Yamaha MTN1000 2016 Service Manual
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Yamaha MTN1000 2016 Service Manual

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2016
SERVICE MANUAL
MTN1000
MTN1000G
B67-28197-E0

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Summary of Contents for Yamaha MTN1000 2016

  • Page 1 2016 SERVICE MANUAL MTN1000 MTN1000G B67-28197-E0...
  • Page 3 EAS20002 MTN1000 MTN1000G SERVICE MANUAL ©2016 by Yamaha Motor Co., Ltd. First edition, March 2016 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.
  • Page 4 EAS20003 IMPORTANT This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one man- ual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
  • Page 5 EAS20004 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. •...

  • Page 6: Symbols

    EAS20005 SYMBOLS The following symbols are used in this manual for easier understanding. 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 Wheel bearing grease Tightening torque...

  • Page 7: Table Of Contents

    TABLE OF CONTENTS EAS10003 GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE COOLING SYSTEM FUEL SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING...

  • Page 9: General Information

    GENERAL INFORMATION IDENTIFICATION....................1-1 VEHICLE IDENTIFICATION NUMBER ............1-1 MODEL LABEL...................1-1 FEATURES .......................1-2 YCC-T (Yamaha Chip Controlled Throttle)..........1-2 OUTLINE OF THE CRUISE CONTROL SYSTEM........1-4 OUTLINE OF THE TCS (Traction Control System)........1-11 MULTI-FUNCTION DISPLAY..............1-14 IMPORTANT INFORMATION .................1-21 PREPARATION FOR REMOVAL AND DISASSEMBLY......1-21 REPLACEMENT PARTS................1-21 GASKETS, OIL SEALS AND O-RINGS ...........1-21...

  • Page 10: Identification

    IDENTIFICATION EAS20007 IDENTIFICATION EAS30002 VEHICLE IDENTIFICATION NUMBER The vehicle identification number “1” is stamped into the right side of the steering head pipe. EAS30003 MODEL LABEL The model label “1” is affixed to the frame under the passenger seat. This information will be needed to order spare parts.

  • Page 11: Features

    Yamaha developed the YCC-T system employing the most advanced electronic control technologies. Electronic control throttle systems have been used on automobiles, but Yamaha has developed a fast- er, more compact system specifically for the needs of a sports motorcycle. The Yamaha-developed system has a high-speed calculating capacity that produces computations of running conditions every 1/1000th of a second.
  • Page 12 FEATURES YCC-T system outline 1. Throttle position sensor 2. Throttle servo motor 3. Accelerator position sensor 4. ECU (Engine Control Unit) 5. Sensor input 6. Gear position sensor 7. Crankshaft position sensor 8. Rear wheel sensor 9. Coolant temperature sensor...

  • Page 13: Outline Of The Cruise Control System

    FEATURES EAS30940 OUTLINE OF THE CRUISE CONTROL SYSTEM This model is equipped with a cruise control system designed to maintain a set cruising speed. Be- cause the vehicle is equipped with the YCC-T system, the cruise control system can be controlled elec- tronically.
  • Page 14 FEATURES EWA17451 WARNING • Improper use of the cruise control system may result in loss of control, which could lead to an accident. Do not activate the cruise control system in heavy traffic, poor weather conditions, or among winding, slippery, hilly, rough or gravel roads. •...
  • Page 15 FEATURES Adjusting the set cruising speed While the cruise control system is operating, push the “RES+” side of the cruise control setting switch to increase the set cruising speed or the “SET–” side to decrease the set speed. Pushing the setting switch once will change the speed in increments of approximately 2.0 km/h (1.2 mph).
  • Page 16 FEATURES Operation chart d. Currently set cruising speed increases A. Operation B. Indication e. Currently set cruising speed decreases f. New cruising speed is set C. Speed g. Currently set cruising speed is canceled D. 180 km/h (112 mph) h. Resume operation starts E.
  • Page 17 Because the automatic deactivation of the cruise control system is stored in the memory of the ECU, the deactivation can be checked using the Yamaha diagnostic tool. In some cases, the cruise control system may not be able to maintain the set cruising speed when the vehicle is traveling uphill or downhill.
  • Page 18 FEATURES Meter displays during cruise control system operation A. Cruise control system is activated (cruising a. Condition for automatically deactivating speed is set) cruise control system is detected B. Cruise control system is turned off (cruise b. 4 seconds elapse (during this time, input from control setting indicator light “SET”...
  • Page 19 “ ” flashes) Yamaha diagnostic tool. C. Cruise control system is turned off (engine e. Cruising speed is set trouble warning light “...

  • Page 20: Outline Of The Tcs (Traction Control System)

    FEATURES This section explains the operation of the cruise control system according to the meter displays when a malfunction is detected in the fuel injection system. EAS30855 OUTLINE OF THE TCS (Traction Control System) The traction control system controls excessive spinning (slipping) of the rear wheel when accelerating on slippery surfaces, such as unpaved or wet roads.
  • Page 21 FEATURES C. Exceeds preset value 1. Front wheel sensor D. Actuator control 2. Rear wheel sensor E. Fuel cut-off 3. ABS ECU F. Ignition timing (retarded) 4. Traction control system switch G. Traction control system indicator light 5. ECU (flashes) A.
  • Page 22 FEATURES TCS “2” TCS “2” provides a moderate level of traction control assist. Select this mode for standard street riding. TCS “3” TCS “3” maximizes traction control assist; wheel spin is most strongly controlled. Select this mode for rain, slippery road conditions, and whenever maximum traction control is desirable. •...

  • Page 23: Multi-Function Display

    FEATURES • an eco indicator EAS30618 MULTI-FUNCTION DISPLAY • a transmission gear display Multi-function meter unit • a drive mode display • a TCS display • a multi-function display • Except when switching to the brightness con- trol mode, turn the key to “ON” before using the “CLOCK”...
  • Page 24 FEATURES Coolant temperature/air temperature dis- ECA19660 NOTICE play Do not operate the engine in the tachometer red zone. Clock 1. Select switch “SELECT” Push the select switch “SELECT” for two sec- onds to switch the display between the coolant 1. Clock temperature mode “C”...
  • Page 25 FEATURES [Air temperature] Transmission gear display 1. Air temperature display 1. Neutral indicator light “ ” 2. Transmission gear display This display shows the air temperature from –9 C to 50 C in 1 C increments. This display shows the selected gear. The neu- tral position is indicated by “...
  • Page 26 FEATURES ODO  TRIP 1  TRIP 2  km/L or L/100 km Multi-function display  AVE – –.– km/L or AVE – –.– L/100 km  For the UK: Push the select switch “SELECT” for one sec- ond to switch the display between the odometer mode “ODO”, tripmeter modes “TRIP 1”...
  • Page 27 FEATURES Instantaneous fuel consumption mode fuel necessary to travel 100 km is shown. • “AVE – –.– MPG” (for the UK): The average distance that can be traveled on 1.0 Imp.gal of fuel is shown. To switch between the average fuel consump- tion display settings, push the “CLOCK”...
  • Page 28 FEATURES [To adjust the brightness of the displays function, otherwise the shift timing indicator and tachometer] light will remain deactivated. 1. Turn the key to “OFF”. 1. Push the “RESET” button to select the de- 2. Push and hold the “CLOCK” button. sired engine speed for deactivating the indi- 3.
  • Page 29 FEATURES Mode “STD” Mode “STD” is suitable for various riding condi- tions. This mode allows the rider to enjoy smooth and sporty drivability from the low-speed range to the high-speed range. Mode “A” Mode “A” offers a sportier engine response than mode “STD”.

  • Page 30: Important Information

    5. Keep all parts away from any source of fire. EAS30007 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace- ments. Use oil and grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality.

  • Page 31: Circlips

    IMPORTANT INFORMATION When installing oil seals, lubricate the oil seal contact the parts. lips with a light coat of lithium-soap-based grease. Oil bearings liberally when installing, if appropriate. ECA13300 NOTICE Do not spin the bearing with compressed air because this will damage the bearing surfac- EAS30011 CIRCLIPS Before reassembly, check all circlips carefully...

  • Page 32: Basic Service Information

    BASIC SERVICE INFORMATION EAS20010 BASIC SERVICE INFORMATION EAS30013 QUICK FASTENERS Rivet type 1. Remove: • Quick fastener To remove the quick fastener, push its pin with a screwdriver, then pull the fastener out. Screw type 1. Remove: • Quick fastener To remove the quick fastener, loosen the screw with a screwdriver, then pull the fastener out.

  • Page 33: Electrical System

    BASIC SERVICE INFORMATION If a battery lead is difficult to disconnect due to rust on the battery terminal, remove the rust us- ing hot water. EAS30014 ELECTRICAL SYSTEM Electrical parts handling ECA16600 NOTICE ECA16760 NOTICE Never disconnect a battery lead while the en- Be sure to connect the battery leads to the gine is running;...
  • Page 34 BASIC SERVICE INFORMATION ECA16610 NOTICE When resetting the ECU by turning the main Turn the main switch to “OFF” before dis- switch to “OFF”, be sure to wait approximately connecting or connecting an electrical com- 5 seconds before turning the main switch back ponent.
  • Page 35 BASIC SERVICE INFORMATION ECA16640 NOTICE ECA16790 For waterproof couplers, never insert the NOTICE tester probes directly into the coupler. When When disconnecting a connector, do not pull performing any checks using a waterproof the leads. Hold both sections of the connec- coupler, use the specified test harness or a tor securely, and then disconnect the con- suitable commercially available test har-...
  • Page 36 BASIC SERVICE INFORMATION • Make sure all connections are tight. 5. Check: • Resistance Pocket tester 90890-03112 Analog pocket tester YU-03112-C 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 4.

  • Page 37: Special Tools

    1-27, 8-193, 90890-03112 8-194, 8-198, Analog pocket tester 8-199, 8-200, YU-03112-C 8-201, 8-203, 8-204, 8-205, 8-206, 8-207, 8-208 Yamaha diagnostic tool 3-4, 3-12, 4-70, 90890-03250 4-71, 8-36, 8-163, 8-178 Thickness gauge 3-6, 3-7, 4-29, 90890-03180 4-39, 5-24, 5-55 Feeler gauge set...
  • Page 38 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Oil filter wrench 3-27 90890-01426 Oil filter wrench YU-38411 Oil pressure gauge joint 18 mm 3-28 90890-04176 YU-04176 ø18 Oil pressure gauge set 3-28 90890-03120 Wheel bearing ring nut tool 4-35, 4-36 90890-01574 YM-01574 Fork spring compressor...
  • Page 39 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Rod puller 4-85, 4-87 90890-01437 Universal damping rod bleeding tool set YM-A8703 YM-A8703 Rod puller attachment (M10) 4-85, 4-87 90890-01436 Universal damping rod bleeding tool set YM-A8703 YM-A8703 Ring nut wrench 4-91 90890-01268 Spanner wrench YU-01268...
  • Page 40 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Compression gauge 90890-03081 90890-03081 Engine compression tester YU-33223 YU-33223 Pivot shaft wrench 90890-01485 Frame mount insert wrench YM-01485 Valve spring compressor 5-17, 5-20, 5-28, 90890-04019 5-33 Valve spring compressor YM-04019 Valve spring compressor attachment 5-28, 5-33 90890-01243 Valve spring compressor adapter (26 mm)
  • Page 41 5-35, 5-36 90890-04171 YM-04171 Crankshaft protector (10mm) 5-35 90890-04180 Crankshaft protector (10mm) YM-04180 Flywheel puller 5-35 90890-01404 Flywheel puller YM-01404 Yamaha bond No. 1215 5-36, 5-65 90890-85505 (Three bond No.1215®) Sheave holder 5-38, 5-39 90890-01701 Primary clutch holder YS-01880-A 1-32...
  • Page 42 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Digital circuit tester 5-42, 8-202 90890-03174 Model 88 Multimeter with tachometer YU-A1927 Universal clutch holder 5-54, 5-58 90890-04086 Universal clutch holder YM-91042 Piston pin puller set 5-70 90890-01304 Piston pin puller YU-01304 YU-01304 Radiator cap tester 6-2, 6-3...
  • Page 43 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Radiator cap tester adapter 6-2, 6-3 90890-01352 Pressure tester adapter YU-33984 YU-33984 Mechanical seal installer 6-12 90890-04132 Water pump seal installer YM-33221-A Middle driven shaft bearing driver 6-12 90890-04058 Middle drive bearing installer 40 & 50 mm YM-04058 Pressure gauge 7-11, 7-12...
  • Page 44 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Ignition checker 8-200 90890-06754 Oppama pet–4000 spark checker YM-34487 Test harness– lean angle sensor (6P) 8-201 90890-03209 Test harness– lean angle sensor (6P) YU-03209 Test harness– speed sensor (3P) 8-206 90890-03208 Test harness– speed sensor (3P) YU-03208 1-35...

  • Page 45: Specifications

    SPECIFICATIONS GENERAL SPECIFICATIONS................2-1 ENGINE SPECIFICATIONS ................2-2 CHASSIS SPECIFICATIONS ................2-7 ELECTRICAL SPECIFICATIONS ..............2-10 TIGHTENING TORQUES ................2-12 GENERAL TIGHTENING TORQUE SPECIFICATIONS......2-12 ENGINE TIGHTENING TORQUES............2-13 CHASSIS TIGHTENING TORQUES............2-13 LUBRICATION POINTS AND LUBRICANT TYPES........2-15 ENGINE....................2-15 CHASSIS....................2-16 LUBRICATION SYSTEM CHART AND DIAGRAMS ........2-19 ENGINE OIL LUBRICATION CHART ............2-19 LUBRICATION DIAGRAMS ..............2-21 COOLING SYSTEM DIAGRAMS ..............2-35 CABLE ROUTING ..................2-39...

  • Page 46: General Specifications

    GENERAL SPECIFICATIONS EAS20013 GENERAL SPECIFICATIONS Model Model B671 (MTN1000_EUR) B675 (MTN1000G) B677 (MTN1000_RUS) Dimensions Overall length 2095 mm (82.5 in) Overall width 800 mm (31.5 in) Overall height 1110 mm (43.7 in) Seat height 825 mm (32.5 in) Wheelbase 1400 mm (55.1 in) Ground clearance 130 mm (5.12 in) Minimum turning radius...

  • Page 47: Engine Specifications

    ENGINE SPECIFICATIONS EAS20014 ENGINE SPECIFICATIONS Engine Combustion cycle 4-stroke Cooling system Liquid cooled Valve train DOHC Displacement 998 cm³ Cylinder arrangement Inline Number of cylinders 4-cylinder Bore  stroke 79.0  50.9 mm (3.11  2.00 in) Compression ratio 12.0 : 1 Compression pressure 1305–1680 kPa/250 r/min (13.1–16.8 kgf/cm²/250 r/min, 185.6–238.9 psi/250 r/min)
  • Page 48 ENGINE SPECIFICATIONS Radiator cap valve opening pressure 108.0–137.4 kPa (1.08–1.37 kgf/cm², 15.7–19.9 psi) Thermostat 69.0–73.0 C (156.20–163.40 F) Valve opening temperature 85.0 C (185.00 F) Valve full open temperature Valve lift (full open) 8.0 mm (0.31 in) Water pump Water pump type Single suction centrifugal pump Impeller shaft tilt limit 0.15 mm (0.006 in)
  • Page 49 ENGINE SPECIFICATIONS Limit 0.100 mm (0.0039 in) Valve stem runout 0.010 mm (0.0004 in) Valve spring Free length (intake) 41.25 mm (1.62 in) Limit 39.18 mm (1.54 in) Free length (exhaust) 42.33 mm (1.67 in) Limit 40.21 mm (1.58 in) Spring tilt (intake) 1.7 mm (0.07 in) Spring tilt (exhaust)
  • Page 50 ENGINE SPECIFICATIONS Code 4 Green Code 5 Yellow Code 6 Pink Code 7 Balancer Balancer shaft runout limit 0.030 mm (0.0012 in) Bearing color code Code 0 White Code 1 Blue Code 2 Black Code 3 Brown Code 4 Green Code 5 Yellow Code 6...
  • Page 51 ENGINE SPECIFICATIONS Air filter Air filter element Oil-coated paper element Fuel pump Pump type Electrical Maximum consumption amperage 5.2 A Fuel injector 12.0  Resistance Throttle body ID mark B671 00 Throttle position sensor Resistance 1.20–2.80 k Accelerator position sensor Resistance 1.20–2.80 k...

  • Page 52: Chassis Specifications

    CHASSIS SPECIFICATIONS EAS20015 CHASSIS SPECIFICATIONS Chassis Frame type Diamond 24.0  Caster angle Trail 102 mm (4.0 in) Front wheel Wheel type Cast wheel Rim size 17M/CxMT3.50 Rim material Aluminum Radial wheel runout limit 1.0 mm (0.04 in) Lateral wheel runout limit 1.0 mm (0.04 in) Rear wheel Wheel type...
  • Page 53 120 mm (4.7 in) Fork spring free length 218.9 mm (8.62 in) Limit 214.5 mm (8.45 in) Recommended oil Yamaha Suspension Oil 01 Quantity (left) 368.0 cm³ (12.44 US oz, 12.98 Imp.oz) Quantity (right) 368.0 cm³ (12.44 US oz, 12.98 Imp.oz) Level (left) 114 mm (4.5 in)
  • Page 54 CHASSIS SPECIFICATIONS Unit for adjustment Adjustment value (Soft) 77.5 Adjustment value (STD) 81.5 Adjustment value (Hard) 85.5 Rebound damping Adjusting system Mechanical adjustable type Unit for adjustment Click Adjustment value from the start position (Soft) Adjustment value from the start position (STD) Adjustment value from the start position (Hard)

  • Page 55: Electrical Specifications

    ELECTRICAL SPECIFICATIONS EAS20016 ELECTRICAL SPECIFICATIONS Voltage System voltage 12 V Ignition system Ignition system Advancer type Digital 5.0 1300 r/min Ignition timing (B.T.D.C.) Engine control unit Model/manufacturer TBDFS1/DENSO Ignition coil 1.19–1.61  Primary coil resistance Secondary coil resistance 8.50–11.50 k Lean angle sensor output voltage 65 ...
  • Page 56 ELECTRICAL SPECIFICATIONS Shift timing indicator light Traction control system indicator/warning light Starter motor Power output 0.75 kW 0.0115–0.0140  Armature coil resistance Brush overall length 11.0 mm (0.43 in) Limit 5.50 mm (0.22 in) Brush spring force 4.80–7.20 N (489–734 gf, 17.28–25.92 oz) Commutator diameter 106.6 mm (4.20 in) Limit...

  • Page 57: Tightening Torques

    TIGHTENING TORQUES EAS20017 TIGHTENING TORQUES EAS30015 GENERAL TIGHTENING TORQUE SPECIFICATIONS This chart specifies tightening torques for stan- dard fasteners with a standard ISO thread pitch. Tightening torque specifications for special com- ponents or assemblies are provided for each chapter of this manual. To avoid warpage, tight- en multi-fastener assemblies in a crisscross pat- tern and progressive stages until the specified tightening torque is reached.

  • Page 58: Engine Tightening Torques

    TIGHTENING TORQUES EAS30016 ENGINE TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Exhaust pipe nut 20 N·m (2.0 kgf·m, 14 lb·ft) Muffler protector bolt 10 N·m (1.0 kgf·m, 7.2 lb·ft) Front muffler protector bolt 10 N·m (1.0 kgf·m, 7.2 lb·ft) Spark plug 13 N·m (1.3 kgf·m, 9.4 lb·ft) Spark plug (new)
  • Page 59 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Stake. Drive sprocket nut 140 N·m (14 kgf·m, 100 lb·ft) Lower ring nut 1. Tighten the ring nut to 52 N·m (5.2 kgf·m, 38 lb·ft) with a torque wrench, then loosen the lower ring nut completely.

  • Page 60: Lubrication Points And Lubricant Types

    LUBRICATION POINTS AND LUBRICANT TYPES EAS20018 LUBRICATION POINTS AND LUBRICANT TYPES EAS30018 ENGINE Lubrication point Lubricant Oil seal lips O-rings Coolant hose insertion part Water or Bearings Rocker arm shaft outer surface Camshaft lobes and journals (intake and exhaust) Valve stem seal (installed on valve guide) Valve pad Valve stems and stem ends (intake and exhaust) Crankshaft big ends...

  • Page 61: Chassis

    Drive sprocket nut and washer Shift drum assembly Shift forks and shift fork guide bars Shift shaft washer Shift shaft moving surface Yamaha bond No. 1215 Crankcase mating surface (Three bond No.1215®) Yamaha bond No. 1215 Stator coil assembly lead grommet (Three bond No.1215®)
  • Page 62 LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant Front wheel oil seal (left and right) Front wheel axle nut mating surface Rear wheel oil seal Rear wheel drive hub oil seal Rear wheel drive hub mating surface Rear wheel drive hub and rear wheel mating surfaces Brake caliper piston seal Master cylinder inside Brake caliper piston dust seal...
  • Page 63 LUBRICATION POINTS AND LUBRICANT TYPES 2-18...

  • Page 64: Lubrication System Chart And Diagrams

    LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20019 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS30020 ENGINE OIL LUBRICATION CHART 2-19...
  • Page 65 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil strainer 2. Oil pump 3. Relief valve 4. Oil cooler 5. Oil filter cartridge 6. Main gallery 7. Oil pressure switch 8. Crankshaft 9. Generator rotor 10.Balancer shaft 11.Oil nozzle 12.Sub gallery 13.Timing chain tensioner 14.Intake rocker arm 15.Intake camshaft 16.Exhaust rocker arm...

  • Page 66: Lubrication Diagrams

    LUBRICATION SYSTEM CHART AND DIAGRAMS EAS30021 LUBRICATION DIAGRAMS Crankcase, cylinder, and cylinder head (left side view) 2-21...
  • Page 67 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Intake camshaft 2. Oil nozzle 3. Oil delivery pipe 2 4. Oil filter cartridge 5. Crankshaft 6. Exhaust camshaft 7. Sub gallery 2-22...
  • Page 68 LUBRICATION SYSTEM CHART AND DIAGRAMS Crankcase and cylinder (right side view) 2-23...
  • Page 69 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Timing chain tensioner 2. Intake camshaft 3. Exhaust camshaft 4. Crankshaft 5. Relief valve 6. Oil pipe 1 7. Oil delivery pipe 1 8. Oil pan 9. Oil strainer 10.Oil pump 11.Shift fork guide bar 12.Shift fork-C 13.Drive axle 2-24...
  • Page 70 LUBRICATION SYSTEM CHART AND DIAGRAMS Timing chain cover and oil pipe (right side view) 2-25...
  • Page 71 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Timing chain cover 2. Oil pipe 3 3. Oil pipe 2 4. Crankshaft 5. Crankcase 2-26...
  • Page 72 LUBRICATION SYSTEM CHART AND DIAGRAMS Oil pump and oil cooler (bottom view) 2-27...
  • Page 73 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil cooler 2. Oil delivery pipe 1 3. Oil cooler outlet hose 4. Oil filter cartridge 5. Oil pressure switch 6. Oil delivery pipe 2 7. Oil strainer 8. Oil pump 9. Oil pipe 1 10.Main gallery 11.Relief valve 12.Oil pipe 2...
  • Page 74 LUBRICATION SYSTEM CHART AND DIAGRAMS Camshaft and balancer shaft (top view) 2-29...
  • Page 75 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Cylinder head 2. Exhaust camshaft 3. Intake camshaft 4. Balancer shaft 2-30...
  • Page 76 LUBRICATION SYSTEM CHART AND DIAGRAMS Crankshaft (rear view) 2-31...
  • Page 77 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil nozzle 2. Oil pipe 3 3. Timing chain cover 4. Crankshaft 5. Oil pipe 2 6. Oil pressure switch 7. Generator rotor 8. Shaft 2-32...
  • Page 78 LUBRICATION SYSTEM CHART AND DIAGRAMS Crankshaft and transmission (top view) 2-33...
  • Page 79 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil pump 2. Main axle 3. Clutch housing 4. Drive axle 5. Oil delivery pipe 3 2-34...

  • Page 80: Cooling System Diagrams

    COOLING SYSTEM DIAGRAMS EAS20020 COOLING SYSTEM DIAGRAMS 2-35...
  • Page 81 COOLING SYSTEM DIAGRAMS 1. Radiator outlet hose 2. Cooling system air bleed hose 3. Thermostat assembly 4. Radiator inlet hose 5. Radiator 6. Water pump outlet pipe 7. Water pump 8. Water pump inlet pipe 2-36...
  • Page 82 COOLING SYSTEM DIAGRAMS 2-37...
  • Page 83 COOLING SYSTEM DIAGRAMS 1. Cooling system air bleed hose 2. Radiator 3. Radiator outlet hose 4. Radiator inlet hose 5. Water pump inlet pipe 6. Water pump outlet pipe 7. Water pump 8. Thermostat assembly 2-38...

  • Page 84: Cable Routing

    CABLE ROUTING EAS20021 CABLE ROUTING Handlebar (front view) 2-39...
  • Page 85 CABLE ROUTING 1. Throttle cable 2. Clutch cable 3. Clamp 4. Horn lead 5. Front brake hose 6. Horn bracket A. Install the clamp of the horn lead to the horn bracket. B. Fasten the front brake hose and horn lead with the clamp.
  • Page 86 CABLE ROUTING Headlight (front view) 2-41...
  • Page 87 CABLE ROUTING 1. Main switch coupler 2. Meter assembly 3. Coupler cover 4. Wire harness clamp 5. Main switch lead 6. Auxiliary light coupler 7. Immobilizer unit coupler A. Install the wire harness clamp to the head- light stay. B. Install the main switch lead clamp to the headlight stay.
  • Page 88 CABLE ROUTING Radiator cover (right side view) 2-43...
  • Page 89 CABLE ROUTING P. Route the steering damper solenoid lead, 1. Horn lead handlebar switch lead (left) and clutch switch 2. Main switch lead lead to the inside of the guide. 3. Clutch cable Q. Blue tape 4. Front turn signal light lead (right) R.
  • Page 90 CABLE ROUTING Clutch cable and O sensor lead (right side view) 2-45...
  • Page 91 CABLE ROUTING 1. Clutch cable 2. Coolant reservoir breather hose 3. Clamp 4. O sensor lead A. Cross the coolant reservoir breather hose so that it is on the outside of the clutch cable. B. Fasten the coolant reservoir breather hose at the painted section and the clutch cable with the clamp.
  • Page 92 CABLE ROUTING Electrical components tray (left side view) 2-47...
  • Page 93 CABLE ROUTING 1. Fuse box 2 2. Fuse box 1 3. Plastic locking tie 4. Relay unit 5. Radiator fan motor relay 6. Front turn signal light lead (left) 7. Wire harness 8. Auxiliary DC jack lead 9. Fuse box 2 lead 10.Clamp 11.Brake light fuse/Cruise control fuse A.
  • Page 94 CABLE ROUTING ECU (Engine Control Unit) (left side view) 2-49...
  • Page 95 CABLE ROUTING 1. ECU (Engine Control Unit) 2. Throttle position sensor 3. ECU lead 4. Fuel tank drain hose 5. Rectifier/regulator lead 6. Gear position sensor lead 7. Clamp 8. Sidestand switch lead 9. O sensor lead 10.Oil pressure switch lead 11.Thermostat assembly 12.Plastic locking tie 13.Stator coil assembly lead...
  • Page 96 CABLE ROUTING Handlebar (top view) 2-51...
  • Page 97 CABLE ROUTING M. Do not fasten the horn lead with the clamp. 1. Headlight stay There is no positioning tape (black) on the 2. Front brake master cylinder horn lead. 3. Throttle cable N. Front of vehicle 4. Handlebar switch (right) O.
  • Page 98 CABLE ROUTING Frame (top view) 2-53...
  • Page 99 CABLE ROUTING 1. Clutch cable 2. Guide 3. Front brake hose 4. Throttle cable 5. Crankshaft position sensor 6. Ignition coil #4 coupler 7. Grip cancel switch lead 8. Accelerator position sensor coupler 9. Ignition coil #3 coupler 10.Throttle servo motor coupler 11.Atmospheric pressure sensor coupler 12.Air induction system solenoid 13.Intake air pressure sensor coupler...
  • Page 100 CABLE ROUTING Frame (top view) 2-55...
  • Page 101 9. Rear brake light switch coupler routed over the canister purge hose (hose 10.Neutral switch coupler joint to canister). 11.Yamaha diagnostic tool coupler G. Route the fuel tank drain hose inside of the 12.Plastic locking tie wire harness. 13.Fuel pump lead H.
  • Page 102 CABLE ROUTING Frame (top view) 2-57...
  • Page 103 I. The starter motor lead, negative battery lead and wire harness may be routed in any order. J. Install the Yamaha diagnostic tool coupler securely to the battery box 2. K. Checking points on the battery box 2 installa- tion.
  • Page 104 CABLE ROUTING Rear fender (top view) 2-59...
  • Page 105 CABLE ROUTING M. Projection on the rear frame 1. Brake light relay N. Install the lean angle sensor so that the “UP” 2. Main fuse mark faces up. 3. EXUP servo motor O. The end of the plastic locking tie should face 4.
  • Page 106 CABLE ROUTING Rear fender (left side view) 2-61...
  • Page 107 CABLE ROUTING 1. Tail/brake light 2. Rectifier/regulator 3. Passenger footrest 4. EXUP cable 1 5. Lean angle sensor lead 6. Starter relay lead 7. Main fuse 8. Brake light relay 9. Brake light relay lead 10.EXUP servo motor lead 11.Starter motor lead 12.Positive battery lead 13.Main fuse lead 14.Plate...
  • Page 108 CABLE ROUTING Rear brake hose (right side view) 2-63...
  • Page 109 CABLE ROUTING J. When installing the brake hose to the master 1. Hydraulic unit brake pipe (hydraulic unit to cylinder, make sure that the stopper contacts rear brake caliper) the outside of the projection on the master 2. Hydraulic unit brake pipe (rear brake master cylinder.
  • Page 110 CABLE ROUTING Front brake hose (left side view) 2-65...
  • Page 111 CABLE ROUTING 1. Brake hose (front brake master cylinder to hydraulic unit) 2. Clamp 3. Brake hose (hydraulic unit to front brake cali- pers) 4. Front wheel sensor lead 5. Front brake hose holder 6. Front brake caliper 7. Front fork 8.
  • Page 112 CABLE ROUTING Front brake hose (left side view) 2-67...
  • Page 113 CABLE ROUTING 1. Clamp 2. Brake hose bracket 3. Frame 4. Brake hose (front brake master cylinder to hydraulic unit) 5. Hydraulic unit 6. Brake hose (hydraulic unit to front brake cali- pers) A. Insert the clamp all the way to the rear of the brake hose bracket.
  • Page 114 CABLE ROUTING Hydraulic unit assembly (top and left side view) 2-69...
  • Page 115 CABLE ROUTING 1. Brake hose (hydraulic unit to front brake cali- pers) 2. Brake hose (front brake master cylinder to hydraulic unit) 3. Hydraulic unit brake pipe (rear brake master cylinder to hydraulic unit) 4. Hydraulic unit brake pipe (hydraulic unit to rear brake caliper) 5.
  • Page 116 CABLE ROUTING Fuel tank (bottom and left side view) 2-71...
  • Page 117 CABLE ROUTING 1. Fuel tank cap 2. Fuel tank 3. Fuel hose 4. Fuel pump A. Align the fuel pump positioning to the inner panel marking (visual guide during installa- tion). B. Connector color: White 2-72...
  • Page 118 CABLE ROUTING Canister 2-73...
  • Page 119 CABLE ROUTING 1. Fuel tank 2. Clip 3. Fuel tank drain hose 4. Fuel hose 5. Canister 6. Fuel tank breather hose 7. Canister holder 8. Clamp 9. Canister purge hose A. The clip may be faced in any direction. Make sure that the clip does not go on top of the stopper.
  • Page 120 CABLE ROUTING Air filter case and throttle bodies (top and left side view) 2-75...
  • Page 121 CABLE ROUTING 1. Air filter case 2. Plug 3. Crankcase breather hose 4. Injector 5. Canister purge hose 6. Throttle body assembly 7. Clamp 8. Fuel hose 9. Throttle cable (accelerator cable) 10.Throttle cable (decelerator cable) A. To canister B. Point the end of the clamp to the right. C.
  • Page 122 CABLE ROUTING Air cut-off valve (right side view) 2-77...
  • Page 123 CABLE ROUTING 1. Air filter case 2. Cylinder head cover 3. Air cut-off valve 4. Air induction system hose (air filter case to air cut-off valve) 5. Reed valve cover 6. Air induction system hose (air cut-off valve to reed valve cover) 7.
  • Page 124 CABLE ROUTING Radiator (left side view) 2-79...
  • Page 125 CABLE ROUTING R. Make sure that the projection on the center of 1. Cooling system air bleed hose the hose clamp contacts with the cut out in 2. Clamp the end of the hose clamp. 3. Thermostat assembly S. Face the opening of the hose clamp to the 4.
  • Page 126 CABLE ROUTING Radiator (right side view) 2-81...
  • Page 127 CABLE ROUTING 1. Cooling system air bleed hose 2. Clamp 3. Radiator outlet hose 4. Hose clamp 5. Water pump inlet pipe 6. Water pump outlet pipe 7. Thermostat assembly A. Install the clamp with the end pointing upward. Make sure that the clamp is not installed on the flange of the hose fitting of the radiator hose.
  • Page 128 CABLE ROUTING Muffler (top and left side view) 2-83...
  • Page 129 CABLE ROUTING 1. Exhaust chamber 2. EXUP valve pulley cover 3. Muffler 4. EXUP servo motor 5. EXUP cable 6. EXUP cable 1 7. EXUP cable 2 A. EXUP cable securing location B. “1” stamped on the bracket C. “2” stamped on the bracket 2-84...
  • Page 130 CABLE ROUTING 2-85...

  • Page 131: Periodic Checks And Adjustments

    INTRODUCTION ..................3-1 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM ....................3-1 GENERAL MAINTENANCE AND LUBRICATION CHART ......3-1 CHECKING THE VEHICLE USING THE YAMAHA DIAGNOSTIC TOOL ......................3-4 CHECKING THE FUEL LINE ..............3-4 CHECKING THE SPARK PLUGS ..............3-5 ADJUSTING THE VALVE CLEARANCE ...........3-5 CHECKING THE CRANKCASE BREATHER HOSE .........3-9...
  • Page 132 CHECKING THE CONNECTING ARM AND RELAY ARM......3-26 CHECKING THE ENGINE OIL LEVEL.............3-26 CHANGING THE ENGINE OIL ..............3-26 MEASURING THE ENGINE OIL PRESSURE .........3-27 CHECKING THE COOLANT LEVEL............3-29 CHECKING THE COOLING SYSTEM .............3-29 CHANGING THE COOLANT..............3-29 ADJUSTING THE EXUP CABLES ............3-32 CHECKING THE FRONT BRAKE LIGHT SWITCH .........3-33 ADJUSTING THE REAR BRAKE LIGHT SWITCH ........3-33 CHECKING AND LUBRICATING THE CABLES ........3-33...

  • Page 133: Periodic Maintenance

    UK, a mileage-based maintenance, is performed instead. • From 50000 km (30000 mi), repeat the maintenance intervals starting from 10000 km (6000 mi). • Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
  • Page 134 PERIODIC MAINTENANCE ODOMETER READING CHECK OR MAINTENANCE ANNUAL ITEM CHECK 1000 km 10000 km 20000 km 30000 km 40000 km (600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi) • Check operation, fluid level, and for fluid leakage.  ...
  • Page 135 PERIODIC MAINTENANCE ODOMETER READING CHECK OR MAINTENANCE ANNUAL ITEM CHECK 1000 km 10000 km 20000 km 30000 km 40000 km (600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi)     Rear suspension • Check operation. relay arm and 24 * connecting arm •...

  • Page 136: Checking The Vehicle Using The Yamaha Diagnostic Tool

    CHECKING THE VEHICLE USING THE CHECKING THE FUEL LINE YAMAHA DIAGNOSTIC TOOL The following procedure applies to all of the fuel, Use the Yamaha diagnostic tool and check the drain and breather hoses. vehicle according to the following procedure. 1. Remove: 1.

  • Page 137: Checking The Spark Plugs

    PERIODIC MAINTENANCE EAS30620 CHECKING THE SPARK PLUGS The following procedure applies to all of the spark plugs. 1. Remove: • Rider seat • Air scoop/Air scoop stay Refer to “GENERAL CHASSIS (1)” on page 4-1. • Fuel tank cover Refer to “GENERAL CHASSIS (2)” on page 7.
  • Page 138 PERIODIC MAINTENANCE • Air scoop/Air scoop stay Refer to “GENERAL CHASSIS (1)” on page 4-1. • Fuel tank cover Refer to “GENERAL CHASSIS (2)” on page 4-13. • Fuel tank Refer to “FUEL TANK” on page 7-1. • Air filter case Refer to “GENERAL CHASSIS (3)”...
  • Page 139 PERIODIC MAINTENANCE i. Measure the valve clearance #2 with a thick- Valve clearance measuring sequence ness gauge. Cylinder #1  #3  #2  #4 Thickness gauge 90890-03180 Feeler gauge set YU-26900-9 j. Turn the crankshaft counterclockwise. k. When piston #4 is at TDC on the compres- sion stroke, align the TDC mark “f”...
  • Page 140 PERIODIC MAINTENANCE 1.63 mm (0.064 in) • Cover the timing chain opening with a rag to The valve pad number is 163. prevent the valve pad from falling into the e. Round off the valve pad number according to the following table, and then select the suit- crankcase.

  • Page 141: Checking The Crankcase Breather Hose

    Make sure the crankcase breather hose is Refer to “CHECKING AND CLEANING THE routed correctly. THROTTLE BODIES” on page 7-8. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the Yamaha diagnostic tool. Use the diagnostic code number “67”. Refer to “SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE” on page 9-5.

  • Page 142: Synchronizing The Throttle Bodies

    PERIODIC MAINTENANCE EAS30797 SYNCHRONIZING THE THROTTLE BODIES Before synchronizing the throttle bodies, check the following items: • Valve clearance • Spark plugs • Air filter element • Throttle body joints • Fuel hose • Exhaust system 5. Install: • Breather hoses •...

  • Page 143: Checking The Throttle Body Joints

    PERIODIC MAINTENANCE mark) of the throttle body that is the stan- 5. Adjust: dard. Otherwise, the engine may run roughly • Throttle grip free play at idle and the throttle bodies may not oper- Refer to “CHECKING THE THROTTLE ate properly. GRIP”...

  • Page 144: Checking The Canister

    Yamaha diagnostic tool. For more information, refer to the opera- tion manual of the Yamaha diagnostic tool. 1. Connect the Yamaha diagnostic tool to the coupler. For information about connecting the Yamaha diagnostic tool, refer to “YAMAHA DIAGNOSTIC TOOL”...

  • Page 145: Adjusting The Clutch Lever Free Play

    PERIODIC MAINTENANCE 3. Check: Refer to “GENERAL CHASSIS (2)” on page • Air filter element “1” 4-13. • Air filter seal • Air scoop stay/Air scoop Damage  Replace. • Rider seat Refer to “GENERAL CHASSIS (1)” on page • Replace the air filter element every 40000 km 4-1.

  • Page 146: Checking The Brake Operation

    PERIODIC MAINTENANCE the adjusting nut on the engine side. specified brake fluid to the proper level. Front brake ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Specified brake fluid ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ DOT 4 Engine side Rear brake a. Loosen the locknut “1”. Specified brake fluid b. Turn the adjusting nut “2” in direction “a” or “b” DOT 4 until the specified clutch lever free play is ob- tained.

  • Page 147: Adjusting The Front Disc Brake

    PERIODIC MAINTENANCE reservoir is horizontal. EAS30633 CHECKING THE FRONT BRAKE PADS The following procedure applies to all of the EAS30630 brake pads. ADJUSTING THE FRONT DISC BRAKE 1. Operate the brake. 1. Adjust: 2. Check: • Brake lever position • Front brake pad (distance “a”...

  • Page 148: Checking The Rear Brake Pads

    PERIODIC MAINTENANCE 4. Check: ECA13510 NOTICE • Brake hose After adjusting the brake pedal position, Brake fluid leakage  Replace the damaged make sure there is no brake drag. hose. Refer to “FRONT BRAKE” on page 4-40. EAS30636 CHECKING THE REAR BRAKE HOSE 1.

  • Page 149: Checking The Wheels

    PERIODIC MAINTENANCE • Repeat the bleeding procedure when the tiny Refer to “HYDRAULIC UNIT OPERATION bubbles in the hose have disappeared. TEST” on page 4-70. ECA17061 1. Bleed: NOTICE • ABS Make sure that the main switch is turned to ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...
  • Page 150 Rear 290 kPa (2.90 kgf/cm², 42 psi) en if a tire combination other than one Maximum load approved by Yamaha is used on this vehicle. 170 kg (375 lb) * Total weight of rider, passenger, cargo Front tire and accessories...

  • Page 151: Checking The Wheel Bearings

    PERIODIC MAINTENANCE no danger of it falling over. For tires with a direction of rotation mark “1”: ECA13550 • Install the tire with the mark pointing in the di- NOTICE rection of wheel rotation. A drive chain that is too tight will overload •...

  • Page 152: Lubricating The Drive Chain

    PERIODIC MAINTENANCE parts. If the drive chain is not maintained proper- ly, it will wear out quickly. Therefore, the drive chain should be serviced, especially when the vehicle is used in dusty areas. This vehicle has a drive chain with small rubber O-rings between each side plate.

  • Page 153: Lubricating The Steering Head

    PERIODIC MAINTENANCE lower bearings. Refer to “STEERING HEAD” on page 4-89. e. Install the rubber washer “7”. f. Install the upper ring nut “8”. g. Finger tighten the upper ring nut, then align the slots of both ring nuts. If necessary, hold the lower ring nut and tighten the upper ring nut until their slots are aligned.

  • Page 154: Lubricating The Clutch Lever

    PERIODIC MAINTENANCE 4. Check: Recommended lubricant • Front fork operation Silicone grease Push down hard on the handlebar several times and check if the front fork rebounds EAS30805 smoothly. LUBRICATING THE CLUTCH LEVER Rough movement  Repair. Lubricate the pivoting point and metal-to-metal Refer to “FRONT FORK”...
  • Page 155 PERIODIC MAINTENANCE ferences in production, the actual number of Spring preload clicks always represents the entire adjusting Minimum (soft) range. To obtain a precise adjustment, it would 0 turn(s) in direction “a” be advisable to check the number of clicks of Standard each damping force adjusting mechanism and 9 turn(s) in direction “a”...

  • Page 156: Checking The Rear Shock Absorber Assembly

    PERIODIC MAINTENANCE each damping force adjusting mechanism and to modify the specifications as necessary. The spring preload setting is determined by measuring distance “c”. The longer distance “c” ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ is, the higher the spring preload; the shorter dis- tance “c” is, the lower the spring preload. EAS30808 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY...
  • Page 157 PERIODIC MAINTENANCE Direction “a” Direction “a” Rebound damping is increased (sus- Compression damping is increased pension is harder). (suspension is harder). Direction “b” Direction “b” Rebound damping is decreased (sus- Compression damping is decreased pension is softer). (suspension is softer). Rebound damping Fast compression damping Minimum (soft)

  • Page 158: Checking The Connecting Arm And Relay Arm

    PERIODIC MAINTENANCE minimum level mark “a” and maximum level Direction “a” mark “b”. Compression damping is increased Below the minimum level mark  Add the (suspension is harder). recommended engine oil to the proper level. Direction “b” Compression damping is decreased (suspension is softer).

  • Page 159: Engine

    PERIODIC MAINTENANCE • Engine oil drain bolt “2” rectly in the groove of the oil filter cartridge. • Gasket “3” c. Tighten the new oil filter cartridge to specifi- cation with an oil filter wrench. Oil filter cartridge 17 N·m (1.7 kgf·m, 12 lb·ft) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...
  • Page 160 PERIODIC MAINTENANCE Below the minimum level mark “a”  Add the recommended engine oil to the proper level. 5. Install: • Oil pressure gauge “1” • Adapter C “2” 2. Start the engine, warm it up for several min- utes, and then turn it off. Oil pressure gauge set 90890-03120 ECA13410...

  • Page 161: Checking The Coolant Level

    PERIODIC MAINTENANCE switch) “2” • Oil pressure switch joint bolt “3” Before checking the coolant level, wait a few minutes until it settles. Oil pressure switch joint bolt 10 N·m (1.0 kgf·m, 7.2 lb·ft) EAS30812 CHECKING THE COOLING SYSTEM 1. Check: •...
  • Page 162 PERIODIC MAINTENANCE cap and slowly turn the radiator cap counter- clockwise toward the detent to allow any re- sidual pressure to escape. When the hissing sound has stopped, press down on the radi- ator cap and turn it counterclockwise to re- move.

  • Page 163: Cooling System

    PERIODIC MAINTENANCE • Quick fastener Coolant reservoir cover bolt 1.5 N·m (0.15 kgf·m, 1.1 lb·ft) 11.Fill: • Cooling system (with the specified amount of the recom- mended coolant) Recommended antifreeze High-quality ethylene glycol anti- 13.Install: freeze containing corrosion • Coolant reservoir cap inhibitors for aluminum engines 14.Loosen the water pump air bleed bolt “1”...

  • Page 164: Adjusting The Exup Cables

    PERIODIC MAINTENANCE EAS31389 Direction “c” ADJUSTING THE EXUP CABLES Free play is increased. 1. Remove: Direction “d” • EXUP valve pulley cover “1” Free play is decreased. e. Tighten the locknut “2”. 2. Check: • EXUP system operation ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Activate the diagnostic mode and select the diagnostic code number “53”.

  • Page 165: Checking The Front Brake Light Switch

    PERIODIC MAINTENANCE rear brake light comes on at the proper time. Direction “a” Brake light comes on sooner. Direction “b” Brake light comes on later. j. Slide the rubber covers to its original position. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 4. Install: • EXUP valve pulley cover EXUP valve pulley cover bolt 10 N·m (1.0 kgf·m, 7.2 lb·ft) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...
  • Page 166 PERIODIC MAINTENANCE 2. Check: • Throttle grip movement Rough movement  Lubricate or replace the defective part(s). Recommended lubricant Suitable cable lubricant With the engine stopped, turn the throttle grip slowly and release it. Make sure that the throttle grip turns smoothly and returns properly when c.

  • Page 167: Checking And Charging The Battery

    PERIODIC MAINTENANCE pletely by the rubber cover. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS30816 CHECKING AND CHARGING THE BATTERY Refer to “CHECKING AND CHARGING THE BATTERY” on page 8-195. EAS30662 CHECKING THE FUSES Refer to “CHECKING THE FUSES” on page 8-194. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Adjust: EAS30664 ADJUSTING THE HEADLIGHT BEAMS •...
  • Page 168 PERIODIC MAINTENANCE Right headlight Direction “b” Headlight beam moves to the left. Direction “c” Headlight beam moves to the right. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3-36...
  • Page 169 CHASSIS GENERAL CHASSIS (1) ..................4-1 REMOVING THE SIDE COVER (left) ............4-10 INSTALLING THE SIDE COVER (left) .............4-10 REMOVING THE SIDE COVER (right) ............4-10 INSTALLING THE SIDE COVER (right)...........4-10 REMOVING THE ECU (Engine Control Unit)...........4-11 INSTALLING THE ECU (Engine Control Unit) .........4-11 REMOVING THE AIR SCOOP..............4-11 INSTALLING THE AIR SCOOP ...............4-11 GENERAL CHASSIS (2) ................4-13...
  • Page 170 REMOVING THE FRONT BRAKE CALIPERS ........4-47 DISASSEMBLING THE FRONT BRAKE CALIPERS.......4-48 CHECKING THE FRONT BRAKE CALIPERS .........4-48 ASSEMBLING THE FRONT BRAKE CALIPERS........4-48 INSTALLING THE FRONT BRAKE CALIPERS ........4-49 REMOVING THE FRONT BRAKE MASTER CYLINDER ......4-50 CHECKING THE FRONT BRAKE MASTER CYLINDER......4-50 ASSEMBLING THE FRONT BRAKE MASTER CYLINDER ....4-50 INSTALLING THE FRONT BRAKE MASTER CYLINDER.......4-50 REAR BRAKE ....................4-53...
  • Page 171 REAR SHOCK ABSORBER ASSEMBLY............4-93 HANDLING THE REAR SHOCK ABSORBER .........4-95 DISPOSING OF A REAR SHOCK ABSORBER ........4-95 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY....4-95 DISASSEMBLING THE REAR SHOCK ABSORBER ASSEMBLY..4-96 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY ....4-96 CHECKING THE CONNECTING ARM AND RELAY ARM......4-96 ASSEMBLING THE REAR SHOCK ABSORBER ASSEMBLY....4-96 INSTALLING THE RELAY ARM...............4-96 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY ....4-97...
  • Page 172 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Rider seat Battery band Negative battery lead Disconnect. Positive battery lead Disconnect. Battery Yamaha diagnostic tool coupler Battery box 2 Seat back assembly...
  • Page 173 GENERAL CHASSIS (1) Removing the rear side covers and rear cowlings 3.5 N ・ m (0.35 kgf ・ m, 2.5 lb ・ ft) 1.8 N ・ m (0.18 kgf ・ m, 1.3 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) 7 N ・...
  • Page 174 GENERAL CHASSIS (1) Removing the tail/brake light and mudguard assembly 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) Order Job/Parts to remove Q’ty...
  • Page 175 GENERAL CHASSIS (1) Disassembling the mudguard assembly 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) 2.3 N ・ m (0.23 kgf ・ m, 1.7 lb ・ ft) 3.8 N ・ m (0.38 kgf ・ m, 2.8 lb ・ ft) 3.8 N ・...
  • Page 176 GENERAL CHASSIS (1) Removing the battery box 1 and rear frame 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) 28 N ・ m (2.8 kgf ・ m, 20 lb ・ ft) 50 N ・ m (5.0 kgf ・ m, 36 lb ・ ft) 50 N ・...
  • Page 177 GENERAL CHASSIS (1) Removing the radiator cover (left) and side cover (left) 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) 1.5 N ・...
  • Page 178 GENERAL CHASSIS (1) Removing the radiator cover (right) and side cover (right) 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) 1.5 N ・ m (0.15 kgf ・ m, 1.1 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) 7 N ・...
  • Page 179 GENERAL CHASSIS (1) Removing the air scoop (left) 1.5 N ・ m (0.15 kgf ・ m, 1.1 lb ・ ft) 1.5 N ・ m (0.15 kgf ・ m, 1.1 lb ・ ft) 1.8 N ・ m (0.18 kgf ・ m, 1.3 lb ・ ft) 7 N ・...
  • Page 180 GENERAL CHASSIS (1) Removing the air scoop (right) 1.8 N ・ m (0.18 kgf ・ m, 1.3 lb ・ ft) 1.5 N ・ m (0.15 kgf ・ m, 1.1 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) 1.5 N ・...
  • Page 181 GENERAL CHASSIS (1) EAS31519 REMOVING THE SIDE COVER (left) 1. Remove: • Side cover (left) “1” ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the side cover bolt “2”. b. Remove the side cover “1” by sliding it for- ward. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS31264 REMOVING THE SIDE COVER (right) 1.
  • Page 182 GENERAL CHASSIS (1) EAS31772 Side cover bolt REMOVING THE AIR SCOOP 1.5 N·m (0.15 kgf·m, 1.1 lb·ft) The following procedure applies to both of the air scoops. 1. Remove: • Quick fastener “1” • Air scoop cap “2” ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS31641 REMOVING THE ECU (Engine Control Unit) 1.
  • Page 183 GENERAL CHASSIS (1) Air scoop bolt 1.5 N·m (0.15 kgf·m, 1.1 lb·ft) 4-12...
  • Page 184 GENERAL CHASSIS (2) EAS20155 GENERAL CHASSIS (2) Removing the meter assembly and auxiliary light 1.8 N ・ m (0.18 kgf ・ m, 1.3 lb ・ ft) 0.8 N ・ m (0.08 kgf ・ m, 0.58 lb ・ ft) 1.3 N ・ m (0.13 kgf ・ m, 0.94 lb ・ ft) 7 N ・...
  • Page 185 GENERAL CHASSIS (2) Removing the headlight assembly 1.3 N ・ m (0.13 kgf ・ m, 0.94 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) 1.3 N ・ m (0.13 kgf ・ m, 0.94 lb ・ ft) 1.5 N ・...
  • Page 186 GENERAL CHASSIS (2) Disassembling the headlight assembly 0.5 N ・ m (0.05 kgf ・ m, 0.36 lb ・ ft) 1.8 N ・ m (0.18 kgf ・ m, 1.3 lb ・ ft) 4.3 N ・ m (0.43 kgf ・ m, 3.1 lb ・ ft) 1.8 N ・...
  • Page 187 GENERAL CHASSIS (2) Removing the headlight stay 18 N ・ m (1.8 kgf ・ m, 13 lb ・ ft) 18 N ・ m (1.8 kgf ・ m, 13 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS (1)” on page Air scoop/Air scoop stay 4-1.
  • Page 188 GENERAL CHASSIS (2) Removing the fuel tank covers 0.4 N ・ m (0.04 kgf ・ m, 0.29 lb ・ ft) 1.5 N ・ m (0.15 kgf ・ m, 1.1 lb ・ ft) 3.8 N ・ m (0.38 kgf ・ m, 2.8 lb ・ ft) 3.8 N ・...
  • Page 189 GENERAL CHASSIS (2) into the grommet “b”. EAS31104 REMOVING THE FUEL TANK COVER • Install the parts “c” on the fuel tank cover into The following procedure applies to both of the the hole “d”. fuel tank covers. 1. Remove: Fuel tank cover screw •...
  • Page 190 GENERAL CHASSIS (2) Slide the fuel tank rivet in the arrow direction, and remove it. 4-19...
  • Page 191 GENERAL CHASSIS (3) EAS20156 GENERAL CHASSIS (3) Removing the air filter case 4.0 N ・ m (0.40 kgf ・ m, 2.9 lb ・ ft) 8 N ・ m (0.8 kgf ・ m, 5.8 lb ・ ft) 1.6 N ・ m (0.16 kgf ・ m, 1.2 lb ・ ft) (10) Order Job/Parts to remove...
  • Page 192 GENERAL CHASSIS (3) EAS30908 REMOVING THE AIR FILTER CASE 1. Remove: • Plug • Air filter case cover 2. Loosen: • Intake funnel assembly bolt “1” ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS32032 CHECKING THE AIR FILTER CASE SEAL 1. Check: • Air filter case seal “1” Damage ...
  • Page 193 FRONT WHEEL EAS20028 FRONT WHEEL Removing the front wheel and brake discs 6 N ・ m (0.6 kgf ・ m, 4.3 lb ・ ft) 3.8 N ・ m (0.38 kgf ・ m, 2.8 lb ・ ft) 6 N ・ m (0.6 kgf ・ m, 4.3 lb ・ ft) 35 N ・...
  • Page 194 FRONT WHEEL Disassembling the front wheel 8 N ・ m (0.8 kgf ・ m, 5.8 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Front wheel sensor rotor Oil seal Wheel bearing Spacer 4-23...
  • Page 195 FRONT WHEEL • If any solvent gets on the wheel sensor ro- EAS30145 REMOVING THE FRONT WHEEL tor, wipe it off immediately. ECA21380 1. Remove: NOTICE • Oil seals Keep magnets (including magnetic pick-up • Wheel bearings tools, magnetic screwdrivers, etc.) away from the front wheel sensor “1”, otherwise ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...
  • Page 196 FRONT WHEEL EAS30151 ASSEMBLING THE FRONT WHEEL ECA21340 NOTICE • Do not drop the wheel sensor rotor or sub- ject it to shocks. • If any solvent gets on the wheel sensor ro- tor, wipe it off immediately. 1. Install: •...
  • Page 197 FRONT WHEEL front wheel sensor rotor. d. Install the new oil seals. • Do not drop or shock the wheel sensor or ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ the wheel sensor rotor. 2. Install: • Front wheel sensor rotor 1. Check: • Front wheel sensor “1” Wheel sensor rotor bolt Cracks/bends/distortion ...
  • Page 198 FRONT WHEEL ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Spin the front wheel. b. When the front wheel stops, put an “X ” mark at the bottom of the wheel. c. Turn the front wheel 90 so that the “X ” mark is positioned as shown. d.
  • Page 199 FRONT WHEEL b. Turn the front wheel 90 so that the heavy spot is positioned as shown. 2. Check: • Front brake discs c. If the heavy spot does not stay in that posi- Refer to “CHECKING THE FRONT BRAKE tion, install a heavier weight.
  • Page 200 FRONT WHEEL fork. However, if the surface of the front axle 8. Measure: end is not parallel to the surface of the front • Distance “a” fork, align a point on the outer edge of the (between the wheel sensor rotor “1” and front axle with the fork, making sure that the axle wheel sensor “2”) Out of specification ...
  • Page 201 FRONT WHEEL EWA13500 WARNING Make sure the brake hose is routed properly. 4-30...
  • Page 202 REAR WHEEL EAS20029 REAR WHEEL Removing the rear wheel 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) 190 N ・ m (19 kgf ・ m, 137 lb ・ ft) 16 N ・ m (1.6 kgf ・ m, 12 lb ・ ft) 16 N ・...
  • Page 203 REAR WHEEL Removing the brake disc and rear wheel sprocket 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) 8 N ・ m (0.8 kgf ・ m, 5.8 lb ・ ft) 8 N ・ m (0.8 kgf ・ m, 5.8 lb ・ ft) 80 N ・...
  • Page 204 REAR WHEEL Disassembling the rear wheel 80 N ・ m (8.0 kgf ・ m, 58 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Collar Wheel bearing Spacer Oil seal Wheel bearing ring nut Wheel bearing 4-33...
  • Page 205 REAR WHEEL EAS30910 REMOVING THE REAR WHEEL ECA21390 NOTICE Keep magnets (including magnetic pick-up tools, magnetic screwdrivers, etc.) away from the rear wheel sensor “1”, otherwise the wheel sensor may be damaged, resulting in improper performance of the ABS. 3. Loosen: •...
  • Page 206 REAR WHEEL 2. Check: EAS30158 DISASSEMBLING THE REAR WHEEL • Tire ECA21340 • Rear wheel NOTICE Damage/wear  Replace. • Do not drop the wheel sensor rotor or sub- Refer to “CHECKING THE TIRES” on page ject it to shocks. 3-17 and “CHECKING THE WHEELS”...
  • Page 207 REAR WHEEL • Oil seal Refer to “ASSEMBLING THE FRONT WHEEL” on page 4-25. 2. Install: • Wheel bearing ring nut Apply locking agent (LOCTITE®) onto the two symmetric places on the circumference of the threads of the wheel bearing ring nut. b.
  • Page 208 REAR WHEEL on page 4-26. EAS30164 ADJUSTING THE REAR WHEEL STATIC BALANCE • After replacing the tire, wheel or both, the rear wheel static balance should be adjusted. • Adjust the rear wheel static balance with the brake disc and rear wheel drive hub installed. 1.
  • Page 209 REAR WHEEL • Rear wheel Rear wheel axle nut • Adjusting blocks 190 N·m (19 kgf·m, 137 lb·ft) • Rear wheel axle Rear brake caliper bolt (front) • Washer 27 N·m (2.7 kgf·m, 20 lb·ft) • Rear wheel axle nut Rear brake caliper bolt (rear) 22 N·m (2.2 kgf·m, 16 lb·ft) •...
  • Page 210 REAR WHEEL ing for looseness, and the rear wheel sensor and sensor rotor installation conditions (warpage caused by overtorque, wrong in- stallation direction, rotor decentering, LOC- TITE® on the mounting surface of the rotor, deformation caused by an impact during ser- vice and caught foreign materials).
  • Page 211 FRONT BRAKE EAS20030 FRONT BRAKE Removing the front brake pads 6 N ・ m (0.6 kgf ・ m, 4.3 lb ・ ft) 5 N ・ m (0.5 kgf ・ m, 3.6 lb ・ ft) 35 N ・ m (3.5 kgf ・ m, 25 lb ・ ft) Order Job/Parts to remove Q’ty...
  • Page 212 FRONT BRAKE Removing the front brake master cylinder 1.5 N ・ m (0.15 kgf ・ m, 1.1 lb ・ ft) 1.0 N ・ m (0.10 kgf ・ m, 0.72 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) 6 N ・...
  • Page 213 FRONT BRAKE Disassembling the front brake master cylinder Order Job/Parts to remove Q’ty Remarks Brake master cylinder kit Brake master cylinder body 4-42...
  • Page 214 FRONT BRAKE Removing the front brake calipers 6 N ・ m (0.6 kgf ・ m, 4.3 lb ・ ft) 32 N ・ m (3.2 kgf ・ m, 23 lb ・ ft) 35 N ・ m (3.5 kgf ・ m, 25 lb ・ ft) Order Job/Parts to remove Q’ty...
  • Page 215 FRONT BRAKE Disassembling the front brake calipers 5 N ・ m (0.5 kgf ・ m, 3.6 lb ・ ft) 5 N ・ m (0.5 kgf ・ m, 3.6 lb ・ ft) Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers.
  • Page 216 FRONT BRAKE d. Hold the dial gauge at a right angle against EAS30168 INTRODUCTION the brake disc surface. EWA14101 e. Measure the runout 1.5 mm (0.06 in) below WARNING the edge of the brake disc. Disc brake components rarely require disas- sembly.
  • Page 217 FRONT BRAKE d. Measure the brake disc runout. 3. Measure: • Brake pad wear limit “a” e. If out of specification, repeat the adjustment Out of specification  Replace the brake steps until the brake disc runout is within specification. pads as a set.
  • Page 218 FRONT BRAKE LOWER c. Tighten the bleed screw. 8. Check: • Brake lever operation Brake caliper bleed screw Soft or spongy feeling  Bleed the brake sys- 5 N·m (0.5 kgf·m, 3.6 lb·ft) tem. d. Install the brake pads and brake pad spring. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM (ABS)”...
  • Page 219 FRONT BRAKE EAS30172 DISASSEMBLING THE FRONT BRAKE Recommended brake component replacement schedule CALIPERS The following procedure applies to both of the Brake pads If necessary brake calipers. Piston seals Every two years 1. Remove: • Brake caliper pistons “1” Piston dust seals Every two years •...
  • Page 220 FRONT BRAKE replace the brake caliper piston dust seals 3. Install: and brake caliper piston seals. • Brake pads • Brake pad spring Specified brake fluid • Brake pad pin DOT 4 • Brake pad clips • Front brake caliper EAS30175 INSTALLING THE FRONT BRAKE CALIPERS Front brake caliper bolt...
  • Page 221 FRONT BRAKE (brake master cylinder body) Obstruction  Blow out with compressed air. 2. Check: LOWER • Brake master cylinder kit Damage/scratches/wear  Replace. 3. Check: • Brake master cylinder reservoir “1” • Brake master cylinder reservoir diaphragm holder “2” Cracks/damage ...
  • Page 222 FRONT BRAKE • Align the end of the front brake master cylinder 3. Fill: with the punch mark “b” on the handlebar. • Brake master cylinder reservoir • First, tighten the upper bolt, then the lower bolt. (with the specified amount of the specified •...
  • Page 223 FRONT BRAKE 6. Check: • Brake lever operation Soft or spongy feeling  Bleed the brake sys- tem. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM (ABS)” on page 3-16. 4-52...
  • Page 224 REAR BRAKE EAS20031 REAR BRAKE Removing the rear brake pads 27 N ・ m (2.7 kgf ・ m, 20 lb ・ ft) 5 N ・ m (0.5 kgf ・ m, 3.6 lb ・ ft) 22 N ・ m (2.2 kgf ・ m, 16 lb ・ ft) 17 N ・...
  • Page 225 REAR BRAKE Removing the rear brake master cylinder 2.5 N ・ m (0.25 kgf ・ m, 1.8 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) 28 N ・...
  • Page 226 REAR BRAKE Removing the rear brake master cylinder 2.5 N ・ m (0.25 kgf ・ m, 1.8 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) 28 N ・...
  • Page 227 REAR BRAKE Disassembling the rear brake master cylinder 18 N ・ m (1.8 kgf ・ m, 13 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Brake master cylinder yoke Brake master cylinder kit Hose joint Bushing Brake master cylinder body 4-56...
  • Page 228 REAR BRAKE Removing the rear brake caliper 27 N ・ m (2.7 kgf ・ m, 20 lb ・ ft) 32 N ・ m (3.2 kgf ・ m, 23 lb ・ ft) 22 N ・ m (2.2 kgf ・ m, 16 lb ・ ft) Order Job/Parts to remove Q’ty...
  • Page 229 REAR BRAKE Disassembling the rear brake caliper 5 N ・ m (0.5 kgf ・ m, 3.6 lb ・ ft) 17 N ・ m (1.7 kgf ・ m, 12 lb ・ ft) 2.5 N ・ m (0.25 kgf ・ m, 1.8 lb ・ ft) Order Job/Parts to remove Q’ty...
  • Page 230 REAR BRAKE EAS30183 INTRODUCTION Brake disc thickness limit 4.5 mm (0.18 in) EWA14101 WARNING 5. Adjust: Disc brake components rarely require disas- • Brake disc runout sembly. Therefore, always follow these pre- Refer to “CHECKING THE FRONT BRAKE ventive measures: DISCS”...
  • Page 231 REAR BRAKE ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Recommended lubricant a. Connect a clear plastic hose “1” tightly to the Silicone grease bleed screw “2”. Put the other end of the hose into an open container. ECA14150 b. Loosen the bleed screw and push the brake NOTICE caliper piston into the brake caliper with your •...
  • Page 232 REAR BRAKE • Brake hose gaskets “2” • Brake hose “3” Put the end of the brake hose into a container and pump out the brake fluid carefully. b. Remove the brake caliper piston dust seal and brake caliper piston seal. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...
  • Page 233 REAR BRAKE EWA13531 2. Check: WARNING • Rear brake caliper bracket “1” Proper brake hose routing is essential to in- Cracks/damage  Replace. sure safe vehicle operation. Refer to “REAR WHEEL” on page 4-31. ECA19080 NOTICE When installing the brake hose onto the brake caliper “1”, make sure the brake pipe “a”...
  • Page 234 REAR BRAKE 4. Fill: EAS30193 REMOVING THE REAR BRAKE MASTER • Brake fluid reservoir CYLINDER (with the specified amount of the specified 1. Remove: brake fluid) • Brake hose union bolt “1” Specified brake fluid • Brake hose gaskets “2” DOT 4 •...
  • Page 235 REAR BRAKE Cracks/damage/wear  Replace. Specified brake fluid DOT 4 EAS30195 ASSEMBLING THE REAR BRAKE MASTER CYLINDER EWA13090 WARNING EWA13520 WARNING • Use only the designated brake fluid. Other • Before installation, all internal brake com- brake fluids may cause the rubber seals to ponents should be cleaned and lubricated deteriorate, causing leakage and poor with clean or new brake fluid.
  • Page 236 ABS (Anti-lock Brake System) EAS20032 ABS (Anti-lock Brake System) Removing the hydraulic unit assembly 26 N ・ m (2.6 kgf ・ m, 19 lb ・ ft) 26 N ・ m (2.6 kgf ・ m, 19 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) 7 N ・...
  • Page 237 ABS (Anti-lock Brake System) Removing the hydraulic unit assembly 26 N ・ m (2.6 kgf ・ m, 19 lb ・ ft) 26 N ・ m (2.6 kgf ・ m, 19 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) 7 N ・...
  • Page 238 7. Front brake caliper 8. Rear wheel sensor 9. Rear wheel sensor rotor 10.Rear brake caliper 11.ABS motor fuse 12.Yamaha diagnostic tool coupler 13.Front brake hose (hydraulic unit to front brake calipers) 14.Front brake hose (front brake master cylinder to hydraulic unit) 15.Rear brake hose (rear brake master cylinder...
  • Page 239 ABS (Anti-lock Brake System) EAS30197 REMOVING THE HYDRAULIC UNIT ASSEMBLY ECA18230 NOTICE Unless necessary, avoid removing and in- stalling the brake pipes of the hydraulic unit assembly. EWA13930 WARNING Refill with the same type of brake fluid that is 2. Remove: already in the system.
  • Page 240 ABS (Anti-lock Brake System) EAS30200 INSTALLING THE HYDRAULIC UNIT Connect the ABS ECU coupler, and then push ASSEMBLY the lock lever of the coupler in the direction of the 1. Install: arrow shown. • Hydraulic unit assembly ECA21371 NOTICE Do not remove the rubber plugs or bolts (M10 ...
  • Page 241 WARNING Securely support the vehicle so that there is no danger of it falling over. 6. Start the Yamaha diagnostic tool and display • For the brake line routing confirmation, use the the diagnosis of function screen. diagnosis of function of the Yamaha diagnostic 7.
  • Page 242 Securely support the vehicle so that there is no danger of it falling over. • For the ABS reaction-force confirmation, use the diagnosis of function of the Yamaha diag- nostic tool. For more information, refer to the operation manual of the Yamaha diagnostic tool.
  • Page 243 • “ON” and “OFF” on the tool screen indicate when the brakes are being applied and re- leased respectively. 6. Start the Yamaha diagnostic tool and display the diagnosis of function screen. 7. Select code No. 1, “ABS reaction-force con- firmation”.
  • Page 244 12.Turn the main switch to “OFF”. 13.Remove the Yamaha diagnostic tool from the Yamaha diagnostic tool coupler, and then in- stall the protective cap. 14.Turn the main switch to “ON”.
  • Page 245 HANDLEBAR EAS20033 HANDLEBAR Removing the handlebar 11 N ・ m (1.1 kgf ・ m, 8.0 lb ・ ft) 22 N ・ m (2.2 kgf ・ m, 16 lb ・ ft) 17 N ・ m (1.7 kgf ・ m, 12 lb ・ ft) 26 N ・...
  • Page 246 HANDLEBAR Removing the handlebar 11 N ・ m (1.1 kgf ・ m, 8.0 lb ・ ft) 22 N ・ m (2.2 kgf ・ m, 16 lb ・ ft) 17 N ・ m (1.7 kgf ・ m, 12 lb ・ ft) 26 N ・...
  • Page 247 HANDLEBAR EAS30203 REMOVING THE HANDLEBAR 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. 2. Remove: • Handlebar grip “1” Blow compressed air between the left handlebar and the handlebar grip, and gradually push the EAS30205 INSTALLING THE HANDLEBAR...
  • Page 248 HANDLEBAR 3. Tighten: Refer to “INSTALLING THE FRONT BRAKE • Lower handlebar holder nuts MASTER CYLINDER” on page 4-50. 7. Install: Lower handlebar holder nut • Clutch lever holder “1” 40 N·m (4.0 kgf·m, 29 lb·ft) • Clutch cable 4. Install: Clutch lever holder pinch bolt •...
  • Page 249 HANDLEBAR end of the left handlebar. b. Side the handlebar grip over the end of the left handlebar. c. Wipe off any excess rubber adhesive with a clean rag. EWA13700 WARNING Do not touch the handlebar grip until the rub- ber adhesive has fully dried.
  • Page 250 FRONT FORK EAS20034 FRONT FORK Removing the front fork legs 26 N ・ m (2.6 kgf ・ m, 19 lb ・ ft) 23 N ・ m (2.3 kgf ・ m, 17 lb ・ ft) 6 N ・ m (0.6 kgf ・ m, 4.3 lb ・ ft) 6 N ・...
  • Page 251 FRONT FORK Disassembling the front fork legs 23 N ・ m (2.3 kgf ・ m, 17 lb ・ ft) 15 N ・ m (1.5 kgf ・ m, 11 lb ・ ft) 21 N ・ m (2.1 kgf ・ m, 15 lb ・ ft) 40 N ・...
  • Page 252 FRONT FORK 1. Turn the spring preload adjusting nut “1” EAS30206 REMOVING THE FRONT FORK LEGS counterclockwise until it stops. The following procedure applies to both of the front fork legs. 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over.
  • Page 253 FRONT FORK ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Hold the front fork leg horizontally. b. Securely clamp the brake caliper bracket in a vise with soft jaws. c. Separate the outer tube from the inner tube by pulling the outer tube forcefully but careful- ECA19880 NOTICE Excessive force will damage the bushings.
  • Page 254 FRONT FORK EWA13650 WARNING Do not attempt to straighten a bent inner tube as this may dangerously weaken it. 4. Check: • Cap bolt “1” • Cap bolt collar projection “2” Cracks/damage  Replace. 2. Measure: • Spring free length “a” Out of specification ...
  • Page 255 3. Lubricate: • Inner tube’s outer surface Fork seal driver 90890-01442 Recommended oil Adjustable fork seal driver (36–46 Yamaha Suspension Oil 01 YM-01442 4. Install: • Dust seal “1” • Oil seal clip “2” • Oil seal “3” • Washer “4”...
  • Page 256 (with the specified amount of the recom- (with the fork seal driver “2”) mended fork oil) Fork seal driver Recommended oil 90890-01442 Yamaha Suspension Oil 01 Adjustable fork seal driver (36–46 Quantity (left) 368.0 cm³ (12.44 US oz, 12.98 YM-01442 Imp.oz) Quantity (right) 368.0 cm³...
  • Page 257 FRONT FORK • When disassembling and assembling the • Damper adjusting rod 2 “4” front fork leg, do not allow any foreign ma- • Damper adjusting rod 1 “5” terial to enter the front fork. • Guide “6” • Cap bolt “7” 12.After filling the front fork leg, slowly stroke the (along with the O-ring damper rod “1”...
  • Page 258 FRONT FORK Rod puller 90890-01437 Universal damping rod bleeding tool set YM-A8703 Rod puller attachment (M10) 90890-01436 Universal damping rod bleeding tool set YM-A8703 Fork spring compressor l. Remove the rod holder and fork spring com- 90890-01441 pressor. Fork spring compressor YM-01441 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...
  • Page 259 FRONT FORK 4. Check: Lower bracket pinch bolt • Cable routing 23 N·m (2.3 kgf·m, 17 lb·ft) Make sure the brake hose, throttle cables, clutch cable, and handlebar switch leads are routed Tighten each bolt to 23 N·m (2.3 kgf·m, 17 lb·ft) properly.
  • Page 260 STEERING HEAD EAS20035 STEERING HEAD Removing the lower bracket 115 N ・ m (11.5 kgf ・ m, 83 lb ・ ft) 52 N ・ m (5.2 kgf ・ m, 38 lb ・ ft) 14 N ・ m (1.4 kgf ・ m, 10 lb ・ ft) 23 N ・...
  • Page 261 STEERING HEAD Removing the lower bracket 115 N ・ m (11.5 kgf ・ m, 83 lb ・ ft) 52 N ・ m (5.2 kgf ・ m, 38 lb ・ ft) 14 N ・ m (1.4 kgf ・ m, 10 lb ・ ft) 23 N ・...
  • Page 262 STEERING HEAD Damage/pitting  Replace the bearings and EAS30213 REMOVING THE LOWER BRACKET bearing races as a set. 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. 2.
  • Page 263 STEERING HEAD Temporarily tighten the upper and lower bracket pinch bolts. EAS30215 CHECKING THE STEERING DAMPER 1. Check: • Steering damper body Damage/oil leaks  Replace the steering damper assembly. • Steering damper rod ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Bends/scratch  Replace the steering 4.
  • Page 264 REAR SHOCK ABSORBER ASSEMBLY EAS20036 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly 35 N ・ m (3.5 kgf ・ m, 25 lb ・ ft) 40 N ・ m (4.0 kgf ・ m, 29 lb ・ ft) 40 N ・ m (4.0 kgf ・ m, 29 lb ・ ft) Order Job/Parts to remove Q’ty...
  • Page 265 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly 35 N ・ m (3.5 kgf ・ m, 25 lb ・ ft) 40 N ・ m (4.0 kgf ・ m, 29 lb ・ ft) 40 N ・ m (4.0 kgf ・ m, 29 lb ・ ft) Order Job/Parts to remove Q’ty...
  • Page 266 REAR SHOCK ABSORBER ASSEMBLY EAS30826 HANDLING THE REAR SHOCK ABSORBER Place the vehicle on a maintenance stand so EWA13740 that the rear wheel is elevated. WARNING This rear shock absorber contains highly 2. Remove: compressed nitrogen gas. Before handling • Connecting arm upper nut the rear shock absorber, read and make sure •...
  • Page 267 REAR SHOCK ABSORBER ASSEMBLY 2. Check: EAS31653 DISASSEMBLING THE REAR SHOCK • Bearings ABSORBER ASSEMBLY • Oil seals 1. Remove: Damage/pitting  Replace. • Oil seal 3. Check: • Bearing “1” • Collars Damage/scratches  Replace. Remove the bearing with a socket “2” that matches its outside diameter.
  • Page 268 REAR SHOCK ABSORBER ASSEMBLY • Press in the oil seal so it does not protrude Relay arm nut from the end surface of the relay arm. 40 N·m (4.0 kgf·m, 29 lb·ft) • Install the connecting arm so that the stamp Rear shock absorber assembly mark “B67”...
  • Page 269 SWINGARM EAS20037 SWINGARM Removing the swingarm 65 N ・ m (6.5 kgf ・ m, 47 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) 7 N ・...
  • Page 270 SWINGARM Removing the swingarm 65 N ・ m (6.5 kgf ・ m, 47 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) 7 N ・...
  • Page 271 SWINGARM 5. Remove: EAS30226 REMOVING THE SWINGARM • Pivot shaft nut 1. Stand the vehicle on a level surface. • Pivot shaft ring nut “1” EWA13120 WARNING Loosen the pivot shaft ring nut with the ring nut Securely support the vehicle so that there is wrench “2”.
  • Page 272 SWINGARM EWA13770 WARNING Do not attempt to straighten a bent pivot shaft. 3. Wash: • Pivot shaft • Dust covers • Collar • Bushing • Washer EAS30228 INSTALLING THE SWINGARM Recommended cleaning solvent 1. Lubricate: Kerosene • Dust covers 4. Check: •...
  • Page 273 SWINGARM Tighten the pivot shaft ring nut with the ring nut wrench “2”. Ring nut wrench 90890-01507 Ring nut wrench YM-01507 5. Install: • Pivot shaft nut “1” A. Left side B. Right side Pivot shaft nut 105 N·m (10.5 kgf·m, 76 lb·ft) 3.
  • Page 274 SWINGARM Drive chain slack (Maintenance stand) 25.0–35.0 mm (0.98–1.38 in) Drive chain slack (Sidestand) 20.0–30.0 mm (0.79–1.18 in) 4-103...
  • Page 275 CHAIN DRIVE EAS20038 CHAIN DRIVE Removing the drive chain 140 N ・ m (14 kgf ・ m, 100 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) 10 N ・...
  • Page 276 CHAIN DRIVE Drive chain 15-link section length “a” = EAS30229 REMOVING THE DRIVE CHAIN (length “b” between pin inner sides + length 1. Stand the vehicle on a level surface. “c” between pin outer sides)/2 EWA13120 WARNING • When measuring a 15-link section of the drive Securely support the vehicle so that there is chain, make sure that the drive chain is taut.
  • Page 277 CHAIN DRIVE ECA19090 NOTICE • This vehicle has a drive chain with small rubber O-rings “1” between the drive chain side plates. Never use high-pressure water or air, steam, gasoline, certain solvents (e.g., benzine), or a coarse brush to clean the drive chain.
  • Page 278 CHAIN DRIVE EAS30234 INSTALLING THE DRIVE CHAIN 1. Install: • Drive chain ECA17410 NOTICE Be sure to put on safety goggles when work- ing. Install the drive chain joint with the drive chain cut & rivet tool. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Lubricate: Drive chain cut &...
  • Page 279 CHAIN DRIVE 7. Adjust: • Drive chain slack Refer to “Adjusting the drive chain slack” on page 3-19. Drive chain slack (Maintenance stand) 25.0–35.0 mm (0.98–1.38 in) Drive chain slack (Sidestand) 20.0–30.0 mm (0.79–1.18 in) ECA13550 5. Install: NOTICE • Shift rod joint “1” A drive chain that is too tight will overload •...
  • Page 280 CHAIN DRIVE c. Tighten both locknuts. Be sure to place the shift rod joints in parallel. The allowable twist of the shift rod joints is ±5. Shift rod locknut 7 N·m (0.7 kgf·m, 5.1 lb·ft) d. Make sure the installed shift rod length is within specification.
  • Page 281 ENGINE ENGINE INSPECTION ..................5-1 MEASURE THE COMPRESSION PRESSURE.........5-1 ENGINE REMOVAL..................5-3 REMOVING THE ENGINE .................5-7 INSTALLING THE ENGINE................5-7 INSTALLING THE EXHAUST PIPE AND MUFFLER.........5-8 CAMSHAFTS....................5-9 REMOVING THE CAMSHAFTS...............5-13 REMOVING THE ROCKER ARMS AND ROCKER ARM SHAFTS..5-14 CHECKING THE CAMSHAFTS ...............5-14 CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS ..5-15 CHECKING THE TIMING CHAIN AND CAMSHAFT SPROCKET ..5-16 CHECKING THE TIMING CHAIN GUIDES..........5-16 CHECKING THE TIMING CHAIN TENSIONER........5-16...
  • Page 282 OIL PUMP.......................5-44 REMOVING THE OIL PAN...............5-47 CHECKING THE SPROCKET AND CHAIN..........5-47 CHECKING THE OIL PUMP ..............5-47 CHECKING THE RELIEF VALVE ............5-48 CHECKING THE OIL DELIVERY PIPES ..........5-48 CHECKING THE OIL STRAINER ............5-48 ASSEMBLING THE OIL PUMP..............5-48 INSTALLING THE OIL PUMP ..............5-49 INSTALLING THE OIL PAN ..............5-50 CLUTCH ......................5-51 REMOVING THE CLUTCH ..............5-54...
  • Page 283 INSTALLING THE THRUST BEARING............5-85 INSTALLING THE BALANCER ASSEMBLY..........5-86 TRANSMISSION.....................5-87 REMOVING THE TRANSMISSION ............5-91 CHECKING THE SHIFT FORKS..............5-91 CHECKING THE SHIFT DRUM ASSEMBLY...........5-92 CHECKING THE TRANSMISSION ............5-92 ASSEMBLING THE MAIN AXLE AND DRIVE AXLE .......5-92 INSTALLING THE TRANSMISSION ............5-93...

  • Page 284: Engine Inspection

    ENGINE INSPECTION EAS20041 ENGINE INSPECTION EAS30249 MEASURE THE COMPRESSION PRESSURE The following procedure applies to all of the cyl- inders. Insufficient compression pressure will result in a loss of performance. 1. Measure: 5. Measure: • Valve clearance • Compression pressure Out of specification ...
  • Page 285 ENGINE INSPECTION Compression pressure (with oil applied into the cylinder) Reading Diagnosis Piston ring(s) wear or Higher than without oil damage  Repair. Piston, valves, cylinder Same as without oil head gasket possibly defective  Repair. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 6. Install: • Spark plugs Spark plug 13 N·m (1.3 kgf·m, 9.4 lb·ft) Spark plug (new)

  • Page 286: Engine Removal

    ENGINE REMOVAL EAS20042 ENGINE REMOVAL Removing the muffler and exhaust pipe 6 N ・ m (0.6 kgf ・ m, 4.3 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) 2.0 N ・ m (0.20 kgf ・ m, 1.4 lb ・ ft) 25 N ・...
  • Page 287 ENGINE REMOVAL Removing the muffler and exhaust pipe 6 N ・ m (0.6 kgf ・ m, 4.3 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) 2.0 N ・ m (0.20 kgf ・ m, 1.4 lb ・ ft) 25 N ・...
  • Page 288 ENGINE REMOVAL Disconnecting the leads and hoses 6 N ・ m (0.6 kgf ・ m, 4.3 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS (3)” on page Air filter case 4-20.
  • Page 289 ENGINE REMOVAL Removing the engine 56 N ・ m (5.6 kgf ・ m, 41 lb ・ ft) 70 N ・ m (7.0 kgf ・ m, 51 lb ・ ft) 56 N ・ m (5.6 kgf ・ m, 41 lb ・ ft) 70 N ・...

  • Page 290: Removing The Engine

    ENGINE REMOVAL EAS30250 REMOVING THE ENGINE • Tighten the engine mounting adjust bolt to 1. Loosen: specification with the pivot shaft wrench. • Engine mounting adjust bolt • Make sure that the flange on the engine mounting adjust bolt contacts the engine. Loosen the engine mounting adjust bolt with the pivot shaft wrench “1”.

  • Page 291: Installing The Exhaust Pipe And Muffler

    ENGINE REMOVAL EAS30252 INSTALLING THE EXHAUST PIPE AND MUFFLER 1. Install: • Exhaust pipe • Gasket “1” (to exhaust chamber) • Muffler When installing the gasket, install it so that the chamfered side “a” of the gasket faces the ex- haust pipe side as shown in the illustration.

  • Page 292: Camshafts

    CAMSHAFTS EAS20043 CAMSHAFTS Removing the cylinder head cover 13 N ・ m (1.3 kgf ・ m, 9.4 lb ・ ft) 8 N ・ m (0.8 kgf ・ m, 5.8 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) Order Job/Parts to remove Q’ty...
  • Page 293 CAMSHAFTS Removing the camshafts 8 N ・ m (0.8 kgf ・ m, 5.8 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) 8 N ・ m (0.8 kgf ・ m, 5.8 lb ・ ft) Order Job/Parts to remove Q’ty...
  • Page 294 CAMSHAFTS Removing the timing chain and timing chain guide 72 N ・ m (7.2 kgf ・ m, 52 lb ・ ft) 9 10 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) 12 N ・ m (1.2 kgf ・ m, 8.7 lb ・ ft) Order Job/Parts to remove Q’ty...
  • Page 295 CAMSHAFTS Removing the rocker arms 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) 6 N ・ m (0.6 kgf ・ m, 4.3 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) Order Job/Parts to remove Q’ty...

  • Page 296: Removing The Camshafts

    CAMSHAFTS EAS30256 REMOVING THE CAMSHAFTS 1. Remove: • Timing mark accessing bolt “1” • Crankshaft end cover “2” 4. Remove: • Camshaft cap “1” ECA13720 NOTICE To prevent damage to the cylinder head, 2. Align: camshafts or camshaft caps, loosen the •...

  • Page 297: Removing The Rocker Arms And Rocker Arm Shafts

    CAMSHAFTS 3. Measure: EAS31655 REMOVING THE ROCKER ARMS AND • Camshaft runout ROCKER ARM SHAFTS Out of specification  Replace. 1. Remove: Camshaft runout limit • Rocker arm shaft bolt “1” 0.030 mm (0.0012 in) • Straight plug “2” • Rocker arm shaft “3” •...

  • Page 298: Checking The Rocker Arms And Rocker Arm Shafts

    CAMSHAFTS c. Install the dowel pins and camshaft caps. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ ECA23010 5. Measure: NOTICE • Camshaft journal diameter “a” There are two kinds of camshaft cap bolts Out of specification  Replace the camshaft. with different lengths. Be sure to install each Within specification ...

  • Page 299: Checking The Timing Chain And Camshaft Sprocket

    CAMSHAFTS ting/scratches  Replace or check the lubri- camshaft sprockets and the timing chain as a cation system. set. 3. Measure: • Rocker arm inside diameter “a” Out of specification  Replace. Rocker arm inside diameter 7.987–8.002 mm (0.3144–0.3150 Limit 8.017 mm (0.3156 in) a.

  • Page 300: Assembling The Timing Chain Cover

    CAMSHAFTS Valve spring compressor Install the oil seal with a socket “2” that matches 90890-04019 its outside diameter. Valve spring compressor YM-04019 Installed depth “a” 4.0–4.5 mm (0.16–0.18 in) 2. Install: • Washer • Circlip EAS31657 INSTALLING THE ROCKER ARMS AND ROCKER ARM SHAFTS 1.
  • Page 301 CAMSHAFTS c. Install the oil pipe bolt “3” and tighten it tem- porarily until there is no clearance at “a” (tim- ing chain cover to oil pipe) and “b” (oil pipe to oil pipe bolt). Apply locking agent (LOCTITE®) onto the oil pipe bolt.

  • Page 302: Installing The Camshafts

    CAMSHAFTS torque following the tightening order shown in the illustration. Oil pipe 3 bolt 10 N·m (1.0 kgf·m, 7.2 lb·ft) LOCTITE® ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Install: • Exhaust camshaft “1” • Intake camshaft “2” • Hang the timing chain on the sprocket from the exhaust camshaft to the intake camshaft.
  • Page 303 CAMSHAFTS 5. Tighten: a. Camshaft cap bolt (black): 40 mm (1.57 in) • Camshaft cap bolts b. Camshaft cap bolt (silver): 35 mm (1.38 in) Camshaft cap bolt A. Intake side 8 N·m (0.8 kgf·m, 5.8 lb·ft) B. Exhaust side Camshaft cap bolt (new) 6.
  • Page 304 CAMSHAFTS b. Keep pressing the timing chain tensioner rod, mount clip “4” into groove “5”, and lock the timing chain tensioner rod. c. In the status of step (b), install the rod assem- bly in the cylinder block. Always use a new gasket. Timing chain tensioner bolt 10 N·m (1.0 kgf·m, 7.2 lb·ft) LOCTITE®...
  • Page 305 CAMSHAFTS Cylinder head cover bolt 10 N·m (1.0 kgf·m, 7.2 lb·ft) • Apply Three bond No.1541C® onto the mating surfaces of the cylinder head cover and cylin- der head cover gasket. • After installing the cylinder head cover gasket “2” to the cylinder head cover, cut off the “a” section.

  • Page 306: Cylinder Head

    CYLINDER HEAD EAS20044 CYLINDER HEAD Removing the cylinder head 12 N ・ m (1.2 kgf ・ m, 8.7 lb ・ ft) 15 N ・ m (1.5 kgf ・ m, 11 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) 25 N ・...

  • Page 307: Removing The Cylinder Head

    CYLINDER HEAD EAS30276 REMOVING THE CYLINDER HEAD 1. Remove: • Intake camshaft • Exhaust camshaft Refer to “REMOVING THE CAMSHAFTS” on page 5-13. 2. Remove: • Cylinder head bolt (M6) ( 2) • Cylinder head bolt (M9) ( 10) • Loosen the bolts in the proper sequence as ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...
  • Page 308 CYLINDER HEAD Refer to “INSTALLING THE CAMSHAFTS” on page 5-19. 2. Install: • Cylinder head • Cylinder head bolt (M6) ( 2) • Cylinder head bolt (M9) ( 10) • Pass the timing chain through the timing chain cavity. • Lubricate the cylinder head bolt (M9) thread and mating surface with engine oil.
  • Page 309 VALVES AND VALVE SPRINGS EAS20045 VALVES AND VALVE SPRINGS Removing the valves and valve springs Order Job/Parts to remove Q’ty Remarks Cylinder head Refer to “CYLINDER HEAD” on page 5-23. Exhaust valve pad Exhaust valve cotter Exhaust valve spring retainer Exhaust valve spring Exhaust valve Exhaust valve stem seal...
  • Page 310 VALVES AND VALVE SPRINGS Removing the valves and valve springs Order Job/Parts to remove Q’ty Remarks Intake valve spring retainer Intake valve spring Intake valve Intake valve stem seal Intake valve spring seat Circlip Intake valve guide 5-27...

  • Page 311: Valves And Valve Springs

    VALVES AND VALVE SPRINGS “1” and the valve spring compressor attachment EAS30283 REMOVING THE VALVES “2”. The following procedure applies to all of the valves and related components. Valve spring compressor 90890-04019 Before removing the internal parts of the cylinder Valve spring compressor head (e.g., valves, valve springs, valve seats), YM-04019...
  • Page 312 VALVES AND VALVE SPRINGS • Valve-stem-to-valve-guide clearance = Valve guide inside diameter “a” - Valve stem diameter “b” Valve-stem-to-valve-guide clear- ance (intake) 0.010–0.037 mm (0.0004–0.0015 Limit 0.080 mm (0.0032 in) Valve-stem-to-valve-guide clear- b. Install the new valve guide with the valve ance (exhaust) guide installer “2”...

  • Page 313: Checking The Valve Seats

    VALVES AND VALVE SPRINGS Valve guide remover (ø4.5) 90890-04116 Valve guide remover (4.5 mm) YM-04116 Valve guide remover (ø5) 90890-04097 Valve guide remover (5.0 mm) YM-04097 Valve guide installer (ø4.5) 90890-04117 Valve guide installer (4.5 mm) EAS30285 YM-04117 CHECKING THE VALVE SEATS Valve guide installer (ø5) The following procedure applies to all of the 90890-04098...

  • Page 314: Checking The Valve Springs

    VALVES AND VALVE SPRINGS For the best lapping results, lightly tap the valve seat while rotating the valve back and forth be- tween your hands. 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 impres- sion.

  • Page 315: Installing The Valves

    VALVES AND VALVE SPRINGS 1. Measure: • Valve spring free length “a” Out of specification  Replace the valve spring. Free length (intake) 41.25 mm (1.62 in) Limit 39.18 mm (1.54 in) Free length (exhaust) 42.33 mm (1.67 in) 2. Lubricate: Limit 40.21 mm (1.58 in) •...
  • Page 316 VALVES AND VALVE SPRINGS 6. Lubricate: b. Smaller pitch • Valve pad 4. Install: (with the recommended lubricant) • Valve cotters Recommended lubricant Molybdenum disulfide oil Install the valve cotters by compressing the valve spring with the valve spring compressor 7.

  • Page 317: Generator

    GENERATOR EAS20134 GENERATOR Removing the stator coil and generator rotor 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) 6 N ・ m (0.6 kgf ・ m, 4.3 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) 75 N ・...

  • Page 318: Removing The Generator

    GENERATOR EAS30829 REMOVING THE GENERATOR Flywheel puller 90890-01404 1. Remove: Flywheel puller • Generator rotor bolt “1” YM-01404 • Washer While holding the generator rotor “2” with the ro- tor holding tool “3”, loosen the generator rotor bolt. 15mm pin type rotor holding tool 90890-04171 YM-04171 EAS30830...
  • Page 319 15mm pin type rotor holding tool 90890-04171 YM-04171 3. Apply: • Sealant (onto the stator coil assembly lead grommet) Yamaha bond No. 1215 90890-85505 (Three bond No.1215®) 4. Install: • Generator cover gasket • Generator cover • Generator cover bolt Generator cover bolt 12 N·m (1.2 kgf·m, 8.7 lb·ft)

  • Page 320: Starter Clutch

    STARTER CLUTCH EAS20049 STARTER CLUTCH Removing the starter clutch 14 N ・ m (1.4 kgf ・ m, 10 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Clutch housing assembly Refer to “CLUTCH” on page 5-51. Starter clutch gear Bearing Starter clutch assembly Circlip Starter clutch idle gear...

  • Page 321: Removing The Starter Clutch

    STARTER CLUTCH EAS30305 REMOVING THE STARTER CLUTCH 1. Remove: • Starter clutch bolt “1” • While holding the clutch housing assembly “2” with the sheave holder “3”, remove the starter clutch bolt. • Fix the flat surface of the clutch housing as- sembly with the sheave holder.
  • Page 322 STARTER CLUTCH • While holding the clutch housing assembly “1” with the sheave holder “2”, tighten the starter clutch holder bolt “3”. • Fix the flat surface of the clutch housing as- sembly with the sheave holder. Sheave holder 90890-01701 Primary clutch holder YS-01880-A 5-39...

  • Page 323: Electric Starter

    ELECTRIC STARTER EAS20052 ELECTRIC STARTER Removing the starter motor 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) 6 N ・ m (0.6 kgf ・ m, 4.3 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS (1)” on page Rider seat/Air scoop/Air scoop stay 4-1.
  • Page 324 ELECTRIC STARTER Disassembling the starter motor 4.5 N ・ m (0.45 kgf ・ m, 3.3 lb ・ ft) Order Job/Parts to remove Q’ty Remarks O-ring Starter motor front cover Starter motor yoke Armature assembly Gasket Brush holder set Starter motor rear cover 5-41...

  • Page 325: Checking The Starter Motor

    ELECTRIC STARTER EAS30325 CHECKING THE STARTER MOTOR 1. Check: • Commutator Dirt  Clean with 600 grit sandpaper. 2. Measure: • Mica undercut “a” Out of specification  Scrape the mica to the proper measurement with a hacksaw blade that has been grounded to fit the commutator. Mica undercut (depth) 1.

  • Page 326: Assembling The Starter Motor

    ELECTRIC STARTER 6. Check: • Gear teeth Damage/wear  Replace the starter motor. 7. Check: • Bearing • Oil seal Damage/wear  Replace the starter motor front cover. EAS30326 ASSEMBLING THE STARTER MOTOR 1. Install: • Starter motor rear cover “1” •...
  • Page 327 OIL PUMP EAS20054 OIL PUMP Removing the oil pan and oil pump 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) 12 N ・...
  • Page 328 OIL PUMP Removing the oil pan and oil pump 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) 12 N ・...
  • Page 329 OIL PUMP Disassembling the oil pump 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Oil pump cover Dowel pin Oil pump outer rotor Oil pump inner rotor Oil pump driven sprocket 5-46...

  • Page 330: Oil Pump

    OIL PUMP EAS30333 EAS30337 REMOVING THE OIL PAN CHECKING THE OIL PUMP 1. Remove: 1. Check: • Oil pan “1” • Oil pump driven sprocket “1” Cracks/damage/wear  Replace. • Gasket • Dowel pins • Oil pump housing “2” Cracks/damage/wear  Replace. Loosen each bolt 1/4 of a turn at a time, in stag- es and in a crisscross pattern.

  • Page 331: Checking The Relief Valve

    OIL PUMP EAS30340 CHECKING THE OIL STRAINER 1. Check: • Oil strainer “1” Damage  Replace. Contaminants  Clean with solvent. EAS30338 CHECKING THE RELIEF VALVE 1. Check: • Relief valve body “1” • Relief valve “2” • Spring “3” •...

  • Page 332: Installing The Oil Pump

    OIL PUMP 3. Check: Oil pump drive chain guide bolt • Oil pump operation 10 N·m (1.0 kgf·m, 7.2 lb·ft) Refer to “CHECKING THE OIL PUMP” on LOCTITE® page 5-47. EAS30343 INSTALLING THE OIL PUMP 1. Install: • Dowel pin •...

  • Page 333: Installing The Oil Pan

    OIL PUMP Oil delivery pipe 2 bolt 10 N·m (1.0 kgf·m, 7.2 lb·ft) LOCTITE® EAS30345 INSTALLING THE OIL PAN 1. Install: • Oil pan gasket • Oil pan • Oil pan bolt 2. Tighten: • Oil pan bolt Oil pan bolt 12 N·m (1.2 kgf·m, 8.7 lb·ft) •...

  • Page 334: Clutch

    CLUTCH EAS20055 CLUTCH Removing the clutch cover 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) (10) 12 N ・ m (1.2 kgf ・ m, 8.7 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Drain. Engine oil Refer to “CHANGING THE ENGINE OIL”...
  • Page 335 CLUTCH Removing the pull lever shaft Order Job/Parts to remove Q’ty Remarks Circlip Pull lever Pull lever spring Circlip Pull lever shaft Oil seal Bearing Bearing 5-52...
  • Page 336 CLUTCH Removing the clutch 125 N ・ m (12.5 kgf ・ m, 90 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Pressure plate 1 Compression spring Pressure plate 2 Pull rod Bearing Press the bearing into pressure plate 2.

  • Page 337: Removing The Clutch

    CLUTCH • Friction plates 2 EAS30346 REMOVING THE CLUTCH • Clutch damper spring 1. Remove: • Clutch damper spring seat • Clutch cover “1” • Gasket Loosen each bolt 1/4 of a turn at a time, in stag- es and in a crisscross pattern. After all of the bolts are fully loosened, remove them.

  • Page 338: Checking The Friction Plates

    CLUTCH • Thrust plate Thickness gauge • Clutch housing assembly 90890-03180 • Bearing Feeler gauge set • Washer YU-26900-9 EAS30348 CHECKING THE FRICTION PLATES Clutch plate 1 thickness The following procedure applies to all of the fric- 2.46–2.74 mm (0.097–0.108 in) tion plates.

  • Page 339: Checking The Clutch Springs

    CLUTCH b. Select the clutch plate from the following ta- EAS30352 CHECKING THE CLUTCH HOUSING ble. 1. Check: • Clutch housing dogs Clutch plate “1” Damage/pitting/wear  Deburr the clutch Part No. Thickness housing dogs or replace the clutch housing. 2CR-16325-10 2.0 mm (0.079 in) Pitting on the clutch housing dogs will cause er-...

  • Page 340: Checking The Primary Drive Gear

    CLUTCH 2. Check: EAS30356 CHECKING THE PRIMARY DRIVE GEAR • Pull rod bearing 1. Check: Damage/wear  Replace. • Primary drive gear Damage/wear  Replace the crankshaft and EAS30363 INSTALLING THE CLUTCH clutch housing as a set. Excessive noise during operation  Replace After assembling the clutch assembly, the noise the crankshaft and clutch housing as a set.
  • Page 341 CLUTCH 2. Install: 3. Lubricate: • Thrust plate • Friction plates • Clutch boss “1” • Clutch plates • Conical spring washer “2” (with the recommended lubricant) • Clutch boss nut “3” Recommended lubricant Engine oil Clutch boss nut 125 N·m (12.5 kgf·m, 90 lb·ft) 4.
  • Page 342 CLUTCH shaft pinion gear are engaged. • Tighten the clutch spring bolts in stages and in a crisscross pattern. • Apply lithium-soap-based grease onto the pull rod. • Position the pull rod so that the teeth “a” face towards the rear of the vehicle. Then, install the clutch cover.

  • Page 343: Shift Shaft

    SHIFT SHAFT EAS20057 SHIFT SHAFT Removing the shift shaft and stopper lever 22 N ・ m (2.2 kgf ・ m, 16 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Clutch assembly Refer to “CLUTCH” on page 5-51. Shift arm Refer to “CHAIN DRIVE”...

  • Page 344: Checking The Shift Shaft

    SHIFT SHAFT ment assembly. EAS30377 CHECKING THE SHIFT SHAFT 1. Check: • Shift shaft “1” Bends/damage/wear  Replace. • Shift shaft spring “2” • Collar Damage/wear  Replace. 2. Install: • Bearing • Oil seal • Washer “1” • Circlip “2” •...

  • Page 345: Crankcase

    CRANKCASE EAS20059 CRANKCASE Removing the crankcase breather cover and switches 12 N ・ m (1.2 kgf ・ m, 8.7 lb ・ ft) 17 N ・ m (1.7 kgf ・ m, 12 lb ・ ft) 70 N ・ m (7.0 kgf ・ m, 51 lb ・ ft) 17 N ・...
  • Page 346 CRANKCASE Removing the crankcase breather cover and switches 12 N ・ m (1.2 kgf ・ m, 8.7 lb ・ ft) 17 N ・ m (1.7 kgf ・ m, 12 lb ・ ft) 70 N ・ m (7.0 kgf ・ m, 51 lb ・ ft) 17 N ・...
  • Page 347 CRANKCASE Separating the crankcase 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) 20 N ・ m (2.0 kgf ・ m, 14 lb ・ ft) 15 N ・ m (1.5 kgf ・ m, 11 lb ・ ft) 24 N ・...

  • Page 348: Disassembling The Crankcase

    Recommended lubricant Engine oil 2. Apply: • Sealant (onto the crankcase mating surfaces) Yamaha bond No. 1215 90890-85505 (Three bond No.1215®) • Do not allow any sealant to come into contact with the oil gallery or crankshaft journal bear- ings, or balancer shaft journal bearings.
  • Page 349 CRANKCASE • Lubricate the bolts “28”, “40” mating surfaces with engine oil. • Apply the bolts “28”, “40” thread with LOC- TITE®. • M9  100 mm (3.94 in) bolts with washers: “1”–“10” • M8  58 mm (2.28 in) bolts with new O-rings: “11”–“18”...

  • Page 350: Installing The Oil Pressure Switch

    CRANKCASE tighten it. Instead, replace the bolt with a new one and perform the procedure again. ECA20890 NOTICE Do not use a torque wrench to tighten the bolt to the specified angle. Tighten the bolts in the tightening sequence cast on the crankcase.

  • Page 351: Installing The Gear Position Sensor

    CRANKCASE 53˚ EAS31658 INSTALLING THE GEAR POSITION SENSOR ECA22630 NOTICE To prevent damage to the gear position sen- sor, keep magnets (including any pickup tool with a magnet, magnetized screwdrivers, etc.) away from the gear position sensor. 1. Install: • O-ring •...
  • Page 352 CONNECTING RODS AND PISTONS EAS20132 CONNECTING RODS AND PISTONS Removing the connecting rods and pistons 24 N ・ m (2.4 kgf ・ m, 17 lb ・ ft) Specified angle 150˚ Order Job/Parts to remove Q’ty Remarks Lower crankcase Refer to “CRANKCASE” on page 5-62. Connecting rod cap Big end lower bearing Big end upper bearing...

  • Page 353: Connecting Rods And Pistons

    CONNECTING RODS AND PISTONS EAS30745 REMOVING THE CONNECTING RODS AND PISTONS The following procedure applies to all of the con- necting rods and pistons. 1. Remove: • Connecting rod cap “1” • Connecting rod • Big end bearings • Identify the position of each big end bearing so that it can be reinstalled in its original place.

  • Page 354: Checking The Piston Rings

    CONNECTING RODS AND PISTONS Measure cylinder bore “C” by taking side-to-side and front-to-back measurements of the cylinder. Bore 79.000–79.010 mm (3.1102– 3.1106 in) Taper limit 0.008 mm (0.0003 in) Out of round limit 0.050 mm (0.0020 in) a. 8.0 mm (0.31 in) from the bottom edge of the piston “C”...

  • Page 355: Checking The Piston Pin

    CONNECTING RODS AND PISTONS 1. Measure: • Piston pin outside diameter “a” Out of specification  Replace the piston pin. Piston pin outside diameter 16.991–17.000 mm (0.6689– 0.6693 in) Limit 16.971 mm (0.6681 in) 2. Install: • Piston ring (into the cylinder) Use the piston crown to level the piston ring near bottom of cylinder “a”, where cylinder wear is lowest.

  • Page 356: Checking The Connecting Rods

    CONNECTING RODS AND PISTONS d. Assemble the connecting rod halves. EAS30750 CHECKING THE CONNECTING RODS ECA18390 1. Measure: NOTICE • Crankshaft-pin-to-big-end-bearing clearance Tighten the connecting rod bolts using the Out of specification  Replace the big end plastic-region tightening angle method. Al- bearings.
  • Page 357 CONNECTING RODS AND PISTONS Connecting rod bolt (1st) 24 N·m (2.4 kgf·m, 17 lb·ft) h. Put a mark “1” on the corner of the connecting rod bolt “2” and the connecting rod cap “3”. a. Side machined face b. Thrusting faces f.

  • Page 358: Installing The Connecting Rod And Piston

    CONNECTING RODS AND PISTONS Bearing color code Code 2 Black Code 3 Brown Code 4 Green Code 5 Yellow Code 6 Pink k. Remove the connecting rod and big end bearings. l. Measure the compressed Plastigauge® width on the crankshaft pin. If the crankshaft- pin-to-big-end-bearing clearance is out of specification, select replacement big end bearings.
  • Page 359 CONNECTING RODS AND PISTONS Connecting rod bolt • Be sure to reinstall each big end bearing in its 30 N·m (3.0 kgf·m, 22 lb·ft) original place. • Align the projections “a” on the big end bear- ings with the notches “b” in the connecting rods To install the connecting rod cap, care should be and connecting rod caps.
  • Page 360 CONNECTING RODS AND PISTONS • Apply engine oil onto the piston pin. • Make sure that the “Y” mark “a” on the connect- ing rod faces left when the punch mark “b” on the piston is pointing up as shown. •...
  • Page 361 CONNECTING RODS AND PISTONS • Make sure the “Y” marks “a” on the connecting rods face towards the left side of the crank- shaft. • Make sure that the projection “b” on the con- necting rod cap faces the same direction as the “Y”...
  • Page 362 CONNECTING RODS AND PISTONS ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 5-79...

  • Page 363: Crankshaft And Balancer Shaft

    CRANKSHAFT AND BALANCER SHAFT EAS20178 CRANKSHAFT AND BALANCER SHAFT Removing the crankshaft and balancer shaft 3.0 N ・ m (0.30 kgf ・ m, 2.2 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) Order Job/Parts to remove Q’ty Remarks...

  • Page 364: Removing The Crankshaft And Balancer Shaft

    CRANKSHAFT AND BALANCER SHAFT EAS31171 REMOVING THE CRANKSHAFT AND BALANCER SHAFT 1. Remove: • Balancer shaft “1” • Balancer shaft journal bearing • Crankshaft assembly “2” • Crankshaft journal bearings Identify the position of each balancer shaft jour- nal bearings and crankshaft journal bearings so 2.
  • Page 365 CRANKSHAFT AND BALANCER SHAFT If the crankshaft-journal-to-crankshaft-jour- nal-bearing clearance is out of specification, select replacement crankshaft journal bear- ings. d. Put a piece of Plastigauge® “1” on each crankshaft journal. Do not put the Plastigauge® over the oil hole in the crankshaft journal.

  • Page 366: Checking The Balancer Shaft

    CRANKSHAFT AND BALANCER SHAFT Scratches/wear  Replace the balancer shaft. • Bearing surfaces Scratches/wear  Replace the balancer shaft journal bearing. 3. Measure: • Balancer shaft journal-to-balancer shaft jour- nal bearing clearance Out of specification  Replace the balancer shaft journal bearings. Balancer shaft journal to balancer shaft bearing clearance 0.028–0.046 mm (0.0011–0.0018...
  • Page 367 CRANKSHAFT AND BALANCER SHAFT 4. Select: • Balancer shaft journal bearing (J –J • The numbers “A” stamped into the balancer shaft web and the numbers “B” stamped into the lower crankcase are used to determine the replacement balancer shaft journal bearing siz- •...

  • Page 368: Installing The Crankshaft

    CRANKSHAFT AND BALANCER SHAFT ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ EAS31077 INSTALLING THE CRANKSHAFT a. Insert the thrust bearing “1” into the slot of the 1. Install: upper crankcase as shown in the illustration • Crankshaft journal upper bearings and slide it in the direction of the arrow. (into the upper crankcase) •...

  • Page 369: Installing The Balancer Assembly

    CRANKSHAFT AND BALANCER SHAFT ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS31172 INSTALLING THE BALANCER ASSEMBLY 1. Install: • Balancer shaft journal upper bearings (into the upper crankcase) • Balancer shaft journal lower bearings (into the lower crankcase) • Align the projections “a” on the balancer shaft journal bearings “1”...

  • Page 370: Transmission

    TRANSMISSION EAS20062 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks 12 N ・ m (1.2 kgf ・ m, 8.7 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) Order Job/Parts to remove Q’ty...
  • Page 371 TRANSMISSION Disassembling the main axle assembly Order Job/Parts to remove Q’ty Remarks Make sure the chamfered side of the pinion 2nd pinion gear gear faces to the left. Toothed lock washer Toothed lock washer retainer 6th pinion gear Collar Washer Circlip 3rd pinion gear Circlip...
  • Page 372 TRANSMISSION Disassembling the drive axle assembly Order Job/Parts to remove Q’ty Remarks Circlip Bearing Washer 1st wheel gear Collar 5th wheel gear Circlip Washer 3rd wheel gear Collar Toothed lock washer Toothed lock washer retainer 4th wheel gear Collar Washer Circlip 6th wheel gear Circlip...
  • Page 373 TRANSMISSION Disassembling the drive axle assembly Order Job/Parts to remove Q’ty Remarks Washer 2nd wheel gear Collar Collar Oil seal Circlip Bearing Drive axle 5-90...

  • Page 374: Removing The Transmission

    TRANSMISSION EAS30430 REMOVING THE TRANSMISSION 1. Remove: • Drive axle assembly “1” • Shift drum retainers “2” • Shift fork guide bars • Shift fork-L • Shift fork-R • Shift drum assembly • Shift fork-C EAS30431 CHECKING THE SHIFT FORKS The following procedure applies to all of the shift forks.

  • Page 375: Checking The Shift Drum Assembly

    TRANSMISSION Out of specification  Replace the drive axle. Drive axle runout limit 0.08 mm (0.0032 in) EAS30432 CHECKING THE SHIFT DRUM ASSEMBLY 1. Check: • Shift drum groove Damage/scratches/wear  Replace the shift drum assembly. • Shift drum segment “1” 3.

  • Page 376: Installing The Transmission

    TRANSMISSION • Be sure the circlip sharp-edged corner “a” is positioned opposite side to the toothed washer and gear. • Install the circlip so that a spline “b” is in the center of the gap between the circlip ends “c” as shown.
  • Page 377 TRANSMISSION • Oil seal 3. Install: • Shift fork-C “1” • Circlip “4” • Shift drum assembly “2” • Drive axle assembly “5” • Shift fork guide bar “3” Shift drum retainer bolt 10 N·m (1.0 kgf·m, 7.2 lb·ft) • The embossed marks on the shift forks should LOCTITE®...
  • Page 378 TRANSMISSION 5-95...
  • Page 379 COOLING SYSTEM RADIATOR......................6-1 REMOVING THE RADIATOR ..............6-2 CHECKING THE RADIATOR..............6-2 INSTALLING THE RADIATOR..............6-3 OIL COOLER....................6-4 CHECKING THE OIL COOLER ..............6-5 INSTALLING THE OIL COOLER ...............6-5 THERMOSTAT....................6-6 REMOVING THE THERMOSTAT ASSEMBLY..........6-7 CHECKING THE THERMOSTAT...............6-7 ASSEMBLING THE THERMOSTAT ASSEMBLY........6-7 INSTALLING THE THERMOSTAT ASSEMBLY ........6-7 WATER PUMP ....................6-9 DISASSEMBLING THE WATER PUMP...........6-11 CHECKING THE WATER PUMP .............6-11...

  • Page 380: Cooling System

    RADIATOR EAS20063 RADIATOR Removing the radiator 1.0 N ・ m (0.10 kgf ・ m, 0.72 lb ・ ft) 8 N ・ m (0.8 kgf ・ m, 5.8 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) 8 N ・...

  • Page 381: Removing The Radiator

    RADIATOR EAS31659 REMOVING THE RADIATOR 1. Remove: • Hose clamp (Clic-R) “1” • Remove the hose clamp using the hose clamp pliers “2”. • When removing the hose clamp, make sure that the thick tip “a” of the hose clamp pliers is directed as shown in the illustration.

  • Page 382: Installing The Radiator

    RADIATOR EAS30440 INSTALLING THE RADIATOR Radiator cap tester 90890-01325 1. Install: Mityvac cooling system tester kit • Radiator YU-24460-A 2. Connect: Radiator cap tester adapter • Radiator inlet hose 90890-01352 • Radiator outlet hose Pressure tester adapter 3. Install: YU-33984 •...

  • Page 383: Oil Cooler

    OIL COOLER EAS20064 OIL COOLER Removing the oil cooler 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) 10 N ・...

  • Page 384: Checking The Oil Cooler

    OIL COOLER EAS30441 CHECKING THE OIL COOLER 1. Check: • Oil cooler Cracks/damage  Replace. • Oil cooler fins Obstruction  Clean. Apply compressed air to the rear of the oil cooler. Damage  Repair or replace. Straighten any flattened fins with a thin, flat-head screwdriver.

  • Page 385: Thermostat

    THERMOSTAT EAS20065 THERMOSTAT Removing the thermostat 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) Order Job/Parts to remove Q’ty...

  • Page 386: Removing The Thermostat Assembly

    THERMOSTAT EAS31660 REMOVING THE THERMOSTAT ASSEMBLY 1. Remove: • Hose clamp (Clic-R) Refer to “REMOVING THE RADIATOR” on page 6-2. • Radiator inlet hose 2. Remove: • Thermostat assembly 159.8 EAS30443 CHECKING THE THERMOSTAT A. Fully closed 1. Check: B. Fully open •...
  • Page 387 THERMOSTAT 2. Install: • Radiator inlet hose • Hose clamp (Clic-R) Refer to “INSTALLING THE RADIATOR” on page 6-3. For more information about installing the hose, refer to “CABLE ROUTING” on page 2-39. 3. Fill: • Cooling system (with the specified amount of the recom- mended coolant) Refer to “CHANGING THE COOLANT”...

  • Page 388: Water Pump

    WATER PUMP EAS20066 WATER PUMP Removing the water pump 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) 10 N ・...
  • Page 389 WATER PUMP Disassembling the water pump 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Water pump housing cover O-ring Circlip Impeller shaft...

  • Page 390: Disassembling The Water Pump

    WATER PUMP EAS30446 EAS30447 DISASSEMBLING THE WATER PUMP CHECKING THE WATER PUMP 1. Remove: 1. Check: • Mechanical seal (housing side) “1” • Water pump housing cover “1” • Impeller shaft “2” Cracks/damage/wear  Replace. Remove the mechanical seal (housing side) •...

  • Page 391: Installing The Water Pump

    WATER PUMP 4. Measure: ECA20330 NOTICE • Impeller shaft tilt Never lubricate the mechanical seal (hous- Out of specification  Repeat steps (3) and ing side) surface with oil or grease. (4). ECA20340 NOTICE Use the special tools and a press to press the Make sure the mechanical seal (impeller mechanical seal (housing side) straight in until it side) is flush with the impeller.
  • Page 392 WATER PUMP 4. Measure: • Radiator cap valve opening pressure Below the specified pressure  Replace the radiator cap. Refer to “CHECKING THE RADIATOR” on page 6-2. 6-13...

  • Page 393: Fuel System

    FUEL SYSTEM FUEL TANK ......................7-1 REMOVING THE FUEL TANK ..............7-3 REMOVING THE FUEL PUMP ..............7-3 CHECKING THE FUEL PUMP BODY............7-3 CHECKING THE FUEL PUMP OPERATION..........7-3 INSTALLING THE FUEL PUMP..............7-4 INSTALLING THE FUEL TANK..............7-4 THROTTLE BODIES ..................7-5 CHECKING THE INJECTORS (BEFORE REMOVING) ......7-8 REMOVING THE FUEL HOSE (FUEL RAIL SIDE) ........7-8 REMOVING THE INJECTORS ..............7-8 CHECKING THE INJECTORS ..............7-8...
  • Page 394 FUEL TANK EAS20067 FUEL TANK Removing the fuel tank 4.0 N ・ m (0.40 kgf ・ m, 2.9 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) 4.0 N ・...
  • Page 395 FUEL TANK Removing the rollover valve and canister 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS (1)” on page Rider seat/Air scoop/Air scoop stay 4-1. Refer to “GENERAL CHASSIS (2)” on page Fuel tank cover 4-13.

  • Page 396: Fuel Tank

    FUEL TANK EAS30450 REMOVING THE FUEL TANK 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. 2. Remove: • Rider seat • Air scoop/Air scoop stay Refer to “GENERAL CHASSIS (1)” on page 4-1.

  • Page 397: Installing The Fuel Pump

    FUEL TANK EAS30456 INSTALLING THE FUEL PUMP • Install the fuel hose onto the fuel pump secure- 1. Install: ly, and slide the fuel hose connector cover “1” • Fuel pump gasket in the direction shown in the illustration. • Fuel pump •...

  • Page 398: Throttle Bodies

    THROTTLE BODIES EAS20070 THROTTLE BODIES Removing the throttle bodies F W F W 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) 3.0 N ・ m (0.30 kgf ・ m, 2.2 lb ・ ft) 4.5 N ・ m (0.45 kgf ・ m, 3.3 lb ・ ft) Order Job/Parts to remove Q’ty...
  • Page 399 THROTTLE BODIES Removing the throttle bodies F W F W 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) 3.0 N ・ m (0.30 kgf ・ m, 2.2 lb ・ ft) 4.5 N ・ m (0.45 kgf ・ m, 3.3 lb ・ ft) Order Job/Parts to remove Q’ty...
  • Page 400 THROTTLE BODIES Removing the sensors 3.5 N ・ m (0.35 kgf ・ m, 2.5 lb ・ ft) 3.5 N ・ m (0.35 kgf ・ m, 2.5 lb ・ ft) 0.28 N ・ m (0.028 kgf ・ m, 0.207 lb ・ ft) 3.5 N ・...

  • Page 401: Checking The Injectors (Before Removing)

    THROTTLE BODIES EAS30475 EAS30476 CHECKING THE INJECTORS (BEFORE REMOVING THE INJECTORS REMOVING) EWA17330 WARNING 1. Check: • Check the injectors in a well-ventilated area • Injectors free of combustible materials. Make sure Use the diagnostic code numbers “36”–“39”. that there is no smoking or use of electric Refer to “SELF-DIAGNOSTIC FUNCTION tools in the vicinity of the injectors.
  • Page 402 Apply the recommended cleaning solvent to Recommended cleaning solvent the throttle valves and the inside of the throt- Yamaha Oil & Brake Cleaner tle bodies to remove any carbon deposits. • Do not allow any cleaning solvent to enter the opening for the injectors.

  • Page 403: Replacing The Throttle Bodies

    THROTTLE BODIES AND DIAGNOSTIC CODE TABLE” on page ECA17590 NOTICE 9-5. • Do not use a tool, such as a wire brush, to 4. Adjust: remove the carbon deposits; otherwise, the • Throttle bodies synchronizing inside of the throttle bodies may be dam- Refer to “SYNCHRONIZING THE THROT- aged.

  • Page 404: Checking The Injector Pressure

    THROTTLE BODIES e. Open the valve on the injector pressure adapter until the specified pressure is reached. Specified air pressure 490 kPa (5.0 kgf/cm², 71.1 psi) ECA17600 NOTICE Never exceed the specified air pressure or damage could occur. 5. Check the injector pressure after the injectors f.

  • Page 405: Installing The Fuel Hose (Fuel Rail Side)

    THROTTLE BODIES EAS31159 INSTALLING THE FUEL HOSE (FUEL RAIL SIDE) 1. Connect: • Fuel hose (fuel rail side) ECA17500 NOTICE When installing the fuel hose, make sure that it is securely connected, and that the fuel hose connector cover on the fuel hose is in the correct position, otherwise the fuel hose c.

  • Page 406: Adjusting The Accelerator Position Sensor

    OPERATION TABLE” on page 9-16. d. Remove the protective cap “1”, and then con- 2. Adjust: nect the Yamaha diagnostic tool to coupler. • Accelerator position sensor angle For information about using the Yamaha diag- Before adjusting the accelerator position sensor, nostic tool, refer to the operation manual that is the throttle bodies must be removed.
  • Page 407 If the Yamaha diagnostic tool screen value is not 94–109, adjust the accelerator position sensor angle. q. Repeat steps (f) to (p) until the Yamaha diag- nostic tool screen values are within the spec- ified ranges. r. If the Yamaha diagnostic tool screen values...

  • Page 408: Air Induction System

    AIR INDUCTION SYSTEM EAS20071 AIR INDUCTION SYSTEM 7-15...
  • Page 409 AIR INDUCTION SYSTEM 1. Air filter case 2. Cylinder head cover 3. Air cut-off valve 4. Air induction system hose (air filter case to air cut-off valve) 5. Air induction system hose (air cut-off valve to reed valve cover) 7-16...
  • Page 410 AIR INDUCTION SYSTEM Removing the air cut-off valve assembly and reed valves 0.3 N ・ m (0.03 kgf ・ m, 0.22 lb ・ ft) 9 N ・ m (0.9 kgf ・ m, 6.5 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) Order Job/Parts to remove Q’ty...
  • Page 411 AIR INDUCTION SYSTEM Removing the air cut-off valve assembly and reed valves 0.3 N ・ m (0.03 kgf ・ m, 0.22 lb ・ ft) 9 N ・ m (0.9 kgf ・ m, 6.5 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) Order Job/Parts to remove Q’ty...

  • Page 412: Checking The Air Induction System

    AIR INDUCTION SYSTEM EAS30488 CHECKING THE AIR INDUCTION SYSTEM Air injection The air induction system burns unburned ex- haust gases by injecting fresh air (secondary air) into the exhaust port, reducing the emission of hydrocarbons. When there is negative pressure at the exhaust port, the reed valve opens, allow- ing secondary air to flow into the exhaust port.

  • Page 413: Installing The Air Induction System

    AIR INDUCTION SYSTEM 3. Install: • Reed valve cover Reed valve cover bolt 10 N·m (1.0 kgf·m, 7.2 lb·ft) LOCTITE® 4. Check: • Air cut-off valve Cracks/damage  Replace. 5. Check: • Air induction system solenoid Refer to “CHECKING THE AIR INDUCTION SYSTEM SOLENOID”...
  • Page 414 AIR INDUCTION SYSTEM 7-21...

  • Page 415: Electrical System

    CIRCUIT DIAGRAM .................8-29 TROUBLESHOOTING ................8-31 FUEL INJECTION SYSTEM................8-33 CIRCUIT DIAGRAM .................8-33 ECU SELF-DIAGNOSTIC FUNCTION.............8-35 TROUBLESHOOTING METHOD.............8-35 YAMAHA DIAGNOSTIC TOOL ..............8-36 TROUBLESHOOTING DETAILS (FAULT CODE) ........8-37 CRUISE CONTROL SYSTEM ..............8-123 CIRCUIT DIAGRAM ................8-123 CRUISE CONTROL CIRCUIT OPERATION..........8-125 BASIC INSTRUCTIONS FOR TROUBLESHOOTING ......8-127 BASIC PROCESS FOR TROUBLESHOOTING ........8-127...

  • Page 416: General Information

    FUEL PUMP SYSTEM..................8-139 CIRCUIT DIAGRAM ................8-139 TROUBLESHOOTING ................8-141 IMMOBILIZER SYSTEM................8-143 CIRCUIT DIAGRAM ................8-143 GENERAL INFORMATION ..............8-145 PARTS REPLACEMENT AND KEY CODE REGISTRATION REQUIREMENTS..................8-145 TROUBLESHOOTING ................8-149 SELF-DIAGNOSIS FAULT CODE INDICATION........8-150 ABS (Anti-lock Brake System) ..............8-153 CIRCUIT DIAGRAM ................8-153 ABS COMPONENTS CHART ..............8-155 ABS COUPLER LOCATION CHART .............8-157 MAINTENANCE OF THE ABS ECU ............8-159 ABS TROUBLESHOOTING OUTLINE...........8-159...
  • Page 417 CHECKING THE STARTER MOTOR OPERATION ......8-202 CHECKING THE STATOR COIL ............8-202 CHECKING THE RECTIFIER/REGULATOR .........8-202 CHECKING THE HORN.................8-203 CHECKING THE FUEL SENDER ............8-203 CHECKING THE FUEL METER/FUEL LEVEL WARNING LIGHT ..8-204 CHECKING THE RADIATOR FAN MOTORS........8-204 CHECKING THE COOLANT TEMPERATURE SENSOR......8-204 CHECKING THE THROTTLE SERVO MOTOR ........8-205 CHECKING THE AIR INDUCTION SYSTEM SOLENOID .....8-206 CHECKING THE CYLINDER IDENTIFICATION SENSOR ....8-206...

  • Page 418: Ignition System

    IGNITION SYSTEM EAS20072 IGNITION SYSTEM EAS30490 CIRCUIT DIAGRAM...
  • Page 419 IGNITION SYSTEM 3. Main switch 4. Main fuse 9. Backup fuse 12.Ignition fuse 18.Battery 19.Engine ground 27.Relay unit 33.Handlebar switch (right) 35.Start/engine stop switch 37.Neutral switch 38.Sidestand switch 41.Joint connector 42.Joint coupler 44.Cylinder identification sensor 48.Crankshaft position sensor 52.Lean angle sensor 54.ECU (Engine Control Unit) 55.Ignition coil #1 56.Ignition coil #2...

  • Page 420: Engine Stopping Due To Sidestand Operation

    IGNITION SYSTEM EAS30491 ENGINE STOPPING DUE TO SIDESTAND OPERATION When the engine is running and the transmission is in gear, the engine will stop if the sidestand is moved down. This is because the electric current from the ECU does not flow to the ignition coils or fuel injectors when the neutral switch or sidestand switch is open.

  • Page 421: Troubleshooting

    IGNITION SYSTEM EAS30492 TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). • Before troubleshooting, remove the following part(s): 1. Rider seat/Air scoop/Air scoop stay/Side cover 2. Fuel tank cover 3. Fuel tank 4. Air filter case 1.
  • Page 422 IGNITION SYSTEM 9. Check the start/engine stop switch. Refer to “CHECKING THE Replace the right handlebar switch. NG SWITCHES” on page 8-191. OK 10.Check the neutral switch. Refer to “CHECKING THE Replace the neutral switch. NG SWITCHES” on page 8-191. OK...
  • Page 423 IGNITION SYSTEM...

  • Page 424: Electric Starting System

    ELECTRIC STARTING SYSTEM EAS20073 ELECTRIC STARTING SYSTEM EAS30493 CIRCUIT DIAGRAM...
  • Page 425 ELECTRIC STARTING SYSTEM 3. Main switch 4. Main fuse 9. Backup fuse 12.Ignition fuse 18.Battery 19.Engine ground 21.Starter relay 22.Starter motor 27.Relay unit 28.Starting circuit cut-off relay 30.Clutch switch 33.Handlebar switch (right) 35.Start/engine stop switch 37.Neutral switch 38.Sidestand switch 41.Joint connector 42.Joint coupler 54.ECU (Engine Control Unit)

  • Page 426: Starting Circuit Cut-Off System Operation

    ELECTRIC STARTING SYSTEM EAS30494 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the main switch is turned to “ON” and the “ ” side of the start/engine stop switch is pushed, the starter motor can only operate if at least one of the following conditions is met: •...

  • Page 427: Troubleshooting

    ELECTRIC STARTING SYSTEM EAS30495 TROUBLESHOOTING The starter motor fails to turn. • Before troubleshooting, remove the following part(s): 1. Rider seat/Air scoop/Air scoop stay/Side cover 2. Fuel tank cover 3. Fuel tank 4. Air filter case 5. Canister 6. Throttle bodies 1.
  • Page 428 ELECTRIC STARTING SYSTEM 9. Check the neutral switch. Refer to “CHECKING THE Replace the neutral switch. NG SWITCHES” on page 8-191. OK 10.Check the sidestand switch. Refer to “CHECKING THE Replace the sidestand switch. NG SWITCHES” on page 8-191. OK 11.Check the clutch switch.
  • Page 429 ELECTRIC STARTING SYSTEM 8-12...

  • Page 430: Charging System

    CHARGING SYSTEM EAS20074 CHARGING SYSTEM EAS30496 CIRCUIT DIAGRAM 8-13...
  • Page 431 CHARGING SYSTEM 1. AC magneto 2. Rectifier/regulator 4. Main fuse 18.Battery 19.Engine ground 8-14...

  • Page 432: Troubleshooting

    CHARGING SYSTEM EAS30497 TROUBLESHOOTING The battery is not being charged. • Before troubleshooting, remove the following part(s): 1. Rider seat 1. Check the fuse. (Main) Replace the fuse. Refer to “CHECKING THE FUSES” NG on page 8-194. OK 2. Check the battery. •...
  • Page 433 CHARGING SYSTEM 8-16...

  • Page 434: Lighting System

    LIGHTING SYSTEM EAS20075 LIGHTING SYSTEM EAS30498 CIRCUIT DIAGRAM 8-17...
  • Page 435 LIGHTING SYSTEM 3. Main switch 4. Main fuse 9. Backup fuse 12.Ignition fuse 13.Signaling system fuse 15.Headlight fuse 18.Battery 19.Engine ground 41.Joint connector 42.Joint coupler 54.ECU (Engine Control Unit) 74.Meter assembly 80.Multi-function meter 88.High beam indicator light 89.Meter light 92.Handlebar switch (left) 95.Dimmer/pass switch 105.Headlight control unit 106.Headlight (high beam)

  • Page 436: Troubleshooting

    LIGHTING SYSTEM EAS30499 TROUBLESHOOTING Any of the following fail to light: headlight, auxiliary light, high beam indicator light, tail/brake light, li- cense plate light or meter light. • Before troubleshooting, remove the following part(s): 1. Rider seat/Air scoop/Air scoop stay/Side cover 2.
  • Page 437 LIGHTING SYSTEM 8-20...

  • Page 438: Signaling System

    SIGNALING SYSTEM EAS20076 SIGNALING SYSTEM EAS30500 CIRCUIT DIAGRAM 8-21...
  • Page 439 SIGNALING SYSTEM 3. Main switch 4. Main fuse 9. Backup fuse 12.Ignition fuse 13.Signaling system fuse 14.ABS ECU fuse 16.Hazard lighting fuse 18.Battery 19.Engine ground 23.Brake light fuse 27.Relay unit 31.Front brake light switch 32.Rear brake light switch 33.Handlebar switch (right) 36.Hazard switch 37.Neutral switch 39.Fuel sender...

  • Page 440: Troubleshooting

    SIGNALING SYSTEM EAS30501 TROUBLESHOOTING • Any of the following fail to light: turn signal light, brake light or an indicator light. • The horn fails to sound. • The fuel meter fails to come on. • The speedometer fails to operate. •...
  • Page 441 SIGNALING SYSTEM 2. Check the horn. Refer to “CHECKING THE HORN” Replace the horn. NG on page 8-203. OK 3. Check the entire signaling system’s wiring. Properly connect or repair the signaling Refer to “CIRCUIT DIAGRAM” on system’s wiring. NG page 8-21.
  • Page 442 SIGNALING SYSTEM The neutral indicator light fails to come on. 1. Check the neutral switch. Refer to “CHECKING THE Replace the neutral switch. NG SWITCHES” on page 8-191. OK 2. Check the relay unit (diode). Refer to “CHECKING THE RELAY Replace the relay unit.
  • Page 443 SIGNALING SYSTEM The fuel meter, fuel level warning light, or both fail to come on. 1. Check the fuel sender. Refer to “CHECKING THE FUEL Replace the fuel pump assembly. NG SENDER” on page 8-203. OK 2. Check the entire signaling system’s wiring.
  • Page 444 SIGNALING SYSTEM 5. Check the shift switch. Refer to “DIAGNOSTIC CODE: SENSOR OPERATION TABLE” on Replace the shift switch. NG page 9-16 and “CHECKING THE SWITCHES” on page 8-191. OK 6. Check the neutral switch. Refer to “DIAGNOSTIC CODE: SENSOR OPERATION TABLE” on Replace the neutral switch.
  • Page 445 SIGNALING SYSTEM • Between joint coupler and ECU coupler. (blue/white–blue/white) (blue/black–blue/black) • Between joint coupler and meter assembly coupler. (blue/white–blue/white) (blue/black–blue/black) 8-28...

  • Page 446: Cooling System

    COOLING SYSTEM EAS20077 COOLING SYSTEM EAS30502 CIRCUIT DIAGRAM 8-29...
  • Page 447 COOLING SYSTEM 3. Main switch 4. Main fuse 5. Radiator fan motor relay 9. Backup fuse 10.Sub radiator fan motor fuse 11.Radiator fan motor fuse 12.Ignition fuse 18.Battery 19.Engine ground 41.Joint connector 49.Coolant temperature sensor 54.ECU (Engine Control Unit) 112.Radiator fan motor (left) 113.Sub radiator fan motor (right) A.

  • Page 448: Troubleshooting

    COOLING SYSTEM EAS30503 TROUBLESHOOTING • Before troubleshooting, remove the following part(s): 1. Rider seat/Air scoop/Air scoop stay/Side cover 2. Fuel tank cover 3. Fuel tank 4. Air filter case 5. Canister 6. Throttle bodies 1. Check the fuses. (Main, ignition, backup, radiator fan motor and sub radiator fan motor) Replace the fuse(s).
  • Page 449 COOLING SYSTEM 8-32...

  • Page 450: Fuel Injection System

    FUEL INJECTION SYSTEM EAS20078 FUEL INJECTION SYSTEM EAS30504 CIRCUIT DIAGRAM 8-33...
  • Page 451 FUEL INJECTION SYSTEM 73.Yamaha diagnostic tool coupler 3. Main switch 74.Meter assembly 4. Main fuse 76.Steering damper warning light 5. Radiator fan motor relay 80.Multi-function meter 7. Fuel injection system fuse 81.Traction control system indicator light 8. Electronic throttle valve fuse 83.Engine trouble warning light...

  • Page 452: Ecu Self-Diagnostic Function

    • Fault code number ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Check the fault code numbers that have a condition of “Detected” using the Yamaha diagnostic tool. b. Identify the faulty system with the fault code number. c. Identify the probable cause of the malfunction.

  • Page 453: Yamaha Diagnostic Tool

    EAS30951 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. Yamaha diagnostic tool 90890-03250 A generic scan tool can also be used to identify malfunctions.

  • Page 454: Troubleshooting Details (Fault Code)

    Write the VIN/frame number in the ECU. View logs: Displays the logging data. However, the Yamaha diagnostic tool cannot be used to freely change the basic vehicle functions, such as adjusting the ignition timing. Connecting the Yamaha diagnostic tool Remove the protective cap “1”, and then connect the Yamaha diagnostic tool to the coupler.
  • Page 455 FUEL INJECTION SYSTEM • Ignition coil #3 • Relay unit • Ignition coil #4 • Brake light relay • Throttle position sensor • Radiator fan motor relay • Accelerator position sensor • Meter assembly • Intake air pressure sensor • Immobilizer unit •...
  • Page 456 Check the locking condition of function mode of the Yamaha the coupler. diagnostic tool. Disconnect the coupler and Condition is “Recovered”  Go check the pins (bent or broken to item 6 and finish the service.
  • Page 457 1. Turn the main switch to “ON”, and then check the condition of the fault code using the mal- function mode of the Yamaha diagnostic tool. Condition is “Recovered”  Go to item 6 and finish the service. Condition is “Detected”  Start the engine, and then check the condition of the fault code.
  • Page 458 Check the locking condition of function mode of the Yamaha the coupler. diagnostic tool. Disconnect the coupler and Condition is “Recovered”  Go check the pins (bent or broken to item 6 and finish the service.
  • Page 459 Between O sensor 2 coupler function mode of the Yamaha diagnostic tool. and ECU coupler. Condition is “Recovered”  Go pink/white–pink/white to item 6 and finish the service.
  • Page 460 When engine is stopped: Atmo- the fault code using the mal- spheric pressure at the current function mode of the Yamaha altitude and weather conditions diagnostic tool. Condition is “Recovered”  Go is indicated.
  • Page 461 Check the locking condition of replace the wire harness. the fault code using the mal- the coupler. function mode of the Yamaha Disconnect the coupler and diagnostic tool. Condition is “Recovered”  Go check the pins (bent or broken terminals and locking condition to item 7 and finish the service.
  • Page 462 FUEL INJECTION SYSTEM Fault code No. P0107, P0108 [P0107] Intake air pressure sensor: ground short circuit detected. Item [P0108] Intake air pressure sensor: open or power short circuit detected. Disconnect the ECU coupler from the ECU. Disconnect the intake air pressure sensor coupler from the intake air pressure sensor. [For P0107] Ground short circuit Between intake air pressure sensor coupler and ground: pink/white–ground If there is continuity, replace the wire harness.
  • Page 463 Improperly installed sensor  the fault code using the mal- Reinstall or replace the sensor. function mode of the Yamaha diagnostic tool. Condition is “Recovered”  Go to item 7 and finish the service.
  • Page 464 (Code No. 03) check the condition of the fault When engine is stopped: code using the malfunction Atmospheric pressure at the mode of the Yamaha diagnostic current altitude and weather tool. Condition is “Recovered”  Go conditions is indicated. At sea level: Approx. 101 kPa to item 7 and finish the service.
  • Page 465 Check the locking condition of replace the wire harness. the fault code using the mal- the coupler. function mode of the Yamaha Disconnect the coupler and diagnostic tool. Condition is “Recovered”  Go check the pins (bent or broken terminals and locking condition to item 7 and finish the service.
  • Page 466 FUEL INJECTION SYSTEM Fault code No. P0112, P0113 [P0112] Intake air temperature sensor: ground short circuit detected. Item [P0113] Intake air temperature sensor: open or power short circuit detected. Br/W Br/W 1. Intake air temperature sensor 2. ECU 3. Sensor output lead 4.
  • Page 467 Improperly installed sensor  the fault code using the mal- Reinstall or replace the sensor. function mode of the Yamaha diagnostic tool. Condition is “Recovered”  Go to item 7 and finish the service.
  • Page 468 Check the locking condition of replace the wire harness. the fault code using the mal- the coupler. function mode of the Yamaha Disconnect the coupler and diagnostic tool. Condition is “Recovered”  Go check the pins (bent or broken terminals and locking condition to item 7 and finish the service.
  • Page 469 Yamaha diagnostic tool. Condition is “Recovered”  Go to item 7 and finish the service. Condition is “Detected”  Go to item 4.
  • Page 470 FUEL INJECTION SYSTEM Fault code No. P0117, P0118 [P0117] Coolant temperature sensor: ground short circuit detected. Item [P0118] Coolant temperature sensor: open or power short circuit detected. [For P0118] Open circuit Between wire harness coupler (ECU side) and ECU coupler: green/white–green/white Between sub-wire harness coupler (coolant temperature sensor side) and coolant temperature sen- sor coupler: green/white–green/white If there is no continuity, replace the wire harness and/or sub-wire harness.
  • Page 471 Improperly installed sensor  the fault code using the mal- Reinstall or replace the sensor. function mode of the Yamaha diagnostic tool. Condition is “Recovered”  Go to item 7 and finish the service.
  • Page 472 Check the locking condition of replace the wire harness. the fault code using the mal- the coupler. function mode of the Yamaha Disconnect the coupler and diagnostic tool. Condition is “Recovered”  Go check the pins (bent or broken terminals and locking condition to item 7 and finish the service.
  • Page 473 FUEL INJECTION SYSTEM Fault code No. P0122, P0123, P0222, P0223, P2135 [P0122] Throttle position sensor: ground short circuit detected. [P0123] Throttle position sensor: open or power short circuit detected. Item [P0222] Throttle position sensor: ground short circuit detected. [P0223] Throttle position sensor: open or power short circuit detected.
  • Page 474 FUEL INJECTION SYSTEM Fault code No. P0122, P0123, P0222, P0223, P2135 [P0122] Throttle position sensor: ground short circuit detected. [P0123] Throttle position sensor: open or power short circuit detected. Item [P0222] Throttle position sensor: ground short circuit detected. [P0223] Throttle position sensor: open or power short circuit detected.
  • Page 475 FUEL INJECTION SYSTEM Fault code No. P0122, P0123, P0222, P0223, P2135 [P0122] Throttle position sensor: ground short circuit detected. [P0123] Throttle position sensor: open or power short circuit detected. Item [P0222] Throttle position sensor: ground short circuit detected. [P0223] Throttle position sensor: open or power short circuit detected.
  • Page 476 Improperly installed sensor  the fault code using the mal- Reinstall or adjust the sensor. function mode of the Yamaha Refer to “ADJUSTING THE diagnostic tool. Condition is “Recovered”  Go THROTTLE POSITION SEN- SOR”...
  • Page 477 Improperly installed sensor  the fault code using the mal- Reinstall or replace the sensor. function mode of the Yamaha diagnostic tool. Condition is “Recovered”  Go to item 7 and finish the service.
  • Page 478 Between O sensor 1 coupler function mode of the Yamaha diagnostic tool. and joint connector. Condition is “Recovered”  Go black/blue–black/blue to item 7 and finish the service.
  • Page 479 Check the locking condition of function mode of the Yamaha the coupler. diagnostic tool. Disconnect the coupler and Condition is “Recovered”  Go check the pins (bent or broken to item 7 and finish the service.

  • Page 480: Specifications

    Actuates fuel injector #1 five times at one-second intervals. Actuation The “check” indicator on the Yamaha diagnostic tool screen comes on each time the fuel injector is actuated. Disconnect the fuel pump coupler. Check that fuel injector #1 is actuated Procedure five times by listening for the operating sound.
  • Page 481 Actuates fuel injector #2 five times at one-second intervals. Actuation The “check” indicator on the Yamaha diagnostic tool screen comes on each time the fuel injector is actuated. Disconnect the fuel pump coupler. Check that fuel injector #2 is actuated Procedure five times by listening for the operating sound.
  • Page 482 Actuates fuel injector #3 five times at one-second intervals. Actuation The “check” indicator on the Yamaha diagnostic tool screen comes on each time the fuel injector is actuated. Disconnect the fuel pump coupler. Check that fuel injector #3 is actuated Procedure five times by listening for the operating sound.
  • Page 483 Actuates fuel injector #4 five times at one-second intervals. Actuation The “check” indicator on the Yamaha diagnostic tool screen comes on each time the fuel injector is actuated. Disconnect the fuel pump coupler. Check that fuel injector #4 is actuated Procedure five times by listening for the operating sound.
  • Page 484 Check the locking condition of replace the wire harness. code using the malfunction the coupler. mode of the Yamaha diagnostic Disconnect the coupler and tool. Condition is “Recovered”  Go check the pins (bent or broken terminals and locking condition to item 7 and finish the service.
  • Page 485 Refer to “CHECKING THE code using the malfunction CRANKSHAFT POSITION mode of the Yamaha diagnostic SENSOR” on page 8-201. tool. Condition is “Recovered”  Go Replace if defective. to item 7 and finish the service.
  • Page 486 Crank the engine, and then the wire harness. check the condition of the fault Between cylinder identification code using the malfunction sensor coupler and ECU cou- mode of the Yamaha diagnostic pler. tool. Condition is “Recovered”  Go white/black–white/black blue–blue to item 7 and finish the service.
  • Page 487 Diagnostic code No. Actuates the cylinder-#1 ignition coil five times at one-second intervals. Actuation The “check” indicator on the Yamaha diagnostic tool screen comes on each time the ignition coil is actuated. Check that a spark is generated five times.
  • Page 488 Diagnostic code No. Actuates the cylinder-#2 ignition coil five times at one-second intervals. Actuation The “check” indicator on the Yamaha diagnostic tool screen comes on each time the ignition coil is actuated. Check that a spark is generated five times.
  • Page 489 Check the condition of the fault Disconnect the coupler and code using the malfunction check the pins (bent or broken mode of the Yamaha diagnostic terminals and locking condition tool. Condition is “Recovered”  Go of the pins).
  • Page 490 Diagnostic code No. Actuates the cylinder-#3 ignition coil five times at one-second intervals. Actuation The “check” indicator on the Yamaha diagnostic tool screen comes on each time the ignition coil is actuated. Check that a spark is generated five times.
  • Page 491 Diagnostic code No. Actuates the cylinder-#4 ignition coil five times at one-second intervals. Actuation The “check” indicator on the Yamaha diagnostic tool screen comes on each time the ignition coil is actuated. Check that a spark is generated five times.
  • Page 492 Check the condition of the fault Disconnect the coupler and code using the malfunction check the pins (bent or broken mode of the Yamaha diagnostic terminals and locking condition tool. Condition is “Recovered”  Go of the pins).
  • Page 493 After the EXUP is fully closed, it stops at the opening base position (inter- mediate position). Actuation This operation takes approximately 3 seconds during which the “check” indicator is displayed on the Yamaha diagnostic tool. Procedure Check the operating sound. Probable cause of...
  • Page 494 After the EXUP is fully closed, it stops at the opening base position (inter- mediate position). Actuation This operation takes approximately 3 seconds during which the “check” indicator is displayed on the Yamaha diagnostic tool. Procedure Check the operating sound. Probable cause of...
  • Page 495 Check the locking condition of replace the wire harness. the fault code using the mal- the coupler. function mode of the Yamaha Disconnect the coupler and diagnostic tool. Condition is “Recovered”  Go check the pins (bent or broken terminals and locking condition to item 6 and finish the service.
  • Page 496 FUEL INJECTION SYSTEM Fault code No. P048D, P048E [P048D] EXUP servo motor: open or ground short circuit detected. Item [P048E] EXUP servo motor: power short circuit detected. [For P048D] Open circuit Between EXUP servo motor coupler and ECU coupler: blue–blue If there is no continuity, replace the wire harness.
  • Page 497 Check the operating sound of the fault code using the mal- the motor. function mode of the Yamaha Replace if defective. diagnostic tool. Condition is “Recovered”  Go to item 6 and finish the service.
  • Page 498 FUEL INJECTION SYSTEM Fault code No. P0500, P1500 In case “P0500” is detected, or both “P0500” and “P1500” are detected, proceed from item A-1. Fault code No. P0500, P1500 Rear wheel sensor: no normal signals are received from the rear wheel sensor. Item Neutral switch: open or short circuit is detected.
  • Page 499 (12 to 19 mph). Confirm that the fault code has a condition of “Recovered” using the malfunction mode of the Yamaha diagnostic tool, and then delete the fault code. Delete this fault code even if it has a condition of “Detected”.
  • Page 500 FUEL INJECTION SYSTEM Fault code No. P0500, P1500 Rear wheel sensor: no normal signals are received from the rear wheel sensor. Item Neutral switch: open or short circuit is detected. Clutch switch: open or short circuit is detected. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No.
  • Page 501 FUEL INJECTION SYSTEM Fault code No. P0500, P1500 Rear wheel sensor: no normal signals are received from the rear wheel sensor. Item Neutral switch: open or short circuit is detected. Clutch switch: open or short circuit is detected. Improperly connected  Con- Connection of ECU coupler.
  • Page 502 (12 to 19 mph). Confirm that the fault code has a condition of “Recovered” using the malfunction mode of the Yamaha diagnostic tool, and then delete the fault code. Delete this fault code even if it has a condition of “Detected”.
  • Page 503 FUEL INJECTION SYSTEM Fault code No. P0500, P1500 Rear wheel sensor: no normal signals are received from the rear wheel sensor. Item Neutral switch: open or short circuit is detected. Clutch switch: open or short circuit is detected. Value does not increase  Go Locate the malfunction.
  • Page 504 FUEL INJECTION SYSTEM Fault code No. P0500, P1500 Rear wheel sensor: no normal signals are received from the rear wheel sensor. Item Neutral switch: open or short circuit is detected. Clutch switch: open or short circuit is detected. Improperly connected  Con- Connection of ECU coupler.
  • Page 505 (12 to 19 mph). Confirm that the fault code has a condition of “Recovered” using the malfunction mode of the Yamaha diagnostic tool, and then delete the fault code. Delete this fault code even if it has a condition of “Detected”.
  • Page 506 FUEL INJECTION SYSTEM Fault code No. P0601, P0606 Fault code No. P0601, P0606 Internal malfunction in ECU. (When this malfunction is detected in Item the ECU, the fault code number might not appear on the tool dis- play.) Able/Unable to start engine Fail-safe system Able/Unable to drive vehicle Diagnostic code No.
  • Page 507 CO EEPROM. the fault code using the mal- concentration of cylinder #1. Refer to “ADJUSTING THE function mode of the Yamaha EXHAUST GAS VOLUME” on diagnostic tool. Condition is “Recovered”  Go page 3-12. After this adjustment is made, to item 8 and finish the service.
  • Page 508 Check the locking condition of replace the wire harness. the fault code using the mal- the coupler. function mode of the Yamaha Disconnect the coupler and diagnostic tool. Condition is “Recovered”  Go check the pins (bent or broken terminals and locking condition to item 8 and finish the service.
  • Page 509 Between throttle servo motor the fault code using the mal- coupler and ECU coupler. function mode of the Yamaha yellow/red–yellow/red diagnostic tool. Condition is “Recovered”  Go light green/red–light green/red Between ECU coupler and fuse to item 8 and finish the service.
  • Page 510 Actuates the relay unit five times at one-second intervals. Actuation The “check” indicator on the Yamaha diagnostic tool screen come on each time the relay is actuated. Check that the relay unit is actuated five times by listening for the operat- Procedure ing sound.
  • Page 511 No operating sound  Replace Check the condition of the fault the relay unit. code using the malfunction mode of the Yamaha diagnostic tool. Condition is “Recovered”  Go to item 7 and finish the service. Condition is “Detected”  Go to item 5.
  • Page 512 Check the locking condition of replace the wire harness. the fault code using the mal- the coupler. function mode of the Yamaha Disconnect the coupler and diagnostic tool. Condition is “Recovered”  Go check the pins (bent or broken terminals and locking condition to item 7 and finish the service.
  • Page 513 FUEL INJECTION SYSTEM Fault code No. P0916, P0917 [P0916] Gear position sensor: open or ground short circuit Item detected. [P0917] Gear position sensor: power short circuit detected. [For P0916] Ground short circuit Between gear position sensor coupler and ground: green/white–ground If there is continuity, replace the wire harness.
  • Page 514 Check for looseness or pinch- Refer to “INSTALLING THE the fault code using the mal- ing. GEAR POSITION SENSOR” on function mode of the Yamaha page 5-68. diagnostic tool. Condition is “Recovered”  Go to item 7 and finish the service.
  • Page 515 Actuates the air induction system solenoid five times at one-second inter- vals. Actuation The “check” indicator on the Yamaha diagnostic tool screen come on each time the air induction system solenoid is actuated. Check that the air induction system solenoid is actuated five times by lis- Procedure tening for the operating sound.
  • Page 516 Disconnect the coupler and function mode of the Yamaha check the pins (bent or broken diagnostic tool. Condition is “Recovered”  Go terminals and locking condition of the pins).
  • Page 517 Check the condition of the fault Disconnect the coupler and code using the malfunction check the pins (bent or broken mode of the Yamaha diagnostic terminals and locking condition tool. Condition is “Recovered”  Go of the pins).
  • Page 518 ECU coupler. Check the condition of the fault blue/yellow–blue/yellow code using the malfunction Between relay unit coupler and mode of the Yamaha diagnostic sidestand switch coupler. tool. Condition is “Recovered”  Go blue/black–blue/black to item 7 and finish the service.
  • Page 519 Disconnect the coupler and function mode of the Yamaha check the pins (bent or broken diagnostic tool. Condition is “Recovered”  Go terminals and locking condition of the pins).
  • Page 520 Check the condition of the fault Disconnect the coupler and code using the malfunction check the pins (bent or broken mode of the Yamaha diagnostic terminals and locking condition tool. Condition is “Recovered”  Go of the pins).
  • Page 521 FUEL INJECTION SYSTEM Fault code No. P1604, P1605 [P1604] Lean angle sensor: ground short circuit detected. Item [P1605] Lean angle sensor: open or power short circuit. 1. Lean angle sensor 2. ECU 3. Sensor input lead 4. Sensor output lead 5.
  • Page 522 FUEL INJECTION SYSTEM Fault code No. P1604, P1605 [P1604] Lean angle sensor: ground short circuit detected. Item [P1605] Lean angle sensor: open or power short circuit. [For P1605] Open circuit Between lean angle sensor coupler and ECU coupler: yellow/green–yellow/green If there is no continuity, replace the wire harness. [For P1605] Open circuit Between lean angle sensor coupler and ECU coupler: black/blue–black/blue If there is no continuity, replace the wire harness.
  • Page 523 “OFF”, and then back to page 8-201. “ON”. Check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool. Condition is “Recovered”  Go to item 6 and finish the service. Condition is “Detected”  Go to item 5.
  • Page 524 Check the locking condition of replace the wire harness. the fault code using the mal- the coupler. function mode of the Yamaha Disconnect the coupler and diagnostic tool. Condition is “Recovered”  Go check the pins (bent or broken terminals and locking condition to item 7 and finish the service.
  • Page 525 FUEL INJECTION SYSTEM Fault code No. P2122, P2123, P2127, P2128, P2138 [P2122] Accelerator position sensor: open or ground short circuit detected. [P2123] Accelerator position sensor: power short circuit detected. Item [P2127] Accelerator position sensor: ground short circuit detected. [P2128] Accelerator position sensor: open or power short circuit detected.
  • Page 526 FUEL INJECTION SYSTEM Fault code No. P2122, P2123, P2127, P2128, P2138 [P2122] Accelerator position sensor: open or ground short circuit detected. [P2123] Accelerator position sensor: power short circuit detected. Item [P2127] Accelerator position sensor: ground short circuit detected. [P2128] Accelerator position sensor: open or power short circuit detected.
  • Page 527 FUEL INJECTION SYSTEM Fault code No. P2122, P2123, P2127, P2128, P2138 [P2122] Accelerator position sensor: open or ground short circuit detected. [P2123] Accelerator position sensor: power short circuit detected. Item [P2127] Accelerator position sensor: ground short circuit detected. [P2128] Accelerator position sensor: open or power short circuit detected.
  • Page 528 Improperly installed sensor  the fault code using the mal- Reinstall or adjust the sensor. function mode of the Yamaha Refer to “ADJUSTING THE diagnostic tool. Condition is “Recovered”  Go ACCELERATOR POSITION SENSOR”...
  • Page 529 Delete the fault code and check Confirm that the fault code has that the engine trouble warning a condition of “Recovered” light goes off. using the Yamaha diagnostic tool, and then delete the fault code. Fault code No. P2158 Fault code No.
  • Page 530 FUEL INJECTION SYSTEM Fault code No. P2158 Front wheel sensor: no normal signals are received from the front Item wheel sensor. Improperly connected  Con- Connection of ABS ECU cou- Execute the diagnostic mode. pler. nect the coupler securely or (Code No.
  • Page 531 (12 to 19 mph). Confirm that the fault code has a condition of “Recovered” using the malfunction mode of the Yamaha diagnostic tool, and then delete the fault code. Delete this fault code even if it has a condition of “Detected”.
  • Page 532 Check the condition of the fault Check the locking condition of code using the malfunction the coupler. mode of the Yamaha diagnostic Disconnect the coupler and tool. check the pins (bent or broken Condition is “Recovered”  Go terminals and locking condition to item 8 and finish the service.
  • Page 533 Check the condition of the fault Refer to “ENGINE REMOVAL” code using the malfunction on page 5-3. mode of the Yamaha diagnostic tool. Condition is “Recovered”  Go to item 8 and finish the service. Condition is “Detected”  Go to item 7.
  • Page 534 Check the condition of the fault Check the locking condition of code using the malfunction the coupler. mode of the Yamaha diagnostic Disconnect the coupler and tool. check the pins (bent or broken Condition is “Recovered”  Go terminals and locking condition to item 8 and finish the service.
  • Page 535 Check the condition of the fault Refer to “ENGINE REMOVAL” code using the malfunction on page 5-3. mode of the Yamaha diagnostic tool. Condition is “Recovered”  Go to item 8 and finish the service. Condition is “Detected”  Go to item 7.
  • Page 536 Disconnect the coupler and function mode of the Yamaha check the pins (bent or broken diagnostic tool. Condition is “Recovered”  Go terminals and locking condition of the pins).
  • Page 537 FUEL INJECTION SYSTEM Fault code No. P2228, P2229 [P2228] Atmospheric pressure sensor: ground short circuit detected. Item [P2229] Atmospheric pressure sensor: open or power short circuit detected. [For P2229] Open circuit Between atmospheric pressure sensor coupler and ECU coupler: blue–blue If there is no continuity, replace the wire harness.
  • Page 538 Improperly installed sensor  the fault code using the mal- Reinstall or replace the sensor. function mode of the Yamaha diagnostic tool. Condition is “Recovered”  Go to item 7 and finish the service.
  • Page 539 Check the locking condition of replace the wire harness. the fault code using the mal- the coupler. function mode of the Yamaha Disconnect the coupler and diagnostic tool. Condition is “Recovered”  Go check the pins (bent or broken terminals and locking condition to item 6 and finish the service.
  • Page 540 CRUISE CONTROL SYSTEM EAS20087 CRUISE CONTROL SYSTEM EAS30544 CIRCUIT DIAGRAM 8-123...
  • Page 541 30.Clutch switch 31.Front brake light switch 32.Rear brake light switch 41.Joint connector 42.Joint coupler 54.ECU (Engine Control Unit) 73.Yamaha diagnostic tool coupler 74.Meter assembly 80.Multi-function meter 86.Cruise control system indicator light 87.Cruise control setting indicator light 92.Handlebar switch (left) 93.Cruise control power switch 94.Cruise control setting switch...
  • Page 542 CRUISE CONTROL SYSTEM EAS30666 CRUISE CONTROL CIRCUIT OPERATION 8-125...
  • Page 543 CRUISE CONTROL SYSTEM 1. Battery 2. Main fuse 3. Main switch 4. Backup fuse 5. Ignition fuse 6. Cruise control fuse 7. Signaling system fuse 8. Brake light fuse 9. Cruise control power switch 10.Cruise control setting switch 11.Grip cancel switch 12.Front brake light switch 13.Rear brake light switch 14.Clutch switch...
  • Page 544 • Use sufficiently charged regular batteries only. [A] Malfunction check using the cruise control system indicator light. [B] Use the Yamaha diagnostic tool to determine the cause of the malfunction for the stored fault code from the condition and place where the malfunction occurred.
  • Page 545 CRUISE CONTROL SYSTEM EWA17441 WARNING When maintenance or checks have been performed on components related to the cruise control system, be sure to perform a final check before delivering the vehicle to the customer. Refer to “[C-2] FINAL CHECK” on page 8-138. EAS30669 [A] CHECKING THE CRUISE CONTROL SYSTEM INDICATOR LIGHT Turn the main switch to “ON”, and then push the cruise control power switch.
  • Page 546 Disconnect the coupler and mode of the Yamaha diagnostic check the pins (bent or broken tool. Condition is “Recovered”  Go terminals and locking condition of the pins).
  • Page 547 Operate the brake lever, and fuse) tem fuse, brake light fuse) then check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool. Condition is “Recovered”  Go to item A-10 and finish the ser- vice.
  • Page 548 Disconnect the coupler and mode of the Yamaha diagnostic check the pins (bent or broken tool. Condition is “Recovered”  Go terminals and locking condition of the pins).
  • Page 549 Disconnect the coupler and mode of the Yamaha diagnostic check the pins (bent or broken tool. Condition is “Recovered”  Go terminals and locking condition of the pins).
  • Page 550 Delete the fault code and check Confirm that the fault code has that the engine trouble warning a condition of “Recovered” light goes off. using the Yamaha diagnostic tool, and then delete the fault code. Fault code No. P0564 Fault code No.
  • Page 551 (bent or broken malfunction mode of the terminals and locking condition Yamaha diagnostic tool. Condition is “Recovered”  Go of the pins). to item A-9 and finish the ser- vice.
  • Page 552 “SET–” side of the cruise con- trol setting switch, and then check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool. Condition is “Recovered”  Go to item A-9 and finish the ser- vice.
  • Page 553 (bent or broken malfunction mode of the terminals and locking condition Yamaha diagnostic tool. Condition is “Recovered”  Go of the pins). to item B-9 and finish the ser- vice.
  • Page 554 “SET–” side of the cruise con- trol setting switch, and then check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool. Condition is “Recovered”  Go to item B-9 and finish the ser- vice.
  • Page 555 EAS30674 [C-1] DELETING THE FAULT CODES 1. Delete the fault code using the malfunction of the Yamaha diagnostic tool, and check that the engine trouble warning light goes off. EAS30675 [C-2] FINAL CHECK 1.
  • Page 556 FUEL PUMP SYSTEM EAS20081 FUEL PUMP SYSTEM EAS30513 CIRCUIT DIAGRAM 8-139...
  • Page 557 FUEL PUMP SYSTEM 3. Main switch 4. Main fuse 7. Fuel injection system fuse 9. Backup fuse 12.Ignition fuse 18.Battery 19.Engine ground 27.Relay unit 29.Fuel pump relay 33.Handlebar switch (right) 35.Start/engine stop switch 40.Fuel pump 41.Joint connector 54.ECU (Engine Control Unit) 8-140...
  • Page 558 FUEL PUMP SYSTEM EAS30514 TROUBLESHOOTING If the fuel pump fails to operate. • Before troubleshooting, remove the following part(s): 1. Rider seat/Air scoop/Air scoop stay/Side cover 2. Fuel tank cover 3. Fuel tank 1. Check the fuses. (Main, ignition, backup and fuel in- jection system) Replace the fuse(s).
  • Page 559 FUEL PUMP SYSTEM 8-142...
  • Page 560 IMMOBILIZER SYSTEM EAS20084 IMMOBILIZER SYSTEM EAS30519 CIRCUIT DIAGRAM 8-143...
  • Page 561 IMMOBILIZER SYSTEM 3. Main switch 4. Main fuse 9. Backup fuse 12.Ignition fuse 18.Battery 19.Engine ground 25.Immobilizer unit 41.Joint connector 54.ECU (Engine Control Unit) 74.Meter assembly 75.Immobilizer system indicator light 80.Multi-function meter 8-144...
  • Page 562 IMMOBILIZER SYSTEM EAS30520 GENERAL INFORMATION This vehicle is equipped with an immobilizer system to help prevent theft by re-registering codes in the standard keys. This system consists of the following: • A code re-registering key (with a red bow) • Two standard keys (with a black bow) that can be re-registered with new codes •...
  • Page 563 IMMOBILIZER SYSTEM Parts to be replaced Main switch/ Key registration immobilizer unit Accessory requirement Standard lock* and Main Immobilizer switch unit  Standard key is lost New standard key All keys have been lost Code re-registering     (including code re-reg- key and standard keys istering key)
  • Page 564 IMMOBILIZER SYSTEM Standard key registration: Standard key registration is required when a standard key is lost and needs to be replaced, or when the code re-registering key is re-registered after the immobilizer unit or ECU are replaced. Do not start the engine with a standard key that has not been registered. If the main switch is turned “ON”...
  • Page 565 IMMOBILIZER SYSTEM Standard key code voiding method a. Main switch “ON” b. Main switch “OFF” c. LED on d. LED off e. Less than 5.0 s f. Code re-registering key g. Remaining standard key h. Registration mode A. If the immobilizer system indicator light stops flashing 5 seconds after the first standard key is registered, the second standard key cannot be registered.
  • Page 566 IMMOBILIZER SYSTEM EAS30522 TROUBLESHOOTING When the main switch is turned to “ON”, the immobilizer system indicator light does not come on nor flashes. 1. Check the fuses. (Main, ignition, and backup) Replace the fuse(s). Refer to “CHECKING THE FUSES” NG on page 8-194.
  • Page 567 IMMOBILIZER SYSTEM EAS30523 SELF-DIAGNOSIS FAULT CODE INDICATION When a system failure occurs, the immobilizer system indicator light blinks. The pattern of blinking shows the fault code. Fault Part Symptom Cause Action code IMMOBILIZER Code cannot be trans- 1. Radio wave interfer- 1.
  • Page 568 IMMOBILIZER SYSTEM Fault Part Symptom Cause Action code Unidentified code is Noise interference or dis- 1. Check the wire received. connected lead/cable. harness and con- nector. 2. Replace the main switch/immobi- lizer unit. 3. Replace the ECU. Refer to “REPLACING THE ECU (Engine Control Unit)”...
  • Page 569 IMMOBILIZER SYSTEM 8-152...
  • Page 570 ABS (Anti-lock Brake System) EAS20085 ABS (Anti-lock Brake System) EAS30843 CIRCUIT DIAGRAM 8-153...
  • Page 571 32.Rear brake light switch 41.Joint connector 42.Joint coupler 54.ECU (Engine Control Unit) 68.Front wheel sensor 69.Rear wheel sensor 70.ABS ECU (Electronic Control Unit) 73.Yamaha diagnostic tool coupler 74.Meter assembly 80.Multi-function meter 90.ABS warning light 108.Tail/brake light 110.Brake light relay 8-154...
  • Page 572 ABS (Anti-lock Brake System) EAS30525 ABS COMPONENTS CHART 8-155...
  • Page 573 3. ABS ECU fuse 4. ABS warning light 5. Front wheel sensor rotor 6. Front wheel sensor 7. Front brake caliper 8. Rear wheel sensor 9. Rear wheel sensor rotor 10.Rear brake caliper 11.ABS motor fuse 12.Yamaha diagnostic tool coupler 8-156...
  • Page 574 ABS (Anti-lock Brake System) EAS30844 ABS COUPLER LOCATION CHART 8-157...
  • Page 575 ABS (Anti-lock Brake System) 1. Meter assembly coupler 2. Front wheel sensor coupler 3. Yamaha diagnostic tool coupler 4. ABS ECU coupler 5. Rear wheel sensor coupler 8-158...
  • Page 576 The following troubleshooting describes the problem identification and service method using the Yamaha diagnostic tool. For information about using the Yamaha diagnostic tool, refer to “[B-2] DIAG- NOSIS USING THE FAULT CODES” on page 8-163. For troubleshooting items other than the following items, follow the normal service method.
  • Page 577 ABS (Anti-lock Brake System) The fault codes recorded in the ABS ECU can be checked using the Yamaha diagnostic tool. When the service is finished, check the normal operation of the vehicle, and then delete the fault code(s). For in- formation about deleting the fault codes, refer to “[B-3] DELETING THE FAULT CODES”...
  • Page 578 ABS ECU? The hydraulic unit assembly • is defective. Can communicate [A-5] ABS ECU and FI ECU The connection with the Yamaha • Return to [A]. fail to communicate. diagnostic tool is defective. • The battery voltage is low.
  • Page 579 EAS31162 [A-3] THE ABS WARNING LIGHT COMES ON Connect the Yamaha diagnostic tool to the Yamaha diagnostic tool coupler and execute functional di- agnosis. (For information about how to execute functional diagnosis, refer to the operation manual that is included with the tool.) Check that communication with the ABS ECU is possible.
  • Page 580 Check for continuity between black terminal of the ABS ECU coupler and the ground. If there is no continuity, the wire harness is defective. Replace the wire harness. • Open circuit in the wire harness between the ABS ECU coupler and the Yamaha diagnostic tool cou- pler.
  • Page 581 Details about the displayed fault codes are shown in the following chart. Refer to this chart and check the vehicle. Once all the work is complete, delete the fault codes. [B-3] Check the inspection points after terminating the connection with the Yamaha diagnostic tool and turn- ing the main switch off. Fault code table Record all of the fault codes displayed and inspect the check points.
  • Page 582 ABS (Anti-lock Brake System) Fault code Item Symptom Check point Rear wheel sensor (abnor- Rear wheel sensor signal is • Foreign material adhered mal pulse period) not received properly. (The around the rear wheel sen- pulse period is abnormal • Incorrect installation of the while the vehicle is traveling.) rear wheel •...
  • Page 583 ABS (Anti-lock Brake System) Fault code Item Symptom Check point Front wheel ABS (intermit- • Pulses from the front wheel • Incorrect installation of the tent wheel speed pulses or sensor are received inter- front wheel sensor • Incorrect rotation of the incorrect depressurization) mittently while the vehicle is traveling.
  • Page 584 ABS (Anti-lock Brake System) Fault code Item Symptom Check point Vehicle CAN communication Short-circuit in CAN commu- • Short-circuit in CAN com- line or power source of vehi- nication line or the voltage munication line • Defective battery cle system that supplies the hydraulic •...
  • Page 585 ABS (Anti-lock Brake System) Fault code No. 12 Fault code No. Item Rear wheel sensor (intermittent pulses or no pulses) Rear wheel sensor signal is not received properly. (Pulses are not Symptom received or are received intermittently while the vehicle is travel- ing.) Order Item/components and probable cause Check or maintenance job...
  • Page 586 ABS (Anti-lock Brake System) • If the front brake ABS operates continuously for 20 seconds or more, fault code No. 26 will be record- ed. If the front brake ABS operates continuously for 36 seconds or more, fault code No. 13 will be re- corded.
  • Page 587 ABS (Anti-lock Brake System) Fault code No. Item Front wheel sensor (open or short circuit) Symptom Open or short circuit is detected in the front wheel sensor. Order Item/components and probable cause Check or maintenance job • Check for continuity between the white terminal “1” Open or short circuit in the wire harness between the front wheel sensor and the and the white terminal “4”...
  • Page 588 ABS (Anti-lock Brake System) Fault code No. Item Rear wheel sensor (open or short circuit) Symptom Open or short circuit is detected in the rear wheel sensor. Order Item/components and probable cause Check or maintenance job • Check for continuity between the white terminal “1” Open or short circuit in the wire harness between the rear wheel sensor and the and the white terminal “4”...
  • Page 589 ABS (Anti-lock Brake System) Fault code No. 31 Fault code No. Item Hydraulic unit assembly (defective ABS solenoid power circuit) Power is not supplied to the solenoid circuit in the hydraulic unit Symptom assembly. Order Item/components and probable cause Check or maintenance job Blown ABS solenoid fuse Check the ABS solenoid fuse.
  • Page 590 ABS (Anti-lock Brake System) Fault code No. 34 Fault code No. Hydraulic unit assembly (short circuit in ABS motor power supply Item circuit) Short circuit is detected in the motor power supply circuit in the Symptom hydraulic unit assembly. Order Item/components and probable cause Check or maintenance job Defective hydraulic unit assembly Replace the hydraulic unit assembly.
  • Page 591 ABS (Anti-lock Brake System) Fault code No. 42 Fault code No. Rear wheel ABS (intermittent wheel speed pulses or incorrect Item depressurization) • Pulses from the rear wheel sensor are received intermittently while the vehicle is traveling. Symptom • Rear wheel will not recover from the locking tendency even though the signal is transmitted from the ABS ECU to reduce the hydraulic pressure.
  • Page 592 ABS (Anti-lock Brake System) After the fault code No. 45 is recorded, fault code No. 43 will be recorded if a certain speed and time are exceeded. Fault code No. 44, 46 Fault code No. Item Rear wheel sensor (missing pulses) Rear wheel sensor signal is not received properly.
  • Page 593 ABS (Anti-lock Brake System) Fault code No. 53 Fault code No. Vehicle system power supply (voltage of ABS ECU power supply is Item low) Power voltage supplied to the ABS ECU in the hydraulic unit assem- Symptom bly is too low. Order Item/components and probable cause Check or maintenance job Defective battery...
  • Page 594 ABS (Anti-lock Brake System) Fault code No. 57 Fault code No. Item Vehicle CAN communication line or power source of vehicle system Short-circuit in CAN communication line or the voltage that sup- Symptom plies the hydraulic unit assembly is too low. Order Item/components and probable cause Check or maintenance job Short-circuit in CAN communication line...
  • Page 595 EAS31167 [B-3] DELETING THE FAULT CODES To delete the fault codes, use the Yamaha diagnostic tool. For information about deleting the fault codes, refer to the operation manual of the Yamaha diagnostic tool. Check that all the displayed fault codes are deleted.
  • Page 596 ABS (Anti-lock Brake System) • Open circuit between the ABS ECU and the meter assembly. Check for continuity between green/orange terminal of the ABS ECU coupler and green/orange ter- minal of the meter assembly coupler. • Malfunction in the meter assembly circuit. •...
  • Page 597 ABS (Anti-lock Brake System) 8-180...
  • Page 598 STEERING DAMPER SYSTEM EAS20259 STEERING DAMPER SYSTEM EAS32036 CIRCUIT DIAGRAM 8-181...
  • Page 599 STEERING DAMPER SYSTEM 3. Main switch 4. Main fuse 9. Backup fuse 12.Ignition fuse 18.Battery 19.Engine ground 41.Joint connector 42.Joint coupler 54.ECU (Engine Control Unit) 71.Steering damper solenoid 73.Yamaha diagnostic tool coupler 74.Meter assembly 76.Steering damper warning light 80.Multi-function meter 8-182...
  • Page 600 • Fault code number ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Check the fault code number that have a condition of “Detected” using the Yamaha diagnostic tool. b. Identify the faulty system with the fault code number. c. Identify the probable cause of the malfunction.
  • Page 601 Check the locking condition of replace the wire harness. the fault code using the mal- the coupler. function mode of the Yamaha Disconnect the coupler and diagnostic tool. Condition is “Recovered”  Go check the pins (bent or broken terminals and locking condition to item 6 and finish the service.
  • Page 602 Steering damper solenoid: open or short circuit detected. Delete the fault code and check Confirm that the fault code has that the engine trouble warning a condition of “Recovered” light goes off. using the Yamaha diagnostic tool, and then delete the fault code. 8-185...
  • Page 603 STEERING DAMPER SYSTEM 8-186...
  • Page 604 ELECTRICAL COMPONENTS EAS20089 ELECTRICAL COMPONENTS 8-187...
  • Page 605 ELECTRICAL COMPONENTS 1. Clutch switch 2. Front brake light switch 3. Grip cancel switch 4. Accelerator position sensor 5. Throttle servo motor 6. Intake air pressure sensor 7. Injector 8. Throttle position sensor 9. Fuel pump 10.Battery 11.Lean angle sensor 12.EXUP servo motor 13.Hydraulic unit assembly 14.Shift switch (OPTION)
  • Page 606 ELECTRICAL COMPONENTS 8-189...
  • Page 607 ELECTRICAL COMPONENTS 1. Relay unit 2. Atmospheric pressure sensor 3. Intake air temperature sensor 4. Ignition coil 5. Coolant temperature sensor 6. Neutral switch 7. Main fuse 8. Brake light relay 9. Starter relay 10.Rectifier/regulator 11.Rear wheel sensor 12.Rear brake light switch 13.Gear position sensor 14.Sidestand switch 15.O...
  • Page 608 ELECTRICAL COMPONENTS EAS30549 CHECKING THE SWITCHES 8-191...
  • Page 609 ELECTRICAL COMPONENTS 1. Cruise control power switch 2. Cruise control setting switch 3. Dimmer/pass switch 4. Horn switch 5. Select switch 6. Traction control system switch 7. Turn signal switch 8. Grip cancel switch 9. Sidestand switch 10.Shift switch (OPTION) 11.Main switch 12.Mode switch 13.Start/engine stop switch...
  • Page 610 ELECTRICAL COMPONENTS 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. ECA14371 NOTICE Never insert the tester probes into the coupler terminal slots. Always insert the probes from the opposite end “a”...
  • Page 611 ELECTRICAL COMPONENTS EAS30551 Amperage CHECKING THE FUSES Fuses Q’ty rating The following procedure applies to all of the fus- Fuel injection system 15.0 A ECA13680 ABS motor 30.0 A NOTICE To avoid a short circuit, always set the main ABS ECU 7.5 A switch to “OFF”...
  • Page 612 ELECTRICAL COMPONENTS ECA22960 Engine idling speed NOTICE 1200–1400 r/min Use only the specified genuine YAMAHA bat- tery. Using a different battery may cause the EAS30552 IMU to fail and the engine to stall. CHECKING AND CHARGING THE BATTERY EWA13290 WARNING...
  • Page 613 ELECTRICAL COMPONENTS tery overheating and battery plate damage. nected). • No charging is necessary when the open-cir- • If it is impossible to regulate the charging current on the battery charger, be careful cuit voltage equals or exceeds 12.8 V. not to overcharge the battery.
  • Page 614 ELECTRICAL COMPONENTS charging. tery. Voltage should be measured 30 minutes after If the current is lower than the standard charging the engine is stopped. current written on the battery, this type of battery charger cannot charge the VRLA (Valve Regu- b.
  • Page 615 ELECTRICAL COMPONENTS Refer to “GENERAL CHASSIS (1)” on page Result 4-1. Continuity (between “3” and “4”) EAS30553 CHECKING THE RELAYS Check each switch for continuity with the pocket Relay unit (fuel pump relay) tester. If the continuity reading is incorrect, re- place the relay.
  • Page 616 ELECTRICAL COMPONENTS Brake light relay Continuity Positive tester probe sky blue “1” Negative tester probe black/yellow “2” No continuity Positive tester probe Lg/B black/yellow “2” Negative tester probe sky blue “1” Continuity Positive tester probe 1. Positive battery terminal sky blue “1” 2.
  • Page 617 ELECTRICAL COMPONENTS unit terminal as shown. Pocket tester c. Check the relay unit (diode) for continuity. 90890-03112 d. Check the relay unit (diode) for no continuity. Analog pocket tester ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ YU-03112-C EAS30558 CHECKING THE IGNITION COILS • Negative tester probe Ignition coil terminal “1”...
  • Page 618 ELECTRICAL COMPONENTS b. Measure the crankshaft position sensor re- 2. Ignition coil sistance. c. Turn the main switch to “ON”. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ d. Measure the ignition spark gap “a”. e. Crank the engine by pushing the “ ” side of EAS30561 the start/engine stop switch and gradually in- CHECKING THE LEAN ANGLE SENSOR crease the spark gap until a misfire occurs.
  • Page 619 ELECTRICAL COMPONENTS EAS30566 CHECKING THE STATOR COIL 1. Disconnect: • Stator coil coupler (from the wire harness) 2. Check: • Stator coil resistance Out of specification  Replace the stator coil. Stator coil resistance 0.112–0.168  (W-W) c. Set the main switch to “ON”. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...
  • Page 620 ELECTRICAL COMPONENTS on page 8-202. Pocket tester 90890-03112 Rectifier/regulator input voltage Analog pocket tester above 14 V at 5000 r/min YU-03112-C ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester (AC 20 V) to the • Positive tester probe positive battery terminal “1” rectifier/regulator coupler as shown.
  • Page 621 ELECTRICAL COMPONENTS Pocket tester 90890-03112 Analog pocket tester YU-03112-C • Positive tester probe  Fuel sender terminal “1” • Negative tester probe  Fuel sender terminal “2” EAS30577 CHECKING THE RADIATOR FAN MOTORS 1. Check: • Radiator fan motor Faulty/rough movement  Replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...
  • Page 622 ELECTRICAL COMPONENTS Coolant temperature sensor re- Coolant temperature sensor sistance 15 N·m (1.5 kgf·m, 11 lb·ft) 2512–2777  at 20 C (2512– 2777  at 68 F) EAS30592 CHECKING THE THROTTLE SERVO MOTOR Coolant temperature sensor re- sistance 1. Remove: 210–220 ...
  • Page 623 ELECTRICAL COMPONENTS 2. Check: EAS30587 CHECKING THE AIR INDUCTION SYSTEM • Cylinder identification sensor output voltage SOLENOID Out of specification  Replace. 1. Check: • Air induction system solenoid resistance Cylinder identification sensor output voltage (ON) Out of specification  Replace. 4.8 V Solenoid resistance Cylinder identification sensor...
  • Page 624 ELECTRICAL COMPONENTS EWA14110 EAS30598 CHECKING THE STEERING DAMPER WARNING SOLENOID • Handle the intake air temperature sensor 1. Remove: with special care. • Air scoop (right) • Never subject the intake air temperature Refer to “GENERAL CHASSIS (1)” on page sensor to strong shocks.
  • Page 625 ELECTRICAL COMPONENTS Out of specification  Replace the fuel injec- tor. Resistance 12.0  ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the fuel injector coupler from the fuel injector. b. Connect the pocket tester (  10) to the fuel injector coupler as shown. Pocket tester 90890-03112 Analog pocket tester...
  • Page 626 ELECTRICAL COMPONENTS 8-209...

  • Page 627: Troubleshooting

    TROUBLESHOOTING TROUBLESHOOTING..................9-1 GENERAL INFORMATION ................9-1 STARTING FAILURES................9-1 INCORRECT ENGINE IDLING SPEED .............9-1 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ......9-2 FAULTY GEAR SHIFTING.................9-2 SHIFT PEDAL DOES NOT MOVE .............9-2 JUMPS OUT OF GEAR................9-2 FAULTY CLUTCH ..................9-2 OVERHEATING ..................9-2 OVERCOOLING..................9-3 POOR BRAKING PERFORMANCE............9-3 FAULTY FRONT FORK LEGS..............9-3 UNSTABLE HANDLING ................9-3 FAULTY LIGHTING OR SIGNALING SYSTEM .........9-3 TROUBLESHOOTING AT THE ABS WARNING LIGHT ......9-4...
  • Page 628 TROUBLESHOOTING 2. Fuse(s) EAS20090 TROUBLESHOOTING • Blown, damaged or incorrect fuse • Improperly installed fuse EAS30599 3. Spark plug(s) GENERAL INFORMATION • Incorrect spark plug gap • Incorrect spark plug heat range The following guide for troubleshooting does not • Fouled spark plug cover all the possible causes of trouble.
  • Page 629 TROUBLESHOOTING • Worn or damaged electrode EAS30849 FAULTY CLUTCH • Worn or damaged insulator Clutch slips 3. Ignition coil(s) 1. Clutch • Broken or shorted primary or secondary coils • Improperly assembled clutch • Cracked or broken ignition coil • Improperly adjusted clutch cable 4.
  • Page 630 TROUBLESHOOTING • Damaged pipe EAS30611 UNSTABLE HANDLING • Improperly connected pipe Handlebar Fuel system • Bent or improperly installed handlebar 1. Throttle body (-ies) Steering head components • Damaged or loose throttle body joint • Improperly installed upper bracket 2. Air filter •...
  • Page 631 TROUBLESHOOTING • Faulty meter assembly • Faulty turn signal light • Incorrect connection • Damaged or faulty wire harness • Improperly grounded circuit • Faulty battery • Blown, damaged or incorrect fuse Turn signal blinks slowly • Faulty meter assembly •...
  • Page 632 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE EAS20116 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE EAS31794 SELF-DIAGNOSTIC FUNCTION TABLE (FOR FUEL INJECTION SYSTEM) For details of the fault code, refer to “TROUBLESHOOTING METHOD” on page 8-35. Fault Probable cause of Fail-safe system Item Vehicle symptom code No.
  • Page 633 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Fault Probable cause of Fail-safe system Item Vehicle symptom code No. malfunction operation P0107 [P0107] Intake air [P0107] Low voltage Engine idling speed is Intake air pressure P0108 pressure sensor of the intake air pres- unstable.
  • Page 634 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Fault Probable cause of Fail-safe system Item Vehicle symptom code No. malfunction operation P0117 [P0117] Coolant tem- [P0117] Low voltage Engine is difficult to The radiator fan motor P0118 perature sensor of the coolant temper- start.
  • Page 635 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Fault Probable cause of Fail-safe system Item Vehicle symptom code No. malfunction operation P0132 sensor 1 (short cir- [P0132] High voltage Increased exhaust feedback is not of the O sensor 1 cir- emissions. cuit detected (power carried out.
  • Page 636 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Fault Probable cause of Fail-safe system Item Vehicle symptom code No. malfunction operation P0335 Crankshaft position • Defective coupler Engine cannot be Does not operate. sensor (no normal between crankshaft started. ISC feedback is not signals are received position sensor and carried out.
  • Page 637 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Fault Probable cause of Fail-safe system Item Vehicle symptom code No. malfunction operation P0476 EXUP servo motor • Defective coupler Loss of engine power. Learning values for (Stuck) between EXUP fully closed EXUP are servo motor and fixed.
  • Page 638 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Fault Probable cause of Fail-safe system Item Vehicle symptom code No. malfunction operation P0560 Rectifier/regulator: • Battery overcharg- Engine is difficult to feedback is not malfunction detected. ing (defective recti- start. carried out. Charging voltage is fier/regulator).
  • Page 639 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Fault Probable cause of Fail-safe system Item Vehicle symptom code No. malfunction operation P062F EEPROM fault code • CO adjustment Increased exhaust CO adjustment value number (an error is value is not properly emissions. for the faulty cylinder detected while read- written.
  • Page 640 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Fault Probable cause of Fail-safe system Item Vehicle symptom code No. malfunction operation P1400 Air induction system • Open or short cir- Increased exhaust Electric current in air solenoid (open or cuit in wire harness. emissions.
  • Page 641 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Fault Probable cause of Fail-safe system Item Vehicle symptom code No. malfunction operation P2122 [P2122] Accelerator [P2122, P2127] Low Engine response is No change in acceler- P2123 position sensor (open voltage of the acceler- poor.
  • Page 642 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Fault Probable cause of Fail-safe system Item Vehicle symptom code No. malfunction operation P2197 sensor 2 (no sig- • Signal voltage is Increased exhaust feedback is not 0.25–0.53 V. emissions. nals are received from carried out.
  • Page 643 Vehicle symptom code No. malfunction operation U0155 CAN communication Communication Defective meter dis- Grip warmer output: (Yamaha error (with the meter) between the ECU and play. OFF is fixed. diagnostic the meter is not possi- Traction control does MAP changeover: tool) not work.
  • Page 644 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Diagnostic Item Meter display Procedure code No. Coolant temperature When engine is cold: Dis- Compare the actually mea- plays temperature closer to sured coolant temperature air temperature. with the meter display value. When engine is hot: Displays current coolant temperature.
  • Page 645 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Diagnostic Item Meter display Procedure code No. Neutral switch and clutch Operate the transmission, switch clutch lever, and sidestand. • Transmission is in neutral • Transmission is in gear or the clutch lever released •...
  • Page 646 Check that a spark is gener- tion coil five times at one- ated five times. • Connect an ignition second intervals. The “check” indicator on the checker. Yamaha diagnostic tool screen come on each time the ignition coil is actuated. 9-19...
  • Page 647 • Connect an ignition second intervals. The “check” indicator on the checker. Yamaha diagnostic tool screen come on each time the ignition coil is actuated. Cylinder-#3 ignition coil Actuates the cylinder-#3 igni- Check that a spark is gener- tion coil five times at one- ated five times.
  • Page 648 After the EXUP is fully Check the operating sound. closed, it stops at the open- ing base position (intermedi- ate position). This operation takes approxi- mately 3 seconds during which the “check” indicator is displayed on the Yamaha diagnostic tool. 9-21...
  • Page 649 EVENT CODE TABLE EAS20164 EVENT CODE TABLE The event code numbers listed below cannot be displayed on the meter. To display the event code numbers, use the Yamaha diagnostic tool. Item Symptom Possible causes Note Intake air pres- Brief abnormality...
  • Page 650 EVENT CODE TABLE Item Symptom Possible causes Note sensor During O feedback, • Open or short circuit in • If a fault code is occurring, the wire harness respond to that first. (Stuck at the the adjustment is between the sensor * Rarely, Code 241 occurs lower limit for maintained at the...
  • Page 651 EVENT CODE TABLE Item Symptom Possible causes Note Cruise control Automatic turning off The cruise control sys- The automatic turning off of of the cruise control tem will automatically the cruise control system system detected turn off under the follow- does not indicate a mal- ing conditions: function in the system.
  • Page 652 EVENT CODE TABLE Event code No. Item Latch up detected. Malfunction in ECU. Replace the ECU. Service is finished. Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-194. 9-25...
  • Page 653 11. Radiator fan motor fuse 71. Steering damper solenoid 12. Ignition fuse 72. Shift switch (OPTION) 13. Signaling system fuse 73. Yamaha diagnostic tool cou- 14. ABS ECU fuse pler 15. Headlight fuse 74. Meter assembly 16. Hazard lighting fuse 75.
  • Page 654 Yellow/Blue EAS30613 COLOR CODE Yellow/Red Black Yellow/White Brown Chocolate Dark green Green Gray Blue Light green Orange Pink Sky blue Violet White Yellow Black/Green Black/Blue Black/Red Black/White Black/Yellow Br/B Brown/Black Br/L Brown/Blue Br/R Brown/Red Br/W Brown/White Br/Y Brown/Yellow Green/Black Green/Blue Green/Orange Green/White Green/Yellow...
  • Page 657 MTN1000/MTN1000G 2016 MTN1000/MTN1000G 2016 MTN1000/MTN1000G 2016 MTN1000/MTN1000G 2016 MTN1000/MTN1000G 2016 SCHÉMA DE CÂBLAGE SCHEMA ELETTRICO WIRING DIAGRAM SCHALTPLAN DIAGRAMA ELÉCTRICO...
  • Page 658 MTN1000/MTN1000G 2016 MTN1000/MTN1000G 2016 MTN1000/MTN1000G 2016 MTN1000/MTN1000G 2016 MTN1000/MTN1000G 2016 SCHÉMA DE CÂBLAGE SCHEMA ELETTRICO WIRING DIAGRAM SCHALTPLAN DIAGRAMA ELÉCTRICO...

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