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Yamaha XP530A Service Manual
Summary of XP530A
Page 1
Service manual xp500a 2012 59c-28197-e1.
Page 2
Eas20040 xp500a service manual ©2011 by yamaha motor co., ltd. First edition, november 2011 all rights reserved. Any reproduction or unauthorized use without the written permission of yamaha motor co., ltd. Is expressly prohibited..
Page 3: Important
Eas20071 important this manual was produced by the yamaha motor company, ltd. Primarily for use by yamaha deal- ers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on y...
Page 4: How To Use This Manual
Eas20091 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 5: Symbols
Eas20101 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: Table of Contents
1 2 3 4 5 6 7 8 9 eas20110 table of contents general information specifications periodic checks and adjustments chassis engine cooling system fuel system electrical system troubleshooting.
Page 9: General Information
1 general information identification ..........................................................................................1-1 vehicle identification number...................................................1-1 model label ............................................................................
Page 10: Identification
Identification 1-1 eas20130 identification eas20140 vehicle identification number the vehicle identification number “1” is stamped into the right side of the frame. Eas20150 model label the model label “1” is affixed to the storage box. This information will be needed to order spare parts..
Page 11: Features
Features 1-2 eas20170 features eas4b51038 outline of fi system the main function of a fuel supply system is to provide fuel to the combustion chamber at the opti- mum air-fuel ratio in accordance with the engine operating conditions. In a conventional carburetor system, the air-fuel ratio of the mix...
Page 12: Features
Features 1-3 eas4b51039 fi system the fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator (in the fuel pump) maintains the fuel pressure that is applied to the fuel injector at a certain level. Accordingly, when the energizing signal from the ecu (engine control ...
Page 13: Features
Features 1-4 eas52240 multi-function display warning ewa12312 be sure to stop the vehicle before making any setting changes to the multi-function display. Changing settings while riding can distract the operator and increase the risk of an accident. The multi-function display is equipped with the fo...
Page 14: Features
Features 1-5 5. Push the left set button and then release it to start the clock. Odometer and tripmeter modes pushing the left set button switches the display between the odometer mode and the tripmeter modes in the following order: odo → trip 1 → trip 2 → v-belt trip → oil trip → odo when approxima...
Page 15: Features
Features 1-6 eca10021 do not continue to operate the engine if it is overheating. Oil change indicator “oil” this indicator flashes at the initial 1000 km (600 mi), then at 5000 km (3000 mi) and every 5000 km (3000 mi) thereafter to indicate that the engine oil should be changed. After changing the ...
Page 16: Features
Features 1-7 ambient temperature display, average fuel consumption and instantaneous fuel con- sumption modes push the right set button to switch the display between the ambient temperature display “air”, the average fuel consumption mode “ave_ _._ km/l” or “ave_ _._ l/100 km”, and the instan- taneo...
Page 17: Features
Features 1-8 tip after resetting an average fuel consumption display, “_ _._” is shown for that display until the vehicle has traveled 1 km (0.6 mi). Instantaneous fuel consumption mode the instantaneous fuel consumption display can be set to either “km/l” or “l/100 km” (except for the uk). For the ...
Page 18: Features
Features 1-9 eca11590 if the display indicates an error code, the vehicle should be checked as soon as pos- sible in order to avoid engine damage..
Page 19: Features
Features 1-10 eas59c2101 outline of the abs 1. The yamaha abs (anti-lock brake system) features an electronic control system, which acts on the front and rear brakes independently. 2. The abs features a compact and lightweight design to help maintain the basic maneuverability of the vehicle. Abs lay...
Page 20: Features
Features 1-11 useful terms • wheel speed: the rotation speed of the front and rear wheels. • chassis speed: the speed of the chassis. When the brakes are applied, wheel speed and chassis speed are reduced. However, the chassis travels forward by its inertia even though the wheel speed is reduced. • ...
Page 21: Features
Features 1-12 brake force and vehicle stability when the brake pressure is increased, wheel speed is reduced. Slipping occurs between the tire and the road surface and brake force is generated. The limit of this brake force is determined by the friction force between the tire and the road surface an...
Page 22: Features
Features 1-13 wheel slip and hydraulic control the abs ecu calculates the wheel speed of each wheel according to the rotation signal received from the front and rear wheel sensors. In addition, the abs ecu calculates the vehicle chassis speed and the rate of speed reduction based on the wheel speed ...
Page 23: Features
Features 1-14 abs operation and vehicle control if the abs starts operating, there is a tendency of the wheel to lock, and the vehicle is approaching the limit of control. To make the rider aware of this condition, the abs has been designed to gener- ate a reaction-force pulsating action in the fron...
Page 24: Features
Features 1-15 electronic abs features the yamaha abs (anti-lock brake system) has been developed with the most advanced electronic technology. The abs control is processed with good response under various vehicle travel conditions. The abs also includes a highly developed self-diagnosis function. Th...
Page 25: Features
Features 1-16 eas59c2102 abs component functions wheel sensors and wheel sensor rotors wheel sensors “1” detect the wheel rotation speed and transmit the wheel rotation signal to the abs ecu. Each wheel sensor contains a hall ic. The wheel sensors are installed in the sensor housing for each wheel. ...
Page 26: Features
Features 1-17 abs warning light the abs warning light “1” comes on to warn the rider if a malfunction in the abs occurs. When the main switch is set to “on”, the abs warning light comes on to check the electrical circuit and the system function (abs self-diagnosis), and goes off when the vehicle is ...
Page 27: Features
Features 1-18 • hydraulic control valve the hydraulic control valve is composed of a inlet solenoid valve and outlet solenoid valve. The electromagnetic force generated in the inlet solenoid valve varies proportionally with the duty cycle control voltage that is supplied to it. Since this voltage is...
Page 28: Features
Features 1-19 • buffer chamber the buffer chamber accumulates the brake fluid that is depressurized while the abs is operating. 1. Buffer chamber (pressurizing phase) 2. Buffer chamber (depressurizing phase) 3. Raised piston.
Page 29: Features
Features 1-20 abs ecu the abs ecu is integrated with the hydraulic unit to achieve a compact and lightweight design. As shown in the following block diagram, the abs ecu receives wheel sensor signals from the front and rear wheels and also receives signals from other monitor circuits. The necessary ...
Page 30: Features
Features 1-21 abs control operation the abs control operation performed in the abs ecu is divided into the following two parts. • hydraulic control • self-diagnosis when a malfunction is detected in the abs, a fault code is stored in the memory of the abs ecu for easy problem identification and trou...
Page 31: Features
Features 1-22 eas59c2103 abs operation the abs hydraulic circuit consists of two systems: the front wheel, and rear wheel. The following describes the system for the front wheel only. Normal braking (abs not activated) when the abs is not activated, the inlet solenoid valve is open and the outlet so...
Page 32: Features
Features 1-23 emergency braking (abs activated) 1. Depressurizing phase when the front wheel is about to lock, the outlet solenoid valve is opened by the “depressuriza- tion” signal transmitted from the abs ecu. When this occurs, the inlet solenoid valve com- presses the spring and closes the brake ...
Page 33: Features
Features 1-24 2. Pressurizing phase the outlet solenoid valve is closed by the “pressurization” signal transmitted from the abs ecu. At this time, the abs ecu controls the opening of the inlet solenoid valve. As the inlet solenoid valve opens, the brake line from the brake master cylinder opens, all...
Page 34: Features
Features 1-25 eas59c2104 abs self-diagnosis function abs warning light the abs warning light “1” comes on when a malfunction is detected by the abs self-diagnosis. It is located in the meter assembly. Instances when the abs warning light comes on 1. The abs warning light comes on when the main switc...
Page 35: Features
Features 1-26 2. The abs warning light comes on while the start switch is being pushed. 3. The abs warning light comes on while riding. If the abs warning light comes on while riding, a malfunction has been detected in the abs. The abs hydraulic control will not be performed. The abs will have recou...
Page 36: Features
Features 1-27 5. The abs warning light “1” flashes and a fault code “2” is indicated on the multi-function display when the test coupler adapter “3” is connected to the abs test coupler “4” for troubleshooting the abs. When the test coupler adapter is connected to the abs test coupler, the abs warni...
Page 37: Features
Features 1-28 eas59c2105 abs warning light and operation abs function warning ewa59c2103 • when hydraulic control is performed by the abs, the brake system alerts the rider that the wheels have a tendency to lock by generating a reaction-force pulsating action in the front brake lever or rear brake ...
Page 38: Important Information
Important information 1-29 eas20180 important information eas20190 preparation for removal and disas- sembly 1. Before removal and disassembly, remove all dirt, mud, dust and foreign material. 2. Use only the proper tools and cleaning equipment. Refer to “special tools” on page 1-37. 3. When disasse...
Page 39: Important Information
Important information 1-30 eas20231 bearings and oil seals install bearings “1” and oil seals “2” so that the manufacturer marks or numbers are visible. When installing oil seals, lubricate the oil seal lips with a light coat of lithium-soap-based grease. Oil bearings liberally when installing, if a...
Page 40: Basic Service Information
Basic service information 1-31 eas30380 basic service information eas30390 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 41: Basic Service Information
Basic service information 1-32 eas30402 electrical system electrical parts handling eca16600 never disconnect a battery lead while the engine is running; otherwise, the electrical components could be damaged. Eca16751 when disconnecting the battery leads from the battery, be sure to disconnect the n...
Page 42: Basic Service Information
Basic service information 1-33 eca16610 set the main switch to “off” before dis- connecting or connecting an electrical component. Eca16620 handle electrical components with special care, and do not subject them to strong shocks. Eca16630 electrical components are very sensitive to and can be damage...
Page 43: Basic Service Information
Basic service information 1-34 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 avail- able test harness. Checking the connections check the lea...
Page 44: Basic Service Information
Basic service information 1-35 • after disassembling and assembling a cou- pler, pull on the leads to make sure that they are installed securely. 4. Connect: • lead • coupler • connector tip • when connecting a coupler or connector, push both sections of the coupler or connec- tor together until the...
Page 45: Basic Service Information
Basic service information 1-36 tip the resistance values shown were obtained at the standard measuring temperature of 20 °c (68 °f). If the measuring temperature is not 20 °c (68 °f), the specified measuring conditions will be shown. Intake air temperature sensor resistance 5.4–6.6 k Ω at 0 °c (32 °...
Page 46: Special Tools
Special tools 1-37 eas20260 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 inappropri- ate tools or improvised techniques. Special tools, part numbers...
Page 47: Special Tools
Special tools 1-38 compression gauge 90890-03081 engine compression tester yu-33223 5-1 oil filter wrench 90890-01469 ym-01469 3-26, 6-6 oil pressure gauge set 90890-03120 3-28 oil pressure adapter b 90890-03124 3-28 test coupler adapter 90890-03149 1-27, 4-73, 4-74 pressure gauge 90890-03153 yu-031...
Page 48: Special Tools
Special tools 1-39 t-handle 90890-01326 t-handle 3/8" drive 60 cm long ym-01326 4-84, 4-85 fork seal driver weight 90890-01367 replacement hammer ym-a9409-7 4-86 fork seal driver attachment (ø43) 90890-01374 replacement 43 mm ym-a5142-3 4-86 yamaha bond no. 1215 90890-85505 (three bond no.1215®) 5-1...
Page 49: Special Tools
Special tools 1-40 valve guide remover (ø4) 90890-04111 valve guide remover (4.0 mm) ym-04111 5-24 valve guide installer (ø4) 90890-04112 valve guide installer (4.0 mm) ym-04112 5-24 valve guide reamer (ø4) 90890-04113 valve guide reamer (4.0 mm) ym-04113 5-24 piston pin puller set 90890-01304 pisto...
Page 50: Special Tools
Special tools 1-41 sheave spring compressor 90890-04134 ym-04134 5-45, 5-47 sheave fixed block 90890-04135 sheave fixed bracket ym-04135 5-45, 5-47 sheave holder 90890-01701 primary clutch holder ys-01880-a 5-53, 5-55 flywheel puller 90890-01362 heavy duty puller yu-33270-b 5-53 rotor holding tool 9...
Page 51: Special Tools
Special tools 1-42 universal clutch holder 90890-04086 ym-91042 5-60, 5-63 plane bearing installer 90890-04139 5-76, 5-80 radiator cap tester 90890-01325 mityvac cooling system tester kit yu-24460-a 6-3 radiator cap tester adapter 90890-01352 pressure tester adapter yu-33984 6-3 mechanical seal inst...
Page 52: Special Tools
Special tools 1-43 middle driven shaft bearing driver 90890-04058 middle drive bearing installer 40 & 50 mm ym-04058 6-12 fuel pressure adapter 90890-03181 ym-03181 7-4 ignition checker 90890-06754 oppama pet-4000 spark checker ym-34487 8-135 thickness gauge 90890-03180 feeler gauge set yu-26900-9 5...
Page 53: Special Tools
Special tools 1-44 digital circuit tester 90890-03189 model 88 multimeter with tachometer yu-a1927 5-37, 8-115, 8- 116, 8-137, 8- 140 yamaha diagnostic tool 90890-03215 8-35 tool name/tool no. Illustration reference pages.
Page 54: Special Tools
Special tools 1-45.
Page 55: Specifications
2 specifications general specifications ......................................................................2-1 engine specifications..........................................................................2-2 chassis specifications....................................................................
Page 56: General Specifications
General specifications 2-1 eas20280 general specifications model model 59c2 dimensions overall length 2200 mm (86.6 in) overall width 775 mm (30.5 in) overall height 1420/1475 mm (55.9/58.1 in) seat height 800 mm (31.5 in) wheelbase 1580 mm (62.2 in) ground clearance 125 mm (4.92 in) minimum turning...
Page 57: Engine Specifications
Engine specifications 2-2 eas20290 engine specifications engine engine type liquid cooled 4-stroke, dohc displacement 530 cm³ cylinder arrangement inline 2-cylinder bore × stroke 68.0 × 73.0 mm (2.68 × 2.87 in) compression ratio 10.90 : 1 standard compression pressure (at sea level) 1950 kpa/470 r/m...
Page 58: Engine Specifications
Engine specifications 2-3 radiator core width 329.0 mm (12.95 in) height 149.8 mm (5.90 in) depth 24.0 mm (0.94 in) water pump water pump type single suction centrifugal pump reduction ratio 23/19 (1.210) impeller shaft tilt limit 0.15 mm (0.0059 in) spark plug(s) manufacturer/model ngk/cr7e spark p...
Page 59: Engine Specifications
Engine specifications 2-4 valve, valve seat, valve guide valve clearance (cold) intake 0.15–0.22 mm (0.0059–0.0087 in) exhaust 0.25–0.32 mm (0.0098–0.0126 in) valve dimensions valve head diameter (intake) 25.9–26.1 mm (1.0197–1.0276 in) valve head diameter (exhaust) 21.9–22.1 mm (0.8622–0.8701 in) v...
Page 60: Engine Specifications
Engine specifications 2-5 free length (exhaust) 36.73 mm (1.45 in) limit 34.89 mm (1.37 in) installed compression spring force (intake) 96.6–111.2 n (9.85–11.34 kgf, 21.72–25.00 lbf) installed compression spring force (exhaust) 96.6–111.2 n (9.85–11.34 kgf, 21.72–25.00 lbf) installed length (intake)...
Page 61: Engine Specifications
Engine specifications 2-6 piston ring top ring ring type barrel dimensions (b × t) 0.90 × 2.60 mm (0.04 × 0.10 in) end gap (installed) 0.25–0.35 mm (0.0098–0.0138 in) limit 0.60 mm (0.0236 in) ring side clearance 0.030–0.065 mm (0.0012–0.0026 in) limit 0.100 mm (0.0039 in) 2nd ring ring type taper d...
Page 62: Engine Specifications
Engine specifications 2-7 balancer balancer drive method piston connecting rod oil clearance 0.036–0.060 mm (0.0014–0.0024 in) clutch clutch type wet, multiple-disc automatic clutch release method automatic friction plate thickness 2.92–3.08 mm (0.115–0.121 in) wear limit 2.82 mm (0.1110 in) plate q...
Page 63: Engine Specifications
Engine specifications 2-8 fuel injection sensor coolant temperature sensor resistance 2.32–2.59 k Ω at 20 °c (68 °f) 310.0–326.0 Ω at 80 °c (176 °f) throttle position sensor maximum resistance 2.64–6.16 k Ω throttle position sensor resistance 0–6.16 k Ω intake air pressure output voltage 3.57–3.71 v...
Page 64: Chassis Specifications
Chassis specifications 2-9 eas20300 chassis specifications chassis frame type diamond caster angle 25.00 ° trail 92 mm (3.6 in) front wheel wheel type cast wheel rim size 15m/c × mt3.50 rim material aluminum wheel travel 120.0 mm (4.72 in) radial wheel runout limit 1.0 mm (0.04 in) lateral wheel run...
Page 65: Chassis Specifications
Chassis specifications 2-10 brake pad lining thickness (inner) 4.0 mm (0.16 in) limit 0.5 mm (0.02 in) brake pad lining thickness (outer) 4.0 mm (0.16 in) limit 0.5 mm (0.02 in) master cylinder inside diameter 15.00 mm (0.59 in) caliper cylinder inside diameter 30.23 mm (1.19 in) 27.00 mm (1.06 in) ...
Page 66: Chassis Specifications
Chassis specifications 2-11 spring installed length 180.0 mm (7.09 in) spring rate k1 225.60 n/mm (23.00 kgf/mm, 1288.18 lb/in) spring rate k2 294.00 n/mm (29.98 kgf/mm, 1678.74 lb/in) spring stroke k1 0.0–28.8 mm (0.00–1.13 in) spring stroke k2 28.8–43.0 mm (1.13–1.69 in) optional spring available ...
Page 67: Electrical Specifications
Electrical specifications 2-12 eas20310 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 tci crankshaft position sensor resistance 248–372 Ω (gy-b) ignition coil minimum ignition spark gap 6.0 ...
Page 68: Electrical Specifications
Electrical specifications 2-13 electric starting system system type constant mesh starter motor power output 0.70 kw armature coil commutator resistance 0.0100–0.0200 Ω armature coil insulation resistance above 1 m Ω brush overall length 12.0 mm (0.47 in) limit 6.50 mm (0.26 in) brush spring force 6...
Page 69: Tightening Torques
Tightening torques 2-14 eas20320 tightening torques eas20331 general tightening torque specifi- cations this chart specifies tightening torques for stan- dard fasteners with a standard iso thread pitch. Tightening torque specifications for spe- cial components or assemblies are provided for each cha...
Page 70: Tightening Torques
Tightening torques 2-15 eas20340 engine tightening torques item thread size q’ty tightening torque remarks camshaft cap bolt m6 12 10 nm (1.0 m·kgf, 7.2 ft·lbf) engine oil check bolt m8 1 15 nm (1.5 m·kgf, 11 ft·lbf) exhaust pipe stud bolt m8 4 15 nm (1.5 m·kgf, 11 ft·lbf) cylinder head nut m9 6 see...
Page 71: Tightening Torques
Tightening torques 2-16 engine oil pressure check point plug m20 1 12 nm (1.2 m·kgf, 8.7 ft·lbf) engine oil check bolt m8 1 20 nm (2.0 m·kgf, 14 ft·lbf) engine oil drain bolt m14 1 43 nm (4.3 m·kgf, 31 ft·lbf) oil tank bolt m6 7 10 nm (1.0 m·kgf, 7.2 ft·lbf) stator coil base screw m6 3 12 nm (1.2 m·...
Page 72: Tightening Torques
Tightening torques 2-17 tip cylinder head nut 1. Tighten the nuts to 10 nm (1.0 m·kgf, 7.2 ft·lbf). 2. Tighten the nuts to 20 nm (2.0 m·kgf, 14 ft·lbf). 3. Tighten the nuts further to reach the specified angle 120 °. Tip cylinder head stud bolt • the tightening torque is for reference only. Install ...
Page 73: Tightening Torques
Tightening torques 2-18 eas20350 chassis tightening torques item thread size q’ty tightening torque remarks engine mounting nut (front upper side) m12 1 88 nm (8.8 m·kgf, 64 ft·lbf) engine mounting bolt (front lower side) m10 4 45 nm (4.5 m·kgf, 33 ft·lbf) engine mounting nut (rear side) m12 1 105 n...
Page 74: Tightening Torques
Tightening torques 2-19 brake master cylinder cap screw m4 4 1.5 nm (0.15 m·kgf, 1.1 ft·lbf) grip end m16 2 26 nm (2.6 m·kgf, 19 ft·lbf) throttle cable bolt m5 2 3.8 nm (0.38 m·kgf, 2.8 ft·lbf) throttle cable adjusting locknut m8 1 3.8 nm (0.38 m·kgf, 2.8 ft·lbf) brake hose union bolt (brake joint s...
Page 75: Tightening Torques
Tightening torques 2-20 tip lower ring nut 1. First, tighten the lower ring nut approximately 52 nm (5.2 m·kgf, 38 ft·lbf) by using the ring nut wrench and turn the steering right and left a few times, then loosen the lower ring nut completely. 2. Retighten the lower ring nut 14 nm (1.4 m·kgf, 10 ft...
Page 76: 2-21
Lubrication points and lubricant types 2-21 eas20360 lubrication points and lubricant types eas20370 engine lubrication point lubricant oil seal lips o-rings coolant hose insertion part water or silicone fluid bearings and bushings cylinder head nut seats and washers camshaft cap bolt seats cranksha...
Page 77: 2-22
Lubrication points and lubricant types 2-22 secondary shaft right end bearing pivot shaft taper roller bearing crankcase mating surface yamaha bond no.1215 (three bond no.1215®) inner v-belt case seal mating surface yamaha bond no.1215 (three bond no.1215®) crankshaft position sensor/stator lead gro...
Page 78: 2-23
Lubrication points and lubricant types 2-23 eas20380 chassis lubrication point lubricant steering bearings (upper and lower) upper bearing cover seal lip and lower bearing dust seal lip tube guide (throttle grip) inner surface and throttle cables rear brake lock cable end (lever end) yamaha grease “...
Page 79: 2-24
Lubrication points and lubricant types 2-24.
Page 80: 2-25
Lubrication system chart and diagrams 2-25 eas20390 lubrication system chart and diagrams eas20400 engine oil lubrication chart.
Page 81: 2-26
Lubrication system chart and diagrams 2-26 1. Intake camshaft 2. Exhaust camshaft 3. Timing chain tensioner 4. Connecting rod 5. To piston 6. Starter clutch gear 7. Crankshaft 8. Balancer connecting rod 9. To balancer piston 10.Oil pipe 11.Check valve 12.Relief valve 13.Oil filter 14.Oil cooler 15.O...
Page 82: 2-27
Lubrication system chart and diagrams 2-27 eas20410 lubrication diagrams.
Page 83: 2-28
Lubrication system chart and diagrams 2-28 1. Exhaust camshaft 2. Intake camshaft 3. Delivery pipe 4. Oil pump assembly 5. Scavenge pump 6. Feed pump 7. Oil pipe 8. Oil cooler 9. Oil filter 10.Relief valve 11.Check valve.
Page 84: 2-29
Lubrication system chart and diagrams 2-29.
Page 85: 2-30
Lubrication system chart and diagrams 2-30 1. Crankshaft 2. Secondary shaft 3. Drive axle 4. Clutch 5. Generator cover.
Page 86: 2-31
Lubrication system chart and diagrams 2-31.
Page 87: 2-32
Lubrication system chart and diagrams 2-32 1. Oil strainer 2. Intake camshaft 3. Exhaust camshaft.
Page 88: 2-33
Lubrication system chart and diagrams 2-33.
Page 89: 2-34
Lubrication system chart and diagrams 2-34 1. Generator cover 2. Oil strainer 3. Main gallery 4. Right crankcase a. Forward.
Page 90: Cooling System Diagrams
Cooling system diagrams 2-35 eas20420 cooling system diagrams.
Page 91: Cooling System Diagrams
Cooling system diagrams 2-36 1. Radiator cap 2. Radiator filler hose 3. Radiator inlet hose 4. Cooling system air bleed hose 5. Coolant pipe 6. Thermostat outlet hose 7. Oil cooler outlet hose 8. Thermostat 9. Oil cooler 10.Coolant hose 11.Water pump inlet pipe 12.Water pump outlet pipe 13.Oil coole...
Page 92: Cooling System Diagrams
Cooling system diagrams 2-37.
Page 93: Cooling System Diagrams
Cooling system diagrams 2-38 1. Thermostat 2. Thermostat outlet hose 3. Cooling system air bleed hose 4. Radiator cap 5. Radiator filler pipe 6. Radiator filler hose 7. Coolant reservoir hose 8. Radiator 9. Radiator inlet hose 10.Coolant pipe 11.Oil cooler 12.Oil cooler outlet hose.
Page 94: Cable Routing
Cable routing 2-39 eas20430 cable routing handlebar (top side view).
Page 95: Cable Routing
Cable routing 2-40 1. Front brake hose (hydraulic unit to front brake hose joint) 2. Lead holder 3. Cap bolt cover 4. Front brake master cylinder 5. Right handlebar switch 6. Front brake hose (front brake master cylin- der to hydraulic unit) 7. Right handlebar switch lead 8. Left handlebar switch le...
Page 96: Cable Routing
Cable routing 2-41 handlebar (front side and left side view).
Page 97: Cable Routing
Cable routing 2-42 1. Right handlebar switch 2. Front brake master cylinder 3. Right handlebar switch lead 4. Front brake hose (front brake master cylin- der to hydraulic unit) 5. Rear brake hose (rear brake master cylin- der to hydraulic unit) 6. Left handlebar switch lead 7. Rear brake master cyli...
Page 98: Cable Routing
Cable routing 2-43 front brake (front side and left side view).
Page 99: Cable Routing
Cable routing 2-44 1. Holder 2. Brake hose 3. Lower bracket cover 4. Horn 5. Horn lead 6. Grommet 7. Front fork 8. Front wheel sensor lead 9. Front brake hose holder 10.Cable guide 11.Front brake caliper 12.Front wheel sensor a. Fasten at a position 0 to 5 mm (0 to 0.20 in) from the protector end of...
Page 100: Cable Routing
Cable routing 2-45 frame (front side view).
Page 101: Cable Routing
Cable routing 2-46 1. Meter lead 2. Ambient temperature sensor lead 3. Abs ecu coupler 4. Fuse box (left) 5. Fuse box lead 6. Lean angle sensor lead 7. Ecu (engine control unit) lead 8. Hydraulic unit assembly 9. Wire harness 10.Handlebar switch lead a. Install the fuse box (right) securely to the p...
Page 102: Cable Routing
Cable routing 2-47 frame (left side view).
Page 103: Cable Routing
Cable routing 2-48 1. Battery 2. Sidestand switch coupler 3. Battery negative lead coupler 4. Battery negative lead 5. Starter motor lead 6. Ac magneto lead 7. Sidestand switch lead 8. Frame 9. Ignition coil 10.Rectifier/regulator 11.Ac magneto coupler 12.Fuel injection system relay 13.Rear brake ho...
Page 104: Cable Routing
Cable routing 2-49 frame (right side view).
Page 105: Cable Routing
Cable routing 2-50 1. Ecu (engine control unit) lead 2. Turn signal/hazard relay 3. Couplers 4. Headlight relay 5. Radiator fan motor relay 6. Throttle position sensor sub-wire harness 7. Fuel pump lead 8. Bracket 1 9. Immobilizer lead 10.Main switch leads 11.Turn signal light lead coupler 12.Headli...
Page 106: Cable Routing
Cable routing 2-51 rear frame (top side and right side view).
Page 107: Cable Routing
Cable routing 2-52 1. Fuel pump coupler 2. Fuel injector #1 3. Fuel tank fitting bracket 4. Intake air pressure sensor 5. Air filter case 6. Intake air temperature sensor 7. Fuel injector #2 8. Fuel tank breather hose 9. Rear brake lock cable 10.O 2 sensor lead 11.Rear wheel sensor lead 12.Rear turn...
Page 108: Cable Routing
Cable routing 2-53 rear brake (top side and left side view).
Page 109: Cable Routing
Cable routing 2-54 1. Rear brake hose 2. Fuel tank fitting bracket 3. Footboard 4. Rear frame 5. Left rear cowling 6. Rear brake hose holder (left) 7. Swingarm 8. Drive pulley cover 9. Passenger footrest 10.Rear brake lock cable holder bracket 11.Crankcase 12.Frame 13.Sidestand switch lead 14.Stay 1...
Page 110: Cable Routing
Cable routing 2-55 throttle body (left side view).
Page 111: Cable Routing
Cable routing 2-56 1. Fast idle plunger inlet coolant hose 2. Intake manifold 3. Radiator 4. Fast idle plunger outlet coolant hose 5. Throttle body assembly 6. Air filter case 7. Intake air pressure sensor a. Insert the throttle body into the intake man- ifold until it does not move any further. Eng...
Page 112: Cable Routing
Cable routing 2-57 fuel tank (top side, left side and right side view).
Page 113: Cable Routing
Cable routing 2-58 1. Fuel hose 2. Fuel tank breather hose 3. Air filter case 4. Intake air pressure sensor 5. Fuel tank 6. Bottom center cowling 7. Radiator outlet hose 8. Fuel tank overflow hose 9. White paint mark 10.Filler cover 11.Fuel tank cap 12.Bracket 2 13.Rollover valve 14.Fuel rail 15.Fue...
Page 114: Cable Routing
Cable routing 2-59 hydraulic unit (top side and front side view).
Page 115: Cable Routing
Cable routing 2-60 1. Front brake hose (hydraulic unit to front brake hose joint) 2. Front brake hose (front brake master cylin- der to hydraulic unit) 3. Rear brake hose (rear brake master cylin- der to hydraulic unit) 4. Rear brake pipe/joint assembly (hydraulic unit to rear brake hose) 5. Hydraul...
Page 116: Cable Routing
Cable routing 2-61.
Page 117
3 periodic checks and adjustments periodic maintenance .........................................................................3-1 introduction ....................................................................................3-1 periodic maintenance chart for the emission control system............
Page 118
Changing the coolant ................................................................ 3-30 replacing the v-belt .................................................................... 3-31 checking the brake light switches ...................................... 3-32 checking and lubricating the cables ...
Page 120: Periodic Maintenance
Periodic maintenance 3-1 eas20451 periodic maintenance eas20460 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 longer service life and redu...
Page 121: Periodic Maintenance
Periodic maintenance 3-2 eas59c1303 general maintenance and lubrication chart no. Item check or maintenance job odometer reading annual check 1000 km (600 mi) 10000 km (6000 mi) 20000 km (12000 mi) 30000 km (18000 mi) 40000 km (24000 mi) 1 air filter element • replace. √ √ 2 * v-belt case air fil- t...
Page 122: Periodic Maintenance
Periodic maintenance 3-3 tip • engine air filter and v-belt air filters • this model’s engine air filter is equipped with a disposable oil-coated paper element, which must not be cleaned with compressed air to avoid damaging it. • the engine air filter element needs to be replaced and the v-belt air...
Page 123: Periodic Maintenance
Periodic maintenance 3-4 eas21030 checking the fuel line the following procedure applies to all of the fuel and breather hoses. 1. Remove: • center cover refer to “general chassis” on page 4-1. • side covers refer to “general chassis” on page 4-1. • footboards refer to “general chassis” on page 4-1....
Page 124: Periodic Maintenance
Periodic maintenance 3-5 8. Install: • spark plug tip before installing the spark plug, clean the spark plug and gasket surface. 9. Connect: • spark plug cap 10. Install: • radiator cover refer to “general chassis” on page 4-1. Eas20490 adjusting the valve clearance the following procedure applies t...
Page 125: Periodic Maintenance
Periodic maintenance 3-6 tip • tdc on the compression stroke can be found when the cylinder #1 camshaft lobes are turned away from each other. • in order to be sure that the piston is at tdc, the alignment mark “c” on the intake cam- shaft sprocket and the alignment mark “d” on the exhaust camshaft ...
Page 126: Periodic Maintenance
Periodic maintenance 3-7 tip • cover the timing chain opening with a rag to prevent the valve pad from falling into the crankcase. • make a note of the position of each valve lifter “1” and valve pad “2” so that they can be installed in the correct place. B. Calculate the difference between the spec...
Page 127: Periodic Maintenance
Periodic maintenance 3-8 • the valve lifter must turn smoothly when rotated by hand. • install the valve lifter and the valve pad in the correct place. G. Install the exhaust and intake camshafts, timing chain and camshaft caps. Tip • refer to “camshafts” on page 5-8. • lubricate the camshaft lobes ...
Page 128: Periodic Maintenance
Periodic maintenance 3-9 6. Install: • side cover (right) refer to “general chassis” on page 4-1. • radiator cover refer to “general chassis” on page 4-1. Eas20571 synchronizing the throttle body tip prior to synchronizing the throttle body, the valve clearance and the engine idling speed should be ...
Page 129: Periodic Maintenance
Periodic maintenance 3-10 5. Start the engine and let it warm up for sev- eral minutes. 6. Check: • engine idling speed out of specification → adjust. Refer to “adjusting the engine idling speed” on page 3-8. 7. Adjust: • throttle body synchronization ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the cylin...
Page 130: Periodic Maintenance
Periodic maintenance 3-11 • footboard (right) refer to “general chassis” on page 4-1. 2. Check: • cylinder head breather hose “1” cracks/damage → replace. Loose connection → connect properly. Eca14920 make sure the cylinder head breather hose is routed correctly. 3. Install: • all removed parts eas2...
Page 131: Periodic Maintenance
Periodic maintenance 3-12 2. Check: • exhaust assembly “1” cracks/damage → replace. • gasket “2” exhaust gas leaks → replace. 3. Check: tightening torque • exhaust assembly nut (front) “3” • exhaust assembly nut (rear) “4” • o 2 sensor “5” 4. Install: • side cover (right) refer to “general chassis” ...
Page 132: Periodic Maintenance
Periodic maintenance 3-13 2. Remove: • v-belt case air filter element (left) “1” 3. Remove: • v-belt case air filter case cover “1” • v-belt case air filter case “2” • v-belt case air filter element (right) “3” 4. Clean: • v-belt case air filter elements blow the compressed air to the outer sur- fac...
Page 133: Periodic Maintenance
Periodic maintenance 3-14 tip drive on the road, operate the front and rear brakes separately and check to see if the brakes are operating properly. Eas21240 checking the brake fluid level 1. Stand the vehicle on a level surface. Tip • place the vehicle on the centerstand. • make sure the vehicle is...
Page 134: Periodic Maintenance
Periodic maintenance 3-15 • a soft or spongy feeling in the brake lever can indicate the presence of air in the brake system. Before the vehicle is oper- ated, the air must be removed by bleeding the brake system. Air in the brake system will considerably reduce in loss of control and possibly an ac...
Page 135: Periodic Maintenance
Periodic maintenance 3-16 eas30770 bleeding the hydraulic brake sys- tem (abs) warning ewa14000 always bleed the brake system when the brake related parts are removed. Eca17050 • bleed the brake system in the following order. • 1st step: front brake calipers • 2rd step: rear brake caliper warning ew...
Page 136: Periodic Maintenance
Periodic maintenance 3-17 l. Tighten the bleed screw to specification. M. Fill the brake master cylinder reservoir to the proper level with the specified brake fluid. Refer to “checking the brake fluid level” on page 3-14. Warning ewa13110 after bleeding the hydraulic brake system, check the brake o...
Page 137: Periodic Maintenance
Periodic maintenance 3-18 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Adjust: • clearance between the brake pad and brake disc. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the cap of the rear brake lock adjusting nut. B. Loosen the rear brake lock adjusting nut “1” slightly. C. Adjust the piston adjusting bolt “...
Page 138: Periodic Maintenance
Periodic maintenance 3-19 4. Check: • rear brake lock caliper boots cracks/damage → replace. Refer to “rear brake” on page 4-50. Eas59c1301 checking the rear brake lock pads the following procedure applies to all of the brake pads. 1. Operate the rear brake lock. 2. Check: • rear brake lock pad wear...
Page 139: Periodic Maintenance
Periodic maintenance 3-20 2. Check: • tire surfaces damage/wear → replace the tire. Warning ewa14090 after extensive tests, the tires listed below have been approved by yamaha motor co., ltd. For this model. The front and rear tires should always be by the same manufac- turer and of the same design....
Page 140: Periodic Maintenance
Periodic maintenance 3-21 2. Check: • drive belt external tooth cracks “a” → replace. Missing teeth “b” → replace. Hook wear “c” → replace. Stone damage “d” → replace if damage is on the edge. Internal tooth cracks (hairline) “e” → ok to run, but monitor condition. Chipping (not serious) “f” → ok to...
Page 141: Periodic Maintenance
Periodic maintenance 3-22 tip measure the drive belt slack after setting the tension gauge at 13.4 position on the scale. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the handle of the tension gauge until indicator “1” and edge “2” of handle to lap over. B. Read the scale at over lap point, which is curre...
Page 142: Periodic Maintenance
Periodic maintenance 3-23 5. Lubricate: • drive axle “1” 6. Lubricate: • drive pulley assembly inner part “2” 7. Install: • all removed parts 8. Adjust: • drive belt slack refer to “adjusting the drive belt slack” on page 3-21. Eas21500 checking and adjusting the steer- ing head 1. Stand the vehicle...
Page 143: Periodic Maintenance
Periodic maintenance 3-24 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the lock washer “1”, the upper ring nut “2”, and the rubber washer “3”. B. Loosen the lower ring nut “4” and then tighten it to specification with a steering nut wrench “5”. Tip • set a torque wrench at a right angle to the steering ...
Page 144: Periodic Maintenance
Periodic maintenance 3-25 eas21720 lubricating the sidestand lubricate the pivoting point, metal-to-metal moving parts and spring contact point of the sidestand. Eas30860 checking the centerstand 1. Check: • centerstand operation check that the centerstand moves smoothly. Rough movement → repair or ...
Page 145: Periodic Maintenance
Periodic maintenance 3-26 eca13361 • engine oil also lubricates the clutch and the wrong oil types or additives could cause clutch slippage. Therefore, do not add any chemical additives or use engine oils with a grade of “cd” or higher and do not use oils labeled “energy conserv- ing ii”. • do not a...
Page 146: Periodic Maintenance
Periodic maintenance 3-27 b. Lubricate the o-ring “3” of the new oil filter cartridge with a thin coat of lithium-soap- based grease. Eca13390 make sure the o-ring “3” is positioned cor- rectly in the groove of the oil filter car- tridge. C. Tighten the new oil filter cartridge to speci- fication wi...
Page 147: Periodic Maintenance
Periodic maintenance 3-28 f. Tighten the oil check bolt to specification. G. Install the bottom side cowling and bottom center cowling. Refer to “general chassis” on page 4- 1. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas20820 measuring the engine oil pressure 1. Check: • engine oil level below the minimum le...
Page 148: Periodic Maintenance
Periodic maintenance 3-29 eas21110 checking the coolant level 1. Stand the vehicle on a level surface. Tip • place the vehicle on the centerstand. • make sure the vehicle is upright. 2. Check: • coolant level the coolant level should be between the maximum level mark “a” and minimum level mark “b”. ...
Page 149: Periodic Maintenance
Periodic maintenance 3-30 3. Install: • footboards refer to “general chassis” on page 4-1. • side covers refer to “general chassis” on page 4-1. • center cover refer to “general chassis” on page 4-1. Eas21131 changing the coolant 1. Remove: • center cover refer to “general chassis” on page 4-1. • si...
Page 150: Periodic Maintenance
Periodic maintenance 3-31 handling notes for coolant coolant is potentially harmful and should be handled with special care. Warning ewa13040 • if coolant splashes in your eyes, thor- oughly wash them with water and consult a doctor. • if coolant splashes on your clothes, quickly wash it away with w...
Page 151: Periodic Maintenance
Periodic maintenance 3-32 2. Check: • v-belt cranks/damage/wear → replace. Grease/oil → clean the primary and sec- ondary pulleys. Refer to “v-belt automatic trans- mission” on page 5-39. Tip replace the v-belt every 20000 km (12500 mi) of operation. 3. Install: • outer v-belt case refer to “v-belt ...
Page 152: Periodic Maintenance
Periodic maintenance 3-33 4. Adjust: • throttle grip free play tip prior to adjusting the throttle grip free play, throttle 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...
Page 153: Periodic Maintenance
Periodic maintenance 3-34 eca13690 avoid touching the glass part of the head- light bulb to keep it free from oil, otherwise the transparency of the glass, the life of the bulb and the luminous flux will be adversely affected. If the headlight bulb gets soiled, thoroughly clean it with a cloth moist...
Page 154: Periodic Maintenance
Periodic maintenance 3-35.
Page 155: Chassis
4 chassis general chassis....................................................................................4-1 removing the windshield.............................................................4-9 installing the windshield............................................................4-9 adjusting ...
Page 156
Front brake .......................................................................................... 4-37 introduction .................................................................................. 4-42 checking the front brake discs ............................................ 4-42 replacing ...
Page 157
Front fork ............................................................................................. 4-81 removing the front fork legs ............................................... 4-83 disassembling the front fork legs ..................................... 4-83 checking the front fork legs......
Page 158: General Chassis
General chassis 4-1 eas21830 general chassis removing the windshield and front cowling assembly order job/parts to remove q’ty remarks front left storage box refer to “general chassis” on page 4-1. Radiator cover refer to “general chassis” on page 4-1. Side panel refer to “general chassis” on page 4...
Page 159: General Chassis
General chassis 4-2 disassembling the front cowling assembly order job/parts to remove q’ty remarks 1 side cowling 2 2 headlight under panel 1 3 turn signal light coupler 2 disconnect. 4 auxiliary light coupler 1 disconnect. 5 left turn signal light 1 6 right turn signal light 1 7 headlight sub-wire...
Page 160: General Chassis
General chassis 4-3 removing the storage compartment order job/parts to remove q’ty remarks front cowling assembly refer to “general chassis” on page 4-1. 1 inner panel center cover 1 2 front left storage box 1 3 battery 1 4 meter coupler 1 disconnect. 5 meter panel assembly 1 6 meter assembly 1 7 m...
Page 161: General Chassis
General chassis 4-4 removing the bottom cowling order job/parts to remove q’ty remarks 1 footboard mat 4 2 radiator cover 1 3 side panel 2 4 center cover 1 5 side cover 2 6 bottom side cowling 2 7 bottom center cowling 1 8 side cover moulding 2 9 footboard 2 for installation, reverse the removal pro...
Page 162: General Chassis
General chassis 4-5 removing the rear cowling assembly order job/parts to remove q’ty remarks side panel refer to “general chassis” on page 4-1. Footboard refer to “general chassis” on page 4-1. O 2 sensor lead refer to “engine removal” on page 5-3. 1 seat 1 2 fuel tank cover 1 3 grab bar 2 4 rear c...
Page 163: General Chassis
General chassis 4-6 removing the rear cowling assembly order job/parts to remove q’ty remarks 14 rear fender 1 15 rear cowling assembly 1 for installation, reverse the removal proce- dure..
Page 164: General Chassis
General chassis 4-7 disassembling the rear cowling assembly order job/parts to remove q’ty remarks 1 taillight bracket 1 2 left rear cowling 1 3 right rear cowling 1 4 left turn signal light 1 5 right turn signal light 1 6 taillight 1 7 taillight cover 1 for assembly, reverse the disassembly pro- ce...
Page 165: General Chassis
General chassis 4-8 removing the storage box order job/parts to remove q’ty remarks 1 fuel pump coupler access cover 1 2 fuel pump coupler 1 disconnect. 3 fuel hose connector cover 1 4 fuel hose 1 disconnect. 5 fuel tank overflow hose 1 6 storage box inner mat 1 7 seat lock 1 8 storage box light con...
Page 166: General Chassis
General chassis 4-9 eas59c1407 removing the windshield 1. Remove: • windshield cover ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the quick fastener “1”. B. Slide it upwards and pull it toward you. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Remove: • windshield ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Removing the wind...
Page 167: General Chassis
General chassis 4-10 eas59c1427 adjusting the windshield height 1. Adjust: • windshield height ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the windshield cover and wind- shield assembly. Refer to “removing the windshield” on page 4-9. B. Remove the rubber caps “1”. C. Install the rubber caps “1” in the...
Page 168: General Chassis
General chassis 4-11 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas59c1410 installing the front cover 1. Install: • front cover ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Insert the three projections “1” of the front cover. B. Fit the two claws “2” of the end of the front cover. C. Installing the quick fastener “3”. D. ...
Page 169: General Chassis
General chassis 4-12 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas59c1412 installing the windshield inner panel 1. Install: • windshield inner panel ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Insert the two projections “1” of the wind- shield inner panel. B. Installing the bolts “2”. C. Installing the quick fasteners “...
Page 170: General Chassis
General chassis 4-13 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas59c1415 removing the center cover 1. Remove: • center cover ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Removing the screws “1”. B. Use an appropriate hook from the service hole “2” to raise the center cover. C. When the center cover is raised, pull the c...
Page 171: General Chassis
General chassis 4-14 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Insert the five projections “1”. B. Insert the five claws “2”. C. Installing the bolts “3”. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas59c1419 removing the side cover moulding 1. Remove: • side cover moulding ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Removing th...
Page 172: General Chassis
General chassis 4-15 c. Remove the three claws “3”. D. Slide the footboard upwards, pull it toward you, and then remove it. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas59c1422 installing the footboard 1. Install: • footboard ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Insert the three hooks of the footboard. B. Fit the...
Page 173: General Chassis
General chassis 4-16 b. Holding the rear side of the rear cover and slightly applying a force upward, slide the cover rearward to remove it. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas59c1424 installing the rear cover 1. Install: • rear cowling ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Insert the four claws “1” of t...
Page 174: General Chassis
General chassis 4-17 eas59c1428 removing the fuel hose 1. Remove: • fuel hose connector cover “1” 2. Disconnect: • fuel hose “2” warning ewa15910 cover fuel hose connections with a cloth when disconnecting them. Residual pres- sure in the fuel lines could cause fuel to spurt out when removing the ho...
Page 175: Front Wheel
Front wheel 4-18 eas21870 front wheel removing the front wheel and brake discs order job/parts to remove q’ty remarks front cowling assembly refer to “general chassis” on page 4-1. 1 front wheel sensor coupler 1 disconnect. 2 front brake hose holder 2 3 cable guide 1 4 front wheel sensor 1 5 front b...
Page 176: Front Wheel
Front wheel 4-19 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 (right) 1 4 collar 1 5 wheel bearing (left) 1 6 air valve 1 for assembly, reverse the disassembly pro- cedure..
Page 177: Front Wheel
Front wheel 4-20 eas21900 removing the front wheel eca59c2405 keep magnets (including magnetic pick-up tools, magnetic screwdrivers, etc.) away from the front wheel hub “1”, otherwise the wheel sensor rotor equipped in the wheel hub may be damaged, resulting in improper performance of the abs system...
Page 178: Front Wheel
Front wheel 4-21 warning ewa13460 do not attempt to straighten a bent wheel axle. 2. Check: • tire • front wheel damage/wear → replace. Refer to “checking the tires” on page 3-19 and “checking the wheels” on page 3-19. 3. Measure: • radial wheel runout “1” • lateral wheel runout “2” over the specifi...
Page 179: Front Wheel
Front wheel 4-22 3. Measure: • front wheel sensor rotor deflection out of specification → clean the installa- tion surface of the wheel sensor rotor and correct the wheel sensor rotor deflection, or replace the wheel sensor rotor. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Hold the dial gauge at a right angl...
Page 180: Front Wheel
Front wheel 4-23 d. Install the new oil seals ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Install: • air valve tip • fasten air valve nut “1” and tighten air valve locknut “2” to 3.0 nm (0.30 m·kgf, 2.2 ft·lbf). • when installing the air valve, orient the air valve referring to the illustration. ▼▼▼▼▼▼▼▼▼▼▼▼▼...
Page 181: Front Wheel
Front wheel 4-24 e. When the wheel stops, put an “x 2 ” mark at the bottom of the wheel. F. Repeat steps (c) through (e) several times until all the marks come to rest at the same spot. G. The spot where all the marks come to rest is the front wheel’s heavy spot “x”. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3...
Page 182: Front Wheel
Front wheel 4-25 2. Check: • front brake discs refer to “checking the front brake discs” on page 4-42. 3. Lubricate: • oil seal lips 4. Install: • collars • front wheel sensor housing • front wheel • front wheel axle tip align the slot “a” in the front wheel sensor housing with the projection “b” of...
Page 183: Front Wheel
Front wheel 4-26 8. Check: • front wheel sensor installation check if the wheel sensor housing is installed properly..
Page 184: Rear Wheel
Rear wheel 4-27 eas22020 rear wheel * when replacing the rear brake caliper or rear brake caliper bracket, replace them as a set. Removing the rear wheel order job/parts to remove q’ty remarks side cover (right) refer to “general chassis” on page 4-1. 1 rear wheel sensor coupler 1 disconnect. 2 rear...
Page 185: Rear Wheel
Rear wheel 4-28 * when replacing the rear brake caliper or rear brake caliper bracket, replace them as a set. Removing the rear wheel order job/parts to remove q’ty remarks 15 wheel axle nut 1 16 washer 1 17 adjusting block (right) 1 18 rear wheel axle 1 19 adjusting block (left) 1 20 rear wheel 1 2...
Page 186: Rear Wheel
Rear wheel 4-29 removing the rear brake disc and rear wheel pulley order job/parts to remove q’ty remarks 1 rear brake disc 1 2 rear wheel sensor rotor 1 3 drive belt guide 1 4 rear wheel pulley 1 5 rear wheel 1 for installation, reverse the removal proce- dure..
Page 187: Rear Wheel
Rear wheel 4-30 disassembling the rear wheel assembly order job/parts to remove q’ty remarks 1 oil seal 2 2 wheel bearing (left) 1 3 collar 1 4 wheel bearing (right) 1 for assembly, reverse the disassembly pro- cedure..
Page 188: Rear Wheel
Rear wheel 4-31 eas22040 removing the rear wheel (disc) eca59c2410 keep magnets (including magnetic pick-up tools, magnetic screwdrivers, etc.) away from the rear wheel hub “1”, otherwise the wheel sensor rotor equipped in the wheel hub may be damaged, resulting in improper performance of the abs sy...
Page 189: Rear Wheel
Rear wheel 4-32 eas22091 checking the rear wheel 1. Check: • wheel axle • wheel bearings • oil seals refer to “checking the front wheel” on page 4-20. 2. Check: • tire • rear wheel damage/wear → replace. Refer to “checking the tires” on page 3-19 and “checking the wheels” on page 3-19. 3. Measure: •...
Page 190: Rear Wheel
Rear wheel 4-33 eas22200 maintenance of the rear wheel sensor and sensor rotor eca59c2411 • handle the abs components with care since they have been accurately adjusted. Keep them away from dirt and do not sub- ject them to shocks. • the rear wheel sensor cannot be disas- sembled. Do not attempt to ...
Page 191: Rear Wheel
Rear wheel 4-34 tip use a socket “4” that matches the diameter of the wheel bearing outer race. B. Install the collar. C. Install the new wheel bearing (left side). Tip place a suitable washer “1” between the socket “2” and the bearing so that both the inner race “3” and outer race “4” are pressed a...
Page 192: Rear Wheel
Rear wheel 4-35 • when installing the rear brake caliper bracket and the rear wheel sensor housing, align the projection “c” on the rear brake caliper bracket with the slot “d” of the rear wheel sensor housing. • after installing the rear wheel to the vehicle, make sure that the projection “e” on th...
Page 193: Rear Wheel
Rear wheel 4-36 8. Measure: tip measure the distance “a” only if the wheel bearings, wheel sensor rotor, or both were replaced. • distance “a” (between the wheel sensor rotor “1” and wheel sensor housing “2”) out of specification → reinstall the bear- ing or replace the wheel sensor rotor. 9. Instal...
Page 194: Front Brake
Front brake 4-37 eas22210 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 front brake hose holder bolt 1 2 front brake caliper bolt 2 3 front brake caliper 1 4 brake pad clip 2 5 brake pad pin 1 6...
Page 195: Front Brake
Front brake 4-38 removing the front brake master cylinder order job/parts to remove q’ty remarks upper handlebar cover refer to “handlebar” on page 4-76. Brake fluid drain. Refer to “bleeding the hydraulic brake system (abs)” on page 3-16. 1 brake master cylinder reservoir cap 1 2 brake master cylin...
Page 196: Front Brake
Front brake 4-39 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 for assembly, reverse the disassembly pro- cedure..
Page 197: Front Brake
Front brake 4-40 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 3-16. 1 front brake hose holder bolt 1 2 brake hose union bol...
Page 198: Front Brake
Front brake 4-41 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 front brake pad 2 5 brake caliper piston 4 6 brake caliper piston dust seal ...
Page 199: Front Brake
Front brake 4-42 eas22221 introduction warning ewa14101 disc brake components rarely require dis- assembly. Therefore, always follow these preventive measures: • never disassemble brake components unless absolutely necessary. • if any connection on the hydraulic brake system is disconnected, the ent...
Page 200: Front Brake
Front brake 4-43 tip tighten the brake disc bolts in stages and in a crisscross pattern. D. Measure the brake disc deflection. E. If out of specification, repeat the adjust- ment steps until the brake disc deflection is within specification. F. If the brake disc deflection cannot be brought within s...
Page 201: Front Brake
Front brake 4-44 c. Tighten the bleed screw. D. Install a brake pads and brake pad spring. Tip the arrow mark “a” on the brake pad spring must point in the direction of disc rotation. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 5. Install: • brake pad pin • brake pad clips • front brake caliper 6. Check: • brake...
Page 202: Front Brake
Front brake 4-45 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Blow compressed air into the brake hose joint opening “a” to force out the pistons from the brake caliper. Warning ewa13560 • cover the brake caliper pistons with a rag. Be careful not to get injured when the pistons are expelled from the brake cali...
Page 203: Front Brake
Front brake 4-46 • never use solvents on internal brake components as they will cause the brake caliper piston dust seals and brake cali- per piston seals to swell and distort. • whenever a brake caliper is disassem- bled, replace the brake caliper piston dust seals and brake caliper piston seals. E...
Page 204: Front Brake
Front brake 4-47 6. Check: • brake fluid level below the minimum level mark “a” → add the specified brake fluid to the proper level. Refer to “checking the brake fluid level” on page 3-14. 7. Check: • brake lever operation soft or spongy feeling → bleed the brake system. Refer to “bleeding the hydra...
Page 205: Front Brake
Front brake 4-48 eas22530 installing the front brake master cylinder 1. Install: • brake master cylinder “1” • brake master cylinder holder “2” tip • install the brake master cylinder holder with the “ ” mark “a” facing up. • align the end of the brake master cylinder holder with the welding line “b...
Page 206: Front Brake
Front brake 4-49 6. Check: • brake lever operation soft or spongy feeling → bleed the brake system. Refer to “bleeding the hydraulic brake system (abs)” on page 3-16..
Page 207: Rear Brake
Rear brake 4-50 eas22550 rear brake removing the rear brake pads order job/parts to remove q’ty remarks 1 rear brake caliper bolt 2 2 rear brake caliper 1 3 rear brake pad 2 4 brake pad support 2 5 bleed screw 1 for installation, reverse the removal proce- dure..
Page 208: Rear Brake
Rear brake 4-51 removing the rear brake master cylinder order job/parts to remove q’ty remarks upper handlebar cover refer to “handlebar” on page 4-76. Brake fluid drain. Refer to “bleeding the hydraulic brake system (abs)” on page 3-16. 1 brake master cylinder reservoir cap 1 2 brake master cylinde...
Page 209: Rear Brake
Rear brake 4-52 disassembling the rear brake master cylinder order job/parts to remove q’ty remarks 1 brake master cylinder kit 1 2 brake master cylinder body 1 for assembly, reverse the disassembly pro- cedure..
Page 210: Rear Brake
Rear brake 4-53 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 3-16. 1 brake hose union bolt 1 2 brake hose gasket 2 3 rear brake hose 1 4 rear brake caliper bolt 2 5 rear brake caliper 1 6 rear b...
Page 211: Rear Brake
Rear brake 4-54 disassembling the rear brake caliper order job/parts to remove q’ty remarks 1 brake caliper piston 1 2 brake caliper piston dust seal 1 3 brake caliper piston seal 1 4 bleed screw 1 5 brake caliper body 1 for assembly, reverse the disassembly pro- cedure..
Page 212: Rear Brake
Rear brake 4-55 removing the rear brake lock pads order job/parts to remove q’ty remarks 1 rear brake lock cable adjusting nut 1 2 pin 1 3 rear brake lock spring 1 4 rear brake lock caliper 1 5 rear brake lock pad 2 for installation, reverse the removal proce- dure..
Page 213: Rear Brake
Rear brake 4-56 removing the rear brake lock caliper order job/parts to remove q’ty remarks 1 rear brake lock cable adjusting nut 1 2 pin 1 3 rear brake lock spring 1 4 rear brake lock caliper 1 for installation, reverse the removal proce- dure..
Page 214: Rear Brake
Rear brake 4-57 disassembling the rear brake lock caliper order job/parts to remove q’ty remarks 1 cap 1 2 rear brake lock adjusting nut 1 3 rear brake lock caliper arm 1 4 boot 1 5 rear brake lock pad 2 6 caliper piston assembly 1 7 boot 1 8 sleeve 1 9 boot 2 10 rear brake lock caliper bracket bolt...
Page 215: Rear Brake
Rear brake 4-58 eas22561 introduction warning ewa14101 disc brake components rarely require dis- assembly. Therefore, always follow these preventive measures: • never disassemble brake components unless absolutely necessary. • if any connection on the hydraulic brake system is disconnected, the enti...
Page 216: Rear Brake
Rear brake 4-59 4. Install: • brake pad supports • rear brake pads tip always install new brake pads, brake pad sup- ports as a set. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 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 ...
Page 217: Rear Brake
Rear brake 4-60 eas22601 disassembling the rear brake cali- per 1. Remove: • brake caliper piston “1” • brake caliper piston dust seal “2” • brake caliper piston seal “3” ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Blow compressed air into the brake hose joint opening “a” to force out the piston from the brak...
Page 218: Rear Brake
Rear brake 4-61 eas22651 assembling the rear brake caliper warning ewa59c1404 • before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. • never use solvents on internal brake components as they will cause the brake caliper piston dust seal...
Page 219: Rear Brake
Rear brake 4-62 5. Bleed: • brake system refer to “bleeding the hydraulic brake system (abs)” on page 3-16. 6. Check: • brake fluid level below the minimum level mark “a” → add the specified brake fluid to the proper level. Refer to “checking the brake fluid level” on page 3-14. 7. Check: • brake le...
Page 220: Rear Brake
Rear brake 4-63 tip • install the brake master cylinder holder with the “ ” mark “a” facing up. • align the end of the brake master cylinder holder with the welding line “b” on the han- dlebar. • first, tighten the upper bolt, then the lower bolt. 2. Install: • brake hose gaskets “1” • rear brake ho...
Page 221: Rear Brake
Rear brake 4-64 6. Check: • brake lever operation soft or spongy feeling → bleed the brake system. Refer to “bleeding the hydraulic brake system (abs)” on page 3-16. Eas59c1401 replacing the rear brake lock pads 1. Remove: • rear brake lock cable adjusting nut “1” • pin “2” • rear brake lock spring ...
Page 222: Rear Brake
Rear brake 4-65 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 5. Measure: • rear brake lock pads wear limit “a” out of specification → replace the rear brake lock pads. 6. Remove: • cap • rear brake lock adjusting nut • rear brake lock caliper arm 7. Adjust: • piston adjusting bolt refer to “assembling the rear br...
Page 223: Rear Brake
Rear brake 4-66 eas59c1402 removing the rear brake lock cali- per 1. Remove: • rear brake lock cable adjusting nut “1” • pin “2” • rear brake lock spring “3” • rear brake lock caliper bolts “4” • rear brake lock caliper “5” eas59c1404 checking the rear brake lock cali- per 1. Check: • rear brake loc...
Page 224: Rear Brake
Rear brake 4-67 5. Install: • shaft l “1” • piston adjusting bolt “2” • locknut “3” 6. Adjust: • piston adjusting bolt ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Tighten shaft l manually until it touches the locknut. B. With shaft l fastened, turn and adjust the piston adjusting bolt so that the length “a” b...
Page 225: Abs (Anti-Lock Brake System)
Abs (anti-lock brake system) 4-68 eas22760 abs (anti-lock brake system) removing the hydraulic unit assembly order job/parts to remove q’ty remarks battery negative lead refer to “general chassis” on page 4-1. Front cowling assembly refer to “general chassis” on page 4-1. Brake fluid drain. Refer to...
Page 226: Abs (Anti-Lock Brake System)
Abs (anti-lock brake system) 4-69 removing the hydraulic unit assembly order job/parts to remove q’ty remarks 6 rear brake hose (rear brake pipe/joint assembly to rear brake caliper) 1 disconnect. 7 rear brake pipe/joint assembly (hydraulic unit to rear brake hose) 1 8 hydraulic unit assembly bracke...
Page 227: Abs (Anti-Lock Brake System)
Abs (anti-lock brake system) 4-70 eas59c2401 removing the hydraulic unit assem- bly eca4b56013 unless necessary, avoid removing and installing the brake pipes of the hydraulic unit assembly. Warning ewa13930 refill with the same type of brake fluid that is already in the system. Mixing fluids may re...
Page 228: Abs (Anti-Lock Brake System)
Abs (anti-lock brake system) 4-71 eas59c2403 checking the brake pipes the following procedure applies to all of the brake pipes. 1. Check: • brake pipe end (flare nut) damage → replace the hydraulic unit, brake pipes, and related parts as a set. Eas59c2404 installing the hydraulic unit assembly 1. I...
Page 229: Abs (Anti-Lock Brake System)
Abs (anti-lock brake system) 4-72 eca59c2413 if the brake hose flare nut does not turn easily, replace the hydraulic unit, brake pipes, and related parts as a set. Tip • when installing the front brake hose (hydrau- lic unit to front brake hose joint), front brake hose (front brake master cylinder t...
Page 230: Abs (Anti-Lock Brake System)
Abs (anti-lock brake system) 4-73 • hydraulic unit operation test 1: this test checks the function of the abs after the sys- tem was disassembled, adjusted, or ser- viced. • hydraulic unit operation test 2: this test gen- erates the same reaction-force pulsating action that is generated in the brake...
Page 231: Abs (Anti-Lock Brake System)
Abs (anti-lock brake system) 4-74 • if the pulse is felt in the rear brake lever before it is felt in the front brake lever, check that the brake hoses and brake pipes are connected correctly to the hydraulic unit assembly. • if the pulse is hardly felt in either the brake levers, check that the bra...
Page 232: Abs (Anti-Lock Brake System)
Abs (anti-lock brake system) 4-75 10. A reaction-force pulsating action is gener- ated in the front brake lever “1” 0.5 second after the brake levers are operated simulta- neously and continues for approximately 1.5 seconds. Tip • the reaction-force pulsating action consists of quick pulses. • be su...
Page 233: Handlebar
Handlebar 4-76 eas22840 handlebar * yamaha grease “f” removing the handlebar order job/parts to remove q’ty remarks rear brake lock cable adjusting nut loosen. Refer to “rear brake” on page 4-50. Front cowling assembly refer to “general chassis” on page 4-1. Meter assembly refer to “general chassis”...
Page 234: Handlebar
Handlebar 4-77 * yamaha grease “f” removing the handlebar order job/parts to remove q’ty remarks 10 front brake master cylinder assembly 1 11 rear brake light switch connector 2 disconnect. 12 rear brake lock holder 1 13 rear brake lock lever 1 14 rear brake lock cable 1 disconnect. 15 left handleba...
Page 235: Handlebar
Handlebar 4-78 eas22860 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 left handle- bar and the handlebar grip, and gradua...
Page 236: Handlebar
Handlebar 4-79 warning ewa13700 do not touch the handlebar grip until the rubber adhesive has fully dried. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 6. Install: • rear brake master cylinder assembly “1” • rear brake master cylinder holder “2” tip • install the rear brake master cylinder holder with the “ ” mar...
Page 237: Handlebar
Handlebar 4-80 tip lubricate the inside of the throttle grip with a thin coat of lithium-soap-based grease and install it onto the handlebar. 12. Install: • right handlebar switch “1” warning ewa13720 make sure the throttle grip operates smoothly. Tip align the projection “a” on the right handlebar ...
Page 238: Front Fork
Front fork 4-81 eas22950 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. Meter assembly refer to “general chassis” on page 4-1. Storage compartment refer to “general chassis” on page 4-1. Front wheel/front...
Page 239: Front Fork
Front fork 4-82 disassembling the front fork legs order job/parts to remove q’ty remarks the following procedure applies to both of the front fork legs. 1 cap bolt 1 2 o-ring 1 3 spacer 1 4 fork spring seat 1 5 fork spring 1 6 dust seal 1 7 oil seal clip 1 8 damper rod bolt 1 9 copper washer 1 10 da...
Page 240: Front Fork
Front fork 4-83 eas22960 removing the front fork legs the following procedure applies to both of the front fork legs. 1. Stand the vehicle on a level surface. Warning ewa13120 securely support the vehicle so that there is no danger of it falling over. Tip place the vehicle on a suitable stand so tha...
Page 241: Front Fork
Front fork 4-84 tip while holding the damper rod with the damper rod holder “2” and t-handle “3”, loosen the damper rod bolt. 5. Remove: • inner tube ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Hold the front fork leg horizontally. B. Securely clamp the brake caliper bracket in a vise with soft jaws. C. Separ...
Page 242: Front Fork
Front fork 4-85 eas23031 assembling the front fork legs the following procedure applies to both of the front fork legs. Warning ewa13660 • make sure the oil levels in both front fork legs are equal. • uneven oil levels can result in poor han- dling and a loss of stability. Tip • when assembling the ...
Page 243: Front Fork
Front fork 4-86 6. Install: • outer tube bushing “1” • washer “2” (with the fork seal driver weight “3” and fork seal driver attachment “4”) 7. Install: • oil seal “1” (with the fork seal driver weight “2” and fork seal driver attachment “3”) eca14220 make sure the numbered side of the oil seal face...
Page 244: Front Fork
Front fork 4-87 eca14230 • be sure to use the recommended fork oil. Other oils may have an adverse effect on front fork performance. • when disassembling and assembling the front fork leg, do not allow any foreign material to enter the front fork. 11. After filling the front fork leg, slowly stroke ...
Page 245: Front Fork
Front fork 4-88 3. Install: • cap bolt cover (right front fork side) upper bracket pinch bolt 30 nm (3.0 m·kgf, 22 ft·lbf) 1.
Page 246: Steering Head
Steering head 4-89 eas23090 steering head removing the lower bracket order job/parts to remove q’ty remarks front cowling assembly refer to “general chassis” on page 4-1. Meter assembly refer to “general chassis” on page 4-1. Front wheel refer to “front wheel” on page 4-18. Handlebar refer to “handl...
Page 247: Steering Head
Steering head 4-90 eas23110 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 tip remove the upper ring nut ...
Page 248: Steering Head
Steering head 4-91 4. Check: • upper bracket • lower bracket (along with the steering stem) bends/cracks/damage → replace. Eas23140 installing the steering head 1. Lubricate: • upper bearing • lower bearing 2. Install: • lower ring nut “1” • rubber washer “2” • upper ring nut “3” • lock washer “4” r...
Page 249: Belt Drive
Belt drive 4-92 eas23510 belt drive * filling the yamaha grease “h” or polyurea grease®. Removing the drive belt order job/parts to remove q’ty remarks rear wheel refer to “rear wheel” on page 4-27. 1 rear brake lock cable holder (swingarm) 1 2 rear brake hose bracket 1 3 rear brake hose holder (rig...
Page 250: Belt Drive
Belt drive 4-93 eas23530 checking the drive belt 1. Clean: • drive belt ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Wipe the drive belt with a clean cloth. B. Put the drive belt in a mixture of mild deter- gent and water. Then, remove any dirt from the drive belt. C. Remove the drive belt from the mixture and...
Page 251: Rear Shock Absorber Assembly
Rear shock absorber assembly 4-94 eas23160 rear shock absorber assembly removing the rear shock absorber assembly order job/parts to remove q’ty remarks exhaust assembly refer to “engine removal” on page 5-3. 1 rear shock absorber assembly front bolt 1 2 lock washer 1 3 collar 1 4 rear shock absorbe...
Page 252: Rear Shock Absorber Assembly
Rear shock absorber assembly 4-95 eas23180 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 informa- tion. The manufacturer cannot be held respo...
Page 253: Rear Shock Absorber Assembly
Rear shock absorber assembly 4-96 2. Install: • rear shock absorber assembly tip • make sure that the warning label “1” on the rear shock absorber assembly faces up. • when installing the rear shock absorber assembly, lift up the swingarm. 3. Tighten: • rear shock absorber assembly rear nut • rear s...
Page 254: Swingarm
Swingarm 4-97 eas23330 swingarm removing the swingarm order job/parts to remove q’ty remarks rear shock absorber assembly refer to “rear shock absorber assembly” on page 4-94. Drive belt refer to “belt drive” on page 4-92. Exhaust assembly refer to “engine removal” on page 5-3. 1 drive belt inner gu...
Page 255: Swingarm
Swingarm 4-98 removing the swingarm order job/parts to remove q’ty remarks 13 collar 1 14 oil seal 1 15 bearing 1 for installation, reverse the removal proce- dure..
Page 256: Swingarm
Swingarm 4-99 eas23340 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 a suitable stand so that the rear wheel is elevated. 2. Measure: • swingarm side play • swingarm...
Page 257: Swingarm
Swingarm 4-100 tip install the parts to the swingarm “4” tempo- rarily, making sure that the portion “a” of the pivot shaft does not protrude past the swingarm surface “b”. 3. Install: • dowel pins • swingarm • swingarm bolts • drive pulley assembly • drive pulley assembly bolt 4. Tighten: • pivot s...
Page 258: Swingarm
Swingarm 4-101.
Page 259: Engine
5 engine engine inspection..................................................................................5-1 measuring the compression pressure .................................5-1 engine removal ......................................................................................5-3 installing ...
Page 260
V-belt automatic transmission ..................................................... 5-39 removing the primary sheave and secondary sheave................................................................................................ 5-44 disassembling the secondary sheave .............................
Page 261
Crankcase ............................................................................................. 5-69 disassembling the crankcase ................................................. 5-72 checking the crankcase ........................................................... 5-72 checking the timing ...
Page 262: Engine Inspection
Engine inspection 5-1 eas59c1501 engine inspection eas59c1502 measuring the compression pres- sure the following procedure applies to all of the cylinders. Tip insufficient compression pressure will result in a loss of performance. 1. Measure: • valve clearance out of specification → adjust. Refer t...
Page 263: Engine Inspection
Engine inspection 5-2 9. Connect: • spark plug caps 10. Install: • radiator cover refer to “general chassis” on page 4-1..
Page 264: Engine Removal
Engine removal 5-3 eas23711 engine removal removing the exhaust assembly order job/parts to remove q’ty remarks side cover (right) refer to “general chassis” on page 4-1. 1 o 2 sensor coupler 1 disconnect. 2 o 2 sensor 1 3 exhaust assembly 1 4 gasket 2 5 front muffler protector 1 6 center muffler pr...
Page 265: Engine Removal
Engine removal 5-4 disconnecting the leads order job/parts to remove q’ty remarks battery refer to “general chassis” on page 4-1. Front cowling assembly/storage box refer to “general chassis” on page 4-1. Engine oil drain. Refer to “changing the engine oil” on page 3-26. Coolant drain. Refer to “cha...
Page 266: Engine Removal
Engine removal 5-5 disconnecting the leads order job/parts to remove q’ty remarks 1 spark plug cap 2 disconnect. 2 crankshaft position sensor coupler 1 disconnect. 3 stator coil coupler 1 disconnect. 4 sidestand switch coupler 1 disconnect. 5 coolant temperature sensor coupler 1 disconnect. 6 ground...
Page 267: Engine Removal
Engine removal 5-6 removing the engine order job/parts to remove q’ty remarks right passenger footrest refer to “v-belt automatic transmis- sion” on page 5-39. 1 damper 2 2 rear frame bolt 2 3 engine mounting nut (rear side) 1 4 engine mounting bolt (rear side) 1 5 spacer 1 6 rear frame 1 7 engine m...
Page 268: Engine Removal
Engine removal 5-7 eas23720 installing the engine 1. Install: • all removed parts tip • apply locking agent (loctite®) to engine mounting bolts (front right lower side) “2”, engine mounting bolts (front left lower side) “3”, and rear frame bolts “5”. • for installation, reverse the removal proce- du...
Page 269: Camshafts
Camshafts 5-8 eas23760 camshafts removing the cylinder head cover order job/parts to remove q’ty remarks engine oil drain. Refer to “changing the engine oil” on page 3-26. Air filter case refer to “throttle body” on page 7-5. 1 spark plug cap 2 disconnect. 2 spark plug 2 3 cylinder head breather hos...
Page 270: Camshafts
Camshafts 5-9 removing the camshafts order job/parts to remove q’ty remarks coolant drain. Refer to “changing the coolant” on page 3-30. Crankshaft end access cover refer to “v-belt automatic transmis- sion” on page 5-39. Storage box refer to “general chassis” on page 4-1. Fuel tank refer to “fuel t...
Page 271: Camshafts
Camshafts 5-10 removing the camshafts order job/parts to remove q’ty remarks 7 dowel pin 4 tip during removal, the dowel pins may still be connected to the camshaft caps. 8 intake camshaft 1 9 exhaust camshaft 1 for installation, reverse the removal proce- dure..
Page 272: Camshafts
Camshafts 5-11 eas23810 removing the camshafts 1. Align: • “i” mark “a” on the generator rotor (with the stationary pointer “b” on the generator cover) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the crankshaft clockwise. B. When piston #1 is at tdc on the compres- sion stroke, align the “i” mark “a” on ...
Page 273: Camshafts
Camshafts 5-12 eas23850 checking the camshafts 1. Check: • camshaft lobes blue discoloration/pitting/scratches → replace the camshaft. 2. Measure: • camshaft lobe dimensions “a” and “b” out of specification → replace the cam- shaft. 3. Measure: • camshaft runout out of specification → replace. Camsh...
Page 274: Camshafts
Camshafts 5-13 4. Measure: • camshaft-journal-to-camshaft-cap clear- ance out of specification → measure the cam- shaft journal diameter. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Install the camshaft into the cylinder head (without the dowel pins and camshaft caps). B. Position a strip of plastigauge® “1” ...
Page 275: Camshafts
Camshafts 5-14 eas23950 checking the timing chain guides 1. Check: • timing chain guide (intake side) “1” • timing chain guide (exhaust side) “2” • timing chain guide (upper side) “3” damage/wear → replace the defective part(s). Eas23960 checking the timing chain ten- sioner 1. Check: • timing chain...
Page 276: Camshafts
Camshafts 5-15 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the crankshaft clockwise. B. When piston #1 is at tdc on the compres- sion stroke, align the “i” mark “a” on the generator rotor with the stationary pointer “b” on the generator cover. C. Install the timing chain onto both camshaft sprockets, and...
Page 277: Camshafts
Camshafts 5-16 tip • lubricate the camshaft cap bolt seats with the engine oil. • when tightening the camshaft cap, tighten the four bolts on the both ends of the cap temporarily to lower the entire cap, while pay- ing attention not to twist the dowel pins and camshaft journal. After the camshaft ca...
Page 278: Camshafts
Camshafts 5-17 7. Measure: • valve clearance out of specification → adjust. Refer to “adjusting the valve clearance” on page 3-5. 8. Install: • timing chain guide (upper side) • gaskets (to the cylinder head cover) tip apply yamaha bond no.1215 “1” onto the mat- ing surfaces of the cylinder head cov...
Page 279: Cylinder Head
Cylinder head 5-18 eas24100 cylinder head removing the cylinder head order job/parts to remove q’ty remarks camshafts refer to “camshafts” on page 5-8. Exhaust assembly refer to “engine removal” on page 5-3. Thermostat/coolant temperature sensor refer to “thermostat” on page 6-7. Radiator bracket re...
Page 280: Cylinder Head
Cylinder head 5-19 eas24120 removing the cylinder head 1. Remove: • cylinder head bolts • cylinder head nuts tip • loosen the bolts and nuts in the proper sequence as shown. • loosen each nut 1/2 of a turn at a time. After all of the nuts are fully loosened, remove them. Eas24160 checking the cylind...
Page 281: Cylinder Head
Cylinder head 5-20 2. Install: • cylinder head • washers • cylinder head nuts • cylinder head bolts tip • pass the timing chain through the timing chain cavity. • lubricate the cylinder head nuts and wash- ers with engine oil. 3. Tighten: • cylinder head nuts “1”–“6” • cylinder head bolts “7”, “8” •...
Page 282: Valves and Valve Springs
Valves and valve springs 5-21 eas24270 valves and valve springs * silicone fluid removing the valves and valve springs order job/parts to remove q’ty remarks cylinder head refer to “cylinder head” on page 5-18. 1 valve lifter 8 2 valve pad 8 3 valve cotter 16 4 valve spring retainer 8 5 valve spring...
Page 283: Valves and Valve Springs
Valves and valve springs 5-22 eas24280 removing the valves the following procedure applies to all of the valves and related components. Tip before removing the internal parts of the cylin- der head (e.G., valves, valve springs, valve seats), make sure the valves properly seal. 1. Remove: • valve lif...
Page 284: Valves and Valve Springs
Valves and valve springs 5-23 eas24290 checking the valves and valve guides the following procedure applies to all of the valves and valve guides. 1. Measure: • valve-stem-to-valve-guide clearance out of specification → replace the valve guide. 2. Replace: • valve guide tip to ease valve guide remov...
Page 285: Valves and Valve Springs
Valves and valve springs 5-24 tip after replacing the valve guide, reface the valve seat. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 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...
Page 286: Valves and Valve Springs
Valves and valve springs 5-25 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Apply mechanic’s blueing dye (dykem) “b” onto the valve face. B. Install the valve into the cylinder head. C. Press the valve through the valve guide and onto the valve seat to make a clear impression. D. Measure the valve seat width. T...
Page 287: Valves and Valve Springs
Valves and valve springs 5-26 f. After every lapping procedure, be sure to clean off all of the lapping compound from the valve face and valve seat. G. Apply mechanic’s blueing dye (dykem) “b” onto the valve face. H. Install the valve into the cylinder head. I. Press the valve through the valve guid...
Page 288: Valves and Valve Springs
Valves and valve springs 5-27 eas24320 checking the valve lifters the following procedure applies to all of the valve lifters. 1. Check: • valve lifter damage/scratches → replace the valve lifters and cylinder head. Eas24340 installing the valves the following procedure applies to all of the valves ...
Page 289: Valves and Valve Springs
Valves and valve springs 5-28 “2” and the valve spring compressor attach- ment “3”. 5. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a soft- face hammer. Eca13800 hitting the valve tip with excessive force could damage the valve. 6. Lubricate: • valve pad (with the ...
Page 290: Cylinder and Pistons
Cylinder and pistons 5-29 eas24370 cylinder and pistons removing the cylinder and pistons order job/parts to remove q’ty remarks cylinder head refer to “cylinder head” on page 5-18. Coolant hose refer to “water pump” on page 6-9. 1 timing chain guide (exhaust side) 1 2 cylinder 1 3 cylinder gasket 1...
Page 291: Cylinder and Pistons
Cylinder and pistons 5-30 eas24380 removing the pistons the following procedure applies to all of the piston. 1. Remove: • piston pin clips “1” • piston pin “2” • piston “3” eca13810 do not use a hammer to drive the piston pin out. Tip • before removing the piston pin clip, cover the crankcase openi...
Page 292: Cylinder and Pistons
Cylinder and pistons 5-31 b. If out of specification, replace the cylinder, piston and piston rings as a set. C. Measure piston skirt diameter “a” with the micrometer. D. If out of specification, replace the piston and piston rings as a set. E. Calculate the piston-to-cylinder clearance with the fol...
Page 293: Cylinder and Pistons
Cylinder and pistons 5-32 3. Measure: • piston ring end gap out of specification → replace the piston ring set. Tip the oil ring expander spacer’s end gap cannot be measured. If the oil ring rail’s gap is exces- sive, replace all three piston rings. Eas24440 checking the piston pins the following pr...
Page 294: Cylinder and Pistons
Cylinder and pistons 5-33 eas24470 installing the pistons and cylinder the following procedure applies to all of the pistons and cylinders. 1. Install: • oil ring expander “1” • lower oil ring rail “2” • upper oil ring rail “3” • 2nd ring “4” • top ring “5” (into the piston) tip be sure to install t...
Page 295: Cylinder and Pistons
Cylinder and pistons 5-34 6. Install: • cylinder • cylinder bolt tip • while compressing the piston rings, install the cylinder. • pass the timing chain and timing chain guide (intake side) through the timing chain cavity. 7. Tighten: • cylinder bolt cylinder bolt 10 nm (1.0 m·kgf, 7.2 ft·lbf).
Page 296: Electric Starter
Electric starter 5-35 eas24780 electric starter removing the starter motor order job/parts to remove q’ty remarks storage box refer to “general chassis” on page 4-1. Fuel tank refer to “fuel tank” on page 7-1. 1 ground lead 1 disconnect. 2 starter motor lead 1 disconnect. 3 starter motor assembly 1 ...
Page 297: Electric Starter
Electric starter 5-36 * when replacing any of the starter motor front cover, armature assembly, starter motor yoke, insu- lator, and starter motor rear cover, replace the starter motor assembly. Disassembling the starter motor order job/parts to remove q’ty remarks 1 starter motor front cover 1 2 ar...
Page 298: Electric Starter
Electric starter 5-37 eas24791 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 299: Electric Starter
Electric starter 5-38 6. Check: • gear teeth damage/wear → replace the starter motor assembly. 7. Check: • bearing damage/pitting → replace the starter motor assembly. Eas24800 assembling the starter motor 1. Install: • insulator “1” tip install the insulator so that the slot “a” is posi- tioned as ...
Page 300: 5-39
V-belt automatic transmission 5-39 eas24610 v-belt automatic transmission * water removing the v-belt case cover order job/parts to remove q’ty remarks footboard (right) refer to “general chassis” on page 4-1. Storage box refer to “general chassis” on page 4-1. V-belt case air filter element (left) ...
Page 301: 5-40
V-belt automatic transmission 5-40 * water removing the v-belt case cover order job/parts to remove q’ty remarks 10 bearing retainer 1 11 bearing 1 12 circlip 1 13 oil seal 1 14 bearing 1 for installation, reverse the removal proce- dure..
Page 302: 5-41
V-belt automatic transmission 5-41 *1 apply shell sunlight grease 3®. *2 apply yamaha grease “h” or polyurea grease®. Removing the v-belt and primary/secondary sheave order job/parts to remove q’ty remarks 1 primary sheave nut 1 2 spacer 1 3 o-ring 2 4 primary sheave assembly 1 5 secondary sheave nu...
Page 303: 5-42
V-belt automatic transmission 5-42 *1 apply yamaha grease “h” or polyurea grease®. *2 when replacing the primary sliding sheave or collar, replace them as a set. Disassembling the primary sheave order job/parts to remove q’ty remarks 1 cam 1 2 slider 8 3 primary sheave weight 8 4 primary sliding she...
Page 304: 5-43
V-belt automatic transmission 5-43 * apply yamaha grease “h” or polyurea grease®. Disassembling the secondary sheave order job/parts to remove q’ty remarks 1 secondary sheave spring seat nut 1 2 upper spring seat 1 3 secondary sheave compression spring 1 4 spring seat 1 5 guide pin 6 6 secondary sli...
Page 305: 5-44
V-belt automatic transmission 5-44 eas4b51022 removing the primary sheave and secondary sheave 1. Remove: • primary sheave nut “1” • secondary sheave nut “2” tip while holding the primary and secondary sheave with the sheave holder “3”, loosen the nut. 2. Remove: • primary sheave assembly “1” • seco...
Page 306: 5-45
V-belt automatic transmission 5-45 eas24670 checking the v-belt 1. Check: • v-belt “1” cracks/damage/wear → replace. Grease/oil → clean the primary and sec- ondary sheave. 2. Measure: • v-belt width “a” out of specification → replace. Tip place plate “2” on the upper of the belt and measure the widt...
Page 307: 5-46
V-belt automatic transmission 5-46 eas24710 checking the secondary sheave 1. Check: • secondary fixed sheave • secondary sliding sheave cracks/damage/wear → replace the secondary fixed and sliding sheaves as a set. 2. Check: • torque cam groove “1” damage/wear → replace the secondary fixed and slidi...
Page 308: 5-47
V-belt automatic transmission 5-47 3. Lubricate: • guide pin groove “1” • o-rings “2” (with the recommended lubricant) 4. Install: • secondary sheave spring seat nut “1” tip • install the secondary sheave spring seat nut with its beveled side “a” facing the spring seat. • attach the sheave spring co...
Page 309: 5-48
V-belt automatic transmission 5-48 eas4b51024 installing the primary sheave assembly, secondary sheave assem- bly and v-belt 1. Apply: • sealant (onto the inner v-belt case seal) 2. Install: • v-belt case air duct joint clamp “1” • v-belt case air duct “2” tip • align the projection “a” in the v-bel...
Page 310: 5-49
V-belt automatic transmission 5-49 tions of the cam are fitted firmly into the serrations of the crankshaft. • also, make sure that cam is properly seated. • apply grease to the thread and seat of the primary sheave nut. Tip while holding the primary sheave with the sheave holder “2”, tighten the pr...
Page 311: Generator and Starter Clutch
Generator and starter clutch 5-50 eas59c1503 generator and starter clutch removing the generator rotor and starter clutch order job/parts to remove q’ty remarks engine oil drain. Refer to “changing the engine oil” on page 3-26. Coolant drain. Refer to “changing the coolant” on page 3-30. Front cowli...
Page 312: Generator and Starter Clutch
Generator and starter clutch 5-51 removing the generator rotor and starter clutch order job/parts to remove q’ty remarks 9 starter clutch idle gear shaft 1 10 starter clutch idle gear 1 11 generator rotor nut 1 12 spacer 1 13 generator rotor 1 14 starter clutch 1 15 woodruff key 1 16 starter clutch ...
Page 313: Generator and Starter Clutch
Generator and starter clutch 5-52 * when replacing the crankshaft position sensor or stator coil, replace them as a set. Removing the stator coil and oil tank order job/parts to remove q’ty remarks 1 oil tank 1 2 oil tank gasket 1 3 dowel pin 2 4 oil strainer 1 5 crankshaft position sensor 1 6 stato...
Page 314: Generator and Starter Clutch
Generator and starter clutch 5-53 eas24490 removing the generator 1. Remove: • generator cover tip loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 2. Remove: • generator rotor nut “1” • spacer “2” tip • while ho...
Page 315: Generator and Starter Clutch
Generator and starter clutch 5-54 2. Check: • starter clutch idle gear “1” • starter clutch gear “2” burrs/chips/roughness/wear → replace the defective part(s). 3. Check: • starter clutch gear contacting surfaces damage/pitting/wear → replace the starter clutch gear. 4. Check: • starter clutch opera...
Page 316: Generator and Starter Clutch
Generator and starter clutch 5-55 eas24500 installing the generator 1. Install: • woodruff key • generator rotor “1” • spacer “2” • generator rotor nut “3” tip • clean the tapered portion of the crankshaft and the generator rotor hub. • when installing the generator rotor, make sure the woodruff key...
Page 317: Generator and Starter Clutch
Generator and starter clutch 5-56 4. Install: • generator cover tip tighten the generator cover bolts in stages and in a crisscross pattern. Generator cover bolt 10 nm (1.0 m·kgf, 7.2 ft·lbf).
Page 318: Clutch
Clutch 5-57 eas25061 clutch removing the clutch order job/parts to remove q’ty remarks generator cover refer to “generator and starter clutch” on page 5-50. 1 clutch assembly nut 1 2 clutch assembly 1 3 washer 1 for installation, reverse the removal proce- dure..
Page 319: Clutch
Clutch 5-58 disassembling the clutch order job/parts to remove q’ty remarks 1 clip 1 2 spring stopper plate 1 3 clutch spring plate 1 4 pressure plate 1 5 clutch plate 2 2 6 clutch damper spring 7 7 friction plate 6 8 clutch plate 1 5 9 clutch spring 6 10 thrust plate 1 11 clutch boss nut 1 12 prima...
Page 320: Clutch
Clutch 5-59 disassembling the clutch order job/parts to remove q’ty remarks 16 thrust plate 1 17 clutch weight 12 18 clutch housing 1 for assembly, reverse the disassembly pro- cedure..
Page 321: Clutch
Clutch 5-60 eas25070 removing the clutch 1. Remove: • clutch assembly nut “1” • clutch assembly “2” tip • before removal, put alignment marks “a” and “b” as shown. • while holding the clutch assembly with the rotor holding tool “3”, loosen the clutch assembly nut. • align these marks during reassemb...
Page 322: Clutch
Clutch 5-61 eas25100 checking the friction plates the following procedure applies to all of the friction plates. 1. Check: • friction plate damage/wear → replace the friction plates as a set. 2. Measure: • friction plate thickness out of specification → replace the fric- tion plates as a set. Tip me...
Page 323: Clutch
Clutch 5-62 eas25140 checking the clutch springs the following procedure applies to all of the clutch springs. 1. Check: • clutch spring damage → replace the clutch springs as a set. 2. Measure: • clutch spring free length out of specification → replace the clutch springs as a set. Eas25150 checking...
Page 324: Clutch
Clutch 5-63 eas4b51029 assembling the clutch 1. Install: • clutch boss • primary drive gear • clutch boss nut 2. Tighten: • clutch boss nut “1” tip while holding the clutch boss “2” with the uni- versal clutch holder “3”, tighten the clutch boss nut. 3. Install: • clutch weights • thrust plate “1” •...
Page 325: Clutch
Clutch 5-64 eas25240 installing the clutch 1. Install: • clutch assembly “1” • clutch assembly nut “2” tip • align the “a” and “b” during reassembly. • while holding the clutch assembly with the rotor holding tool “3”, tighten the clutch assembly nut. Clutch assembly nut 65 nm (6.5 m·kgf, 47 ft·lbf)...
Page 326: Oil Pump
Oil pump 5-65 eas24901 oil pump removing the oil pump assembly order job/parts to remove q’ty remarks starter clutch gear refer to “generator and starter clutch” on page 5-50. 1 oil pump assembly 1 2 oil pump drive chain 1 3 gasket 2 4 oil delivery pipe 1 5 oil pipe 1 6 relief valve assembly 1 for i...
Page 327: Oil Pump
Oil pump 5-66 * when replacing any of the part, replace the oil pump assembly. Disassembling the oil pump assembly order job/parts to remove q’ty remarks 1 oil pump housing 1 1 2 dowel pin 2 3 oil pump outer rotor 1 1 4 oil pump inner rotor 1 1 5 pin 1 6 washer 1 7 oil pump housing center 1 8 oil pu...
Page 328: Oil Pump
Oil pump 5-67 eas24960 checking the oil pump 1. Check: • oil pump driven gear “1” • oil pump housing 2 “2” • oil pump housing 1 “3” cracks/damage/wear → replace the oil pump assembly. 2. Check: • oil pump operation rough movement → repeat steps (1) and (2) or replace the oil pump assembly. Eas24971 ...
Page 329: Oil Pump
Oil pump 5-68 eca13890 after tightening the bolts, make sure the oil pump turns smoothly..
Page 330: Crankcase
Crankcase 5-69 eas25540 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 5-18. Cylinder/pistons refer to “cylinder and pistons” on page 5-29. Oil cooler refer to “oil cooler” on page...
Page 331: Crankcase
Crankcase 5-70 separating the crankcase order job/parts to remove q’ty remarks 4 left crankcase 1 5 dowel pin 2 6 oil strainer 1 7 right crankcase 1 for installation, reverse the removal proce- dure..
Page 332: Crankcase
Crankcase 5-71 removing the oil seals and bearings order job/parts to remove q’ty remarks crankshaft assembly refer to “crankshaft” on page 5-74. Transmission refer to “transmission” on page 5-83. 1 bearing retainer 2 2 oil seal 2 3 bearing 5 for installation, reverse the removal proce- dure..
Page 333: Crankcase
Crankcase 5-72 eas25560 disassembling the crankcase 1. Remove: • crankcase bolts tip loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. • m6 × 35 mm (1.38 in) bolts “1” • m6 × 50 mm (1.97 in) bolts “2” • m8 × 110 m...
Page 334: Crankcase
Crankcase 5-73 5. Install: • crankcase bolts (m8) • crankcase bolts (m6) tip tighten each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. • m8 × 110 mm (4.33 in) bolts “1” • m6 × 50 mm (1.97 in) bolts “2” • m6 × 35 mm (1.38 in) bolts “3” 6. Check: • crankshaft and transmission o...
Page 335: Crankshaft
Crankshaft 5-74 eas25960 crankshaft removing the crankshaft assembly order job/parts to remove q’ty remarks crankcase separate. Refer to “crankcase” on page 5-69. 1 dowel pin 2 2 balancer cylinder 1 3 crankshaft assembly 1 4 oil seal 1 5 crankshaft journal bearing 2 for installation, reverse the rem...
Page 336: Crankshaft
Crankshaft 5-75 removing the connecting rods order job/parts to remove q’ty remarks 1 connecting rod cap 2 2 big end lower bearing 2 3 connecting rod 2 4 big end upper bearing 2 5 circlip 2 6 balancer piston pin 1 7 balancer piston 1 8 balancer connecting rod cap 1 9 balancer big end lower bearing 1...
Page 337: Crankshaft
Crankshaft 5-76 eas26010 removing the connecting rods the following procedure applies to all of the connecting rods. 1. Remove: • connecting rod cap “1” • connecting rod “2” • big end bearings tip identify the position of each big end bearing so that it can be reinstalled in its original place. Eas2...
Page 338: Crankshaft
Crankshaft 5-77 3. Measure: • crankshaft-pin-to-big-end-bearing clear- ance out of specification → replace the big end bearings. The following procedure applies to all of the connecting rods and balancer connecting rod. Eca13930 do not interchange the big end bearings and connecting rods. To obtain ...
Page 339: Crankshaft
Crankshaft 5-78 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 4. Select: • big end bearings (p 1 –p 3 ) tip • the numbers “a” stamped into the crank- shaft web and the numbers “b” on the con- necting rods are used to determine the replacement big end bearing sizes. • p 1 –p 3 refer to the bearings shown in the cra...
Page 340: Crankshaft
Crankshaft 5-79 places. If it is out of specification, replace the crankshaft. D. Measure the crankshaft journal bearing inside diameter “b” of each crankshaft jour- nal bearing at two places. E. If crankshaft journal bearing inside diame- ter is “55.03” and crankshaft journal diame- ter is “54.98”,...
Page 341: Crankshaft
Crankshaft 5-80 eas25630 installing the crankshaft jour- nal bearings the following procedure applies to both of the crankshaft journal bearings. 1. Attach: • crankshaft journal bearing “1” tip attach the crankshaft journal bearing to the plane bearing installer “2”. 2. Install: • crankshaft journal...
Page 342: Crankshaft
Crankshaft 5-81 • make sure the characters “d” on both the connecting rod and connecting rod cap are aligned. 4. Tighten: • connecting rod nuts ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ warning ewa59c1502 replace the connecting rod bolts and nuts with new ones. Tip tighten the connecting rod nuts using the fol...
Page 343: Crankshaft
Crankshaft 5-82 • make sure the characters “d” on both the bal- ancer connecting rod and balancer connect- ing rod cap are aligned. 6. Tighten: • balancer connecting rod nuts eca4b51020 • when tightening the nuts, be sure to use a beam type torque wrench. • tighten the nuts to the specified torque. ...
Page 344: Transmission
Transmission 5-83 eas26241 transmission removing the transmission order job/parts to remove q’ty remarks crankcase separate. Refer to “crankcase” on page 5-69. 1 secondary shaft 1 2 collar 1 3 primary driven gear 1 4 main axle 1 tip when installing main axle, install the main axle with groove “a” fa...
Page 345: Transmission
Transmission 5-84 eas31560 checking the transmission 1. Check: • transmission gears blue discoloration/pitting/wear → replace. 2. Check: • transmission gear movement rough movement → replace the defec- tive part(s). 3. Check: • main axle cracks/damage/wear → replace the main axle. 4. Measure: • driv...
Page 346: Transmission
Transmission 5-85.
Page 347: Cooling System
6 cooling system radiator ....................................................................................................6-1 checking the radiator..................................................................6-3 installing the radiator ..........................................................
Page 348: Radiator
Radiator 6-1 eas26380 radiator removing the radiator order job/parts to remove q’ty remarks footboards refer to “general chassis” on page 4-1. Coolant drain. Refer to “changing the coolant” on page 3-30. 1 coolant reservoir hose 1 2 coolant reservoir 1 3 coolant reservoir cap 1 4 coolant reservoir b...
Page 349: Radiator
Radiator 6-2 removing the radiator order job/parts to remove q’ty remarks 12 radiator 1 13 radiator fan 1 14 radiator inlet hose 1 15 radiator bracket 1 for installation, reverse the removal proce- dure..
Page 350: Radiator
Radiator 6-3 eas26390 checking the radiator 1. Check: • radiator fins obstruction → clean. Apply compressed air to the rear of the radiator. Damage → repair or replace. Tip straighten any flattened fins with a thin, flat- head screwdriver. 2. Check: • radiator hoses • radiator pipes cracks/damage → ...
Page 351: Radiator
Radiator 6-4 b. Apply 137.3 kpa (1.37 kgf/cm 2 , 19.9 psi) of pressure. C. Measure the indicated pressure with the gauge. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲.
Page 352: Oil Cooler
Oil cooler 6-5 eas26410 oil cooler removing the oil cooler order job/parts to remove q’ty remarks storage box refer to “general chassis” on page 4-1. Fuel tank refer to “fuel tank” on page 7-1. Engine oil drain. Refer to “changing the engine oil” on page 3-26. Coolant drain. Refer to “changing the c...
Page 353: Oil Cooler
Oil cooler 6-6 eas26420 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. Eas26430 installing the oil cooler 1. Clean: • mating surfaces of the oil cooler and the crankcase (with a cloth da...
Page 354: Thermostat
Thermostat 6-7 eas26440 thermostat removing the thermostat order job/parts to remove q’ty remarks storage box refer to “general chassis” on page 4-1. Fuel tank refer to “fuel tank” on page 7-1. Coolant drain. Refer to “changing the coolant” on page 3-30. 1 coolant temperature sensor coupler 1 discon...
Page 355: Thermostat
Thermostat 6-8 eas26450 checking the thermostat 1. Check: • thermostat does not open at 71–85 °c (159.8–185.0 °f) → replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Suspend the thermostat “1” in a container “2” filled with water. B. Slowly heat the water “3”. C. Place a thermometer “4” in the water. D. Wh...
Page 356: Water Pump
Water pump 6-9 eas26500 water pump * water or silicone fluid removing the water pump order job/parts to remove q’ty remarks footboard (left) refer to “general chassis” on page 4-1. Coolant drain. Refer to “changing the coolant” on page 3-30. 1 v-belt case air filter element joint clamp 1 loosen. 2 v...
Page 357: Water Pump
Water pump 6-10 disassembling the water pump order job/parts to remove q’ty remarks 1 water pump housing cover 1 2 circlip 1 3 impeller shaft 1 4 water pump seal 1 5 bearing 1 6 oil seal 1 7 water pump housing 1 for assembly, reverse the disassembly pro- cedure..
Page 358: Water Pump
Water pump 6-11 eas26510 disassembling the water pump 1. Remove: • rubber damper holder “1” • rubber damper “2” (from the impeller, with a thin, flathead screwdriver) tip do not scratch the impeller shaft. 2. Remove: • water pump seal “1” tip remove the water pump seal from the inside of the water p...
Page 359: Water Pump
Water pump 6-12 eca14080 never lubricate the water pump seal sur- face with oil or grease. Tip • install the water pump seal with the special tools. • before installing the water pump seal, apply yamaha bond no.1215 “2” to the water pump housing “3”. 3. Install: • rubber damper holder “1” • rubber d...
Page 360: Water Pump
Water pump 6-13 2. Fill: • cooling system (with the specified amount of the recom- mended coolant) refer to “changing the coolant” on page 3-30. 3. Check: • cooling system leaks → repair or replace any faulty part. Refer to “installing the radiator” on page 6-3. 4. Measure: • radiator cap opening pr...
Page 361: Fuel System
7 fuel system fuel tank ..................................................................................................7-1 removing the fuel hose ...............................................................7-2 removing the fuel tank ................................................................
Page 362: Fuel Tank
Fuel tank 7-1 eas26620 fuel tank removing the fuel tank order job/parts to remove q’ty remarks storage box refer to “general chassis” on page 4-1. 1 fuel pump coupler 1 disconnect. 2 fuel hose connector cover 1 3 fuel hose 1 disconnect. 4 fuel tank overflow hose 1 5 fuel tank breather hose 2 6 rollo...
Page 363: Fuel Tank
Fuel tank 7-2 eas59c1701 removing the fuel hose 1. Remove: • fuel hose connector cover “1” 2. Disconnect: • fuel hose “2” warning ewa15910 cover fuel hose connections with a cloth when disconnecting them. Residual pres- sure in the fuel lines could cause fuel to spurt out when removing the hose. Eca...
Page 364: Fuel Tank
Fuel tank 7-3 eas59c1703 installing the fuel pump 1. Install: • fuel pump gasket • fuel pump • fuel pump bracket 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 as shown in the illustra- tion. ...
Page 365: Fuel Tank
Fuel tank 7-4 eca59c17001 • be sure to disconnect the fuel hose by hand. Do not forcefully disconnect the hose with tools. • although the fuel has been removed from the fuel tank, be careful when removing the fuel hose, since there may be fuel remaining in it. • do not disconnect the fuel hose from ...
Page 366: Throttle Body
Throttle body 7-5 eas26970 throttle body removing the throttle body order job/parts to remove q’ty remarks storage box refer to “general chassis” on page 4-1. Fuel tank refer to “fuel tank” on page 7-1. Coolant drain. Refer to “changing the coolant” on page 3-30. 1 intake air temperature sensor coup...
Page 367: Throttle Body
Throttle body 7-6 removing the throttle body order job/parts to remove q’ty remarks 12 throttle position sensor sub-wire harness cou- pler 1 disconnect. 13 throttle body joint clamp 4 loosen. 14 throttle body assembly 1 15 throttle position sensor sub-wire harness 1 16 throttle body joint 2 17 fuel ...
Page 368: Throttle Body
Throttle body 7-7 disassembling the throttle body assembly order job/parts to remove q’ty remarks tip before disassembling the throttle body assembly, make sure to note the number of times the air screw is turned out from the seated position to its set position. 1 throttle position sensor 1 2 idling...
Page 369: Throttle Body
Throttle body 7-8 eas59c1705 removing the fuel hose (injector side) 1. Disconnect: • fuel hose (injector side) warning ewa15910 cover fuel hose connections with a cloth when disconnecting them. Residual pres- sure in the fuel lines could cause fuel to spurt out when removing the hose. Eca17490 be su...
Page 370: Throttle Body
Throttle body 7-9 3. Install a new seal onto the end of each injector. 4. Install the injector assembly to the intake manifold with the screws and new gaskets. 5. Check the fuel pressure. Refer to “checking the fuel pres- sure” on page 7-3. Eas59c1707 installing the fuel hose (injector side) 1. Conn...
Page 371: Throttle Body
Throttle body 7-10 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ throttle position sensor screw 3.5 nm (0.35 m·kgf, 2.5 ft·lbf).
Page 372: Throttle Body
Throttle body 7-11.
Page 373: Electrical System
8 electrical system ignition system.......................................................................................8-1 circuit diagram................................................................................8-1 troubleshooting ..............................................................
Page 374
Abs (anti-lock brake system) ........................................................ 8-85 circuit diagram.............................................................................. 8-85 abs components chart............................................................... 8-87 abs coupler location ...
Page 376: Ignition System
Ignition system 8-1 eas27090 ignition system eas27110 circuit diagram.
Page 377: Ignition System
Ignition system 8-2 1. Crankshaft position sensor 4. Frame ground 5. Joint 6. Main switch 8. Joint coupler 16.Ignition fuse 19.Battery 20.Negative lead 21.Main fuse 26.Right handlebar switch 27.Engine stop switch 38.Sidestand switch 39.Ecu (engine control unit) 40.Ignition coil 41.Spark plug 49.Lean...
Page 378: Ignition System
Ignition system 8-3 eas27140 troubleshooting the ignition system fails to operate (no spark or intermittent spark). Tip • before troubleshooting, remove the following part(s): 1. Footboards 2. Front cowling assembly ng → ok ↓ ng → ok ↓ ng → ok ↓ ok → ng ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. Check the f...
Page 379: Ignition System
Ignition system 8-4 ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 8. Check the main switch. Refer to “checking the switches” on page 8-123. Replace the main switch/immobilizer unit. 9. Check the engine stop switch. Refer to “checking the switches” on page 8-123. The engine stop switch is faulty....
Page 380: Electric Starting System
Electric starting system 8-5 eas27160 electric starting system eas27170 circuit diagram.
Page 381: Electric Starting System
Electric starting system 8-6 4. Frame ground 5. Joint 6. Main switch 8. Joint coupler 14.Signaling system fuse 16.Ignition fuse 19.Battery 20.Negative lead 21.Main fuse 22.Starter relay 23.Starter motor 24.Starting circuit cut-off relay 2 25.Diode 1 26.Right handlebar switch 27.Engine stop switch 28...
Page 382: Electric Starting System
Electric starting system 8-7 eas27180 starting circuit cut-off system operation if the engine stop switch is set to “ ” and the main switch is set to “on” (both switches are closed), the starter motor can only operate if at least one of the following conditions is met: • the front brake lever is pul...
Page 383: Electric Starting System
Electric starting system 8-8 1. Battery 2. Main fuse 3. Main switch 4. Signaling system fuse 5. Ignition fuse 6. Engine stop switch 7. Diode 2 8. Starting circuit cut-off relay 1 9. Front brake light switch 10.Rear brake light switch 11.Sidestand switch 12.Starting circuit cut-off relay 2 13.Start s...
Page 384: Electric Starting System
Electric starting system 8-9 eas27190 troubleshooting the starter motor fails to turn. Tip • before troubleshooting, remove the following part(s): 1. Front cowling assembly 2. Storage box 3. Fuel tank ng → ok ↓ ng → ok ↓ ok → ng ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. Check the fuses. (main, ig...
Page 385: Electric Starting System
Electric starting system 8-10 ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 8. Check the starter relay. Refer to “checking the relays” on page 8-131. Replace the starter relay. 9. Check the main switch. Refer to “checking the switches” on page 8-123. Replace the mai...
Page 386: Charging System
Charging system 8-11 eas27200 charging system eas27210 circuit diagram.
Page 387: Charging System
Charging system 8-12 2. Ac magneto 3. Rectifier/regulator 4. Frame ground 5. Joint 19.Battery 20.Negative lead 21.Main fuse.
Page 388: Charging System
Charging system 8-13 eas27220 troubleshooting the battery is not being charged. Tip • before troubleshooting, remove the following part(s): 1. Front cowling assembly 2. Storage box ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. Check the fuse. (main) refer to “checking the fuses” on page 8-127...
Page 389: Charging System
Charging system 8-14.
Page 390: Lighting System
Lighting system 8-15 eas27240 lighting system eas27250 circuit diagram.
Page 391: Lighting System
Lighting system 8-16 4. Frame ground 5. Joint 6. Main switch 8. Joint coupler 9. Storage box light switch 10.Storage box light 13.Backup fuse 15.Headlight fuse 16.Ignition fuse 18.Parking lighting fuse 19.Battery 20.Negative lead 21.Main fuse 39.Ecu (engine control unit) 63.License plate light 64.Ta...
Page 392: Lighting System
Lighting system 8-17 eas27260 troubleshooting any of the following fail to light: headlight, auxiliary light, high beam indicator light, taillight, license plate light, meter light or storage box light. Tip • before troubleshooting, remove the following part(s): 1. Front cowling assembly 2. Mudguard...
Page 393: Lighting System
Lighting system 8-18 ng → ok ↓ ng → ok ↓ 8. Check the storage box light switch. Refer to “checking the switches” on page 8-123. Replace the storage box light switch. 9. Check the entire lighting system’s wiring. Refer to “circuit diagram” on page 8-15. Properly connect or repair the lighting system’...
Page 394: Signaling System
Signaling system 8-19 eas27270 signaling system eas27280 circuit diagram.
Page 395: Signaling System
Signaling system 8-20 4. Frame ground 5. Joint 6. Main switch 8. Joint coupler 13.Backup fuse 14.Signaling system fuse 16.Ignition fuse 18.Parking lighting fuse 19.Battery 20.Negative lead 21.Main fuse 26.Right handlebar switch 29.Hazard switch 30.Front brake light switch 37.Fuel sender 39.Ecu (engi...
Page 396: Signaling System
Signaling system 8-21 eas27290 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 operate. • the speedometer fails to operate. Tip • before troubleshooting, remove the following part(s): 1. ...
Page 397: Signaling System
Signaling system 8-22 ng → ok ↓ the tail/brake light fails to come on. Ng → ok ↓ ng → ok ↓ ng → ok ↓ the turn signal light, turn signal indicator light or both fail to blink. Ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 3. Check the entire signaling system’s wiring. Refer to “circuit diagram” on page 8-1...
Page 398: Signaling System
Signaling system 8-23 ng → ok ↓ the fuel meter fails to operate. Ng → ok ↓ ng → ok ↓ the speedometer/v-belt replacement indicator/oil change indicator fails to operate. Ng → ok ↓ ng → ok ↓ tip repair or replace if there is an open or short circuit. • between front wheel sensor coupler and abs ecu co...
Page 399: Signaling System
Signaling system 8-24.
Page 400: Cooling System
Cooling system 8-25 eas27300 cooling system eas27310 circuit diagram.
Page 401: Cooling System
Cooling system 8-26 4. Frame ground 5. Joint 6. Main switch 8. Joint coupler 13.Backup fuse 16.Ignition fuse 17.Radiator fan fuse 19.Battery 20.Negative lead 21.Main fuse 39.Ecu (engine control unit) 44.Coolant temperature sensor 50.Diagnostic tool coupler 60.Radiator fan motor relay 61.Radiator fan...
Page 402: Cooling System
Cooling system 8-27 eas27320 troubleshooting tip • before troubleshooting, remove the following part(s): 1. Front cowling assembly 2. Storage box 3. Fuel tank ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. Check the fuses. (main, ignition, radiator fan and backup) refer to “checking ...
Page 403: Cooling System
Cooling system 8-28 ng → ok ↓ 7. Check the entire cooling system’s wiring. Refer to “circuit diagram” on page 8-25. Properly connect or repair the cooling system’s wiring. Replace the ecu (engine control unit) or meter assembly..
Page 404: Fuel Injection System
Fuel injection system 8-29 eas27331 fuel injection system eas27340 circuit diagram.
Page 405: Fuel Injection System
Fuel injection system 8-30 1. Crankshaft position sensor 4. Frame ground 5. Joint 6. Main switch 8. Joint coupler 12.Fuel injection system fuse 13.Backup fuse 14.Signaling system fuse 15.Headlight fuse 16.Ignition fuse 19.Battery 20.Negative lead 21.Main fuse 26.Right handlebar switch 27.Engine stop...
Page 406: Fuel Injection System
Fuel injection system 8-31 eas27351 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 engine under substitute char...
Page 407: Fuel Injection System
Fuel injection system 8-32 ecu detects an abnormal signal from a sensor if the ecu detects an abnormal signal from a sensor while the vehicle is being driven, the ecu illu- minates the engine trouble warning light and provides the engine with alternate operating instruc- tions that are appropriate f...
Page 408: Fuel Injection System
Fuel injection system 8-33 eas27402 troubleshooting method the engine operation is not normal and the engine trouble warning light comes on. 1. Check: • fault code number ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Check the fault code number displayed on the meter. B. Identify the faulty system with the faul...
Page 409: Fuel Injection System
Fuel injection system 8-34 eas27431 diagnostic mode setting the diagnostic mode 1. Set the main switch to “off” and set the engine stop switch to “ ”. 2. Disconnect the wire harness coupler from the fuel pump. 3. Simultaneously press and hold the left set button “1” and right set button “2”, set the...
Page 410: Fuel Injection System
Fuel injection system 8-35 eas59c1803 yamaha diagnostic tool this model uses the yamaha diagnostic tool to identify malfunctions. For information about using the yamaha diagnostic tool, refer to the operation manual that is included with the tool. Features of the yamaha diagnostic tool you can use t...
Page 411: Fuel Injection System
Fuel injection system 8-36 connecting the yamaha diagnostic tool disconnect the coupler (yellow/blue, red/green, black/white) “1”, and then connect the yamaha diagnostic tool to the coupler. Tip when the yamaha diagnostic tool is connected to the vehicle, the operation of the multi-function meter an...
Page 412: Fuel Injection System
Fuel injection system 8-37 eas27462 troubleshooting details this section describes the measures per fault code number displayed on the meter. Check and ser- vice the items or components that are the probable cause of the malfunction following the order given. After the check and service of the malfu...
Page 413: Fuel Injection System
Fuel injection system 8-38 5 crankshaft position sensor malfunction sensor inspection procedure refer to “checking the crankshaft position sensor” on page 8-135. Replace if defective. Crank the engine, and check the fault code indication. No fault code indicated. → recovered. Fault code indicated. →...
Page 414: Fuel Injection System
Fuel injection system 8-39 3 continuity of wire harness open or short circuit → replace the wire harness. Black/blue–black/blue pink/white–pink/white blue–blue place the main switch to the on position, and check the fault code indication. No fault code indicated. → recovered. Fault code indicated. →...
Page 415: Fuel Injection System
Fuel injection system 8-40 tip if fault codes 13 and 14 are indicated simultaneously, take the actions specified for fault code 13 first. 5 intake air pressure sensor malfunction check in the diagnostic mode (code no. D:03). When engine is stopped: atmospheric pressure at the current altitude and we...
Page 416: Fuel Injection System
Fuel injection system 8-41 fault code no. 14 item intake air pressure sensor: hose system malfunction (clogged or detached hose). Intake system malfunction (the pressure is not sup- plied to the intake air pressure sensor in a stable condition). Fail-safe system able to start engine able to drive ve...
Page 417: Fuel Injection System
Fuel injection system 8-42 tip if fault codes 13 and 14 are indicated simultaneously, take the actions specified for fault code 13 first. 2 intake air pressure sensor malfunction check in the diagnostic mode (code no. D:03). When engine is stopped: atmospheric pressure at the current altitude and we...
Page 418: Fuel Injection System
Fuel injection system 8-43 fault code no. 15 item throttle position sensor: open or short circuit detected. (no normal signals are received from the throttle position sensor.) fail-safe system under certain conditions under certain conditions diagnostic code no. D:01 meter display throttle position ...
Page 419: Fuel Injection System
Fuel injection system 8-44 tip if fault codes 15 and 16 are indicated simultaneously, take the actions specified for fault code 15 first. 6 supply voltage of throttle position sensor lead check the supply voltage. Black/blue–yellow refer to “checking the throttle position sen- sor” on page 8-139. Pl...
Page 420: Fuel Injection System
Fuel injection system 8-45 tip • if fault codes 15 and 16 are indicated simultaneously, take the actions specified for fault code 15 first. • if fault codes 16 and 37 are indicated simultaneously, take the actions specified for fault code 16 first. Fault code no. 16 item throttle position sensor: st...
Page 421: Fuel Injection System
Fuel injection system 8-46 fault code no. 19 item sidestand switch: a break or disconnection of the light green lead of the ecu is detected. (no normal signals are received from the side- stand switch.) fail-safe system unable to start engine unable to drive vehicle diagnostic code no. D:20 meter di...
Page 422: Fuel Injection System
Fuel injection system 8-47 fault code no. 21 item coolant temperature sensor: open or short circuit detected. (no nor- mal signals are received from the coolant temperature sensor.) fail-safe system able to start engine able to drive vehicle diagnostic code no. D:06 meter display displays the coolan...
Page 423: Fuel Injection System
Fuel injection system 8-48 tip work in a complete cold-engine condition. 6 ecu malfunction replace the ecu. Fault code no. 22 item intake air temperature sensor: open or short circuit detected. (no normal signals are received from the intake air temperature sensor.) fail-safe system able to start en...
Page 424: Fuel Injection System
Fuel injection system 8-49 tip work in a complete cold-engine condition. 4 installation status of intake air temperature sensor check the mounting section for a loose or pinched mount- ing. Make sure that the mounting position is correct. Place the main switch to the on position, and check the fault...
Page 425: Fuel Injection System
Fuel injection system 8-50 fault code no. 24 item o 2 sensor: not activated. (no normal signals are received from the o 2 sensor.) fail-safe system able to start engine able to drive vehicle diagnostic code no. — meter display — procedure — item/components and probable cause check or maintenance job...
Page 426: Fuel Injection System
Fuel injection system 8-51 6 o 2 sensor malfunction check the o 2 sensor for an abnormality. Refer to “engine removal” on page 5-3. O 2 sensor malfunction → replace the o 2 sensor. Either start and warm up the engine, and then racing it, or reset it with diagnostic code no. D:63. No fault code indic...
Page 427: Fuel Injection System
Fuel injection system 8-52 2 sensor installation status check for a loose mounting, pinched mounting, or sensor mounting direction (up or down). Make sure that the mounting position is correct. Rotate the main switch to the off position first, and then rotate it to the on position again. Then, check...
Page 428: Fuel Injection System
Fuel injection system 8-53 fault code no. 33 item ignition coil: open or short circuit detected in the primary lead of the ignition coil. (no normal signals are received from the ignition sys- tem.) fail-safe system unable to start engine unable to drive vehicle diagnostic code no. D:30 actuation ac...
Page 429: Fuel Injection System
Fuel injection system 8-54 5 ignition coil malfunction (check the continuity of pri- mary coil.) ignition coil inspection method refer to “checking the ignition coil” on page 8- 134. Start and idle the engine for approximately 5 seconds. Then, check the fault code indication. No fault code indicated...
Page 430: Fuel Injection System
Fuel injection system 8-55 tip • do not remove the fast idle plunger. • if fault codes 16 and 37 are indicated simultaneously, take the actions specified for fault code 16 first. • if fault codes 37 and 42 are indicated simultaneously, take the actions specified for fault code 42 first. • if fault c...
Page 431: Fuel Injection System
Fuel injection system 8-56 fault code no. 41 item lean angle sensor: open or short circuit detected. (no normal sig- nals are received from the lean angle sensor.) fail-safe system unable to start engine unable to drive vehicle diagnostic code no. D:08 meter display lean angle sensor output voltage ...
Page 432: Fuel Injection System
Fuel injection system 8-57 4 lean angle sensor malfunc- tion check in the diagnostic mode (code no. D:08). Sensor inspection procedure refer to “checking the lean angle sensor” on page 8-135. In vertical position: 0.4–1.4 v when turned over: 3.7–4.4 v indication is incorrect. → replace the lean angl...
Page 433: Fuel Injection System
Fuel injection system 8-58 2 connection of wire harness abs ecu coupler check the connection of the coupler is secure. Disconnect the coupler, and check each pin (for bending, wear, or locking). Poor connection → connect it securely, or repair/replace the wire harness. Place the main switch to the “...
Page 434: Fuel Injection System
Fuel injection system 8-59 tip if fault codes 37 and 42 are indicated simultaneously, take the actions specified for fault code 42 first. 5 front wheel sensor malfunc- tion check the front wheel sensor. Check in the diagnostic mode (code no. D:07). Front wheel stop: the pulse integrated value should...
Page 435: Fuel Injection System
Fuel injection system 8-60 fault code no. 43 item fuel system voltage: incorrect voltage supplied to the fuel injector and fuel pump. Fail-safe system able to start engine able to drive vehicle diagnostic code no. D:09, d:50 d:09 meter display fuel system voltage (battery voltage) approximately 12.0...
Page 436: Fuel Injection System
Fuel injection system 8-61 5 fuel injection system relay malfunction check in the diagnostic mode (code no. D:09) fuel-related voltage: 3 v or less → replace the fuel injec- tion system relay. Start and idle the engine for approximately 5 seconds. Then, check the fault code indication. No fault code...
Page 437: Fuel Injection System
Fuel injection system 8-62 2 “01” is indicated in diagnostic mode (code no. D:60) eeprom data error for adjustment of co concentra- tion of cylinder #1 change the co concentra- tion of cylinder #1, and rewrite in eeprom. Refer to “adjusting the exhaust gas volume” on page 3-11. After this adjustment...
Page 438: Fuel Injection System
Fuel injection system 8-63 tip if fault codes 37 and 46 are indicated simultaneously, take the actions specified for fault code 46 first. Fault code no. 46 item incorrect voltage is supplied to the ecu. Fail-safe system able to start engine able to drive vehicle diagnostic code no. — meter display —...
Page 439: Fuel Injection System
Fuel injection system 8-64 fault code no. Er-1 item ecu internal malfunction (output signal error): no signals are received from the ecu. Fail-safe system able to start engine (unable if ecu failure) able to drive vehicle (unable if ecu failure) diagnostic code no. — meter display — procedure — item...
Page 440: Fuel Injection System
Fuel injection system 8-65 fault code no. Er-2 item ecu internal malfunction (output signal error): no signals are received from the ecu within the specified duration. Fail-safe system able to start engine able to drive vehicle diagnostic code no. — meter display — procedure — item/components and pr...
Page 441: Fuel Injection System
Fuel injection system 8-66 fault code no. Er-3 item ecu internal malfunction (output signal error): data from the ecu cannot be received correctly. Fail-safe system able to start engine able to drive vehicle diagnostic code no. — meter display — procedure — item/components and probable cause check o...
Page 442: Fuel Injection System
Fuel injection system 8-67 fault code no. Er-4 item ecu internal malfunction (input signal error): non-registered data has been received from the meter. Fail-safe system able to start engine able to drive vehicle diagnostic code no. — meter display — procedure — item/components and probable cause ch...
Page 443: Fuel Injection System
Fuel injection system 8-68 eas30660 diagnostic code table tip the following tables contain information about diagnostic code numbers that do not have a corre- sponding fault code number. (these items are not listed in “troubleshooting details”.) diag- nostic code no. Item meter display/actuation pro...
Page 444: Fuel Injection System
Fuel injection system 8-69 set the main switch to “off” to cancel the diagnostic mode. Tip information about each diagnostic code no. Is organized in this manual as follows: • if a diagnostic code no. Has a corresponding fault code no., the information is shown in trou- bleshooting details. (refer t...
Page 445: Fuel Injection System
Fuel injection system 8-70
Page 446: Fuel Pump System
Fuel pump system 8-71 eas27550 fuel pump system eas27560 circuit diagram.
Page 447: Fuel Pump System
Fuel pump system 8-72 4. Frame ground 5. Joint 6. Main switch 8. Joint coupler 12.Fuel injection system fuse 16.Ignition fuse 19.Battery 20.Negative lead 21.Main fuse 26.Right handlebar switch 27.Engine stop switch 35.Fuel injection system relay 36.Fuel pump 39.Ecu (engine control unit).
Page 448: Fuel Pump System
Fuel pump system 8-73 eas27570 troubleshooting if the fuel pump fails to operate. Tip • before troubleshooting, remove the following part(s): 1. Front cowling assembly 2. Storage box ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. Check the fuses. (main, ignition and fuel in...
Page 449: Fuel Pump System
Fuel pump system 8-74.
Page 450: Immobilizer System
Immobilizer system 8-75 eas27640 immobilizer system eas27650 circuit diagram.
Page 451: Immobilizer System
Immobilizer system 8-76 4. Frame ground 5. Joint 6. Main switch 7. Immobilizer unit 8. Joint coupler 13.Backup fuse 16.Ignition fuse 19.Battery 20.Negative lead 21.Main fuse 39.Ecu (engine control unit) 50.Diagnostic tool coupler 82.Meter assembly 83.Immobilizer system indicator light 92.Multi-funct...
Page 452: Immobilizer System
Immobilizer system 8-77 eas27671 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) that...
Page 453: Immobilizer System
Immobilizer system 8-78 eas27691 part replacement and key code registration requirements in the course of use, you may encounter the following cases where replacement of parts and regis- tration of code re-registering/standard keys are required. Tip each standard key is registered during production,...
Page 454: Immobilizer System
Immobilizer system 8-79 standby mode: to enable the immobilizer system, set the ignition key to “off”. 30 seconds later, the indicator light will start flashing continuously in the standby flashing mode pattern for up to 24 hours. After that time, the indicator light will stop flashing, but the immo...
Page 455: Immobilizer System
Immobilizer system 8-80 standard key registration voiding the standard key code: if a standard key has been lost, it is possible to disable its use by re-registering the remaining stan- dard key. Standard key registration erases the stored standard key code from the memory, thus dis- abling the lost...
Page 456: Immobilizer System
Immobilizer system 8-81 eas27701 troubleshooting when the main switch is set to “on”, the immobilizer system indicator light does not come on nor flashes. Ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. Check the fuses. (main, ignition and backup) refer to “checking the fuses” on page 8-127. Replace the ...
Page 457: Immobilizer System
Immobilizer system 8-82 eas27721 self-diagnosis fault code indication when a system malfunction occurs, the fault code number is indicated in the lcd display of the meter assembly and the immobilizer system indicator light flashes at the same time. The pattern of flashing also shows the fault code. ...
Page 458: Immobilizer System
Immobilizer system 8-83 immobilizer system indicator light fault code indication units of 10: cycles of on for 1 second and off for 1.5 seconds. Units of 1: cycles of on for 0.5 second and off for 0.5 second. Example: fault code 52 54 immobilizer unit codes transmitted between the ecu (engine contro...
Page 459: Immobilizer System
Immobilizer system 8-84.
Page 460: Abs (Anti-Lock Brake System)
Abs (anti-lock brake system) 8-85 eas28790 abs (anti-lock brake system) eas27730 circuit diagram.
Page 461: Abs (Anti-Lock Brake System)
Abs (anti-lock brake system) 8-86 4. Frame ground 5. Joint 6. Main switch 8. Joint coupler 13.Backup fuse 14.Signaling system fuse 16.Ignition fuse 19.Battery 20.Negative lead 21.Main fuse 22.Starter relay 24.Starting circuit cut-off relay 2 25.Diode 1 26.Right handlebar switch 27.Engine stop switch...
Page 462: Abs (Anti-Lock Brake System)
Abs (anti-lock brake system) 8-87 eas27740 abs components chart.
Page 463: Abs (Anti-Lock Brake System)
Abs (anti-lock brake system) 8-88 1. Hydraulic unit assembly (abs ecu) 2. Fuse box (right) 3. Fuse box (left) 4. Abs warning light 5. Abs test coupler 6. Rear wheel sensor rotor 7. Rear wheel sensor 8. Front wheel sensor 9. Front wheel sensor rotor.
Page 464: Abs (Anti-Lock Brake System)
Abs (anti-lock brake system) 8-89 eas27750 abs coupler location chart.
Page 465: Abs (Anti-Lock Brake System)
Abs (anti-lock brake system) 8-90 1. Front wheel sensor coupler 2. Meter assembly coupler 3. Abs test coupler 4. Rear wheel sensor coupler 5. Abs ecu coupler.
Page 466: Abs (Anti-Lock Brake System)
Abs (anti-lock brake system) 8-91 eas27770 maintenance of the abs ecu checking the abs ecu 1. Check: • terminals “1” of the abs ecu cracks/damages → replace the hydraulic unit assembly and the brake pipes that are con- nected to the assembly as a set. • terminals “2” of the abs ecu coupler connectio...
Page 467: Abs (Anti-Lock Brake System)
Abs (anti-lock brake system) 8-92 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 malfunction history. The multi-function ...
Page 468: Abs (Anti-Lock Brake System)
Abs (anti-lock brake system) 8-93 eas27810 basic process for troubleshooting.
Page 469: Abs (Anti-Lock Brake System)
Abs (anti-lock brake system) 8-94 warning ewa59c2803 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. (refer to “[c-3] final check” on page 8-117.) eas27830 [a] checking the abs warning li...
Page 470: Abs (Anti-Lock Brake System)
Abs (anti-lock brake system) 8-95 eas59c2803 [a-3] the abs warning light flashes 1. Checking the test coupler adapter • check if the test coupler adapter is connected to the abs test coupler. • if the test coupler adapter is connected, disconnect it, install the protective cap onto the abs test coup...
Page 471: Abs (Anti-Lock Brake System)
Abs (anti-lock brake system) 8-96 eas59c2805 [b-1] the multi-function display does not display the fault code 1. A malfunction that keeps the abs warning light on is detected. [b-2] 2. The abs warning light flashes every 0.5 second for more than 6 seconds. No malfunction is detected. The abs warning...
Page 472: Abs (Anti-Lock Brake System)
Abs (anti-lock brake system) 8-97 6. The meter assembly circuit is defective. • disconnect the abs ecu coupler. • the white/red terminal of the abs ecu coupler is short-circuited to the ground. • set the main switch to “on”, and then check the abs warning light. • if the abs warning light is on, the...
Page 473: Abs (Anti-Lock Brake System)
Abs (anti-lock brake system) 8-98 abs_17 abs_45 missing pulses detected in the front wheel sensor signal. • front wheel sensor rotor • front wheel sensor housing • front wheel abs_18 abs_46 missing pulses detected in the rear wheel sensor signal. • rear wheel sensor rotor • rear wheel sensor housing...
Page 474: Abs (Anti-Lock Brake System)
Abs (anti-lock brake system) 8-99 * a fault code is indicated if the rear wheel rotates for longer than about 20 seconds (fault code no. Abs_11) or for longer than about 2 seconds (fault code no. Abs_25) with the front wheel stopped (e.G., when the vehicle is on the suitable stand). Tip fault codes ...
Page 475: Abs (Anti-Lock Brake System)
Abs (anti-lock brake system) 8-100 tip with front wheel stopped, rear wheel was rotated for longer than about 20 seconds (fault code no. Abs_11) or for longer than about 2 seconds (fault code no. Abs_25). 4 defective sensor rotor. Check the surface of the sensor rotor for damage. Replace the sensor ...
Page 476: Abs (Anti-Lock Brake System)
Abs (anti-lock brake system) 8-101 tip vehicle possibly ridden on uneven roads. Tip vehicle possibly ridden on uneven roads. 4 defective sensor rotor. Check the surface of the sensor rotor for damage. If there is visible damage, replace the sensor rotor. Refer to “maintenance of the front wheel sens...
Page 477: Abs (Anti-Lock Brake System)
Abs (anti-lock brake system) 8-102 fault code no. Abs_15 symptom no continuity in the front wheel sensor circuit. Order item/components and probable cause check or maintenance job 1 connections • front wheel sensor coupler • abs ecu coupler • check the coupler for any pins that may be pulled out. • ...
Page 478: Abs (Anti-Lock Brake System)
Abs (anti-lock brake system) 8-103 fault code no. Abs_16 symptom no continuity in the rear wheel sensor circuit. Order item/components and probable cause check or maintenance job 1 connections • rear wheel sensor coupler • abs ecu coupler • check the coupler for any pins that may be pulled out. • ch...
Page 479: Abs (Anti-Lock Brake System)
Abs (anti-lock brake system) 8-104 fault code no. Abs_17 abs_45 symptom missing pulses detected in the front wheel sen- sor signal. Order item/components and probable cause check or maintenance job 1 installed condition of wheel bear- ings, axle, sensor housing, and sensor rotor. Check the component...
Page 480: Abs (Anti-Lock Brake System)
Abs (anti-lock brake system) 8-105 2 connections • starter relay coupler • abs ecu coupler • right handlebar switch coupler • check the coupler for any pins that may be pulled out. • check the locking condition of the coupler. • if there is a malfunction, repair it and connect the coupler securely. ...
Page 481: Abs (Anti-Lock Brake System)
Abs (anti-lock brake system) 8-106 fault code no. Abs_31 symptom solenoid relay is defective. Power is not supplied to the solenoid relay. Order item/components and probable cause check or maintenance job 1 battery voltage recharge or replace the battery. Refer to “checking and charging the bat- ter...
Page 482: Abs (Anti-Lock Brake System)
Abs (anti-lock brake system) 8-107 3 connections • abs ecu coupler • starter relay coupler • check the coupler for any pins that may be pulled out. • check the locking condition of the coupler. • if there is a malfunction, repair it and connect the coupler securely. Tip set the main switch to “off” ...
Page 483: Abs (Anti-Lock Brake System)
Abs (anti-lock brake system) 8-108 warning ewa59c2805 the front brakes will not function properly if the connections are reversed. • front brake hose (hydraulic unit to front brake hose joint) “1”: to the front brake calipers • front brake hose (front brake master cylinder to hydraulic unit) “2”: fr...
Page 484: Abs (Anti-Lock Brake System)
Abs (anti-lock brake system) 8-109 fault code no. Abs_42 abs_47 symptom rear wheel will not recover from wheel lock even though the signal is continuously transmitted from the abs ecu and the hydraulic pressure has been released. Order item/components and probable cause check or maintenance job 1 ro...
Page 485: Abs (Anti-Lock Brake System)
Abs (anti-lock brake system) 8-110 warning ewa59c2806 the rear brake will not function properly if the connections are reversed. • rear brake hose (rear brake master cylinder to hydraulic unit) “1”: from the rear brake mas- ter cylinder • rear brake pipe/joint assembly (hydraulic unit to rear brake ...
Page 486: Abs (Anti-Lock Brake System)
Abs (anti-lock brake system) 8-111 4 defective sensor rotor. • check the surface of the sensor rotor for damage. • if there is visible damage, replace the sensor rotor. Fault code no. Abs_51 abs_52 symptom power voltage is too high. Order item/components and probable cause check or maintenance job 1...
Page 487: Abs (Anti-Lock Brake System)
Abs (anti-lock brake system) 8-112 2 connections • abs ecu coupler • starter relay coupler • check the coupler for any pins that may be pulled out. • check the locking condition of the coupler. • if there is a malfunction, repair it and connect the coupler securely. Tip set the main switch to “off” ...
Page 488: Abs (Anti-Lock Brake System)
Abs (anti-lock brake system) 8-113 2 short circuit in front wheel sensor lead. • check that there is no short circuit between the white terminal “3” and the gray terminal “4”. • check that there is no short circuit between the frame ground and the white terminal “3”. • if there is a short circuit, t...
Page 489: Abs (Anti-Lock Brake System)
Abs (anti-lock brake system) 8-114 2 short circuit in rear wheel sensor lead. • check that there is no short circuit between the white terminal “3” and the gray terminal “4”. • check that there is no short circuit between the frame ground and the white terminal “3”. • if there is a short circuit, th...
Page 490: Abs (Anti-Lock Brake System)
Abs (anti-lock brake system) 8-115 eas59c2808 [c-1] deleting the fault codes eca59c2802 since the fault codes remain in the memory of the abs ecu until they are deleted, always delete the fault codes after the ser- vice has been completed. 1. Connect the test coupler adapter “1” to the abs test coup...
Page 491: Abs (Anti-Lock Brake System)
Abs (anti-lock brake system) 8-116 b. Measure the abs ecu voltage. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 6. Check: • abs-ecu-to-start-switch-lead continuity no continuity → replace or repair the wire harness. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the digital circuit tester to the abs ecu coupler and ri...
Page 492: Abs (Anti-Lock Brake System)
Abs (anti-lock brake system) 8-117 eas59c2810 [c-3] final check checking procedures 1. Check the brake fluid level in the brake master cylinder reservoir. Refer to “checking the brake fluid level” on page 3-14. 2. Check the wheel sensor housings and wheel sensors for proper installation. Refer to “i...
Page 493: Abs (Anti-Lock Brake System)
Abs (anti-lock brake system) 8-118.
Page 494: Electrical Components
Electrical components 8-119 eas27973 electrical components.
Page 495: Electrical Components
Electrical components 8-120 1. Hydraulic unit assembly 2. Fuse box (left) 3. Rear brake light switch 4. Battery 5. Fuel injection system relay 6. Starting circuit cut-off relay 1 7. Starting circuit cut-off relay 2 8. Main fuse 9. Starter relay 10.Diode 2 11.Diode 1 12.Rectifier/regulator 13.Ignitio...
Page 496: Electrical Components
Electrical components 8-121.
Page 497: Electrical Components
Electrical components 8-122 1. Main switch/immobilizer unit 2. Intake air pressure sensor 3. Coolant temperature sensor 4. Fuel pump 5. Rear wheel sensor 6. O 2 sensor 7. Crankshaft position sensor 8. Stator coil 9. Sidestand switch 10.Radiator fan 11.Front wheel sensor 12.Throttle position sensor 1...
Page 498: Electrical Components
Electrical components 8-123 eas27981 checking the switches.
Page 499: Electrical Components
Electrical components 8-124 1. Pass switch 2. Dimmer switch 3. Horn switch 4. Turn signal switch 5. Rear brake light switch 6. Engine stop switch 7. Start switch 8. Hazard switch 9. Front brake light switch 10.Sidestand switch 11.Main switch 12.Storage box light switch.
Page 500: Electrical Components
Electrical components 8-125 check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. Eca14370 never insert the tester probes into the coupler terminal slots “a”. Always insert the probes from t...
Page 501: Electrical Components
Electrical components 8-126 eas27990 checking the bulbs and bulb sock- ets tip do not check any of the lights that use leds. Check each bulb and bulb socket for damage or wear, proper connections, and also for conti- nuity between the terminals. Damage/wear → repair or replace the bulb, bulb socket ...
Page 502: Electrical Components
Electrical components 8-127 tip check each bulb socket for continuity in the same manner as described in the bulb section, however, note the following. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Install a good bulb into the bulb socket. B. Connect the pocket tester probes to the respective leads of the bulb ...
Page 503: Electrical Components
Electrical components 8-128 • keep batteries away from fire, sparks or open flames (e.G., welding equipment, lighted cigarettes). • do not smoke when charging or han- dling batteries. • keep batteries and electrolyte out of reach of children. • avoid bodily contact with electrolyte as it can cause s...
Page 504: Electrical Components
Electrical components 8-129 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 5. Charge: • battery (refer to the appropriate charging method) warning ewa13300 do not quick charge a battery. Eca13671 • do not use a high-rate battery charger since it forces a high-amperage current into the battery quickly and can cause ...
Page 505: Electrical Components
Electrical components 8-130 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 battery will be over-charged. C. Make sure that the current is higher than the standar...
Page 506: Electrical Components
Electrical components 8-131 10. Install: • front left storage box refer to “general chassis” on page 4-1. Eas28040 checking the relays check each switch for continuity with the pocket tester. If the continuity reading is incor- rect, replace the relay. 1. Disconnect the relay from the wire harness. ...
Page 507: Electrical Components
Electrical components 8-132 headlight relay radiator fan motor relay fuel injection system relay grip warmer relay (option) eas4b51020 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 s...
Page 508: Electrical Components
Electrical components 8-133 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester (dc 20 v) to the turn signal/hazard relay terminal as shown. B. Set the main switch to “on”. C. Measure the turn signal/hazard relay input voltage. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Check: • turn signal/hazard re...
Page 509: Electrical Components
Electrical components 8-134 c. Check the diode 2 for continuity. D. Check the diode 2 for no continuity. Tip when you switch the positive and negative tester probes, the readings in the above chart will be reversed. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas28070 checking the spark plug caps the following p...
Page 510: Electrical Components
Electrical components 8-135 c. Measure the secondary coil resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas28930 checking the ignition spark gap 1. Check: • ignition spark gap out of specification → perform the igni- tion system troubleshooting, starting with step 5. Refer to “troubleshooting” on page ...
Page 511: Electrical Components
Electrical components 8-136 2. Check: • lean angle sensor output voltage out of specification → replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the test harness-lean angle sen- sor (6p) “1” to the lean angle sensor and wire harness as shown. B. Connect the pocket tester (dc 20 v) to the test harn...
Page 512: Electrical Components
Electrical components 8-137 b. Measure the stator coil resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas28170 checking the rectifier/regulator 1. Check: • battery charging voltage out of specification → check the stator coil condition. If the stator coil does not have a problem, replace the rectifier/r...
Page 513: Electrical Components
Electrical components 8-138 c. Measure the horn resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Check: • horn sound faulty sound → replace. Eas28230 checking the fuel sender 1. Remove: • fuel pump (from the fuel tank) refer to “fuel tank” on page 7-1. 2. Check: • fuel sender resistance out of specific...
Page 514: Electrical Components
Electrical components 8-139 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the radiator fan motor coupler from the wire harness. B. Connect the battery (dc 12 v) as shown. C. Measure the radiator fan motor movement. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas28260 checking the coolant temperature sensor 1. Rem...
Page 515: Electrical Components
Electrical components 8-140 c. Connect the pocket tester ( Ω × 1 k) to the throttle position sensor as shown. D. While slowly turning the throttle position sensor shaft, check that the throttle posi- tion sensor resistance is within the speci- fied range. The resistance does not change or it changes...
Page 516: Electrical Components
Electrical components 8-141 • never subject the intake air temperature sensor to strong shocks. If the intake air temperature sensor is dropped, replace it. 2. Check: • intake air temperature sensor resistance out of specification → replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket teste...
Page 517: Troubleshooting
9 troubleshooting troubleshooting ..................................................................................9-1 general information .....................................................................9-1 starting failure/hard starting ................................................9-1 poor...
Page 518: Troubleshooting
Troubleshooting 9-1 eas28451 troubleshooting eas28460 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 troubleshooting. Refer to the relative proce- dure in this manual for checks, ad...
Page 519: Troubleshooting
Troubleshooting 9-2 fuel system 1. Throttle body • damaged or loose throttle body joint • improperly synchronized throttle body • improperly adjusted engine idling speed (idle adjusting screw) • improper throttle grip free play • flooded throttle body electrical system 1. Battery • discharged batter...
Page 520: Troubleshooting
Troubleshooting 9-3 2. Engine oil • incorrect oil level • incorrect oil viscosity • inferior oil quality cooling system 1. Coolant • low coolant level 2. Radiator • damaged or leaking radiator • faulty radiator cap • bent or damaged radiator fin 3. Water pump • damaged or faulty water pump • thermos...
Page 521: Troubleshooting
Troubleshooting 9-4 6. Tire(s) • uneven tire pressures (front and rear) • incorrect tire pressure • uneven tire wear 7. Wheel(s) • incorrect wheel balance • deformed cast wheel • damaged wheel bearing • bent or loose wheel axle • excessive wheel runout 8. Frame • bent frame • damaged steering head p...
Page 522: 9-5
Self-diagnostic function and diagnostic code table 9-5 eas59c1001 self-diagnostic function and diagnostic code table self-diagnostic function table fault code no. Item reference pages fault code no. Item reference pages 12 crankshaft position sensor 8-37 30 lean angle sensor (turnover of vehicle) 8-...
Page 523: 9-6
Self-diagnostic function and diagnostic code table 9-6 communication error with the meter diagnostic code: sensor operation table fault code no. Item reference pages fault code no. Item reference pages er-1 ecu internal mal- function (output sig- nal error) 8-64 er-3 ecu internal mal- function (outp...
Page 524: 9-7
Self-diagnostic function and diagnostic code table 9-7 d:09 fuel system voltage (battery voltage) approximately 12.0 set the engine stop switch to “ ”, and then compare with the actually measured battery voltage. (if the bat- tery voltage is lower, per- form recharging.) d:20 sidestand switch set on...
Page 525: 9-8
Self-diagnostic function and diagnostic code table 9-8 diagnostic code: actuator operation table diag- nostic code no. Item actuation checking method d:30 ignition coil actuates the ignition coil five times at one-second inter- vals. Illuminates the engine trou- ble warning light. Check the spark fi...
Page 526: Wiring Diagram
Eas28740 wiring diagram xp500a 2012 1. Crankshaft position sensor 2. Ac magneto 3. Rectifier/regulator 4. Frame ground 5. Joint 6. Main switch 7. Immobilizer unit 8. Joint coupler 9. Storage box light switch 10. Storage box light 11. Anti-theft alarm 12. Fuel injection system fuse 13. Backup fuse 14...
Page 529: Wiring Diagram
Wiring diagram xp500a schema de cablage xp500a schaltplan xp500a schema elettrico xp500a diagrama de conexiones de xp500a.
Page 530: Wiring Diagram
Wiring diagram xp500a schema de cablage xp500a schaltplan xp500a schema elettrico xp500a diagrama de conexiones de xp500a.