pivot shaft wrench 90890-...

  • Page 37: Special Tools

    Special tools 1-28 valve spring compressor 90890-04019 valve spring compressor ym-04019 5-23, 5-28 valve spring compressor attachment 90890-04179 valve spring compressor adapter 23 mm ym-04179 5-23, 5-28 valve guide remover (ø4.5) 90890-04116 valve guide remover (4.5 mm) ym-04116 5-25 valve guide in...

  • Page 38: Special Tools

    Special tools 1-29 universal clutch holder 90890-04086 universal clutch holder ym-91042 5-42, 5-46 piston pin puller set 90890-01304 piston pin puller yu-01304 5-62 piston installing tool 90890-04161 piston installing tool ym-04161 5-69 radiator cap tester 90890-01325 mityvac cooling system tester k...

  • Page 39: Special Tools

    Special tools 1-30 radiator cap tester adapter 90890-01352 pressure tester adapter yu-33984 6-2 mechanical seal installer 90890-04078 water pump seal installer ym-33221-a 6-11 middle driven shaft bearing driver 90890-04058 middle drive bearing installer 40 & 50 mm ym-04058 6-11 fuel injector pressur...

  • Page 40: Special Tools

    Special tools 1-31 test harness– lean angle sensor (6p) 90890-03209 test harness– lean angle sensor (6p) yu-03209 8-165 test harness s– pressure sensor (3p) 90890-03207 test harness s– pressure sensor (3p) yu-03207 8-172 tool name/tool no. Illustration reference pages.

  • Page 41: Specifications

    1 2 3 4 5 6 7 8 9 specifications general specifications..........................................................................2-1 engine specifications .............................................................................2-2 chassis specifications ............................................

  • Page 42: General Specifications

    General specifications 2-1 eas20013 general specifications model model 2scl (mt09tra_eur/hrv/tur/zaf) 2scm (mt09trah) 2sct (mt09tra_rus) dimensions overall length 2160 mm (85.0 in) overall width 950 mm (37.4 in) overall height 1345/1375 mm (53.0/54.1 in) seat height 845/860 mm (33.3/33.9 in) wheelba...

  • Page 43: Engine Specifications

    Engine specifications 2-2 eas20014 engine specifications engine combustion cycle 4-stroke cooling system liquid cooled valve train dohc displacement 847 cm³ cylinder arrangement inline number of cylinders 3-cylinder bore  stroke 78.0  59.1 mm (3.07  2.33 in) compression ratio 11.5 : 1 compression...

  • Page 44: Engine Specifications

    Engine specifications 2-3 water pump water pump type single suction centrifugal pump impeller shaft tilt limit 0.15 mm (0.006 in) spark plug(s) manufacturer/model ngk/cpr9ea9 spark plug gap 0.8–0.9 mm (0.031–0.035 in) cylinder head warpage limit 0.10 mm (0.0039 in) camshaft camshaft cap inside diame...

  • Page 45: Engine Specifications

    Engine specifications 2-4 wear limit 78.060 mm (3.0732 in) piston diameter 77.975–77.990 mm (3.0699–3.0705 in) measuring point (from piston skirt bottom) 12.0 mm (0.47 in) piston-to-cylinder clearance 0.010–0.035 mm (0.0004–0.0014 in) piston pin bore inside diameter 17.002–17.013 mm (0.6694–0.6698 i...

  • Page 46: Engine Specifications

    Engine specifications 2-5 clutch clutch type wet, multiple-disc clutch lever free play 10.0–15.0 mm (0.39–0.59 in) friction plate 1 thickness 2.92–3.08 mm (0.115–0.121 in) wear limit 2.82 mm (0.111 in) plate quantity 3 pcs friction plate 2 thickness 2.92–3.08 mm (0.115–0.121 in) wear limit 2.82 mm (...

  • Page 47: Engine Specifications

    Engine specifications 2-6 idling condition engine idling speed 1100–1300 r/min ai system inactive o 2 feedback control inactive exhaust gas sampling point sampling port on the exhaust pipe to be measured coolant temperature temperature 90–110 c (194–230 f) co% 1.5–3.5 % difference in vacuum pressu...

  • Page 48: Chassis Specifications

    Chassis specifications 2-7 eas20015 chassis specifications chassis frame type diamond caster angle 24.0 trail 100 mm (3.9 in) front wheel wheel type cast wheel rim size 17m/c x mt3.50 rim material aluminum radial wheel runout limit 1.0 mm (0.04 in) lateral wheel runout limit 0.5 mm (0.02 in) rear wh...

  • Page 49: Chassis Specifications

    Chassis specifications 2-8 brake disc runout limit (as measured on wheel) 0.15 mm (0.0059 in) brake pad lining thickness 6.0 mm (0.24 in) limit 1.0 mm (0.04 in) master cylinder inside diameter 12.7 mm (0.50 in) caliper cylinder inside diameter 38.18 mm (1.50 in) specified brake fluid dot 4 front sus...

  • Page 50: Chassis Specifications

    Chassis specifications 2-9 adjustment value from the start position (hard) 0 drive chain size did525v10 chain type sealed type number of links 110 drive chain slack 5.0–15.0 mm (0.20–0.59 in) 15-link length limit 239.3 mm (9.42 in).

  • Page 51: Electrical Specifications

    Electrical specifications 2-10 eas20016 electrical specifications voltage system voltage 12 v ignition system ignition system tci advancer type digital ignition timing (b.T.D.C.) 5.0 1200 r/min engine control unit model tbdf0c (mt09trah) tbdfz7 (mt09tra) ignition coil primary coil resistance 1.19–...

  • Page 52: Electrical Specifications

    Electrical specifications 2-11 starter motor power output 0.70 kw armature coil resistance 0.0050–0.0150  brush overall length 12.0 mm (0.47 in) limit 6.50 mm (0.26 in) brush spring force 6.03–6.52 n (615–665 gf, 21.71–23.47 oz) mica undercut (depth) 0.70 mm (0.03 in) oil level switch oil level swi...

  • Page 53: Tightening Torques

    Tightening torques 2-12 eas20017 tightening torques eas30015 general tightening torque specifications this chart specifies tightening torques for stan- dard fasteners with a standard iso thread pitch. Tightening torque specifications for special com- ponents or assemblies are provided for each chapt...

  • Page 54: Tightening Torques

    Tightening torques 2-13 eas30016 engine tightening torques eas30017 chassis tightening torques item thread size q’ty tightening torque remarks exhaust pipe nut m8 6 20 n·m (2.0 kgf·m, 14 lb·ft) muffler protector bolt m6 3 10 n·m (1.0 kgf·m, 7.2 lb·ft) spark plug m10 3 13 n·m (1.3 kgf·m, 9.4 lb·ft) c...

  • Page 55: Tightening Torques

    Tightening torques 2-14 tip lower ring nut 1. Tighten the ring nut to approximately 52 n·m (5.2 kgf·m, 38 lb·ft) with a torque wrench, then loosen the lower ring nut completely. 2. Tighten the lower ring nut to 18 n·m (1.8 kgf·m, 13 lb·ft). Drive sprocket nut m22 1 95 n·m (9.5 kgf·m, 69 lb·ft) stake...

  • Page 56: 2-15

    Lubrication points and lubricant types 2-15 eas20018 lubrication points and lubricant types eas30018 engine lubrication point lubricant oil seal lips o-rings coolant hose insertion part water or bearing cylinder head cover bolt gasket and timing chain bolt gasket camshaft lobes and journals (intake ...

  • Page 57: 2-16

    Lubrication points and lubricant types 2-16 eas30019 chassis clutch boss conical washer transmission gears inner surface transmission collar transmission gears outer surface (shift fork contact parts) drive sprocket washer shift drum moving surface shift fork pin shift forks guide bar outer surface ...

  • Page 58: 2-17

    Lubrication points and lubricant types 2-17 front wheel oil seal (left and right) rear wheel oil seal rear wheel drive hub oil seal rear wheel drive hub mating surface brake caliper piston seal master cylinder inside brake caliper piston dust seal brake caliper bolts lubrication point lubricant ls l...

  • Page 59: 2-18

    Lubrication points and lubricant types 2-18.

  • Page 60: 2-19

    Lubrication system chart and diagrams 2-19 eas20019 lubrication system chart and diagrams eas30020 engine oil lubrication chart 1 3 4 5 11 12 13 13 14 15 16 17 13 7 8 9 10 10 10 10 6 2.

  • Page 61: 2-20

    Lubrication system chart and diagrams 2-20 1. Oil strainer 2. Oil pump 3. Relief valve 4. Oil cooler 5. Oil filter cartridge 6. Main gallery 7. Drive axle 8. Main axle 9. Shift fork (upper) 10.Mission shower 11.Crankshaft 12.Ac magneto 13.Oil nozzle 14.Balancer shaft 15.Timing chain tensioner 16.Int...

  • Page 62: 2-21

    Lubrication system chart and diagrams 2-21 eas30021 lubrication diagrams 1 2 3 4.

  • Page 63: 2-22

    Lubrication system chart and diagrams 2-22 1. Oil level switch 2. Oil filter cartridge union bolt 3. Oil filter cartridge 4. Crankshaft.

  • Page 64: 2-23

    Lubrication system chart and diagrams 2-23 4 7 7 8 9 5 6 2 3 1.

  • Page 65: 2-24

    Lubrication system chart and diagrams 2-24 1. Timing chain tensioner 2. Intake camshaft 3. Exhaust camshaft 4. Balancer shaft 5. Crankshaft 6. Oil cooler 7. Oil strainer 8. Oil drain bolt 9. Oil pump driven sprocket.

  • Page 66: 2-25

    Lubrication system chart and diagrams 2-25 4 5 6 2 3 1.

  • Page 67: 2-26

    Lubrication system chart and diagrams 2-26 1. Oil cooler 2. Oil filter cartridge 3. Oil level switch 4. Oil strainer 5. Oil pump 6. Main gallery bolt.

  • Page 68: 2-27

    Lubrication system chart and diagrams 2-27 6 5 3 2 7 4 1.

  • Page 69: 2-28

    Lubrication system chart and diagrams 2-28 1. Balancer shaft 2. Crankshaft 3. Main axle 4. Shift fork guide bar (shift fork-c side) 5. Drive axle 6. Sub gallery bolt 7. Shift fork.

  • Page 70: 2-29

    Lubrication system chart and diagrams 2-29 9 8 7 6 3 3 2 5 4 1.

  • Page 71: 2-30

    Lubrication system chart and diagrams 2-30 1. Cylinder head 2. Exhaust camshaft 3. Intake camshaft 4. Oil passage to the timing chain tensioner 5. Oil passage to the cylinder head 6. Oil passage to the clutch chamber 7. Oil return passage from the cylinder head 8. Crankshaft 9. Main gallery.

  • Page 72: Cooling System Diagrams

    Cooling system diagrams 2-31 eas20020 cooling system diagrams 1 1 2 3.

  • Page 73: Cooling System Diagrams

    Cooling system diagrams 2-32 1. Water pump 2. Thermostat 3. Radiator.

  • Page 74: Cooling System Diagrams

    Cooling system diagrams 2-33 1 2 3 4 5 6.

  • Page 75: Cooling System Diagrams

    Cooling system diagrams 2-34 1. Water jacket 2. Thermostat 3. Radiator 4. Water pump 5. Oil cooler 6. Coolant reservoir.

  • Page 76: Cable Routing

    Cable routing 2-35 eas20021 cable routing handlebar (top view).

  • Page 77: Cable Routing

    Cable routing 2-36 1. Front brake master cylinder 2. Throttle cable 3. Rubber cover 4. Handlebar 5. Front brake light switch connector 6. Front brake light switch 7. Front brake hose a. When installing the rubber cover, silicone water or soapy water may be applied to the inside of the rubber cover. ...

  • Page 78: Cable Routing

    Cable routing 2-37 handlebar (front view).

  • Page 79: Cable Routing

    Cable routing 2-38 1. Throttle cable 2. Clutch cable 3. Handlebar switch lead (left) 4. Main switch lead/immobilizer lead 5. Steering stopper 6. Horn lead 7. Handlebar switch lead (right) 8. Front brake hose a. Fasten the handlebar switch lead (right) onto the handlebar with the clamp. Face the catc...

  • Page 80: Cable Routing

    Cable routing 2-39 radiator (front side view and right side view).

  • Page 81: Cable Routing

    Cable routing 2-40 1. Radiator cap 2. Radiator 3. Radiator fan 4. Radiator outlet hose 5. Thermostat assembly 6. Water jacket joint 7. Coolant reservoir 8. Radiator inlet hose a. Install the radiator outlet hose with its white paint mark facing inward. B. Install the radiator outlet hose up to the b...

  • Page 82: Cable Routing

    Cable routing 2-41 fuel tank (left and bottom view).

  • Page 83: Cable Routing

    Cable routing 2-42 1. Frame 2. Fuel tank 3. Fuel pump 4. Fuel tank drain hose 5. Clip 6. Fuel hose assembly a. Insert the fuel tank drain hose up to the sec- tion where the fuel tank pipe increases in diameter. Install it so that the white paint mark faces the rearward. Position the hose so that its...

  • Page 84: Cable Routing

    Cable routing 2-43 canister (top view and left side view).

  • Page 85: Cable Routing

    Cable routing 2-44 1. Frame 2. Clamp 3. Canister 4. Canister holder 5. Canister breather hose 6. Fuel tank drain hose 7. Fuel tank breather hose 8. Canister purge hose 9. Fuel tank 10.Rear shock absorber assembly 11.Canister bracket a. Front side of the vehicle b. Right side of the vehicle c. Face t...

  • Page 86: Cable Routing

    Cable routing 2-45 air filter case and throttle body (top view and left side view).

  • Page 87: Cable Routing

    Cable routing 2-46 1. Air filter case joint clamp 2. Ecu (engine control unit) 3. Air filter case 4. Throttle body 5. Clip 6. Cylinder head breather hose 7. Throttle cable (decelerator cable) (white plat- ing) 8. Throttle cable (accelerator cable) (black plat- ing) 9. Injector lead 10.Injector coupl...

  • Page 88: Cable Routing

    Cable routing 2-47 air cut-off valve (left side view).

  • Page 89: Cable Routing

    Cable routing 2-48 1. Radiator fan cover 2. Air filter case 3. Clip 4. Air induction system hose (air filter case to air cut-off valve) 5. Air induction system hose (air cut-off valve to reed valve cover #1) 6. Air induction system hose (air cut-off valve to reed valve cover #2/#3) 7. Air cut-off va...

  • Page 90: Cable Routing

    Cable routing 2-49 frame and engine (right side view).

  • Page 91: Cable Routing

    Cable routing 2-50 1. Clamp 2. Rear brake light switch lead 3. O 2 sensor coupler 4. Radiator fan motor coupler 5. Handlebar switch coupler (right) 6. Inner panel 7. Front right turn signal light coupler 8. Fuse box 1 9. Front turn signal light lead (right) 10.Bracket 11.Fuse box 2 12.Coupler cover ...

  • Page 92: Cable Routing

    Cable routing 2-51 frame and engine (right side view).

  • Page 93: Cable Routing

    Cable routing 2-52 1. Guide 2. Wire harness 3. Pipe (headlight stay) 4. Clamp 5. Frame 6. Auxiliary dc jack coupler (color: natural) 7. Auxiliary dc jack coupler (color: black) 8. Auxiliary dc jack lead 9. Auxiliary light lead 10.Coupler cover 11.Auxiliary light coupler 12.Throttle cable 13.Wire har...

  • Page 94: Cable Routing

    Cable routing 2-53 frame and engine (left side view).

  • Page 95: Cable Routing

    Cable routing 2-54 1. Air induction system hose (air filter case to air cut-off valve) 2. Air filter case 3. Throttle cables 4. Stator coil assembly lead 5. Clamp 6. Positive battery lead 7. Starter motor lead 8. Stator coil lead 9. Wire harness (to rectifier/regulator) 10.Gear position switch lead ...

  • Page 96: Cable Routing

    Cable routing 2-55 frame (top view).

  • Page 97: Cable Routing

    Cable routing 2-56 1. Injector #1 coupler 2. Injector #2 coupler 3. Clamp 4. Ignition coil #1 coupler 5. Ignition coil #2 coupler 6. Air cut-off valve coupler 7. Ignition coil #3 coupler 8. Injector #3 coupler 9. Throttle position sensor coupler 10.Throttle servo motor coupler 11.Cross tube 12.Accel...

  • Page 98: Cable Routing

    Cable routing 2-57 frame (top view).

  • Page 99: Cable Routing

    Cable routing 2-58 1. Stator coil assembly lead 2. Oil level switch coupler 3. Rear brake light switch coupler 4. Sidestand switch coupler 5. Gear position switch coupler 1 6. Gear position switch coupler 2 7. Negative battery lead coupler 8. Lean angle sensor 9. Starter motor lead 10.Negative batte...

  • Page 100: Cable Routing

    Cable routing 2-59 frame (top view).

  • Page 101: Cable Routing

    Cable routing 2-60 1. Rear wheel sensor coupler 2. Negative battery lead coupler 3. Positive battery terminal 4. Negative battery lead 5. Radiator fan motor relay 6. Negative battery terminal 7. Fuse box 8. Relay unit 9. Turn signal/hazard relay 10.Clamp 11.Rear turn signal light coupler (left/right...

  • Page 102: Cable Routing

    Cable routing 2-61 front brake (right side view and left side view).

  • Page 103: Cable Routing

    Cable routing 2-62 1. Front brake hose assembly 1 2. Front wheel sensor lead 3. Clamp 4. Bracket 5. Brake caliper (right) 6. Front fender 7. Reflector (left and right) 8. Brake caliper (left) 9. Clamp 10.Clamp a. Make sure that the bracket has contact with the axle bracket, and install it. B. Instal...

  • Page 104: Cable Routing

    Cable routing 2-63 rear brake.

  • Page 105: Cable Routing

    Cable routing 2-64 1. Brake fluid reservoir 2. Rear frame 3. Rear frame (welded portion) 4. Rear brake master cylinder 5. Rear wheel sensor 6. Rear wheel sensor lead 7. Rear brake caliper 8. Rear brake hose 9. Clamp 10.Brake fluid reservoir hose 11.Swingarm assembly a. Install the clamp on the brake...

  • Page 106: Cable Routing

    Cable routing 2-65 hydraulic unit (top view and left side view).

  • Page 107: Cable Routing

    Cable routing 2-66 1. Wire harness 2. Battery box 3. Brake hose (front brake master cylinder to hydraulic unit) 4. Brake hose (hydraulic unit to front brake cali- pers) 5. Brake hose (rear brake master cylinder to hydraulic unit) 6. Brake hose (hydraulic unit to rear brake cali- per) 7. Plug 8. Rear...

  • Page 108: Cable Routing

    Cable routing 2-67.

  • Page 109

    1 2 3 4 5 6 7 8 9 periodic checks and adjustments periodic maintenance .............................................................................3-1 introduction ........................................................................................3-1 periodic maintenance chart for the emission...

  • Page 110

    Adjusting the rear shock absorber assembly...................3-23 checking the connecting arm and relay arm......................3-24 checking the engine oil level.....................................................3-24 changing the engine oil ..........................................................

  • Page 111: Periodic Maintenance

    Periodic maintenance 3-1 eas20022 periodic maintenance eas30022 introduction this chapter includes all information necessary to perform recommended checks and adjustments. If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a lon- ger service life and re...

  • Page 112: Periodic Maintenance

    Periodic maintenance 3-2 4 * front brake • check operation, fluid level, and for fluid leakage. • replace brake pads if neces- sary. 5 * rear brake • check operation, fluid level, and for fluid leakage. • replace brake pads if neces- sary. 6 * brake hoses • check for cracks or damage. • replace. Eve...

  • Page 113: Periodic Maintenance

    Periodic maintenance 3-3 tip • air filter • this model’s air filter is equipped with a disposable oil-coated paper element, which must not be cleaned with compressed air to avoid damaging it. • the air filter element needs to be replaced more frequently when riding in unusually wet or dusty areas. •...

  • Page 114: Periodic Maintenance

    Periodic maintenance 3-4 eas32024 checking the vehicle using the yamaha diagnostic tool use the yamaha diagnostic tool and check the vehicle according to the following procedure. 1. Remove: • rider seat/passenger seat refer to “general chassis (1)” on page 4-1. 2. Remove the protective cap “1”, and ...

  • Page 115: Periodic Maintenance

    Periodic maintenance 3-5 4-6. Eas30620 checking the spark plugs the following procedure applies to all of the spark plugs. 1. Remove: • fuel tank front cover/front side panel/front side cowling refer to “general chassis (2)” on page 4-6. • passenger seat/rider seat refer to “general chassis (1)” on ...

  • Page 116: Periodic Maintenance

    Periodic maintenance 3-6 refer to “general chassis (2)” on page 4-6. • passenger seat/rider seat refer to “general chassis (1)” on page 4-1. • fuel tank cover refer to “general chassis (3)” on page 4-13. • fuel tank refer to “fuel tank” on page 7-1. • air filter case refer to “general chassis (3)” o...

  • Page 117: Periodic Maintenance

    Periodic maintenance 3-7 d. To measure the valve clearances of the other cylinders, starting with cylinder #1 at tdc, turn the crankshaft counterclockwise as specified in the following table. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 5. Remove: • camshaft tip • refer to “camshafts” on page 5-9. • when removi...

  • Page 118: Periodic Maintenance

    Periodic maintenance 3-8 the following table, and then select the suit- able valve pad. Tip refer to the following table for the available valve pads. Example: valve pad number = 163 rounded value = 165 new valve pad number = 165 f. Install the new valve pad “1” and the valve lift- er “2”. Tip • lub...

  • Page 119: Periodic Maintenance

    Periodic maintenance 3-9 eas30797 synchronizing the throttle bodies tip before synchronizing the throttle bodies, check the following items: • valve clearance • spark plugs • air filter element • throttle body joints • fuel hose • exhaust system • breather hoses checking the throttle body synchroniz...

  • Page 120: Periodic Maintenance

    Periodic maintenance 3-10 dard. Otherwise, the engine may run roughly at idle and the throttle bodies may not oper- ate properly. Tip • turn the bypass air screw using the carburetor angle driver. • after each step, rev the engine two or three times, each time for less than a second, and check the s...

  • Page 121: Periodic Maintenance

    Periodic maintenance 3-11 3. Install: • fuel tank refer to “fuel tank” on page 7-1. • fuel tank cover refer to “general chassis (3)” on page 4-13. • rider seat/passenger seat refer to “general chassis (1)” on page 4-1. • front side cowling/front side panel/fuel tank front cover refer to “general cha...

  • Page 122: Periodic Maintenance

    Periodic maintenance 3-12 are riding in unusually wet or dusty areas. 4. Install: • air filter element • air filter case cover • ecu (engine control unit) notice eca20710 never operate the engine without the air filter element installed. Unfiltered air will cause rapid wear of engine parts and may d...

  • Page 123: Periodic Maintenance

    Periodic maintenance 3-13 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas30801 checking the brake operation 1. Check: • brake operation brake not working properly  check the brake system. Refer to “front brake” on page 4-35 and “rear brake” on page 4-48. Tip drive on the dry road, operate the front and rear b...

  • Page 124: Periodic Maintenance

    Periodic maintenance 3-14 tip • while pushing the brake lever forward, turn the adjusting dial “1” until the brake lever is in the desired position. • be sure to align the setting on the adjusting dial with the arrow mark “2” on the brake lever hold- er. Warning ewa17050 • after adjusting the brake ...

  • Page 125: Periodic Maintenance

    Periodic maintenance 3-15 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Adjust: • rear brake light switch refer to “adjusting the rear brake light switch” on page 3-29. Eas30634 checking the rear brake pads the following procedure applies to all of the brake pads. 1. Operate the brake. 2. Check: • rear brake ...

  • Page 126: Periodic Maintenance

    Periodic maintenance 3-16 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Fill the brake master cylinder reservoir or brake fluid reservoir to the proper level with the specified brake fluid. B. Install the diaphragm (brake master cylinder reservoir or brake fluid reservoir). C. Connect a clear plastic hose “1”...

  • Page 127: Periodic Maintenance

    Periodic maintenance 3-17 warning ewa13181 • the tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperature. • the tire pressure and the suspension must be adjusted according to the total weight (including cargo, rider, passenger and ac- cessories...

  • Page 128: Periodic Maintenance

    Periodic maintenance 3-18 eas30641 checking the wheel bearings the following procedure applies to all of the wheel bearings. 1. Check: • wheel bearings refer to “checking the front wheel” on page 4-21 and “checking the rear wheel” on page 4-31. Eas30802 checking the swingarm operation 1. Check: • sw...

  • Page 129: Periodic Maintenance

    Periodic maintenance 3-19 tip • to maintain the proper wheel alignment, adjust both sides evenly. • there should be no clearance between the ad- justing block and adjusting bolt. C. Tighten the wheel axle nut to specification. D. Tighten the locknuts to specification. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...

  • Page 130: Periodic Maintenance

    Periodic maintenance 3-20 c. Loosen the lower ring nut “6” completely, then tighten it to specification. Warning ewa13140 do not overtighten the lower ring nut. D. Check the steering head for looseness or binding by turning the front fork all the way in both directions. If any binding is felt, remov...

  • Page 131: Periodic Maintenance

    Periodic maintenance 3-21 2. Adjust: • installed shift rod length ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Loosen both locknuts “1”. B. Turn the shift rod “2” in direction “a” or “b” to obtain the correct shift pedal position. C. Tighten both locknuts. D. Make sure the installed shift rod length is withi...

  • Page 132: Periodic Maintenance

    Periodic maintenance 3-22 front fork legs. Warning ewa13120 securely support the vehicle so that there is no danger of it falling over. Spring preload warning ewa17040 always adjust both front fork legs evenly. Uneven adjustment can result in poor han- dling and loss of stability. Notice eca13590 ne...

  • Page 133: Periodic Maintenance

    Periodic maintenance 3-23 range. To obtain a precise adjustment, it would be advisable to check the number of clicks of each damping force adjusting mechanism and to modify the specifications as necessary. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas30808 checking the rear shock absorber assembly refer to “...

  • Page 134: Periodic Maintenance

    Periodic maintenance 3-24 ifications listed due to small differences in production. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas30809 checking the connecting arm and relay arm refer to “checking the connecting arm and relay arm” on page 4-92. Eas30656 checking the engine oil level 1. Stand the vehicle on a ...

  • Page 135: Periodic Maintenance

    Periodic maintenance 3-25 4. Drain: • engine oil (completely from the crankcase) 5. If the oil filter cartridge is also to be replaced, perform the following procedure. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the oil filter cartridge “1” with an oil filter wrench “2”. B. Lubricate the o-ring “3” ...

  • Page 136: Periodic Maintenance

    Periodic maintenance 3-26 warning ewa12980 the engine, muffler and engine oil are ex- tremely hot. 4. Install: • pressure gauge “1” • oil pressure adapter h “2” 5. Measure: • oil pressure (at the following conditions) out of specification  check. 6. Install: • main gallery bolt eas30811 checking th...

  • Page 137: Periodic Maintenance

    Periodic maintenance 3-27 • oil cooler “4” • oil cooler inlet hose “5” • oil cooler outlet hose “6” • water jacket joint “7” • water pump inlet hose “8” cracks/damage  replace. Refer to “radiator” on page 6-1, “oil cooler” on page 6-4, “thermostat” on page 6-6 and “water pump” on page 6-8. Eas30813...

  • Page 138: Periodic Maintenance

    Periodic maintenance 3-28 6. Drain: • coolant (from the engine and radiator) 7. Install: • water pump drain bolt • copper washer 8. Install: • collars • coolant reservoir • coolant reservoir cover • coolant reservoir bolt 9. Fill: • cooling system (with the specified amount of the recom- mended cool...

  • Page 139: Periodic Maintenance

    Periodic maintenance 3-29 eas30659 adjusting the rear brake light switch tip the rear brake light switch is operated by move- ment of the brake pedal. The rear brake light switch is properly adjusted when the brake light comes on just before the braking effect starts. 1. Check: • rear brake light op...

  • Page 140: Periodic Maintenance

    Periodic maintenance 3-30 tle body synchronization should be adjusted properly. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Slide back the rubber cover “1”. B. Loosen the locknut “2”. C. Turn the adjusting nut “3” in direction “a” or “b” until the specified throttle grip free play is ob- tained. D. Tighten ...

  • Page 141: Chassis

    1 2 3 4 5 6 7 8 9 chassis general chassis (1) ..................................................................................4-1 installing the seats..........................................................................4-4 general chassis (2) .....................................................

  • Page 142

    Assembling the front brake master cylinder ....................4-45 installing the front brake master cylinder.......................4-45 rear brake ................................................................................................4-48 introduction ........................................

  • Page 143

    Installing the relay arm...............................................................4-93 installing the rear shock absorber assembly ..................4-93 swingarm....................................................................................................4-95 removing the swingarm..........

  • Page 144: General Chassis (1)

    General chassis (1) 4-1 eas20026 general chassis (1) removing the seats and battery order job/parts to remove q’ty remarks 1 passenger seat 1 2 cap 1 3 rider seat 1 4 rider seat height position adjuster 1 5 battery band 1 6 negative battery lead 1 disconnect. 7 positive battery lead 1 disconnect. 8 ...

  • Page 145: General Chassis (1)

    General chassis (1) 4-2 removing the rear side covers order job/parts to remove q’ty remarks passenger seat/rider seat refer to “general chassis (1)” on page 4-1. Grab bar refer to “general chassis (1)” on page 4-1. 1 top cover 1 2 stay (right) 1 3 rear side cover (right) 1 4 seat lock bracket 1 5 s...

  • Page 146: General Chassis (1)

    General chassis (1) 4-3 removing the tail/brake light and mudguard assembly order job/parts to remove q’ty remarks passenger seat/rider seat refer to “general chassis (1)” on page 4-1. Grab bar refer to “general chassis (1)” on page 4-1. Rear side cover refer to “general chassis (1)” on page 4-1. 1 ...

  • Page 147: General Chassis (1)

    General chassis (1) 4-4 eas30125 installing the seats 1. Install: • rider seat height position adjuster “1” • rider seat “2” tip the rider seat height can be adjusted to one of two positions to suit the rider’s preference. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ to install the rider seat in the high positi...

  • Page 148: General Chassis (1)

    General chassis (1) 4-5 1 a b.

  • Page 149: General Chassis (2)

    General chassis (2) 4-6 eas20155 general chassis (2) removing the fuel tank front cover, front side panels and front side cowlings order job/parts to remove q’ty remarks 1 fuel tank front cover 1 2 front side panel (left) 1 3 turn signal light coupler (left) 1 disconnect. 4 front side cowling (left)...

  • Page 150: General Chassis (2)

    General chassis (2) 4-7 removing the headlight assembly and meter assembly order job/parts to remove q’ty remarks fuel tank front cover/front side panel/front side cowling refer to “general chassis (2)” on page 4-6. 1 windshield 1 2 front cover 1 3 support stay 1 4 inner panel 1 5 auxiliary light co...

  • Page 151: General Chassis (2)

    General chassis (2) 4-8 disassembling the headlight assembly order job/parts to remove q’ty remarks 1 headlight top cover (left) 1 2 headlight top cover (right) 1 3 headlight side cover (left) 1 4 headlight side cover (right) 1 5 center cover 1 6 headlight control unit coupler 1 disconnect. 7 headli...

  • Page 152: General Chassis (2)

    General chassis (2) 4-9 removing the headlight stay order job/parts to remove q’ty remarks fuel tank front cover/front side panel/front side cowling refer to “general chassis (2)” on page 4-6. Headlight assembly refer to “general chassis (2)” on page 4-6. Meter assembly refer to “general chassis (2)...

  • Page 153: General Chassis (2)

    General chassis (2) 4-10 eas31379 removing the fuel tank front cover 1. Remove: • fuel tank front cover “1” ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the quick fastener screws “2” and fuel tank front cover bolts “3”. B. Remove the fuel tank front cover “1” by slid- ing it rearward. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...

  • Page 154: General Chassis (2)

    General chassis (2) 4-11 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Remove: • front side cowling (right) “1” ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the front side cowling bolts “2”, front side cowling screw “3” and quick fastener screw “4”. B. Disengage portion “a”, and then remove the front side cowli...

  • Page 155: General Chassis (2)

    General chassis (2) 4-12 2. Install: • front side cowling (right) “1” ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Insert the slot “a” into the projection “b”, and then install the front side cowling as shown in the illustration. B. Install the quick fastener screw “2”, front side cowling screw “3” and front...

  • Page 156: General Chassis (3)

    General chassis (3) 4-13 eas20156 general chassis (3) removing the fuel tank covers and fuel tank protector order job/parts to remove q’ty remarks fuel tank front cover/front side panel/front side cowling refer to “general chassis (2)” on page 4-6. Passenger seat/rider seat refer to “general chassis...

  • Page 157: General Chassis (3)

    General chassis (3) 4-14 removing the electrical components tray (left) order job/parts to remove q’ty remarks fuel tank front cover/front side panel/front side cowling refer to “general chassis (2)” on page 4-6. Passenger seat/rider seat refer to “general chassis (1)” on page 4-1. Fuel tank cover r...

  • Page 158: General Chassis (3)

    General chassis (3) 4-15 removing the electrical components tray (right) order job/parts to remove q’ty remarks fuel tank front cover/front side panel/front side cowling refer to “general chassis (2)” on page 4-6. Passenger seat/rider seat refer to “general chassis (1)” on page 4-1. Fuel tank cover ...

  • Page 159: General Chassis (3)

    General chassis (3) 4-16 removing the air filter case order job/parts to remove q’ty remarks fuel tank front cover/front side panel/front side cowling refer to “general chassis (2)” on page 4-6. Passenger seat/rider seat refer to “general chassis (1)” on page 4-1. Fuel tank cover refer to “general c...

  • Page 160: General Chassis (3)

    General chassis (3) 4-17 eas31384 removing the fuel tank covers 1. Remove: • fuel tank front cover • front side panel • front side cowling 2. Remove: • passenger seat • rider seat 3. Remove: • fuel tank cover (left) “1” ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the fuel tank cover bolt “2” b. Disen...

  • Page 161: General Chassis (3)

    General chassis (3) 4-18 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Install: • rider seat • passenger seat 4. Install: • front side cowling • front side panel • fuel tank front cover 2.

  • Page 162: Front Wheel

    Front wheel 4-19 eas20028 front wheel removing the front wheel and brake discs order job/parts to remove q’ty remarks 1 reflector 2 2 front brake caliper 2 3 front wheel sensor bracket 1 4 front wheel sensor 1 5 wheel axle pinch bolt 1 loosen. 6 wheel axle 1 7 front wheel 1 8 collar 2 9 front brake ...

  • Page 163: Front Wheel

    Front wheel 4-20 disassembling the front wheel order job/parts to remove q’ty remarks 1 front wheel sensor rotor 1 2 oil seal 2 3 wheel bearing 2 4 spacer 1 a 1 2 3 4 2 3 (3) lt 8 n ・m (0.8 kgf・m, 5.8 lb・ft).

  • Page 164: Front Wheel

    Front wheel 4-21 eas30145 removing the front wheel notice eca21380 keep magnets (including magnetic pick-up tools, magnetic screwdrivers, etc.) away from the front wheel sensor “1”, otherwise the wheel sensor may be damaged, resulting in improper performance of the abs. 1. Stand the vehicle on a lev...

  • Page 165: Front Wheel

    Front wheel 4-22 2. Check: • tire • front wheel damage/wear  replace. Refer to “checking the tires” on page 3-16 and “checking the wheels” on page 3-16. 3. Measure: • radial wheel runout “1” • lateral wheel runout “2” over the specified limits  replace. 4. Check: • wheel bearings front wheel turns...

  • Page 166: Front Wheel

    Front wheel 4-23 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Install: • front wheel sensor rotor notice eca17200 replace the wheel sensor rotor bolts with new ones. Tip install the wheel sensor rotor with the stamped mark “1” facing outward. 3. Measure: • wheel sensor rotor runout out of specification  cor...

  • Page 167: Front Wheel

    Front wheel 4-24 c. If the runout is above specification, remove the sensor rotor from the wheel, rotate it by two or three bolt holes, and then install it. Notice eca17200 replace the wheel sensor rotor bolts with new ones. D. If the runout is still above specification, re- place the wheel sensor r...

  • Page 168: Front Wheel

    Front wheel 4-25 c. If the heavy spot does not stay in that posi- tion, install a heavier weight. D. Repeat steps (b) and (c) until the front wheel is balanced. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 4. Check: • front wheel static balance ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the front wheel and make s...

  • Page 169: Front Wheel

    Front wheel 4-26 6. Install: • front wheel sensor • front wheel sensor bracket notice eca21020 make sure there are no foreign materials in the front wheel sensor rotor and front wheel sensor. Foreign materials cause damage to the front wheel sensor rotor and front wheel sensor. Tip when installing t...

  • Page 170: Rear Wheel

    Rear wheel 4-27 eas20029 rear wheel removing the rear wheel order job/parts to remove q’ty remarks rear brake caliper refer to “rear brake” on page 4-48. 1 rear wheel sensor 1 2 locknut 2 loosen. 3 adjusting bolt 2 loosen. 4 wheel axle nut 1 5 washer 1 6 wheel axle 1 7 adjusting block (left) 1 8 adj...

  • Page 171: Rear Wheel

    Rear wheel 4-28 removing the brake disc and rear wheel sprocket order job/parts to remove q’ty remarks 1 rear brake disc 1 2 bracket 1 3 rear wheel sprocket 1 4 collar 1 5 collar 1 6 oil seal 1 7 bearing 1 8 rear wheel drive hub 1 9 collar 1 10 rear wheel drive hub damper 6 11 rear wheel 1 1 2 3 3 4...

  • Page 172: Rear Wheel

    Rear wheel 4-29 disassembling the rear wheel order job/parts to remove q’ty remarks 1 rear wheel sensor rotor 1 2 oil seal 1 3 wheel bearing 1 4 spacer 1 5 wheel bearing 1 a 1 3 4 lt 2 (3) 5 8 n ・m (0.8 kgf・m, 5.8 lb・ft).

  • Page 173: Rear Wheel

    Rear wheel 4-30 eas30156 removing the rear wheel notice eca21390 keep magnets (including magnetic pick-up tools, magnetic screwdrivers, etc.) away from the rear wheel sensor “1”, otherwise the wheel sensor may be damaged, resulting in improper performance of the abs. 1. Stand the vehicle on a level ...

  • Page 174: Rear Wheel

    Rear wheel 4-31 eas30159 checking the rear wheel 1. Check: • wheel axle • wheel bearings • oil seals refer to “checking the front wheel” on page 4-21. 2. Check: • tire • rear wheel damage/wear  replace. Refer to “checking the tires” on page 3-16 and “checking the wheels” on page 3-16. 3. Measure: •...

  • Page 175: Rear Wheel

    Rear wheel 4-32 1. Install: • wheel bearings • oil seal refer to “assembling the front wheel” on page 4-22. Eas30167 maintenance of the rear wheel sensor and sensor rotor notice eca21060 • handle the abs components with care since they have been accurately adjusted. Keep them away from dirt and do n...

  • Page 176: Rear Wheel

    Rear wheel 4-33 5. Install: • rear brake caliper • rear brake caliper bolts 6. Adjust: • drive chain slack refer to “drive chain slack” on page 3-18. 7. Tighten: • wheel axle nut • rear brake caliper bolts warning ewa13500 make sure the brake hose is routed properly. Tip when tightening the wheel ax...

  • Page 177: Rear Wheel

    Rear wheel 4-34 thickness gauge 90890-03180 feeler gauge set yu-26900-9 1 2 a.

  • Page 178: Front Brake

    Front brake 4-35 eas20030 front brake removing the front brake pads order job/parts to remove q’ty remarks the following procedure applies to both of the front brake calipers. 1 brake pad clip 2 2 brake pad pin 1 3 brake pad spring 1 4 brake pad 2 5 reflector 1 6 front brake caliper 1 7 bleed screw ...

  • Page 179: Front Brake

    Front brake 4-36 removing the front brake master cylinder order job/parts to remove q’ty remarks windshield refer to “general chassis (2)” on page 4-6. Brake fluid drain. Refer to “bleeding the hydraulic brake system (abs)” on page 3-15. 1 rearview mirror 1 2 handguard 1 3 grip end 2 1 4 brake maste...

  • Page 180: Front Brake

    Front brake 4-37 disassembling the front brake master cylinder order job/parts to remove q’ty remarks 1 brake master cylinder kit 1 2 brake master cylinder body 1 2 1 s bf bf.

  • Page 181: Front Brake

    Front brake 4-38 removing the front brake calipers order job/parts to remove q’ty remarks the following procedure applies to both of the front brake calipers. Brake fluid drain. Refer to “bleeding the hydraulic brake system (abs)” on page 3-15. 1 brake hose union bolt 1 2 brake hose gasket 1 3 brake...

  • Page 182: Front Brake

    Front brake 4-39 disassembling the front brake calipers order job/parts to remove q’ty remarks the following procedure applies to both of the front brake calipers. 1 brake pad clip 2 2 brake pad pin 1 3 brake pad spring 1 4 brake pad 2 5 brake caliper piston 4 6 brake caliper piston dust seal 4 7 br...

  • Page 183: Front Brake

    Front brake 4-40 eas30168 introduction warning ewa14101 disc brake components rarely require disas- sembly. Therefore, always follow these pre- ventive measures: • never disassemble brake components un- less absolutely necessary. • if any connection on the hydraulic brake system is disconnected, the...

  • Page 184: Front Brake

    Front brake 4-41 d. Measure the brake disc runout. E. If out of specification, repeat the adjustment steps until the brake disc runout is within specification. F. If the brake disc runout cannot be brought within specification, replace the brake disc. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 6. Install: • f...

  • Page 185: Front Brake

    Front brake 4-42 c. Tighten the bleed screw. D. Install the brake pads and brake pad spring. Tip the arrow mark “a” on the brake pad spring must point in the direction of disc rotation. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 6. Install: • brake pad pin • brake pad clips • front brake caliper 7. Check: • b...

  • Page 186: Front Brake

    Front brake 4-43 eas30172 disassembling the front brake calipers the following procedure applies to both of the brake calipers. 1. Remove: • brake caliper pistons “1” • brake caliper piston dust seals “2” • brake caliper piston seals “3” ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Secure the right side brak...

  • Page 187: Front Brake

    Front brake 4-44 replace the brake caliper piston dust seals and brake caliper piston seals. Eas30175 installing the front brake calipers the following procedure applies to both of the brake calipers. 1. Install: • front brake caliper “1” (temporarily) • brake hose gaskets • brake hoses “2” • brake ...

  • Page 188: Front Brake

    Front brake 4-45 7. Check: • brake lever operation soft or spongy feeling  bleed the brake sys- tem. Refer to “bleeding the hydraulic brake system (abs)” on page 3-15. Eas30179 removing the front brake master cylinder tip before removing the front brake master cylinder, drain the brake fluid from t...

  • Page 189: Front Brake

    Front brake 4-46 • align the end of the front brake master cylinder holder with the punch mark “b” on the handle- bar. • first, tighten the upper bolt, then the lower bolt. • there should be more than 11 mm (0.43 in) for clearance between the handlebar switch (right) and the front brake master cylin...

  • Page 190: Front Brake

    Front brake 4-47 brake system (abs)” on page 3-15..

  • Page 191: Rear Brake

    Rear brake 4-48 eas20031 rear brake removing the rear brake pads order job/parts to remove q’ty remarks 1 screw plug 1 2 brake pad retaining bolt 1 3 rear brake caliper 1 4 brake pad 2 5 brake pad shim 2 6 brake pad insulator 2 7 brake pad spring 1 8 bleed screw 1 lt s s s s 5 n ・m (0.5 kgf・m, 3.6 l...

  • Page 192: Rear Brake

    Rear brake 4-49 removing the rear brake master cylinder order job/parts to remove q’ty remarks fuel tank front cover/front side panel/front side cowling refer to “general chassis (2)” on page 4-6. Passenger seat/rider seat refer to “general chassis (1)” on page 4-1. Fuel tank cover refer to “general...

  • Page 193: Rear Brake

    Rear brake 4-50 removing the rear brake master cylinder order job/parts to remove q’ty remarks 12 brake pedal 1 13 rear brake master cylinder assembly 1 14 rear brake light switch 1 lt 13 14 12 3.8 n ・m (0.38 kgf・m, 2.8 lb・ft) 23 n ・m (2.3 kgf・m, 17 lb・ft) 30 n ・m (3.0 kgf・m, 22 lb・ft) 30 n ・m (3.0 ...

  • Page 194: Rear Brake

    Rear brake 4-51 disassembling the rear brake master cylinder order job/parts to remove q’ty remarks 1 brake master cylinder yoke 1 2 brake master cylinder kit 1 3 hose joint 1 4 bushing 1 5 brake master cylinder body 1 s bf bf 18 n ・m (1.8 kgf・m, 13 lb・ft).

  • Page 195: Rear Brake

    Rear brake 4-52 removing the rear brake caliper order job/parts to remove q’ty remarks brake fluid drain. Refer to “bleeding the hydraulic brake system (abs)” on page 3-15. 1 brake hose union bolt 1 2 brake hose gasket 2 3 brake hose 1 4 rear brake caliper 1 lt s s 30 n ・m (3.0 kgf・m, 22 lb・ft) 22 n...

  • Page 196: Rear Brake

    Rear brake 4-53 disassembling the rear brake caliper order job/parts to remove q’ty remarks 1 screw plug 1 2 brake pad retaining bolt 1 3 brake pad 2 4 brake pad shim 2 5 brake pad insulator 2 6 brake pad spring 1 7 brake caliper piston 1 8 brake caliper piston dust seal 1 9 brake caliper piston sea...

  • Page 197: Rear Brake

    Rear brake 4-54 eas30183 introduction warning ewa14101 disc brake components rarely require disas- sembly. Therefore, always follow these pre- ventive measures: • never disassemble brake components un- less absolutely necessary. • if any connection on the hydraulic brake system is disconnected, the ...

  • Page 198: Rear Brake

    Rear brake 4-55 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect a clear plastic hose “1” tightly to the bleed screw “2”. Put the other end of the hose into an open container. B. Loosen the bleed screw and push the brake caliper piston into the brake caliper with your finger. C. Tighten the bleed screw. ...

  • Page 199: Rear Brake

    Rear brake 4-56 • brake hose gaskets “2” • brake hose “3” tip put the end of the brake hose into a container and pump out the brake fluid carefully. Eas30187 disassembling the rear brake caliper 1. Remove: • brake caliper piston “1” • brake caliper piston dust seal “2” • brake caliper piston seal “3...

  • Page 200: Rear Brake

    Rear brake 4-57 2. Check: • rear brake caliper bracket “1” cracks/damage  replace. Refer to “rear wheel” on page 4-27. Eas30189 assembling the rear brake caliper warning ewa17080 • before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. •...

  • Page 201: Rear Brake

    Rear brake 4-58 • brake fluid reservoir (with the specified amount of the specified brake fluid) warning ewa13090 • use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. • refill with the same type of brake flui...

  • Page 202: Rear Brake

    Rear brake 4-59 eas30195 assembling the rear brake master cylinder warning ewa13520 • before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. • never use solvents on internal brake com- ponents. 1. Install: • brake master cylinder kit eas3...

  • Page 203: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 4-60 eas20032 abs (anti-lock brake system) removing the hydraulic unit assembly order job/parts to remove q’ty remarks fuel tank front cover/front side panel/front side cowling refer to “general chassis (2)” on page 4-6. Passenger seat/rider seat refer to “general chassi...

  • Page 204: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 4-61 removing the hydraulic unit assembly order job/parts to remove q’ty remarks 9 front brake hose (hydraulic unit to front brake caliper) 1 disconnect. 10 brake hose union bolt/gasket 1/2 11 front brake hose (front brake master cylinder to hydraulic unit) 1 disconnect....

  • Page 205: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 4-62 eas30728 abs components chart 1 2 3 4 5 9 1 10 11 12 13 8 6 7 1. Hydraulic unit assembly 2. Fuse box 3 3. Yamaha diagnostic tool coupler 4. Rear wheel sensor 5. Rear wheel sensor rotor 6. Front wheel sensor 7. Front wheel sensor rotor 8. Abs warning light 9. Fuse bo...

  • Page 206: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 4-63 eas30197 removing the hydraulic unit assembly notice eca21091 unless necessary, avoid removing and in- stalling the brake hoses of the hydraulic unit assembly. Warning ewa13930 refill with the same type of brake fluid that is already in the system. Mixing fluids may...

  • Page 207: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 4-64 tip do not allow any foreign materials to enter the hydraulic unit assembly or the brake hoses when installing the hydraulic unit assembly. 2. Remove: • rubber plugs or bolts (m10  1.0) 3. Install: • front brake hose (front brake master cylinder to hydraulic unit) ...

  • Page 208: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 4-65 6. Bleed: • brake system refer to “bleeding the hydraulic brake system (abs)” on page 3-15. 7. Check the operation of the hydraulic unit ac- cording to the brake lever and the brake ped- al response. (refer to “hydraulic unit operation tests” on page 4-65.) notice e...

  • Page 209: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 4-66 • the operation of the hydraulic unit can be con- firmed using the indicator. On: the hydraulic unit is operating. Flashing: the conditions for operating the hy- draulic unit have not been met. Off: the brake lever and brake pedal are not being operated. 9. Check: •...

  • Page 210: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 4-67 5. Removing the protective cap “1”, and then connect the yamaha diagnostic tool to the yamaha diagnostic tool coupler (4p). 6. Start the yamaha diagnostic tool and display the diagnosis of function screen. 7. Select code no. 1, “abs reaction-force con- firmation”. 8...

  • Page 211: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 4-68 when the brakes are being applied and re- leased respectively. 11.After the pulsating action has stopped in the brake pedal, it is generated in the brake lever and continues for a few seconds. Tip • the reaction-force pulsating action consists of quick pulses. • “on...

  • Page 212: Handlebar

    Handlebar 4-69 eas20033 handlebar removing the handlebar 1/2 order job/parts to remove q’ty remarks windshield refer to “general chassis (2)” on page 4-6. 1 rearview mirror 2 2 handguard 2 3 grip end 2 2 4 handlebar cover 2 5 lever cover 2 6 upper handguard bracket 2 7 lower handguard bracket 2 1 2 ...

  • Page 213: Handlebar

    Handlebar 4-70 removing the handlebar 2/2 order job/parts to remove q’ty remarks fuel tank front cover/front side panel/front side cowling refer to “general chassis (2)” on page 4-6. 1 front brake light switch connector 2 disconnect. 2 front brake master cylinder holder 1 3 front brake master cylind...

  • Page 214: Handlebar

    Handlebar 4-71 eas31396 adjusting the handlebar position 1. Check: • handlebar position tip the handlebar position can be adjusted in two positions to suit the rider’s preference. 2. Remove: • fuel tank front cover • front side panel • front side cowling refer to “general chassis (2)” on page 4-6. 3...

  • Page 215: Handlebar

    Handlebar 4-72 eas30203 removing the handlebar 1. Stand the vehicle on a level surface. Warning ewa13120 securely support the vehicle so that there is no danger of it falling over. 2. Remove: • handlebar grip “1” tip blow compressed air between the handlebar (left) and the handlebar grip, and gradua...

  • Page 216: Handlebar

    Handlebar 4-73 4. Install: • throttle grip “1” • throttle cables • throttle cable housings “2” • grip end tip align the projection “a” on the throttle cable housing with the hole “b” in the handlebar. 5. Install: • handlebar switch screw (right) tip align the projection “a” on the handlebar switch (...

  • Page 217: Handlebar

    Handlebar 4-74 warning ewa13700 do not touch the handlebar grip until the rub- ber adhesive has fully dried. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 10.Adjust: • throttle grip free play refer to “checking the throttle grip” on page 3-29. 11.Adjust: • clutch lever free play refer to “adjusting the clutch le...

  • Page 218: Handlebar

    Handlebar 4-75 b. Tighten the handguard bracket bolts “3” to specification. C. Tighten the rearview mirror locknut “4” to specification. D. Tighten the handguard bolt “5” to specifica- tion. E. Tighten the handguard bracket nut “6” to specification. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ handguard bracket...

  • Page 219: Front Fork

    Front fork 4-76 eas20034 front fork removing the front fork legs order job/parts to remove q’ty remarks the following procedure applies to both of the front fork legs. Front wheel refer to “front wheel” on page 4-19. 1 front fender 1 2 upper bracket pinch bolt 1 loosen. 3 cap bolt 1 loosen. 4 lower ...

  • Page 220: Front Fork

    Front fork 4-77 disassembling the left front fork leg order job/parts to remove q’ty remarks 1 cap bolt 1 2 o-ring 1 3 washer 1 4 spacer 1 5 fork spring 1 6 locknut 1 7 dust seal 1 8 oil seal clip 1 9 outer tube 1 10 oil seal 1 11 washer 1 12 outer tube bushing 1 13 inner tube bushing 1 14 damper ro...

  • Page 221: Front Fork

    Front fork 4-78 disassembling the right front fork leg order job/parts to remove q’ty remarks 1 cap bolt 1 2 o-ring 1 3 washer 1 4 spacer 1 5 fork spring 1 6 locknut 1 7 damper adjusting rod 1 8 dust seal 1 9 oil seal clip 1 10 outer tube 1 11 oil seal 1 12 washer 1 13 outer tube bushing 1 14 inner ...

  • Page 222: Front Fork

    Front fork 4-79 eas30206 removing the front fork legs the following procedure applies to both of the front fork legs. Tip each front fork leg is equipped with a spring pre- load adjusting bolt, the right fork leg is equipped with a rebound damping force adjusting screw. Pay attention not to mistake ...

  • Page 223: Front Fork

    Front fork 4-80 • oil seal clip “2” (with a flat-head screwdriver) notice eca19100 do not scratch the outer tube. 4. Remove: • outer tube ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Hold the front fork leg horizontally. B. Securely clamp the brake caliper bracket in a vise with soft jaws. C. Separate the ou...

  • Page 224: Front Fork

    Front fork 4-81 3. Check: • damper rod “1” damage/wear  replace. Obstruction  blow out all of the oil passag- es with compressed air. Notice eca19110 • the front fork leg has a very sophisticated internal construction, which are particular- ly sensitive to foreign material. • when disassembling an...

  • Page 225: Front Fork

    Front fork 4-82 damper rod holder “1”, tighten the damper rod assembly bolt. 3. Lubricate: • inner tube’s outer surface 4. Install: • dust seal “1” • oil seal clip “2” • oil seal “3” • washer “4” • outer tube bushing “5” • inner tube bushing “6” notice eca19170 make sure the numbered side of the oil...

  • Page 226: Front Fork

    Front fork 4-83 8. Install: • oil seal clip “1” tip adjust the oil seal clip so that it fits into the outer tube’s groove. 9. Install: • dust seal “1” (with the fork seal driver “2”) 10.Install: • rod puller “1” • rod puller attachment (m10 long) “2” (onto the damper rod “3”) 11.Fill: • front fork l...

  • Page 227: Front Fork

    Front fork 4-84 tip be sure to bleed the front fork leg of any residual air. 14.Measure: • front fork leg oil level “a” (from the top of the outer tube, with the outer tube fully compressed and without the fork spring) out of specification  correct. 15.Install: • fork spring (left side) “1” • space...

  • Page 228: Front Fork

    Front fork 4-85 ment. J. Install the washer and cap bolt, and then fin- ger tighten the cap bolt. Warning ewa13670 always use a new cap bolt o-ring. K. Hold the cap bolt “5” and tighten the locknut “3” to specification. L. Remove the rod holder and fork spring com- pressor. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...

  • Page 229: Front Fork

    Front fork 4-86 ment. J. Position the locknut “3” as specified “b”. K. Set the cap bolt distance “c” to specification. L. Install the damper adjusting rod, washer and cap bolt, and then finger tighten the cap bolt. Warning ewa13670 always use a new cap bolt o-ring. M. Hold the cap bolt “5” and tight...

  • Page 230: Steering Head

    Steering head 4-87 eas20035 steering head removing the lower bracket order job/parts to remove q’ty remarks fuel tank refer to “fuel tank” on page 7-1. Air filter case refer to “general chassis (3)” on page 4-13. Headlight assembly refer to “general chassis (2)” on page 4-6. Meter assembly refer to ...

  • Page 231: Steering Head

    Steering head 4-88 removing the lower bracket order job/parts to remove q’ty remarks 11 horn bracket 1 12 lower bracket cap 1 13 steering stem nut 1 14 upper bracket 1 15 lock washer 1 16 upper ring nut 1 17 rubber washer 1 18 lower ring nut 1 19 lower bracket 1 20 bearing cover 1 21 lower bearing d...

  • Page 232: Steering Head

    Steering head 4-89 eas30213 removing the lower bracket 1. Stand the vehicle on a level surface. Warning ewa13120 securely support the vehicle so that there is no danger of it falling over. 2. Remove: • upper ring nut • rubber washer • lower ring nut “1” • lower bracket warning ewa13730 securely supp...

  • Page 233: Steering Head

    Steering head 4-90 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 4. Check: • upper bracket • lower bracket (along with the steering stem) bends/cracks/damage  replace. Eas30216 installing the steering head 1. Lubricate: • upper bearing • lower bearing 2. Install: • lower ring nut “1” • rubber washer “2” • upper...

  • Page 234: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-91 eas20036 rear shock absorber assembly removing the rear shock absorber assembly order job/parts to remove q’ty remarks fuel tank front cover/front side panel/front side cowling refer to “general chassis (2)” on page 4-6. Passenger seat/rider seat refer to “general c...

  • Page 235: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-92 eas30826 handling the rear shock absorber warning ewa13740 this rear shock absorber contains highly compressed nitrogen gas. Before handling the rear shock absorber, read and make sure you understand the following information. The manufacturer cannot be held respons...

  • Page 236: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-93 2. Check: • bearings • oil seals damage/pitting  replace. 3. Check: • collars damage/scratches  replace. Eas30222 installing the relay arm 1. Lubricate: • collars • oil seals 2. Install: • bearings “1” (to the relay arm) • oil seals “2” (to the relay arm) tip • wh...

  • Page 237: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-94 rear shock absorber assembly nut (upper) 44 n·m (4.4 kgf·m, 32 lb·ft) relay arm nut 61 n·m (6.1 kgf·m, 44 lb·ft) connecting arm lower nut 55 n·m (5.5 kgf·m, 40 lb·ft) t r . ..

  • Page 238: Swingarm

    Swingarm 4-95 eas20037 swingarm removing the swingarm order job/parts to remove q’ty remarks rear brake caliper refer to “rear brake” on page 4-48. Rear wheel refer to “rear wheel” on page 4-27. Muffler assembly refer to “engine removal” on page 5-3. Drive chain refer to “chain drive” on page 4-98. ...

  • Page 239: Swingarm

    Swingarm 4-96 eas30226 removing the swingarm 1. Stand the vehicle on a level surface. Warning ewa13120 securely support the vehicle so that there is no danger of it falling over. Tip place the vehicle on the centerstand so that the rear wheel is elevated. 2. Remove: • connecting arm lower nut “1” • ...

  • Page 240: Swingarm

    Swingarm 4-97 • collars “3” damage/scratches  replace. • bearings “4” damage/pitting  replace. Eas30228 installing the swingarm 1. Lubricate: • dust covers • pivot shaft • oil seals • collars 2. Install: • bearings “1” (to the swingarm) • oil seals “2” (to the swingarm) tip when installing the oil...

  • Page 241: Chain Drive

    Chain drive 4-98 eas20038 chain drive removing the drive chain order job/parts to remove q’ty remarks 1 locknut 2 2 shift rod 1 3 shift arm 1 4 drive sprocket cover 1 5 drive chain guide 1 6 drive sprocket nut 1 7 washer 1 8 drive sprocket 1 9 drive chain 1 1 2 3 4 5 6 7 8 9 e 1 lt e 10 n ・m (1.0 kg...

  • Page 242: Chain Drive

    Chain drive 4-99 eas30229 removing the drive chain 1. Stand the vehicle on a level surface. Warning ewa13120 securely support the vehicle so that there is no danger of it falling over. Tip place the vehicle on the centerstand so that the rear wheel is elevated. 2. Straighten the drive sprocket nut r...

  • Page 243: Chain Drive

    Chain drive 4-100 notice eca19090 • this vehicle has a drive chain with small rubber o-rings “1” between the drive chain side plates. Never use high-pressure water or air, steam, gasoline, certain solvents (e.G., benzine), or a coarse brush to clean the drive chain. High-pressure methods could force...

  • Page 244: Chain Drive

    Chain drive 4-101 eas30234 installing the drive chain 1. Install: • drive chain notice eca17410 be sure to put on safety goggles when work- ing. Tip install the drive chain joint with the drive chain cut & rivet tool. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. When press fitting the connecting plate “1”, m...

  • Page 245: Chain Drive

    Chain drive 4-102 5. Adjust: • drive chain slack refer to “drive chain slack” on page 3-18. Notice eca13550 a drive chain that is too tight will overload the engine and other vital parts, and one that is too loose can skip and damage the swing- arm or cause an accident. Therefore, keep the drive cha...

  • Page 246: Chain Drive

    Chain drive 4-103.

  • Page 247: Engine

    1 2 3 4 5 6 7 8 9 engine engine inspection .....................................................................................5-1 measure the compression pressure.........................................5-1 engine removal................................................................................

  • Page 248

    Checking the clutch housing .....................................................5-44 checking the clutch boss............................................................5-45 checking the pressure plate .....................................................5-45 checking the primary drive gear...........

  • Page 249

    Checking the shift drum assembly...........................................5-82 checking the transmission ..........................................................5-82 assembling the main axle and drive axle ...............................5-82 installing the transmission ..............................

  • Page 250: Engine Inspection

    Engine inspection 5-1 eas20041 engine inspection eas30249 measure the compression pressure the following procedure applies to all of the cyl- inders. Tip insufficient compression pressure will result in a loss of performance. 1. Measure: • valve clearance out of specification  adjust. Refer to “adj...

  • Page 251: Engine Inspection

    Engine inspection 5-2 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 6. Install: • spark plugs 7. Install: • ignition coils refer to “camshafts” on page 5-9. • air cut-off valve refer to “air induction system” on page 7-15. • air filter case refer to “general chassis (3)” on page 4-13. • fuel tank refer to “fuel ...

  • Page 252: Engine Removal

    Engine removal 5-3 eas20042 engine removal removing the muffler and exhaust pipe order job/parts to remove q’ty remarks 1 spring 1 2 centerstand 1 3 o 2 sensor coupler bracket 1 4 o 2 sensor coupler 1 disconnect. 5 muffler assembly 1 6 exhaust gasket 3 7 muffler protector 1 3 4 5 6 7 (6) lt lt 1 2 1...

  • Page 253: Engine Removal

    Engine removal 5-4 disconnecting the leads and hoses order job/parts to remove q’ty remarks fuel tank front cover/front side panel/front side cowling refer to “general chassis (2)” on page 4-6. Passenger seat/rider seat/rear side cover (left) refer to “general chassis (1)” on page 4-1. Fuel tank cov...

  • Page 254: Engine Removal

    Engine removal 5-5 disconnecting the leads and hoses order job/parts to remove q’ty remarks 7 gear position switch coupler 2 disconnect. 8 crankshaft position sensor coupler 1 disconnect. 9 stator coil coupler 1 disconnect. 7 8 9 12 n ・m (1.2 kgf・m, 8.7 lb・ft) 7 n ・m (0.7 kgf・m, 5.1 lb・ft).

  • Page 255: Engine Removal

    Engine removal 5-6 removing the engine order job/parts to remove q’ty remarks 1 engine mounting bolt (right front upper side) 1 2 centerstand bracket bolt (right) 1 3 engine mounting bolt (right front lower side) /engine mounting bolt (left front lower side) /engine mounting bolt (left front upper s...

  • Page 256: Engine Removal

    Engine removal 5-7 eas30250 removing the engine 1. Loosen: • engine mounting adjust bolt (front) tip loosen the engine mounting adjust bolt with the pivot shaft wrench “1”. 2. Loosen: • engine mounting adjust bolt (rear) tip loosen the engine mounting adjust bolts with the pivot shaft wrench “1” and...

  • Page 257: Engine Removal

    Engine removal 5-8 7. Tighten: • engine mounting adjust bolt (rear) “2” tip • tighten the engine mounting adjust bolts to specification with the pivot shaft wrench and pivot shaft wrench adapter. • make sure that the flange on the engine mounting adjust bolt contacts the engine. 8. Install: • center...

  • Page 258: Camshafts

    Camshafts 5-9 eas20043 camshafts removing the cylinder head cover order job/parts to remove q’ty remarks fuel tank front cover/front side panel/front side cowling refer to “general chassis (2)” on page 4-6. Passenger seat/rider seat refer to “general chassis (1)” on page 4-1. Fuel tank cover refer t...

  • Page 259: Camshafts

    Camshafts 5-10 removing the camshafts order job/parts to remove q’ty remarks crankshaft end cover/timing mark accessing bolt refer to “generator and starter clutch” on page 5-29. 1 timing chain cover 1 2 timing chain cover gasket 1 3 timing chain tensioner 1 4 timing chain tensioner gasket 1 5 intak...

  • Page 260: Camshafts

    Camshafts 5-11 eas30256 removing the camshafts 1. Remove: • timing mark accessing bolt “1” • crankshaft end cover “2” 2. Align: • mark “a” on the generator rotor (with the generator rotor cover mark “b”) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the crankshaft counterclockwise. B. When piston #1 is a...

  • Page 261: Camshafts

    Camshafts 5-12 eas30257 checking the camshafts 1. Check: • camshaft lobes blue discoloration/pitting/scratches  re- place the camshaft. 2. Measure: • camshaft lobe dimensions “a” out of specification  replace the camshaft. 3. Measure: • camshaft runout out of specification  replace. 4. Measure: •...

  • Page 262: Camshafts

    Camshafts 5-13 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 5. Measure: • camshaft journal diameter “a” out of specification  replace the camshaft. Within specification  replace the cylinder head and the camshaft caps as a set. Eas30258 checking the timing chain and camshaft sprocket 1. Check: • timing chain ...

  • Page 263: Camshafts

    Camshafts 5-14 b. Make sure that the timing chain tensioner rod moves in and out of the timing chain tension- er housing smoothly. If there is rough move- ment, replace the timing chain tensioner. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas30269 installing the camshafts 1. Remove: • timing mark accessing b...

  • Page 264: Camshafts

    Camshafts 5-15 shaft faces up. • when installing the camshaft, no need to align the mark “b” on the camshaft sprocket. 5. Install: • camshaft cap • intake camshaft cap • exhaust camshaft cap tip • make sure each camshaft cap is installed in its original place. Refer to the identification marks as fo...

  • Page 265: Camshafts

    Camshafts 5-16 8. Check: • camshaft punch mark “a” make sure the camshaft punch mark “a” on the camshaft is aligned with the camshaft cap alignment mark “b”. 9. Install: • timing chain tensioner • timing chain tensioner gasket ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. While lightly pressing the timing cha...

  • Page 266: Camshafts

    Camshafts 5-17 10.Turn: • crankshaft (several turns counterclockwise) 11.Check: • mark “a” make sure the mark “a” on the generator rotor is aligned with the generator rotor cover mark “b”. • camshaft punch mark “c” make sure the camshaft punch mark “c” on the camshaft is aligned with the camshaft ca...

  • Page 267: Camshafts

    Camshafts 5-18 tip install the ignition coils “1” in the direction shown in the illustration. 1.

  • Page 268: Cylinder Head

    Cylinder head 5-19 eas20044 cylinder head removing the cylinder head order job/parts to remove q’ty remarks engine refer to “engine removal” on page 5-3. Intake camshaft refer to “camshafts” on page 5-9. Exhaust camshaft refer to “camshafts” on page 5-9. 1 coolant temperature sensor 1 2 cylinder hea...

  • Page 269: Cylinder Head

    Cylinder head 5-20 eas30276 removing the cylinder head 1. Remove: • intake camshaft • exhaust camshaft refer to “removing the camshafts” on page 5-11. 2. Remove: • cylinder head bolt (m6) (4) • cylinder head bolt (m9) (8) tip • loosen the bolts in the proper sequence as shown. • loosen each bolt 1...

  • Page 270: Cylinder Head

    Cylinder head 5-21 eas30282 installing the cylinder head 1. Install: • timing chain guide (exhaust side) “1” • cylinder head gasket “2” • dowel pins “3” 2. Install: • cylinder head • cylinder head bolt (m6) (4) • cylinder head bolt (m9) (8) tip • pass the timing chain through the timing chain cavi...

  • Page 271: Valves and Valve Springs

    Valves and valve springs 5-22 eas20045 valves and valve springs removing the valves and valve springs order job/parts to remove q’ty remarks cylinder head refer to “cylinder head” on page 5-19. 1 intake valve lifter 6 2 intake valve pad 6 3 intake valve cotter 12 4 intake valve spring retainer 6 5 i...

  • Page 272: Valves and Valve Springs

    Valves and valve springs 5-23 eas30283 removing the valves the following procedure applies to all of the valves and related components. Tip before removing the internal parts of the cylinder head (e.G., valves, valve springs, valve seats), make sure the valves properly seal. 1. Remove: • valve lifte...

  • Page 273: Valves and Valve Springs

    Valves and valve springs 5-24 1. Measure: • valve-stem-to-valve-guide clearance out of specification  replace the valve guide. 2. Replace: • valve guide tip to ease valve guide removal and installation, and to maintain the correct fit, heat the cylinder head to 100 c (212 f) in an oven. ▼▼▼▼▼▼▼▼▼...

  • Page 274: Valves and Valve Springs

    Valves and valve springs 5-25 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Eliminate: • carbon deposits (from the valve face and valve seat) 4. Check: • valve face pitting/wear  grind the valve face. • valve stem end mushroom shape or diameter larger than the body of the valve stem  replace the valve. 5. M...

  • Page 275: Valves and Valve Springs

    Valves and valve springs 5-26 tip after replacing the cylinder head or replacing the valve and valve guide, the valve seat and valve face should be lapped. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Apply a coarse lapping compound “a” to the valve face. Notice eca13790 do not let the lapping compound enter...

  • Page 276: Valves and Valve Springs

    Valves and valve springs 5-27 2. Measure: • valve spring tilt “a” out of specification  replace the valve spring. Eas30287 checking the valve lifters the following procedure applies to all of the valve lifters. 1. Check: • valve lifter damage/scratches  replace the valve lift- ers and cylinder hea...

  • Page 277: Valves and Valve Springs

    Valves and valve springs 5-28 4. Install: • valve cotters “1” tip install the valve cotters by compressing the valve spring with the valve spring compressor “2” and the valve spring compressor attachment “3”. 5. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a soft-f...

  • Page 278: Generator and Starter Clutch

    Generator and starter clutch 5-29 eas20140 generator and starter clutch removing the stator coil, generator rotor and starter clutch order job/parts to remove q’ty remarks fuel tank front cover/front side panel/front side cowling refer to “general chassis (2)” on page 4-6. Passenger seat/rider seat/...

  • Page 279: Generator and Starter Clutch

    Generator and starter clutch 5-30 removing the stator coil, generator rotor and starter clutch order job/parts to remove q’ty remarks 9 generator rotor 1 10 starter clutch 1 11 starter clutch gear 1 12 woodruff key 1 13 starter clutch idle gear shaft 1 14 starter clutch idle gear 1 15 crankshaft end...

  • Page 280: Generator and Starter Clutch

    Generator and starter clutch 5-31 eas30867 removing the generator 1. Remove: • generator rotor bolt “1” • washer tip while holding the generator rotor “2” with the sheave holder “3”, loosen the generator rotor bolt. 2. Remove: • generator rotor “1” (with the flywheel puller “2”) • woodruff key notic...

  • Page 281: Generator and Starter Clutch

    Generator and starter clutch 5-32 erator rotor “2” and hold the generator rotor. B. When turning the starter clutch gear clock- wise “a”, the starter clutch and the starter clutch gear should engage, otherwise the starter clutch is faulty and must be replaced. C. When turning the starter clutch gear...

  • Page 282: Generator and Starter Clutch

    Generator and starter clutch 5-33 3. Apply: • sealant (onto the stator coil assembly lead grommet) 4. Install: • generator cover gasket • generator cover tip tighten the generator cover bolts in stages and in a crisscross pattern. 5. Connect: • stator coil coupler • crankshaft position sensor couple...

  • Page 283: Electric Starter

    Electric starter 5-34 eas20052 electric starter removing the starter motor order job/parts to remove q’ty remarks fuel tank front cover/front side panel/front side cowling refer to “general chassis (2)” on page 4-6. Passenger seat/rider seat refer to “general chassis (1)” on page 4-1. Fuel tank cove...

  • Page 284: Electric Starter

    Electric starter 5-35 disassembling the starter motor order job/parts to remove q’ty remarks 1 o-ring 1 2 starter motor front cover 1 3 starter motor yoke 1 4 armature assembly 1 5 gasket 2 6 brush holder set 1 7 starter motor rear cover 1 5 n ・m (0.5 kgf・m, 3.6 lb・ft) 11 n ・m (1.1 kgf・m, 8.0 lb・ft).

  • Page 285: Electric Starter

    Electric starter 5-36 eas30325 checking the starter motor 1. Check: • commutator dirt  clean with 600 grit sandpaper. 2. Measure: • mica undercut “a” out of specification  scrape the mica to the proper measurement with a hacksaw blade that has been grounded to fit the commutator. Tip the mica of t...

  • Page 286: Electric Starter

    Electric starter 5-37 6. Check: • gear teeth damage/wear  replace the starter motor. 7. Check: • bearing • oil seal damage/wear  replace the starter motor. Eas30326 assembling the starter motor 1. Install: • brush holder set • insulator “1” tip install the insulator as shown in the illustration. 2...

  • Page 287: Clutch

    Clutch 5-38 eas20055 clutch removing the clutch cover order job/parts to remove q’ty remarks engine oil drain. Refer to “changing the engine oil” on page 3-24. 1 clutch cable 1 disconnect. 2 cover 1 3 o 2 sensor coupler bracket 1 4 clutch cover 1 5 clutch cover gasket 1 6 dowel pin 2 7 oil filler ca...

  • Page 288: Clutch

    Clutch 5-39 removing the pull lever shaft order job/parts to remove q’ty remarks 1 clutch cover damper plate 1 install the clutch cover damper plate with its folded-up side facing upward. 2 clutch cover damper 1 3 circlip 1 4 pull lever 1 5 pull lever spring 1 6 circlip 1 7 pull lever shaft 1 8 oil ...

  • Page 289: Clutch

    Clutch 5-40 removing the clutch order job/parts to remove q’ty remarks oil pump driven sprocket refer to “oil pump” on page 5-51. 1 pressure plate 1 1 2 clutch spring 3 3 absorber 3 4 pressure plate 2 1 5 pull rod 1 6 bearing 1 7 friction plate 1 3 inside diameter: 126 mm (4.96 in) 8 clutch plate 1 ...

  • Page 290: Clutch

    Clutch 5-41 removing the clutch order job/parts to remove q’ty remarks 17 thrust plate 1 18 clutch housing 1 19 oil pump drive chain 1 20 bearing 1 21 spacer 1 22 thrust plate 1 23 thrust plate 1 e 17 18 19 20 21 22 23 lt e e e 10 n ・m (1.0 kgf・m, 7.2 lb・ft) 125 n ・m (12.5 kgf・m, 90 lb・ft).

  • Page 291: Clutch

    Clutch 5-42 eas30346 removing the clutch 1. Remove: • cover “1” • clutch cover “2” • gasket tip loosen each bolt 1/4 of a turn at a time, in stag- es and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 2. Remove: • oil pump driven sprocket “1” refer to “oil pump” on ...

  • Page 292: Clutch

    Clutch 5-43 8. Remove: • clutch boss nut • conical spring washer • washer • clutch boss • thrust plate • clutch housing • oil pump drive chain eas30348 checking the friction plates the following procedure applies to all of the fric- tion plates. 1. Check: • friction plate 1, 2 damage/wear  replace ...

  • Page 293: Clutch

    Clutch 5-44 out of specification  adjust. Tip • perform the thickness measurement without applying the oil. • this step should be performed only if the fric- tion plates and clutch plates were replaced. • to measure the total width of the friction plates and clutch plates, combine 9 friction plates...

  • Page 294: Clutch

    Clutch 5-45 2. Check: • oil pump drive sprocket “1” cracks/damage/wear  replace. 3. Check: • bearing damage/wear  replace the bearing and clutch housing. Eas30353 checking the clutch boss 1. Check: • clutch boss splines damage/pitting/wear  replace the clutch boss. Tip pitting on the clutch boss ...

  • Page 295: Clutch

    Clutch 5-46 2. Check: • pull rod bearing damage/wear  replace. Eas30363 installing the clutch 1. Install: • oil pump drive chain “1” • clutch housing “2” tip install the oil pump drive chain onto the oil pump drive sprocket “a”. 2. Install: • thrust plate • clutch boss “1” • washer • conical spring...

  • Page 296: Clutch

    Clutch 5-47 • clutch springs • pressure plate 1 • clutch spring bolts “1” • oil pump driven sprocket “2” tip • tighten the clutch spring bolts in stages and in a crisscross pattern. • apply lithium-soap-based grease onto the pull rod. • position the pull rod so that the teeth “a” face towards the ho...

  • Page 297: Clutch

    Clutch 5-48 8. Adjust: • clutch lever free play refer to “adjusting the clutch lever free play” on page 3-12. Clutch lever free play 10.0–15.0 mm (0.39–0.59 in) 1 2 3 a b c.

  • Page 298: Shift Shaft

    Shift shaft 5-49 eas20057 shift shaft removing the shift shaft and stopper lever order job/parts to remove q’ty remarks clutch assembly refer to “clutch” on page 5-38. Shift arm refer to “chain drive” on page 4-98. 1 circlip 1 2 washer 1 3 shift shaft 1 4 washer 1 5 circlip 1 6 washer 1 7 stopper le...

  • Page 299: Shift Shaft

    Shift shaft 5-50 eas30377 checking the shift shaft 1. Check: • shift shaft “1” bends/damage/wear  replace. • shift shaft spring “2” • collar damage/wear  replace. Eas30378 checking the stopper lever 1. Check: • stopper lever “1” bends/damage  replace. Roller turns roughly  replace the stopper le...

  • Page 300: Oil Pump

    Oil pump 5-51 eas20054 oil pump removing the oil pump order job/parts to remove q’ty remarks clutch cover refer to “clutch” on page 5-38. 1 oil pump driven sprocket 1 2 oil pump assembly 1 1 2 lt 10 n ・m (1.0 kgf・m, 7.2 lb・ft) 10 n ・m (1.0 kgf・m, 7.2 lb・ft) 15 n ・m (1.5 kgf・m, 11 lb・ft).

  • Page 301: Oil Pump

    Oil pump 5-52 disassembling the oil pump order job/parts to remove q’ty remarks 1 oil pump cover 1 2 oil pump shaft 1 3 pin 1 4 oil pump inner rotor 1 5 oil pump outer rotor 1 6 circlip 1 hold down the washer when removing the circlip. 7 washer 1 8 spring 1 9 relief valve 1 10 dowel pin 2 e 1 2 3 4 ...

  • Page 302: Oil Pump

    Oil pump 5-53 eas30336 checking the sprocket and chain 1. Check: • oil pump drive sprocket refer to “checking the clutch hous- ing” on page 5-44. 2. Check: • oil pump drive chain “1” damage/stiffness  replace the oil pump drive chain and oil pump drive sprocket (clutch housing) as a set. Eas30337 c...

  • Page 303: Oil Pump

    Oil pump 5-54 eas30342 assembling the oil pump 1. Lubricate: • inner rotor • outer rotor • oil pump shaft (with the recommended lubricant) 2. Install: • outer rotor “1” • inner rotor “2” • pin “3” • oil pump cover “4” • oil pump cover screw tip align the pin “3” in the oil pump shaft with the groove...

  • Page 304: Oil Pan

    Oil pan 5-55 eas20177 oil pan removing the oil pan order job/parts to remove q’ty remarks fuel tank front cover/front side panel/front side cowling refer to “general chassis (2)” on page 4-6. Passenger seat/rider seat refer to “general chassis (1)” on page 4-1. Fuel tank cover refer to “general chas...

  • Page 305: Oil Pan

    Oil pan 5-56 eas31068 removing the oil pan 1. Remove: • oil level switch “1” • oil pan “2” • oil pan gasket tip loosen each bolt 1/4 of a turn at a time, in stag- es and in a crisscross pattern. After all of the bolts are fully loosened, remove them. Eas31069 checking the oil strainer 1. Check: • oi...

  • Page 306: Crankcase

    Crankcase 5-57 eas20059 crankcase separating the crankcase order job/parts to remove q’ty remarks engine refer to “engine removal” on page 5-3. Cylinder head refer to “cylinder head” on page 5-19. Water pump refer to “water pump” on page 6-8. Starter clutch refer to “generator and starter clutch” on...

  • Page 307: Crankcase

    Crankcase 5-58 eas30389 disassembling the crankcase 1. Place the engine upside down. 2. Remove: • crankcase bolt (30) tip • loosen each bolt 1/4 of a turn at a time, in stag- es and in a crisscross pattern. After all of the bolts are fully loosened, remove them. • loosen the bolts in the proper seq...

  • Page 308: Crankcase

    Crankcase 5-59 4. Set the shift drum assembly and transmission gears in the neutral position. 5. Install: • lower crankcase “1” (onto the upper crankcase “2”) notice eca13980 before tightening the crankcase bolts, make sure the transmission gears shift correctly when the shift drum assembly is turne...

  • Page 309: Crankcase

    Crankcase 5-60 8. Tighten: • crankcase bolts “9”–“30” tip tighten the bolts in the tightening sequence cast on the crankcase. Crankcase bolts “9”–“14” 24 n·m (2.4 kgf·m, 17 lb·ft) crankcase bolts “15”–“30” 10 n·m (1.0 kgf·m, 7.2 lb·ft) 8 1 2 3 4 5 6 7 8 t r . . 22 9 10 11 12 13 14 15 16 17 18 19 20 ...

  • Page 310: Connecting Rods and Pistons

    Connecting rods and pistons 5-61 eas20132 connecting rods and pistons removing the connecting rods and pistons order job/parts to remove q’ty remarks lower crankcase refer to “crankcase” on page 5-57. 1 connecting rod cap 3 2 big end lower bearing 3 3 piston pin clip 6 4 piston pin 3 5 piston 3 6 co...

  • Page 311: Connecting Rods and Pistons

    Connecting rods and pistons 5-62 eas30745 removing the connecting rods and pistons the following procedure applies to all of the con- necting rods and pistons. 1. Remove: • connecting rod cap “1” • connecting rod • big end bearings tip • identify the position of each big end bearing so that it can b...

  • Page 312: Connecting Rods and Pistons

    Connecting rods and pistons 5-63 tip measure cylinder bore “c” by taking side-to-side and front-to-back measurements of the cylinder. B. If out of specification, replace the cylinder, and replace the piston and piston rings as a set. C. Measure piston skirt diameter “p” with the mi- crometer. D. If ...

  • Page 313: Connecting Rods and Pistons

    Connecting rods and pistons 5-64 3. Measure: • piston ring end gap out of specification  replace the piston ring. Tip the oil ring expander spacer’s end gap cannot be measured. If the oil ring rail’s gap is exces- sive, replace all three piston rings. Eas30749 checking the piston pin the following ...

  • Page 314: Connecting Rods and Pistons

    Connecting rods and pistons 5-65 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ the following procedure applies to all of the connecting rods. Notice eca13930 do not interchange the big end bearings and connecting rods. To obtain the correct crankshaft-pin-to-big-end-bearing clear- ance and prevent engine damage,...

  • Page 315: Connecting Rods and Pistons

    Connecting rods and pistons 5-66 necting rod cap faces the same direction as the “y” mark “b” on the connecting rod. • make sure the “y” marks “b” on the connecting rods face towards the left side of the crank- shaft. G. Tighten the connecting rod bolts with a torque wrench. H. Put a mark “1” on the...

  • Page 316: Connecting Rods and Pistons

    Connecting rods and pistons 5-67 eas30751 installing the connecting rod and piston the following procedure applies to all of the con- necting rods and pistons. 1. Install: • big end bearings • connecting rod cap (onto the connecting rod) tip • be sure to reinstall each big end bearing in its origina...

  • Page 317: Connecting Rods and Pistons

    Connecting rods and pistons 5-68 tip to install the big end bearing, care should be taken not to install it at an angle and the position should not be out of alignment. E. Loosen the connecting rod bolt, remove the connecting rod and connecting rod cap and install these parts to the crankshaft with ...

  • Page 318: Connecting Rods and Pistons

    Connecting rods and pistons 5-69 7. Lubricate: • crankshaft pins • connecting rod big end bearing inner surface (with the recommended lubricant) 8. Install: • piston assemblies “1” (into the cylinder “2” and onto the crankshaft pin) notice eca21490 if the projection “a” of the piston installing tool...

  • Page 319: Connecting Rods and Pistons

    Connecting rods and pistons 5-70 warning ewa16610 if the bolt is tightened more than the speci- fied angle, do not loosen the bolt and then re- tighten it. Instead, replace the bolt with a new one and perform the procedure again. Notice eca20890 do not use a torque wrench to tighten the bolt to the ...

  • Page 320: 5-71

    Crankshaft and balancer shaft 5-71 eas20178 crankshaft and balancer shaft removing the crankshaft and balancer shaft order job/parts to remove q’ty remarks lower crankcase refer to “crankcase” on page 5-57. Connecting rod refer to “removing the connecting rods and pistons” on page 5-62. 1 balancer s...

  • Page 321: 5-72

    Crankshaft and balancer shaft 5-72 eas31171 removing the crankshaft and balancer shaft 1. Remove: • balancer shaft “1” • balancer shaft journal bearing • crankshaft assembly “2” • crankshaft journal bearings tip identify the position of each balancer shaft jour- nal bearings and crankshaft journal b...

  • Page 322: 5-73

    Crankshaft and balancer shaft 5-73 d. Put a piece of plastigauge® “1” on each crankshaft journal. Tip do not put the plastigauge® over the oil hole in the crankshaft journal. E. Install the crankshaft journal lower bearings “1” into the lower crankcase and assemble the crankcase halves. Tip • align ...

  • Page 323: 5-74

    Crankshaft and balancer shaft 5-74 eas31076 checking the balancer shaft 1. Measure: • balancer shaft runout out of specification  replace the balancer shaft. 2. Check: • balancer shaft journal surfaces • bearing surfaces scratches/wear  replace the balancer shaft. 3. Measure: • balancer shaft jour...

  • Page 324: 5-75

    Crankshaft and balancer shaft 5-75 e. Install the balancer shaft journal lower bear- ings “1” into the lower crankcase and assem- ble the crankcase halves. Tip • align the projections “a” of the balancer shaft journal lower bearings with the notches “b” in the crankcase. • do not move the balancer s...

  • Page 325: 5-76

    Crankshaft and balancer shaft 5-76 • crankshaft journal lower bearings (into the lower crankcase) • crankshaft tip • align the projections “a” on the crankshaft jour- nal bearings “1” with the notches “b” in the crankcase. • be sure to install each crankshaft journal bear- ings in its original place...

  • Page 326: Transmission

    Transmission 5-77 eas20062 transmission removing the transmission, shift drum assembly, and shift forks order job/parts to remove q’ty remarks lower crankcase refer to “crankcase” on page 5-57. 1 drive axle assembly 1 2 oil seal 1 3 bearing 1 4 washer 1 5 shift drum retainer 2 6 shift fork guide bar...

  • Page 327: Transmission

    Transmission 5-78 disassembling the main axle assembly order job/parts to remove q’ty remarks 1 2nd pinion gear 1 2 toothed lock washer 1 3 toothed lock washer retainer 1 4 6th pinion gear 1 5 collar 1 6 washer 1 7 circlip 1 8 3rd pinion gear 1 9 circlip 1 10 washer 1 11 5th pinion gear 1 12 collar ...

  • Page 328: Transmission

    Transmission 5-79 disassembling the drive axle assembly order job/parts to remove q’ty remarks 1 bearing 1 2 washer 1 3 1st wheel gear 1 4 collar 1 5 5th wheel gear 1 6 circlip 1 7 washer 1 8 3rd wheel gear 1 9 collar 1 10 toothed lock washer 1 11 toothed lock washer retainer 1 12 4th wheel gear 1 1...

  • Page 329: Transmission

    Transmission 5-80 disassembling the drive axle assembly order job/parts to remove q’ty remarks 21 collar 1 22 bearing 1 23 circlip 1 24 drive axle 1 21 m m e m e 22 23 24 m m m m m m.

  • Page 330: Transmission

    Transmission 5-81 eas30430 removing the transmission 1. Remove: • drive axle assembly “1” • shift drum retainers “2” • shift fork guide bars • shift fork-l • shift fork-r • shift drum assembly • shift fork-c 2. Remove: • bearing housing “1” • main axle assembly “2” ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a...

  • Page 331: Transmission

    Transmission 5-82 eas30432 checking the shift drum assembly 1. Check: • shift drum groove damage/scratches/wear  replace the shift drum assembly. • shift drum segment “1” damage/wear  replace the shift drum as- sembly. • shift drum bearing “2” damage/pitting  replace the shift drum as- sembly. Ea...

  • Page 332: Transmission

    Transmission 5-83 positioned opposite side to the toothed washer and gear. • align the opening between the ends “b” of the circlip with a groove “c” in the axle. • install the circlip so that a spline “d” is in the center of the gap between the circlip ends “e” as shown. 2. Install: • toothed lock w...

  • Page 333: Transmission

    Transmission 5-84 3. Install: • shift fork-c “1” • shift drum assembly “2” • shift fork guide bar “3” tip • the embossed marks on the shift forks should face towards the right side of the engine and be in the following sequence: “r”, “c”, “l”. • carefully position the shift forks so that they are in...

  • Page 334: Transmission

    Transmission 5-85.

  • Page 335: Cooling System

    1 2 3 4 5 6 7 8 9 cooling system radiator........................................................................................................6-1 checking the radiator.....................................................................6-2 installing the radiator.....................................

  • Page 336: Radiator

    Radiator 6-1 eas20063 radiator removing the radiator order job/parts to remove q’ty remarks fuel tank front cover/front side panel/front side cowling refer to “general chassis (2)” on page 4-6. Coolant drain. Refer to “changing the coolant” on page 3-27. 1 coolant reservoir hose 1 disconnect. 2 cool...

  • Page 337: Radiator

    Radiator 6-2 eas30439 checking the radiator 1. Check: • radiator fins obstruction  clean. Apply compressed air to the rear of the radia- tor. Damage  repair or replace. Tip straighten any flattened fins with a thin, flat-head screwdriver. 2. Check: • radiator hoses • radiator pipes cracks/damage ...

  • Page 338: Radiator

    Radiator 6-3 pressure. C. Measure the indicated pressure with the gauge. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Measure: • radiator cap opening pressure below the specified pressure  replace the radiator cap. Refer to “checking the radiator” on page 6-2..

  • Page 339: Oil Cooler

    Oil cooler 6-4 eas20064 oil cooler removing the oil cooler order job/parts to remove q’ty remarks coolant reservoir refer to “radiator” on page 6-1. Muffler assembly refer to “engine removal” on page 5-3. Coolant drain. Refer to “changing the coolant” on page 3-27. Engine oil drain. Refer to “changi...

  • Page 340: Oil Cooler

    Oil cooler 6-5 eas30441 checking the oil cooler 1. Check: • oil cooler cracks/damage  replace. 2. Check: • oil cooler inlet hose • oil cooler outlet hose cracks/damage/wear  replace. Eas30442 installing the oil cooler 1. Clean: • mating surfaces of the oil cooler and the crankcase (with a cloth da...

  • Page 341: Thermostat

    Thermostat 6-6 eas20065 thermostat removing the thermostat assembly order job/parts to remove q’ty remarks muffler assembly refer to “engine removal” on page 5-3. Coolant drain. Refer to “changing the coolant” on page 3-27. 1 radiator outlet hose 1 2 water pump inlet hose 1 3 oil cooler outlet hose ...

  • Page 342: Thermostat

    Thermostat 6-7 eas30443 checking the thermostat 1. Check: • thermostat assembly “1” cracks/damage  replace. Eas30445 installing the thermostat assembly 1. Install: • thermostat assembly 2. Fill: • cooling system (with the specified amount of the recom- mended coolant) refer to “changing the coolant...

  • Page 343: Water Pump

    Water pump 6-8 eas20066 water pump removing the water pump order job/parts to remove q’ty remarks coolant drain. Refer to “changing the coolant” on page 3-27. 1 water pump inlet hose 1 disconnect. 2 water pump assembly 1 1 2 12 n ・m (1.2 kgf・m, 8.7 lb・ft).

  • Page 344: Water Pump

    Water pump 6-9 disassembling the water pump order job/parts to remove q’ty remarks 1 water pump housing cover 1 2 o-ring 1 3 circlip 1 4 water pump driven gear 1 5 pin 1 6 washer 1 7 impeller shaft 1 8 mechanical seal 1 9 bearing 1 10 oil seal 1 e e 1 2 3 4 5 6 7 8 9 10 10 n ・m (1.0 kgf・m, 7.2 lb・ft...

  • Page 345: Water Pump

    Water pump 6-10 eas30446 disassembling the water pump 1. Remove: • mechanical seal (housing side) “1” tip remove the mechanical seal (housing side) from the inside of the water pump housing “2”. 2. Remove: • bearing “1” • oil seal “2” tip remove the oil seal and bearing from the out- side of the wat...

  • Page 346: Water Pump

    Water pump 6-11 ing side) surface with oil or grease. Tip use the special tools and a press to press the mechanical seal (housing side) straight in until it touches the water pump housing. 3. Install: • mechanical seal (impeller side) “1” tip • before installing the mechanical seal (impeller side), ...

  • Page 347: Fuel System

    1 2 3 4 5 6 7 8 9 fuel system fuel tank ......................................................................................................7-1 removing the fuel tank ...................................................................7-3 removing the fuel pump ........................................

  • Page 348: Fuel Tank

    Fuel tank 7-1 eas20067 fuel tank removing the fuel tank order job/parts to remove q’ty remarks fuel tank front cover/front side panel/front side cowling refer to “general chassis (2)” on page 4-6. Passenger seat/rider seat refer to “general chassis (1)” on page 4-1. Fuel tank cover refer to “general...

  • Page 349: Fuel Tank

    Fuel tank 7-2 removing the canister order job/parts to remove q’ty remarks fuel tank front cover/front side panel/front side cowling refer to “general chassis (2)” on page 4-6. Passenger seat/rider seat refer to “general chassis (1)” on page 4-1. Fuel tank cover refer to “general chassis (3)” on pag...

  • Page 350: Fuel Tank

    Fuel tank 7-3 eas30450 removing the fuel tank 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. 2. Remove: • fuel tank front cover/front side panel/front side cowling refer to “general chassis (2)” on page 4-6. • passenger seat/rider seat refer to “general chassis (1)” on p...

  • Page 351: Fuel Tank

    Fuel tank 7-4 eas30456 installing the fuel pump 1. Install: • fuel pump gasket • fuel pump • fuel pump bracket • fuel pump bolts tip • do not damage the installation surfaces of the fuel tank when installing the fuel pump. • always use a new fuel pump gasket. • install the fuel pump gasket so that t...

  • Page 352: Throttle Bodies

    Throttle bodies 7-5 eas20070 throttle bodies removing the throttle bodies order job/parts to remove q’ty remarks fuel tank front cover/front side panel/front side cowling refer to “general chassis (2)” on page 4-6. Passenger seat/rider seat refer to “general chassis (1)” on page 4-1. Fuel tank cover...

  • Page 353: Throttle Bodies

    Throttle bodies 7-6 removing the sensors order job/parts to remove q’ty remarks 1 negative pressure hose 6 2 hose joint 2 3 canister purge hose 4 4 hose joint 2 5 intake air pressure sensor 2 1 6 intake air pressure sensor 1 1 7 throttle position sensor 1 8 accelerator position sensor 1 1 1 1 3 5 6 ...

  • Page 354: Throttle Bodies

    Throttle bodies 7-7 removing the injectors order job/parts to remove q’ty remarks throttle bodies/throttle body joint refer to “throttle bodies” on page 7-5. 1 fuel rail 1 2 injector 3 3 injector coupler 2 disconnect. 4 injector lead 1 5 injector lead coupler 1 disconnect. 6 wire harness 1 7 adapter...

  • Page 355: Throttle Bodies

    Throttle bodies 7-8 eas30475 checking the injectors (before removing) 1. Check: • injectors use the diagnostic code numbers “36”–“38”. Refer to “self-diagnostic function and diagnostic code table” on page 9-5. Eas31158 removing the fuel hose (fuel rail side) 1. Remove: • fuel tank refer to “removing...

  • Page 356: Throttle Bodies

    Throttle bodies 7-9 warning ewa17340 if the throttle bodies are subjected to strong shocks or dropped during cleaning, replace them as a set. 1. Check: • throttle bodies cracks/damage  replace the throttle bod- ies as a set. 2. Clean: • throttle bodies notice eca21540 • observe the following precau...

  • Page 357: Throttle Bodies

    Throttle bodies 7-10 • do not allow carbon deposits or other for- eign materials to enter any of the passages in each throttle body or in the space be- tween the throttle valve shaft and the throt- tle body. F. After removing the carbon deposits, clean the inside of the throttle bodies with the reco...

  • Page 358: Throttle Bodies

    Throttle bodies 7-11 to the fuel rail joint “2”, and then connect an air compressor “3” to the adapter. B. Connect the pressure gauge “4” to the fuel in- jector pressure adapter “1”. C. Close the valve on the fuel injector pressure adapter. D. Apply air pressure with the air compressor. E. Open the ...

  • Page 359: Throttle Bodies

    Throttle bodies 7-12 d. Start the engine. E. Measure the fuel line pressure. Faulty  replace the fuel pump. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Install: • fuel tank refer to “fuel tank” on page 7-1. • fuel tank cover refer to “general chassis (3)” on page 4-13. • rider seat/passenger seat refer to ...

  • Page 360: Throttle Bodies

    Throttle bodies 7-13 e. Diagnostic code number “01” is selected. F. Adjust the position of the throttle position sen- sor angle so that 11–21 can appear in the yamaha diagnostic tool screen. G. After adjusting the throttle position sensor an- gle, tighten the throttle position sensor screws “2”. ▲▲▲...

  • Page 361: Throttle Bodies

    Throttle bodies 7-14 l. Select the diagnostic code number “15”. M. Turn the throttle grip to the fully closed posi- tion. N. Check the yamaha diagnostic tool screen value. If the yamaha diagnostic tool screen value is not 10–24, adjust the accelerator po- sition sensor angle. O. Turn the throttle gr...

  • Page 362: Air Induction System

    Air induction system 7-15 eas20071 air induction system 1 2 3 2 3 4 4.

  • Page 363: Air Induction System

    Air induction system 7-16 1. Air filter case 2. Air induction system hose (air filter case to air cut-off valve) 3. Air cut-off valve 4. Air induction system hose (air cut-off valve to reed valve cover).

  • Page 364: Air Induction System

    Air induction system 7-17 removing the air cut-off valve assembly and reed valves order job/parts to remove q’ty remarks fuel tank front cover/front side panel/front side cowling refer to “general chassis (2)” on page 4-6. Passenger seat/rider seat refer to “general chassis (1)” on page 4-1. Fuel ta...

  • Page 365: Air Induction System

    Air induction system 7-18 order job/parts to remove q’ty remarks 11 reed valve assembly 2 1 12 reed valve plate 2 lt 11 lt lt 12 10 n ・m (1.0 kgf・m, 7.2 lb・ft) 10 n ・m (1.0 kgf・m, 7.2 lb・ft).

  • Page 366: Air Induction System

    Air induction system 7-19 eas30488 checking the air induction system air injection the air induction system burns unburned ex- haust gases by injecting fresh air (secondary air) into the exhaust port, reducing the emission of hydrocarbons. When there is negative pressure at the exhaust port, the ree...

  • Page 367: Air Induction System

    Air induction system 7-20 2. Install: • reed valve assembly 1 • reed valve assembly 2 tip • install the reed valve assembly 1 so that the open side turns to the exhaust side of the en- gine. • install the reed valve assembly 2 so that the open side turns to the intake side of the engine. 3. Install:...

  • Page 368: Air Induction System

    Air induction system 7-21.

  • Page 369: Electrical System

    1 2 3 4 5 6 7 8 9 electrical system ignition system ..........................................................................................8-1 circuit diagram ...................................................................................8-1 engine stopping due to sidestand operation............

  • Page 370

    Abs (anti-lock brake system)..........................................................8-117 circuit diagram ...............................................................................8-117 abs components chart ................................................................8-119 abs coupler loca...

  • Page 372: Ignition System

    Ignition system 8-1 eas20072 ignition system eas30490 circuit diagram.

  • Page 373: Ignition System

    Ignition system 8-2 3. Main switch 4. Main fuse 11.Ignition fuse 15.Battery 16.Engine ground 17.Fuel injection system fuse 20.Joint connector 21.Joint coupler 22.Relay unit 25.Sidestand switch 28.Ecu (engine control unit) 29.Ignition coil #1 30.Ignition coil #2 31.Ignition coil #3 32.Spark plug 40.C...

  • Page 374: Ignition System

    Ignition system 8-3 eas30491 engine stopping due to sidestand operation when the engine is running and the transmission is in gear, the engine will stop if the sidestand is moved down. This is because the electric current from the ignition coils does not flow to the ecu when both the gear position s...

  • Page 375: Ignition System

    Ignition system 8-4 eas30492 troubleshooting the ignition system fails to operate (no spark or intermittent spark). Tip • before troubleshooting, remove the following part(s): 1. Fuel tank front cover/front side panel/front side cowling 2. Passenger seat/rider seat 3. Fuel tank cover 4. Fuel tank 5....

  • Page 376: Ignition System

    Ignition system 8-5 9. Check the gear position switch. Refer to “checking the gear position switch” on page 8-173. Ng replace the gear position switch. Ok 10.Check the sidestand switch. Refer to “checking the switches” on page 8-153. Ng replace the sidestand switch. Ok 11.Check the relay unit (d...

  • Page 377: Ignition System

    Ignition system 8-6.

  • Page 378: Electric Starting System

    Electric starting system 8-7 eas20073 electric starting system eas30493 circuit diagram.

  • Page 379: Electric Starting System

    Electric starting system 8-8 3. Main switch 4. Main fuse 11.Ignition fuse 15.Battery 16.Engine ground 17.Fuel injection system fuse 18.Starter relay 19.Starter motor 20.Joint connector 21.Joint coupler 22.Relay unit 23.Starting circuit cut-off relay 25.Sidestand switch 67.Gear position switch 70.Han...

  • Page 380: Electric Starting System

    Electric starting system 8-9 eas30494 starting circuit cut-off system operation if the main switch is turned to “on” and the “ ” side of the start/engine stop switch is pushed, the starter motor can only operate if at least one of the following conditions is met: • the transmission is in neutral (th...

  • Page 381: Electric Starting System

    Electric starting system 8-10 a. When the transmission is in neu- tral b. When the sidestand is up and the clutch lever is pulled to the han- dlebar 1. Battery 2. Main fuse 3. Main switch 4. Ignition fuse 5. Start/engine stop switch 6. Starting circuit cut-off relay 7. Diode 8. Clutch switch 9. Side...

  • Page 382: Electric Starting System

    Electric starting system 8-11 eas30495 troubleshooting the starter motor fails to turn. Tip • before troubleshooting, remove the following part(s): 1. Fuel tank front cover/front side panel/front side cowling 2. Passenger seat/rider seat 3. Fuel tank cover 4. Fuel tank 5. Air filter case 6. Throttle...

  • Page 383: Electric Starting System

    Electric starting system 8-12 9. Check the gear position switch. Refer to “checking the gear position switch” on page 8-173. Ng replace the gear position switch. Ok 10.Check the sidestand switch. Refer to “checking the switches” on page 8-153. Ng replace the sidestand switch. Ok 11.Check the clu...

  • Page 384: Charging System

    Charging system 8-13 eas20074 charging system eas30496 circuit diagram.

  • Page 385: Charging System

    Charging system 8-14 1. Ac magneto 2. Rectifier/regulator 4. Main fuse 15.Battery 16.Engine ground a. Wire harness d. Negative battery sub-wire harness.

  • Page 386: Charging System

    Charging system 8-15 eas30497 troubleshooting the battery is not being charged. Tip • before troubleshooting, remove the following part(s): 1. Passenger seat/rider seat 2. Rear side cover (left)/lower tail cover 1. Check the fuse. (main) refer to “checking the fuses” on page 8-157. Ng replace the f...

  • Page 387: Charging System

    Charging system 8-16.

  • Page 388: Lighting System

    Lighting system 8-17 eas20075 lighting system eas30498 circuit diagram.

  • Page 389: Lighting System

    Lighting system 8-18 3. Main switch 4. Main fuse 11.Ignition fuse 13.Signaling system fuse 15.Battery 16.Engine ground 20.Joint connector 21.Joint coupler 28.Ecu (engine control unit) 53.Meter assembly 56.Meter light 62.High beam indicator light 77.Handlebar switch (left) 84.Dimmer/pass switch 89.He...

  • Page 390: Lighting System

    Lighting system 8-19 eas30499 troubleshooting any of the following fail to light: headlight, high beam indicator light, taillight, license light or meter light. Tip • before troubleshooting, remove the following part(s): 1. Fuel tank front cover/front side panel/front side cowling 2. Passenger seat/...

  • Page 391: Lighting System

    Lighting system 8-20

  • Page 392: Signaling System

    Signaling system 8-21 eas20076 signaling system eas30500 circuit diagram.

  • Page 393: Signaling System

    Signaling system 8-22 3. Main switch 4. Main fuse 11.Ignition fuse 13.Signaling system fuse 15.Battery 16.Engine ground 20.Joint connector 21.Joint coupler 22.Relay unit 28.Ecu (engine control unit) 42.Coolant temperature sensor 47.Rear wheel sensor 48.Abs ecu (electronic control unit) 53.Meter asse...

  • Page 394: Signaling System

    Signaling system 8-23 eas30501 troubleshooting • any of the following fail to light: turn signal light, brake light or an indicator light. • the horn fails to sound. • the fuel meter fails to comeon. • the speedometer fails to operate. Tip • before troubleshooting, remove the following part(s): 1. F...

  • Page 395: Signaling System

    Signaling system 8-24 the tail/brake light fails to come on. The turn signal light, turn signal indicator light or both fail to blink. 3. Check the entire signaling system’s wiring. Refer to “circuit diagram” on page 8-21. Ng properly connect or repair the signaling system’s wiring. Ok this circui...

  • Page 396: Signaling System

    Signaling system 8-25 the neutral indicator light fails to come on. The oil level warning light fails to come on. The fuel meter, fuel level warning light, or both fail to come on. 5. Check the entire signaling system’s wiring. Refer to “circuit diagram” on page 8-21. Ng properly connect or repair ...

  • Page 397: Signaling System

    Signaling system 8-26 the speedometer fails to operate. Tip repair or replace if there is an open or short circuit. • between rear wheel sensor coupler and abs ecu coupler. (white–white) (black–black) • between abs ecu coupler and ecu coupler. (white/green–white/green) (white/yellow–white/yellow) • ...

  • Page 398: Cooling System

    Cooling system 8-27 eas20077 cooling system eas30502 circuit diagram.

  • Page 399: Cooling System

    Cooling system 8-28 3. Main switch 4. Main fuse 9. Radiator fan motor fuse 11.Ignition fuse 15.Battery 16.Engine ground 20.Joint connector 21.Joint coupler 28.Ecu (engine control unit) 42.Coolant temperature sensor 96.Radiator fan motor relay 97.Radiator fan motor a. Wire harness c. Sub-wire harness...

  • Page 400: Cooling System

    Cooling system 8-29 eas30503 troubleshooting tip • before troubleshooting, remove the following part(s): 1. Fuel tank front cover/front side panel/front side cowling 2. Passenger seat/rider seat 3. Fuel tank cover 4. Fuel tank 5. Air filter case 6. Canister 7. Throttle bodies 1. Check the fuses. (ma...

  • Page 401: Cooling System

    Cooling system 8-30

  • Page 402: Fuel Injection System

    Fuel injection system 8-31 eas20078 fuel injection system eas30504 circuit diagram.

  • Page 403: Fuel Injection System

    Fuel injection system 8-32 3. Main switch 4. Main fuse 7. Electronic throttle valve fuse 8. Backup fuse 11.Ignition fuse 15.Battery 16.Engine ground 17.Fuel injection system fuse 18.Starter relay 20.Joint connector 21.Joint coupler 22.Relay unit 23.Starting circuit cut-off relay 24.Fuel pump relay 2...

  • Page 404: Fuel Injection System

    Fuel injection system 8-33 eas30505 ecu self-diagnostic function the ecu is equipped with a self-diagnostic function in order to ensure that the fuel injection system is operating normally. If this function detects a malfunction in the system, it immediately operates the en- gine under substitute ch...

  • Page 405: Fuel Injection System

    Fuel injection system 8-34 if a malfunction is detected in the sensors or actuators, repair or replace all faulty parts. If no malfunction is detected in the sensors and actuators, check and repair the inner parts of the engine. Eas30951 yamaha diagnostic tool this model uses the yamaha diagnostic t...

  • Page 406: Fuel Injection System

    Fuel injection system 8-35 functions of the yamaha diagnostic tool however, the yamaha diagnostic tool cannot be used to freely change the basic vehicle functions, such as adjusting the ignition timing. Connecting the yamaha diagnostic tool remove the protective cap “1”, and then connect the yamaha ...

  • Page 407: Fuel Injection System

    Fuel injection system 8-36 parts connected to the ecu the following parts are connected to the ecu. When checking for a power short circuit, the couplers must be disconnected from all of the following parts beforehand. Fault code no. P0030 tip • if fault code numbers “p0030” and “p0112” are both ind...

  • Page 408: Fuel Injection System

    Fuel injection system 8-37 1 connection of o 2 sensor cou- pler. Check the locking condition of the coupler. Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the pins). Improperly connected  con- nect the coupler securely or replace the wire harness. Turn...

  • Page 409: Fuel Injection System

    Fuel injection system 8-38 fault code no. P0107, p0108 4 defective o 2 sensor heater. Replace the o 2 sensor. Turn the main switch to “on”, and then check the condition of the fault code using the mal- function mode of the yamaha diagnostic tool. Condition is “recovered”  go to item 6 and finish th...

  • Page 410: Fuel Injection System

    Fuel injection system 8-39 2 connection of ecu coupler. Check the locking condition of the coupler. Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the pins). Improperly connected  con- nect the coupler securely or replace the wire harness. Turn the main...

  • Page 411: Fuel Injection System

    Fuel injection system 8-40 3-4 [for p0108] open circuit between intake air pressure sensor 1 coupler and ecu coupler: blue–blue if there is no continuity, replace the wire harness. 3-5 [for p0108] open circuit between intake air pressure sensor 1 coupler and ecu coupler: pink–pink if there is no con...

  • Page 412: Fuel Injection System

    Fuel injection system 8-41 3-8 [for p0107/p0108] short circuit between intake air pressure sensor 1 output terminal (pink) “a” of ecu coupler and any other ecu coupler terminal “b”. If there is continuity, replace the wire harness. 4 installed condition of intake air pressure sensor 1. Check for loo...

  • Page 413: Fuel Injection System

    Fuel injection system 8-42 fault code no. P0112, p0113 tip perform this procedure when the engine is cold. 7 delete the fault code and check that the engine trouble warning light goes off. Confirm that the fault code has a condition of “recovered” using the yamaha diagnostic tool, and then delete th...

  • Page 414: Fuel Injection System

    Fuel injection system 8-43 3-1 1. Intake air temperature sensor 2. Ecu 3. Sensor output lead 4. Sensor ground lead 3-2 disconnect the ecu coupler from the ecu. Disconnect the intake air temperature sensor coupler from the intake air temperature sensor. 3-3 [for p0112] ground short circuit between in...

  • Page 415: Fuel Injection System

    Fuel injection system 8-44 3-5 [for p0113] open circuit between intake air temperature sensor coupler and ecu coupler: black/blue–black/blue if there is no continuity, replace the wire harness. 3-6 disconnect the couplers from the parts that are connected to the ecu. Refer to “parts connected to the...

  • Page 416: Fuel Injection System

    Fuel injection system 8-45 fault code no. P0117, p0118 tip perform this procedure when the engine is cold. 6 malfunction in ecu. Replace the ecu. Refer to “replacing the ecu (engine control unit)” on page 8-157. Service is finished. 7 delete the fault code and check that the engine trouble warning l...

  • Page 417: Fuel Injection System

    Fuel injection system 8-46 3 wire harness and/or sub-wire harness continuity. Open or short circuit  replace the wire harness and/or sub- wire harness. Turn the main switch to “on”, and then check the condition of the fault code using the mal- function mode of the yamaha diagnostic tool. Condition ...

  • Page 418: Fuel Injection System

    Fuel injection system 8-47 3-4 [for p0118] open circuit between wire harness coupler (ecu side) and ecu coupler: green/white–green/white between sub-wire harness coupler (coolant temperature sensor side) and coolant temperature sen- sor coupler: green/white–green/white if there is no continuity, rep...

  • Page 419: Fuel Injection System

    Fuel injection system 8-48 3-7 [for p0117/p0118] short circuit between wire harness (ecu side) output terminal (green/white) “a” of ecu coupler and any other ecu coupler terminal “b”. Between sub-wire harness (coolant temperature sensor side) output terminal (green/white) “c” and output terminal (bl...

  • Page 420: Fuel Injection System

    Fuel injection system 8-49 fault code no. P0122, p0123, p0222, p0223, p2135 tip if a fault code other than no. P2135 (p0122/p0123/p0222/p0223) is detected, perform troubleshooting first. Fault code no. P0122, p0123, p0222, p0223, p2135 item [p0122] throttle position sensor: ground short circuit dete...

  • Page 421: Fuel Injection System

    Fuel injection system 8-50 3-1 1. Throttle position sensor 2. Ecu 3. Sensor input lead 4. Sensor output lead 1 5. Sensor output lead 2 6. Sensor ground lead 3-2 disconnect the ecu coupler from the ecu. Disconnect the throttle position sensor coupler from the throttle position sensor. 3-3 [for p0122]...

  • Page 422: Fuel Injection System

    Fuel injection system 8-51 3-4 [for p0123] open circuit between throttle position sensor coupler and ecu coupler: white–white if there is no continuity, replace the wire harness. 3-5 [for p0222] ground short circuit between throttle position sensor coupler and ground: black–ground if there is contin...

  • Page 423: Fuel Injection System

    Fuel injection system 8-52 3-7 [for p0123/p0223] open circuit between throttle position sensor coupler and ecu coupler: blue–blue if there is no continuity, replace the wire harness. 3-8 [for p0123/p0223] open circuit between throttle position sensor coupler and ecu coupler: black/blue–black/blue if...

  • Page 424: Fuel Injection System

    Fuel injection system 8-53 3-11 [for p0222/p0223] short circuit between throttle position sensor output terminal (black) “a” of ecu coupler and any other ecu cou- pler terminal “b”. If there is continuity, replace the wire harness. 4 installed condition of throttle position sensor. Check for loosene...

  • Page 425: Fuel Injection System

    Fuel injection system 8-54 fault code no. P0132 6 defective throttle position sen- sor. Check throttle position sensor signal 1. Execute the diagnostic mode. (code no. 01) when the throttle valves are fully closed: a value of 11–21 is indicated. When throttle valves are fully open: a value of 96–106...

  • Page 426: Fuel Injection System

    Fuel injection system 8-55 1 installed condition of o 2 sensor. Check for looseness or pinch- ing. Improperly installed sensor  reinstall or replace the sensor. Turn the main switch to “on”, and then check the condition of the fault code using the mal- function mode of the yamaha diagnostic tool. C...

  • Page 427: Fuel Injection System

    Fuel injection system 8-56 fault code no. P0201 fault code no. P0201 item fuel injector #1: malfunction in fuel injector #1. Fail-safe system able to start engine (depending on the number of faulty cylinders) able to drive vehicle (depending on the number of faulty cylinders) diagnostic code no. 36 ...

  • Page 428: Fuel Injection System

    Fuel injection system 8-57 fault code no. P0202 fault code no. P0202 item fuel injector #2: malfunction in fuel injector #2. Fail-safe system able to start engine (depending on the number of faulty cylinders) able to drive vehicle (depending on the number of faulty cylinders) diagnostic code no. 37 ...

  • Page 429: Fuel Injection System

    Fuel injection system 8-58 fault code no. P0203 6 malfunction in ecu. Replace the ecu. Refer to “replacing the ecu (engine control unit)” on page 8-157. 7 delete the fault code and check that the engine trouble warning light goes off. Start the engine and let it idle for approximately 5 seconds. Con...

  • Page 430: Fuel Injection System

    Fuel injection system 8-59 fault code no. P0335 4 wire harness continuity. Open or short circuit  replace the wire harness. Between fuel injector coupler and ecu coupler. Blue/black–blue/black between fuel injector coupler and relay unit coupler. Red/blue–red/blue execute the diagnostic mode. (code...

  • Page 431: Fuel Injection System

    Fuel injection system 8-60 3 wire harness continuity. Open or short circuit  replace the wire harness. Between crankshaft position sensor coupler and ecu cou- pler. Gray–gray between crankshaft position sensor coupler and joint con- nector. Black/blue–black/blue between joint connector and ecu coup...

  • Page 432: Fuel Injection System

    Fuel injection system 8-61 fault code no. P0351 fault code no. P0351 item cylinder-#1 ignition coil: open or short circuit detected in the pri- mary lead of the cylinder-#1 ignition coil. Fail-safe system able to start engine (depending on the number of faulty cylinders) able to drive vehicle (depen...

  • Page 433: Fuel Injection System

    Fuel injection system 8-62 fault code no. P0352 5 defective cylinder-#1 ignition coil. Measure the primary coil resis- tance of the cylinder-#1 ignition coil. Replace if out of specification. Refer to “checking the ignition coils” on page 8-163. Start the engine and let it idle for approximately 5 s...

  • Page 434: Fuel Injection System

    Fuel injection system 8-63 2 connection of ecu coupler. Check the locking condition of the coupler. Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the pins). Improperly connected  con- nect the coupler securely or replace the wire harness. Start the eng...

  • Page 435: Fuel Injection System

    Fuel injection system 8-64 fault code no. P0353 fault code no. P0353 item cylinder-#3 ignition coil: open or short circuit detected in the pri- mary lead of the cylinder-#3 ignition coil. Fail-safe system able to start engine (depending on the number of faulty cylinders) able to drive vehicle (depen...

  • Page 436: Fuel Injection System

    Fuel injection system 8-65 fault code no. P0500, p1500 tip in case “p0500” is detected, or both “p0500” and “p1500” are detected, proceed from item a-1. 5 defective cylinder-#3 ignition coil. Measure the primary coil resis- tance of the cylinder-#3 ignition coil. Replace if out of specification. Ref...

  • Page 437: Fuel Injection System

    Fuel injection system 8-66 a-1 locate the malfunction. (fault code no. P0500 or p0500 and p1500 detected.) execute the diagnostic mode. (code no. 07) rotate the rear wheel by hand and check that the indicated value increases. Value does not increase  go to item a-2. (fault code no. P1500 detected.)...

  • Page 438: Fuel Injection System

    Fuel injection system 8-67 a-5 rear wheel sensor lead continu- ity, or defective rear wheel sen- sor. Open or short circuit, or defec- tive sensor  replace the rear wheel sensor. Between rear wheel sensor cou- pler and abs ecu coupler. Black–black white–white between abs ecu coupler and ecu coupler...

  • Page 439: Fuel Injection System

    Fuel injection system 8-68 fault code no. P0500, p1500 item a rear wheel sensor: no normal signals are received from the rear wheel sensor. B neutral switch: open or short circuit is detected. C clutch switch: open or short circuit is detected. Fail-safe system able to start engine able to drive veh...

  • Page 440: Fuel Injection System

    Fuel injection system 8-69 b-3 connection of ecu coupler. Check the locking condition of the coupler. Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the pins). Improperly connected  con- nect the coupler securely or replace the wire harness. Execute the...

  • Page 441: Fuel Injection System

    Fuel injection system 8-70 b-8 malfunction in ecu. Replace the ecu. Refer to “replacing the ecu (engine control unit)” on page 8-157. Service is finished. B-9 delete the fault code and check that the engine trouble warning light goes off. Turn the main switch to “on”, and then rotate the rear wheel ...

  • Page 442: Fuel Injection System

    Fuel injection system 8-71 c-1 locate the malfunction. (fault code no. P0500 or p0500 and p1500 detected.) execute the diagnostic mode. (code no. 07) rotate the rear wheel by hand and check that the indicated value increases. Value does not increase  go to item a-2 for the rear wheel sensor. (fault...

  • Page 443: Fuel Injection System

    Fuel injection system 8-72 c-4 connection of ecu coupler. Check the locking condition of the coupler. Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the pins). Improperly connected  con- nect the coupler securely or replace the wire harness. Execute the...

  • Page 444: Fuel Injection System

    Fuel injection system 8-73 fault code no. P0560 c-8 delete the fault code and check that the engine trouble warning light goes off. Turn the main switch to “on”, and then rotate the rear wheel by hand. Start the engine, and input the vehicle speed signals by operat- ing the vehicle at 20 to 30 km/h ...

  • Page 445: Fuel Injection System

    Fuel injection system 8-74 fault code no. P0601, p0606 fault code no. P062f fault code no. P0601, p0606 item internal malfunction in ecu. (when this malfunction is detected in the ecu, the fault code number might not appear on the tool dis- play.) fail-safe system able/unable to start engine able/un...

  • Page 446: Fuel Injection System

    Fuel injection system 8-75 2 “01” is indicated in diagnostic mode (code no. 60). Eeprom data error for adjustment of co concentration of cylinder #1. Change the co concentration of cylinder #1, and rewrite in eeprom. Refer to “adjusting the exhaust gas volume” on page 3-11. After this adjustment is ...

  • Page 447: Fuel Injection System

    Fuel injection system 8-76 fault code no. P0638 fault code no. P0638 item ycc-t drive system: malfunction detected. Fail-safe system able/unable to start engine able/unable to drive vehicle diagnostic code no. — tool display — procedure — item probable cause of malfunc- tion and check maintenance jo...

  • Page 448: Fuel Injection System

    Fuel injection system 8-77 fault code no. P0657 6 defective throttle bodies. Check the throttle bodies. Replace if defective. Refer to “checking the throttle servo motor” on page 8-171. Turn the main switch to “on”, and then check the condition of the fault code using the mal- function mode of the y...

  • Page 449: Fuel Injection System

    Fuel injection system 8-78 2 connection of ecu coupler. Check the locking condition of the coupler. Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the pins). Improperly connected  con- nect the coupler securely or replace the wire harness. Start the eng...

  • Page 450: Fuel Injection System

    Fuel injection system 8-79 fault code no. P1004 fault code no. P1004 item intake air pressure sensor 1 or intake air pressure sensor 2: when the main switch is turned to “on”, the intake air pressure sensor 1 voltage and intake air pressure sensor 2 voltage differ greatly. Fail-safe system able to s...

  • Page 451: Fuel Injection System

    Fuel injection system 8-80 fault code no. P1400 3 malfunction in ecu. Replace the ecu. Refer to “replacing the ecu (engine control unit)” on page 8-157. Service is finished. 4 delete the fault code and check that the engine trouble warning light goes off. Confirm that the fault code has a condition ...

  • Page 452: Fuel Injection System

    Fuel injection system 8-81 2 connection of ecu coupler. Check the locking condition of the coupler. Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the pins). Improperly connected  con- nect the coupler securely or replace the wire harness. Turn the main...

  • Page 453: Fuel Injection System

    Fuel injection system 8-82 fault code no. P1601 6 delete the fault code and check that the engine trouble warning light goes off. Confirm that the fault code has a condition of “recovered” using the yamaha diagnostic tool, and then delete the fault code. Fault code no. P1601 item sidestand switch: o...

  • Page 454: Fuel Injection System

    Fuel injection system 8-83 fault code no. P1602 4 wire harness continuity. Open or short circuit  replace the wire harness. Between relay unit coupler and ecu coupler. Black/red–black/red between relay unit coupler and sidestand switch coupler. Blue/black–blue/black turn the main switch to “on”, an...

  • Page 455: Fuel Injection System

    Fuel injection system 8-84 2 connection of starter relay cou- pler. Check the locking condition of the coupler. Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the pins). Improperly connected  con- nect the coupler securely or replace the wire harness. T...

  • Page 456: Fuel Injection System

    Fuel injection system 8-85 fault code no. P1604, p1605 fault code no. P1604, p1605 item [p1604] lean angle sensor: ground short circuit detected. [p1605] lean angle sensor: open or power short circuit. Fail-safe system unable to start engine unable to drive vehicle diagnostic code no. 08 tool displa...

  • Page 457: Fuel Injection System

    Fuel injection system 8-86 3-1 1. Lean angle sensor 2. Ecu 3. Sensor input lead 4. Sensor output lead 5. Sensor ground lead 3-2 disconnect the ecu coupler from the ecu. Disconnect the lean angle sensor coupler from the lean angle sensor. 3-3 [for p1604] ground short circuit between lean angle sensor...

  • Page 458: Fuel Injection System

    Fuel injection system 8-87 3-5 [for p1605] open circuit between lean angle sensor coupler and ecu coupler: yellow/green–yellow/green if there is no continuity, replace the wire harness. 3-6 [for p1605] open circuit between lean angle sensor coupler and ecu coupler: black/blue–black/blue if there is ...

  • Page 459: Fuel Injection System

    Fuel injection system 8-88 fault code no. P1606, p1607 4 defective lean angle sensor. Refer to “checking the lean angle sensor” on page 8-165. Turn the main switch to “on”, then to “off”, and then back to “on”. Check the condition of the fault code using the malfunction mode of the yamaha diagnostic...

  • Page 460: Fuel Injection System

    Fuel injection system 8-89 3 wire harness continuity. Open or short circuit  replace the wire harness. Turn the main switch to “on”, and then check the condition of the fault code using the mal- function mode of the yamaha diagnostic tool. Condition is “recovered”  go to item 7 and finish the serv...

  • Page 461: Fuel Injection System

    Fuel injection system 8-90 3-4 [for p1607] open circuit between intake air pressure sensor 2 coupler and ecu coupler: blue–blue if there is no continuity, replace the wire harness. 3-5 [for p1607] open circuit between intake air pressure sensor 2 coupler and ecu coupler: pink/white–pink/white if the...

  • Page 462: Fuel Injection System

    Fuel injection system 8-91 3-8 [for p1606/p1607] short circuit between intake air pressure sensor 2 output terminal (pink/white) “a” of ecu coupler and any other ecu coupler terminal “b”. If there is continuity, replace the wire harness. 4 installed condition of intake air pressure sensor 2. Check f...

  • Page 463: Fuel Injection System

    Fuel injection system 8-92 fault code no. P2122, p2123, p2127, p2128, p2138 tip if a fault code other than no. P2138 (p2122/p2123/p2127/p2128) is detected, perform troubleshooting first. 7 delete the fault code and check that the engine trouble warning light goes off. Confirm that the fault code has...

  • Page 464: Fuel Injection System

    Fuel injection system 8-93 2 connection of ecu coupler. Check the locking condition of the coupler. Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the pins). Improperly connected  con- nect the coupler securely or replace the wire harness. Turn the main...

  • Page 465: Fuel Injection System

    Fuel injection system 8-94 3-3 [for p2122] ground short circuit between accelerator position sensor coupler and ground: white–ground if there is continuity, replace the wire harness. 3-4 [for p2122] open circuit between accelerator position sensor coupler and ecu coupler: white–white if there is no ...

  • Page 466: Fuel Injection System

    Fuel injection system 8-95 3-6 [for p2128] open circuit between accelerator position sensor coupler and ecu coupler: black–black if there is no continuity, replace the wire harness. 3-7 [for p2122/p2128] open circuit between accelerator position sensor coupler and ecu coupler: blue–blue if there is ...

  • Page 467: Fuel Injection System

    Fuel injection system 8-96 3-10 [for p2122/p2123] short circuit between accelerator position sensor output terminal (white) “a” of ecu coupler and any other ecu coupler terminal “b”. If there is continuity, replace the wire harness. 3-11 [for p2127/p2128] short circuit between accelerator position s...

  • Page 468: Fuel Injection System

    Fuel injection system 8-97 fault code no. P2158 6 defective accelerator position sensor. Check accelerator position sen- sor signal 1. Execute the diagnostic mode. (code no. 14) when the throttle grip is fully closed: a value of 12–22 is indicated. When throttle grip is are fully open: a value of 97...

  • Page 469: Fuel Injection System

    Fuel injection system 8-98 1 locate the malfunction. If the abs warning light is on, refer to “basic instruc- tions for troubleshoot- ing” on page 8-124. If the abs warning light is off, perform the following procedure. Execute the diagnostic mode. (code no. 16) rotate the front wheel by hand and ch...

  • Page 470: Fuel Injection System

    Fuel injection system 8-99 fault code no. P2195 tip if fault code numbers “p2195” and “p0030” are both indicated, take the actions specified for fault code number “p0030” first. 6 defective front wheel sensor. Improperly installed sensor  reinstall or replace the sensor. Execute the diagnostic mode...

  • Page 471: Fuel Injection System

    Fuel injection system 8-100 1 installed condition of o 2 sensor. Check for looseness or pinch- ing. Improperly installed sensor  reinstall or replace the sensor. Start the engine and let it idle for approximately 10 seconds. Check the condition of the fault code using the malfunction mode of the ya...

  • Page 472: Fuel Injection System

    Fuel injection system 8-101 event code no. U0155 or “err” tip “err” is displayed on the clock display of the multi-function meter, but the engine trouble warning light does not come on. 5 check fuel pressure. Refer to “checking the fuel pressure” on page 7-11. Start the engine and let it idle for ap...

  • Page 473: Fuel Injection System

    Fuel injection system 8-102 2 connection of ecu coupler. Check the locking condition of the coupler. Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the pins). Improperly connected  con- nect the coupler securely or replace the wire harness. Turn the mai...

  • Page 474: Fuel Pump System

    Fuel pump system 8-103 eas20081 fuel pump system eas30513 circuit diagram.

  • Page 475: Fuel Pump System

    Fuel pump system 8-104 3. Main switch 4. Main fuse 11.Ignition fuse 15.Battery 16.Engine ground 17.Fuel injection system fuse 20.Joint connector 21.Joint coupler 22.Relay unit 24.Fuel pump relay 28.Ecu (engine control unit) 69.Fuel pump 70.Handlebar switch (right) 72.Start/engine stop switch a. Wire...

  • Page 476: Fuel Pump System

    Fuel pump system 8-105 eas30514 troubleshooting if the fuel pump fails to operate. Tip • before troubleshooting, remove the following part(s): 1. Fuel tank front cover/front side panel/front side cowling 2. Passenger seat/rider seat 3. Fuel tank cover 4. Fuel tank 1. Check the fuses. (main, ignition...

  • Page 477: Fuel Pump System

    Fuel pump system 8-106.

  • Page 478: Immobilizer System

    Immobilizer system 8-107 eas20084 immobilizer system eas30519 circuit diagram.

  • Page 479: Immobilizer System

    Immobilizer system 8-108 3. Main switch 4. Main fuse 8. Backup fuse 11.Ignition fuse 15.Battery 16.Engine ground 20.Joint connector 21.Joint coupler 26.Immobilizer unit 28.Ecu (engine control unit) 53.Meter assembly 54.Immobilizer system indicator light 58.Multi-function meter a. Wire harness d. Neg...

  • Page 480: Immobilizer System

    Immobilizer system 8-109 eas30520 general information this vehicle is equipped with an immobilizer system to help prevent theft by re-registering codes in the standard keys. This system consists of the following: • a code re-registering key (with a red bow) • two standard keys (with a black bow) tha...

  • Page 481: Immobilizer System

    Immobilizer system 8-110 * accessory locks mean the seat lock and fuel tank cap. Code re-registering key registration: when the immobilizer unit or ecu is replaced, the code re-registering key must be registered to the unit. To register a code re-registering key: 1. Turn the main switch to “on” with...

  • Page 482: Immobilizer System

    Immobilizer system 8-111 standard key registration: standard key registration is required when a standard key is lost and needs to be replaced, or when the code re-registering key is re-registered after the immobilizer unit or ecu are replaced. Tip do not start the engine with a standard key that ha...

  • Page 483: Immobilizer System

    Immobilizer system 8-112 standard key code voiding method a. Main switch “on” b. Main switch “off” c. Led on d. Led off e. Less than 5.0 s f. Code re-registering key g. Remaining standard key h. Registration mode a. If the immobilizer system indicator light stops flashing 5 seconds after the first s...

  • Page 484: Immobilizer System

    Immobilizer system 8-113 eas30522 troubleshooting when the main switch is turned to “on”, the immobilizer system indicator light does not come on nor flashes. 1. Check the fuses. (main, ignition, and backup) refer to “checking the fuses” on page 8-157. Ng replace the fuse(s). Ok 2. Check the batte...

  • Page 485: Immobilizer System

    Immobilizer system 8-114 eas30523 self-diagnosis fault code indication when a system failure occurs, the immobilizer system indicator light blinks. The pattern of blinking shows the fault code. Fault code part symptom cause action 51 immobilizer unit code cannot be trans- mitted between the key and ...

  • Page 486: Immobilizer System

    Immobilizer system 8-115 immobilizer system indicator light fault code indication digit of 10 : cycles of 1 sec. On and 1.5 sec. Off. Digit of 1 : cycles of 0.5 sec. On and 0.5 sec. Off. Example: fault code 52 56 ecu unidentified code is received. Noise interference or dis- connected lead/cable. 1. ...

  • Page 487: Immobilizer System

    Immobilizer system 8-116.

  • Page 488: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-117 eas20085 abs (anti-lock brake system) eas30843 circuit diagram.

  • Page 489: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-118 3. Main switch 4. Main fuse 5. Abs motor fuse 6. Abs solenoid fuse 11.Ignition fuse 12.Abs control unit fuse 13.Signaling system fuse 15.Battery 16.Engine ground 20.Joint connector 21.Joint coupler 22.Relay unit 23.Starting circuit cut-off relay 28.Ecu (engine cont...

  • Page 490: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-119 eas30525 abs components chart 1 2 3 4 5 8 9 1 6 7.

  • Page 491: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-120 1. Hydraulic unit assembly 2. Fuse box 3 3. Yamaha diagnostic tool coupler 4. Rear wheel sensor 5. Rear wheel sensor rotor 6. Front wheel sensor 7. Front wheel sensor rotor 8. Abs warning light 9. Fuse box 2.

  • Page 492: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-121 eas30844 abs coupler location chart 2 1 3 4 5.

  • Page 493: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-122 1. Meter assembly coupler 2. Rear wheel sensor coupler 3. Abs ecu coupler 4. Yamaha diagnostic tool coupler 5. Front wheel sensor coupler.

  • Page 494: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-123 eas30845 maintenance of the abs ecu checking the abs ecu 1. Check: • terminals “1” of the abs ecu cracks/damages  replace the hydraulic unit assembly, brake hoses, and brake pipes that are connected to the assembly as a set. • terminals “2” of the abs ecu coupler ...

  • Page 495: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-124 self-diagnosis and servicing the abs ecu has a self-diagnosis function. By utilizing this function, quick problem identification and service are possible. Previous malfunctions can be checked since the abs ecu also stores the mal- function history. The fault codes ...

  • Page 496: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-125 eas30530 basic process for troubleshooting [a-1] does only the abs warning light fail to come on? [a-2] do all indicator lights fail to come on? [a-4] only the abs ecu fails to communicate. [a-5] abs ecu and fi ecu fail to communicate. The abs warning light (led) i...

  • Page 497: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-126 warning ewa16710 when maintenance or checks have been performed on components related to the abs, be sure to perform a final check before delivering the vehicle to the customer. Tip to final check, refer to “[c-1] final check” on page 8-147. Eas30531 [a] checking t...

  • Page 498: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-127 eas31163 [a-4] only the abs ecu fails to communicate 1. Abs ecu fuse • check the abs ecu fuse for continuity. Refer to “checking the fuses” on page 8-157. • if the abs ecu fuse is blown, replace the fuse. 2. Abs ecu coupler • check that the abs ecu coupler is conne...

  • Page 499: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-128 connecting the yamaha diagnostic tool removing the rider seat. Refer to “general chassis (1)” on page 4-1. Removing the protective cap “1”, and then connect the yamaha diagnostic tool to the coupler. Details about the displayed fault codes are shown in the followin...

  • Page 500: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-129 14* 27* rear wheel sensor (abnor- mal pulse period) rear wheel sensor signal is not received properly. (the pulse period is abnormal while the vehicle is traveling.) • foreign material adhered around the rear wheel sen- sor • incorrect installation of the rear whee...

  • Page 501: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-130 24 brake light switch or tail/brake light brake light signal is not received properly while the vehicle is traveling. (brake light circuit, or front or rear brake light switch circuit.) • defective signaling system (tail/brake light or brake light switch) • defecti...

  • Page 502: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-131 42 47 rear wheel abs (intermit- tent wheel speed pulses or incorrect depressurization) • pulses from the rear wheel sensor are received inter- mittently while the vehicle is traveling. (for fault code no. 42) • rear wheel will not recover from the locking tendency ...

  • Page 503: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-132 * the fault code number varies according to the vehicle conditions. For details, refer to the “trouble- shooting details”. Troubleshooting details fault code no. 11, 25 55 hydraulic unit assembly (defective abs ecu) abnormal data is detected in the hydraulic unit a...

  • Page 504: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-133 tip with the front wheel stopped, the rear wheel was rotated for longer than about 20 seconds (fault code no. 11) or for longer than about 2 seconds (fault code no. 25). Fault code no. 12 fault code no. 13, 26 fault code no. 12 item rear wheel sensor (intermittent ...

  • Page 505: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-134 tip • if the front brake abs operates continuously for 20 seconds or more, fault code no. 26 will be record- ed. If the front brake abs operates continuously for 36 seconds or more, fault code no. 13 will be re- corded. • vehicle possibly ridden on uneven roads. Fa...

  • Page 506: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-135 fault code no. 16 2 open or short circuit in the wire harness between the front wheel sensor and the hydraulic unit assembly • check for continuity between the white terminal “1” and the white terminal “4” and between the black ter- minal “2” and the black terminal...

  • Page 507: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-136 fault code no. 17, 45 2 open or short circuit in the wire harness between the rear wheel sensor and the hydraulic unit assembly • check for continuity between the white terminal “1” and the white terminal “4” and between the black ter- minal “2” and the black termi...

  • Page 508: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-137 tip if pulse gaps are detected when the vehicle is traveling at a speed of 30 km/h (19 mi/h) or more, fault code no. 17 will be recorded. If the vehicle is traveling at a speed of 29 km/h (18 mi/h) or less, fault code no. 45 will be recorded first and fault code no...

  • Page 509: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-138 fault code no. 21 fault code no. 24 fault code no. 31 fault code no. 21 item hydraulic unit assembly (defective solenoid drive circuit) symptom solenoid drive circuit in the hydraulic unit assembly is open or short-circuited. Order item/components and probable caus...

  • Page 510: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-139 fault code no. 32 fault code no. 33 2 defective coupler between the battery and the hydraulic unit assembly • check the locking condition of the coupler. • if there is a malfunction, repair it and connect the cou- pler securely. Tip turn the main switch to “off” be...

  • Page 511: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-140 fault code no. 34 fault code no. 41 3 open or short circuit in the wire harness between the battery and the hydraulic unit assembly • replace if there is an open or short circuit. • between abs ecu coupler and starter relay coupler (abs motor fuse). (red/blue–red/b...

  • Page 512: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-141 fault code no. 42, 47 3 front brake dragging check that the brake fluid pressure is correctly transmit- ted to the brake caliper when the brake lever is operated and that the pressure decreases when the lever is released. Refer to “checking the front brake discs” o...

  • Page 513: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-142 fault code no. 43 fault code no. 44 fault code no. 43 item front wheel sensor (missing pulses) symptom front wheel sensor signal is not received properly. (missing pulses are detected in the signal while the vehicle is traveling.) order item/components and probable...

  • Page 514: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-143 fault code no. 51, 52 fault code no. 53 fault code no. 51 52 item • vehicle system power supply (voltage of abs ecu power supply is high) (for fault code no. 51) • vehicle system power supply (voltage of wheel sensor power sup- ply is high) (for fault code no. 52) ...

  • Page 515: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-144 fault code no. 54 fault code no. 55 fault code no. 54 item hydraulic unit assembly (defective abs solenoid and abs motor power supply circuits) symptom abnormality is detected in the solenoid or motor power supply cir- cuit in the hydraulic unit assembly. Order ite...

  • Page 516: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-145 fault code no. 56 fault code no. 63 fault code no. 56 item hydraulic unit assembly (abnormal internal power supply) symptom abnormality is detected in the power supply circuit in the hydraulic unit assembly. Order item/components and probable cause check or mainten...

  • Page 517: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-146 fault code no. 64 3 defective hydraulic unit assembly replace the hydraulic unit assembly. Refer to “abs (anti-lock brake system)” on page 4-60. Fault code no. 64 item rear wheel sensor power supply (voltage of power supply is low) symptom power voltage supplied fr...

  • Page 518: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-147 eas31167 [b-3] deleting the fault codes to delete the fault codes, use the yamaha diagnostic tool. For information about deleting the fault codes, refer to the operation manual of the yamaha diagnostic tool. Check that all the displayed fault codes are deleted. Con...

  • Page 519: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-148 check for continuity between green/red terminal of the abs ecu coupler and green/red terminal of the meter assembly coupler. • malfunction in the meter assembly circuit. • malfunction in the abs warning light circuit in the hydraulic unit assembly..

  • Page 520: Electrical Components

    Electrical components 8-149 eas20089 electrical components.

  • Page 521: Electrical Components

    Electrical components 8-150 1. Main switch/immobilizer unit 2. Clutch switch 3. Front brake light switch 4. Hydraulic unit assembly 5. Battery 6. Fuse box 3 7. Main fuse 8. Fuel injection system fuse 9. Starter relay 10.Rectifier/regulator 11.Rear wheel sensor 12.Rear brake light switch 13.Gear posi...

  • Page 522: Electrical Components

    Electrical components 8-151 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19.

  • Page 523: Electrical Components

    Electrical components 8-152 1. Intake air temperature sensor 2. Ecu (engine control unit) 3. Fuel pump 4. Lean angle sensor 5. Radiator fan motor relay 6. Turn signal/hazard relay 7. Relay unit 8. Stator coil 9. Crankshaft position sensor 10.Coolant temperature sensor 11.Throttle servo motor 12.Acce...

  • Page 524: Electrical Components

    Electrical components 8-153 eas30549 checking the switches b/y w/r b w/g br b/r dg ch y/b br/w b/w y w/l w/g dg br/w b/w ch r/b r/w b w/l b/l b/l 2 1 3 4 6 5 7 8 12 13 14 9 10 11.

  • Page 525: Electrical Components

    Electrical components 8-154 1. Dimmer/pass switch 2. Turn signal switch 3. Horn switch 4. Select switch 5. Menu switch 6. Clutch switch 7. Oil level switch 8. Sidestand switch 9. Hazard switch 10.Start/engine stop switch 11.Drive mode switch 12.Front brake light switch 13.Main switch 14.Rear brake l...

  • Page 526: Electrical Components

    Electrical components 8-155 check each switch for continuity with the digital curcuit tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. Notice eca14371 never insert the tester probes into the coupler terminal slots. Always insert the p...

  • Page 527: Electrical Components

    Electrical components 8-156 eas30550 checking the bulbs and bulb sockets check each bulb and bulb socket for damage or wear, proper connections, and also for continuity between the terminals. Damage/wear  repair or replace the bulb, bulb socket or both. Improperly connected  properly connect. No c...

  • Page 528: Electrical Components

    Electrical components 8-157 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas30551 checking the fuses the following procedure applies to all of the fus- es. Notice eca13680 to avoid a short circuit, always set the main switch to “off” when checking or replacing a fuse. 1. Remove: • passenger seat/rider seat refe...

  • Page 529: Electrical Components

    Electrical components 8-158 refer to “checking and cleaning the throttle bodies” on page 7-8. 4. Check: • engine idling speed start the engine, warm it up, and then mea- sure the engine idling speed. Eas30552 checking and charging the battery warning ewa13290 batteries generate explosive hydrogen ga...

  • Page 530: Electrical Components

    Electrical components 8-159 nected). • no charging is necessary when the open-cir- cuit voltage equals or exceeds 12.8 v. B. Check the charge of the battery, as shown in the charts and the following example. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 5. Charge: • battery (refer to the appropriate charging met...

  • Page 531: Electrical Components

    Electrical components 8-160 charging. Tip voltage should be measured 30 minutes after the engine is stopped. B. Connect a charger and ammeter to the bat- tery and start charging. Tip set the charging voltage to 16–17 v. If the set- ting is lower, charging will be insufficient. If too high, the batte...

  • Page 532: Electrical Components

    Electrical components 8-161 10.Install: • rider seat/passenger seat refer to “general chassis (1)” on page 4-1. Eas30553 checking the relays check each switch for continuity with the digital circuit tester. If the continuity reading is incor- rect, replace the relay. 1. Disconnect the relay from the...

  • Page 533: Electrical Components

    Electrical components 8-162 radiator fan motor relay eas30794 checking the turn signal/hazard relay 1. Check: • turn signal/hazard relay input voltage out of specification  the wiring circuit from the main switch to the turn signal/hazard re- lay coupler is faulty and must be repaired. ▼▼▼▼▼▼▼▼▼▼▼▼...

  • Page 534: Electrical Components

    Electrical components 8-163 eas30795 checking the relay unit (diode) 1. Check: • relay unit (diode) out of specification  replace. Tip the digital circuit tester readings are shown in the following table. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the relay unit coupler from the wire harness. B...

  • Page 535: Electrical Components

    Electrical components 8-164 c. Measure the primary coil resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Check: • secondary coil resistance out of specification  replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the digital circuit tester () to the ig- nition coil as shown. B. Measure the second...

  • Page 536: Electrical Components

    Electrical components 8-165 b. Measure the crankshaft position sensor re- sistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas30561 checking the lean angle sensor 1. Remove: • lean angle sensor (from the fuel tank bracket) 2. Check: • lean angle sensor output voltage out of specification  replace. ▼▼▼▼▼▼...

  • Page 537: Electrical Components

    Electrical components 8-166 fluid is in the vicinity. B. Check the starter motor operation. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas30566 checking the stator coil 1. Disconnect: • stator coil coupler (from the wire harness) 2. Check: • stator coil resistance out of specification  replace the stator coi...

  • Page 538: Electrical Components

    Electrical components 8-167 c. Start the engine and let it run at approximate- ly 5000 r/min. D. Measure the rectifier/regulator input voltage. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Check: • rectifier/regulator output voltage out of specification  replace the rectifi- er/regulator. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...

  • Page 539: Electrical Components

    Electrical components 8-168 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the digital circuit tester () to the oil level switch terminal as shown. B. Measure the oil level switch resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas30573 checking the fuel sender 1. Disconnect: • fuel pump coupler (from th...

  • Page 540: Electrical Components

    Electrical components 8-169 1. Check: • fuel meter/fuel level warning light “1” (turn the main switch to “on”.) warning light comes on for a few seconds, then goes off  warning light is ok. Warning light does not come on  replace the meter assembly. Warning light flashes eight times, then goes off...

  • Page 541: Electrical Components

    Electrical components 8-170 b. Immerse the coolant temperature sensor “1” in a container filled with coolant “2”. Tip make sure the coolant temperature sensor ter- minals do not get wet. C. Place a thermometer “3” in the coolant. D. Heat the coolant or let it cool down to the specified temperatures....

  • Page 542: Electrical Components

    Electrical components 8-171 tance out of specification  replace the accelera- tor position sensor. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the digital circuit tester () to the ac- celerator position sensor terminals as shown. B. Measure the accelerator position sensor maximum resistance. ▲▲▲▲▲...

  • Page 543: Electrical Components

    Electrical components 8-172 c. Measure the air induction system solenoid re- sistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas30593 checking the intake air pressure sensor 1. Check: • intake air pressure sensor output voltage out of specification  replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect t...

  • Page 544: Electrical Components

    Electrical components 8-173 with special care. • never subject the intake air temperature sensor to strong shocks. If the intake air temperature sensor is dropped, replace it. 2. Check: • intake air temperature sensor resistance out of specification  replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Con...

  • Page 545: Electrical Components

    Electrical components 8-174 eas30681 checking the fuel injectors the following procedure applies to all of the fuel injectors. 1. Remove: • fuel injector refer to “throttle bodies” on page 7-5. 2. Check: • fuel injector resistance out of specification  replace the fuel injec- tor. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...

  • Page 546: Electrical Components

    Electrical components 8-175.

  • Page 547: Troubleshooting

    1 2 3 4 5 6 7 8 9 troubleshooting troubleshooting......................................................................................9-1 general information ........................................................................9-1 starting failures...................................................

  • Page 548: Troubleshooting

    Troubleshooting 9-1 eas20090 troubleshooting eas30599 general information tip the following guide for troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to basic trouble- shooting. Refer to the relative procedure in this manual for checks, ad...

  • Page 549: Troubleshooting

    Troubleshooting 9-2 • worn or damaged electrode • worn or damaged insulator 3. Ignition coil(s) • broken or shorted primary or secondary coils • cracked or broken ignition coil 4. Ignition system • faulty ecu • faulty crankshaft position sensor • broken generator rotor woodruff key eas30602 poor med...

  • Page 550: Troubleshooting

    Troubleshooting 9-3 • damaged pipe • improperly connected pipe fuel system 1. Throttle body (-ies) • damaged or loose throttle body joint 2. Air filter • clogged air filter element chassis 1. Brake(s) • dragging brake electrical system 1. Spark plug(s) • incorrect spark plug gap • incorrect spark pl...

  • Page 551: Troubleshooting

    Troubleshooting 9-4 • incorrect connection • faulty tail/brake light assembly turn signal does not come on • faulty turn signal switch • faulty turn signal/hazard relay • burnt-out turn signal bulb • incorrect connection • damaged or faulty wire harness • improperly grounded circuit • faulty battery...

  • Page 552: 9-5

    Self-diagnostic function and diagnostic code table 9-5 eas20116 self-diagnostic function and diagnostic code table eas31794 self-diagnostic function table (for fuel injection system) tip for details of the fault code, refer to “troubleshooting method” on page 8-33. Fault code no. Item probable cause...

  • Page 553: 9-6

    Self-diagnostic function and diagnostic code table 9-6 p0117 p0118 [p0117] coolant tem- perature sensor (ground short circuit detected) [p0118] coolant tem- perature sensor (open or power short circuit detected) [p0117] low voltage of the coolant temper- ature sensor circuit (0.1 v or less) [p0118] ...

  • Page 554: 9-7

    Self-diagnostic function and diagnostic code table 9-7 p0132 o 2 sensor (short cir- cuit detected (power short circuit)) [p0132] high voltage of the o 2 sensor cir- cuit (4.8 v or more) • improperly installed o 2 sensor. • defective coupler between o 2 sensor and ecu. • open or short cir- cuit in wi...

  • Page 555: 9-8

    Self-diagnostic function and diagnostic code table 9-8 p0351 p0352 p0353 [p0351] cylinder-#1 ignition coil (open or short circuit detected in the primary lead of the cylinder-#1 igni- tion coil.) [p0352] cylinder-#2 ignition coil (open or short circuit detected in the primary lead of the cylinder-#2...

  • Page 556: 9-9

    Self-diagnostic function and diagnostic code table 9-9 p0601 internal malfunction in ecu (rom data error) (when this mal- function is detected in the ecu, the fault code number might not appear on the tool display.) • malfunction in ecu. Engine cannot be started. Engine cannot be started. P0606 inte...

  • Page 557: 9-10

    Self-diagnostic function and diagnostic code table 9-10 p1004 intake air pressure sensor 1 or intake air pressure sensor 2: when the main switch is turned to “on”, the intake air pressure sensor 1 voltage and intake air pressure sensor 2 voltage differ greatly. • malfunction in ecu. • hose of intake...

  • Page 558: 9-11

    Self-diagnostic function and diagnostic code table 9-11 p1602 malfunction in ecu internal circuit (mal- function of ecu power cut-off function) • open or short cir- cuit in wire harness between ecu and battery. • open or short cir- cuit in wire harness between ecu and main switch. • blown backup fus...

  • Page 559: 9-12

    Self-diagnostic function and diagnostic code table 9-12 p2122 p2123 p2127 p2128 p2138 [p2122] accelerator position sensor (open or ground short cir- cuit detected) [p2123] accelerator position sensor (power short circuit detected) [p2127] accelerator position sensor (ground short circuit detected) [...

  • Page 560: 9-13

    Self-diagnostic function and diagnostic code table 9-13 eas31795 self-diagnostic function table (for immobilizer system) tip for details of the fault code, refer to “self-diagnosis fault code indication” on page 8-114. Eas31119 communication error with the meter eas31120 diagnostic code: sensor oper...

  • Page 561: 9-14

    Self-diagnostic function and diagnostic code table 9-14 05 air temperature displays the air temperature. Compare the actually mea- sured air temperature with the tool display value. 06 coolant temperature when engine is cold: dis- plays temperature closer to air temperature. When engine is hot: disp...

  • Page 562: 9-15

    Self-diagnostic function and diagnostic code table 9-15 20 sidestand switch extend and retract the sides- tand (with the transmission in gear). • stand retracted on • stand extended off 21 gear position switch and clutch switch operate the transmission, clutch lever, and sidestand. • transmission is...

  • Page 563: 9-16

    Self-diagnostic function and diagnostic code table 9-16 * diagnostic code no. 86 is the diagnostic code number for the optional shift switch. Eas31121 diagnostic code: actuator operation table 86 * shift switch check the switch condition by operating the shift pedal. • shift pedal up position on • o...

  • Page 564: 9-17

    Self-diagnostic function and diagnostic code table 9-17 38 injector #3 actuates the injector #3 five times at one-second inter- vals. The “check” indicator on the yamaha diagnostic tool screen come on each time the injector is actuated. Disconnect the fuel pump coupler. Check that injector #3 is act...

  • Page 565: Event Code Table

    Event code table 9-18 eas20164 event code table no. Item symptom possible causes note 192 intake air pres- sure sensor 1 brief abnormality detected in the intake air pressure sensor 1 same as for fault code number p0107 and p0108 perform the checks and maintenance jobs for fault code number p0107 an...

  • Page 566: Event Code Table

    Event code table 9-19 242 isc (stuck at the upper limit for adjustment) during idling, the adjustment is main- tained at the upper limit idling engine speed is slow • clogged throttle body • poorly adjusted throttle cable • poorly adjusted clutch cable • malfunction in the fuel injection system • di...

  • Page 567: Event Code Table

    Event code table 9-20 eas32023 troubleshooting details (event code) event code no. 30 event code no. 30 item latch up detected. Fail-safe system unable to start engine unable to drive vehicle diagnostic code no. 08 tool display lean angle sensor output voltage • 0.4–1.4 (upright) • 3.7–4.4 (overturn...

  • Page 568: Event Code Table

    Event code table 9-21 event code no. 70 tip if another error code is displayed at the same time, check the other error code first and repair it. Event code no. 70 item engine forcibly stops when the vehicle is left idling for a long period of time. Item probable cause of malfunc- tion and check main...

  • Page 569: Wiring Diagram

    Eas20091 wiring diagram mt09tra/mt09trah 2017 1. Ac magneto 2. Rectifier/regulator 3. Main switch 4. Main fuse 5. Abs motor fuse 6. Abs solenoid fuse 7. Electronic throttle valve fuse 8. Backup fuse 9. Radiator fan motor fuse 10. Auxiliary fuse 2 11. Ignition fuse 12. Abs control unit fuse 13. Signa...

  • Page 570

    Eas30613 color code b black br brown ch chocolate dg dark green g green gy gray l blue lg light green o orange p pink r red sb sky blue v violet w white y yellow b/l black/blue b/r black/red b/w black/white b/y black/yellow br/b brown/black br/l brown/blue br/r brown/red br/w brown/white br/y brown/...

  • Page 573

    Mt09tra/mt09trah 2017 wiring diagram mt09tra/mt09trah 2017 schÉma de cblage mt09tra/mt09trah 2017 schaltplan mt09tra/mt09trah 2017 schema elettrico mt09tra/mt09trah 2017 diagrama elÉctrico 2sc-28197-e0_w.D.Indd 1 2016/10/28 16:52:49.

  • Page 574

    Mt09tra/mt09trah 2017 wiring diagram mt09tra/mt09trah 2017 schÉma de cblage mt09tra/mt09trah 2017 schaltplan mt09tra/mt09trah 2017 schema elettrico mt09tra/mt09trah 2017 diagrama elÉctrico 2sc-28197-e0_w.D.Indd 2 2016/10/28 16:52:50