Yamaha MTN850-A 2017 Service Manual
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Yamaha MTN850-A 2017 Service Manual

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Table of Contents

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2017
SERVICE MANUAL
MTN850-A
MTN850-AH
BS2-28197-E0

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Summary of Contents for Yamaha MTN850-A 2017

  • Page 1 2017 SERVICE MANUAL MTN850-A MTN850-AH BS2-28197-E0...
  • Page 3 EAS20002 MTN850-A MTN850-AH SERVICE MANUAL ©2016 by Yamaha Motor Co., Ltd. First edition, November 2016 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.
  • Page 4 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 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 TCS (Traction Control System)........1-4 INSTRUMENT FUNCTIONS ..............1-8 IMPORTANT INFORMATION .................1-13 PREPARATION FOR REMOVAL AND DISASSEMBLY......1-13 REPLACEMENT PARTS................1-13 GASKETS, OIL SEALS AND O-RINGS ...........1-13 LOCK WASHERS/PLATES AND COTTER PINS ........1-13...

  • 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. 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 switch 7. Crankshaft position sensor 8. Rear wheel sensor 9. Coolant temperature sensor...

  • Page 13: Outline Of The Tcs (Traction Control System)

    FEATURES EAS30855 OUTLINE OF THE TCS (Traction Control System) The traction control system controls excessive spinning (slipping) of the rear wheel when accelerating on slippery surfaces, such as unpaved or wet roads. The ECU monitors the front and rear wheel speeds using the signals from the front and rear wheel sen- sors, and detects rear wheel slipping according to the difference between the wheel speeds.
  • Page 14 FEATURES TCS (Traction control system) block diagram The signals from the front and rear wheel sensors are sent to the ECU through the ABS ECU, and the ECU calculates the amount of slip according to the difference between the detected front and rear wheel speeds.
  • Page 15 FEATURES Traction control system The traction control system (TCS) helps maintain traction when accelerating on slippery surfaces, such as unpaved or wet roads. If sensors detect that the rear wheel is starting to slip (uncontrolled spinning), the traction control system assists by regulating engine power as needed until traction is restored.
  • Page 16 FEATURES Resetting the traction control system The traction control system will automatically disable when: • the front wheel or rear wheel comes off the ground while riding. • excessive rear wheel spin is detected while riding. • either wheel is rotated with the key turned to “ON” (such as when performing maintenance). If the traction control system is disabled, both the “...

  • Page 17: Instrument Functions

    FEATURES • a multi-function display EAS30682 INSTRUMENT FUNCTIONS Multi-function meter unit • Except when switching to the brightness con- trol mode or to display the clock, turn the key to “ON” before using the “SELECT” and “RESET” buttons to adjust the multi-function meter. •...
  • Page 18 FEATURES Clock Eco indicator 1. Clock 1. Eco indicator “ECO” The clock uses a 12-hour time system. When This indicator comes on when the vehicle is be- the key is not in the “ON” position, the clock can ing operated in an environmentally friendly, fuel- be viewed by pushing the “SELECT”...
  • Page 19 FEATURES Drive mode display • an instantaneous fuel consumption display • an average fuel consumption display • a coolant temperature display • an air intake temperature display • a brightness control display • The odometer will lock at 999999 and cannot be reset.
  • Page 20 FEATURES • If you do not reset the fuel reserve tripmeter have been set to miles:). manually, it resets automatically and disap- • “AVE_ _._ km/L”: The average distance that pears after refueling and traveling 5 km (3 mi). can be traveled on 1.0 L of fuel is shown. •...
  • Page 21 FEATURES temperature of the air drawn into the air filter case. This display shows the air intake temperature from –9 C to 99 C in 1 C increments. • –9 C will be displayed even if the air intake temperature falls below –9 C. •...

  • Page 22: 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 23: 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 24: 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 25: 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 26 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 27 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 28 BASIC SERVICE INFORMATION • Make sure all connections are tight. 5. Check: • Resistance Digital circuit tester (CD732) 90890-03243 Model 88 Multimeter with tachom- eter YU-A1927 The resistance values shown were obtained at the standard measuring temperature of 20 C (68 F).

  • Page 29: Special Tools

    8-157, 8-161, YU-A1927 8-162, 8-163, 8-164, 8-165, 8-166, 8-167, 8-168, 8-169, 8-170, 8-171, 8-172, 8-173, 8-174 Yamaha diagnostic tool USB 3-4, 3-11, 4-54, 90890-03250 4-56, 8-36, 8-127, 8-147 Yamaha diagnostic tool (A/I) 3-4, 3-11, 4-54, 90890-03252 4-56, 8-36, 8-127, 8-147...
  • Page 30 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Vacuum gauge 90890-03094 Vacuummate YU-44456 YU-44456 Carburetor angle driver 2 3-10 90890-03173 Steering nut wrench 3-20, 4-73 90890-01403 Exhaust flange nut wrench YU-A9472 Oil filter wrench 3-25 90890-01426 Oil filter wrench YU-38411 Pressure gauge 3-26, 7-11 90890-03153...
  • Page 31 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Rod holder 4-64, 4-69 90890-01434 Damper rod holder double ended YM-01434 Damper rod holder (ø27) 4-65, 4-66 90890-01582 Damper rod holder YM-01582 Fork seal driver 4-67, 4-68 90890-01442 Adjustable fork seal driver (36–46 mm) YM-01442 Rod puller 4-68, 4-69...
  • Page 32 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Drive chain cut & rivet tool 4-83, 4-85 90890-01550 Drive chain cut & rivet tool YM-01550 Compression gauge 90890-03081 90890-03081 Engine compression tester YU-33223 YU-33223 Extension 90890-04136 Pivot shaft wrench 90890-01485 Frame mount insert wrench YM-01485 Pivot shaft wrench 5-7, 5-8...
  • Page 33 Valve guide reamer (ø4.5) 5-25 90890-04118 Valve guide reamer (4.5 mm) YM-04118 Sheave holder 5-31, 5-32, 90890-01701 Primary clutch holder YS-01880-A Flywheel puller 5-31 90890-01362 Heavy duty puller YU-33270-B Yamaha bond No. 1215 5-33, 5-58 90890-85505 (Three bond No.1215®) 1-24...
  • Page 34 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Universal clutch holder 5-42, 5-46 90890-04086 Universal clutch holder YM-91042 Piston pin puller set 5-62 90890-01304 Piston pin puller YU-01304 YU-01304 Piston installing tool 5-69 90890-04161 Piston installing tool YM-04161 Radiator cap tester 90890-01325 Mityvac cooling system tester kit YU-24460-A...
  • Page 35 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Radiator cap tester adapter 90890-01352 Pressure tester adapter YU-33984 YU-33984 Mechanical seal installer 6-11 90890-04078 Water pump seal installer YM-33221-A Middle driven shaft bearing driver 6-11 90890-04058 Middle drive bearing installer 40 & 50 mm YM-04058 Fuel injector pressure adapter 7-11...
  • Page 36 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Test harness– lean angle sensor (6P) 8-165 90890-03209 Test harness– lean angle sensor (6P) YU-03209 Test harness S– pressure sensor (3P) 8-172 90890-03207 Test harness S– pressure sensor (3P) YU-03207 1-27...

  • Page 37: 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 ..............2-31 CABLE ROUTING ..................2-35...

  • Page 38: General Specifications

    GENERAL SPECIFICATIONS EAS20013 GENERAL SPECIFICATIONS Model Model BS21 (MTN850-A_EUR/HRV/TUR/ZAF) BS22 (MTN850-AH) BS27 (MTN850-A_RUS) Dimensions Overall length 2075 mm (81.7 in) Overall width 815 mm (32.1 in) Overall height 1120 mm (44.1 in) Seat height 820 mm (32.3 in) Wheelbase 1440 mm (56.7 in) Ground clearance 135 mm (5.31 in) Minimum turning radius...

  • Page 39: Engine Specifications

    ENGINE SPECIFICATIONS EAS20014 ENGINE SPECIFICATIONS Engine Combustion cycle 4-stroke Cooling system Liquid cooled Valve train DOHC Displacement 847 cm³ Cylinder arrangement Inline Number of cylinders 3-cylinder Bore  stroke 78.0  59.1 mm (3.07  2.33 in) Compression ratio 11.5 : 1 Compression pressure 1331–1713 kPa/680 r/min (13.3–17.1 kgf/cm²/680 r/min, 189.3–243.7 psi/680 r/min)
  • Page 40 ENGINE SPECIFICATIONS Radiator cap valve opening pressure 93.3–122.7 kPa (0.93–1.23 kgf/cm², 13.5–17.8 psi) Water pump Water pump type Single suction centrifugal pump Impeller shaft tilt limit 0.15 mm (0.006 in) Spark plug(s) Manufacturer/model NGK/CPR9EA9 Spark plug gap 0.8–0.9 mm (0.031–0.035 in) Cylinder head Warpage limit 0.10 mm (0.0039 in)
  • Page 41 ENGINE SPECIFICATIONS Cylinder Bore 78.000–78.010 mm (3.0709–3.0713 in) Wear limit 78.060 mm (3.0732 in) Piston Diameter 77.975–77.990 mm (3.0699–3.0705 in) Measuring point (from piston skirt bottom) 12.0 mm (0.47 in) Piston-to-cylinder clearance 0.010–0.035 mm (0.0004–0.0014 in) Piston pin bore inside diameter 17.002–17.013 mm (0.6694–0.6698 in) Limit 17.043 mm (0.6710 in)
  • Page 42 ENGINE SPECIFICATIONS Balancer shaft journal to balancer shaft bear- 0.024–0.048 mm (0.0009–0.0019 in) ing clearance Clutch Clutch type Wet, multiple-disc Clutch lever free play 10.0–15.0 mm (0.39–0.59 in) Friction plate 1 thickness 2.92–3.08 mm (0.115–0.121 in) Wear limit 2.82 mm (0.111 in) Plate quantity 3 pcs Friction plate 2 thickness...
  • Page 43 ENGINE SPECIFICATIONS Output voltage 0.63–0.73 V Idling condition Engine idling speed 1100–1300 r/min AI system Inactive feedback control Inactive Exhaust gas sampling point Sampling port on the exhaust pipe To be measured Coolant temperature 90–110 C (194–230 F) Temperature 1.5–3.5 % Difference in vacuum pressure between the 1.3 kPa (10 mmHg, 0.4 inHg) cylinders...

  • Page 44: Chassis Specifications

    CHASSIS SPECIFICATIONS EAS20015 CHASSIS SPECIFICATIONS Chassis Frame type Diamond 25.0  Caster angle Trail 103 mm (4.1 in) Front wheel Wheel type Cast wheel Rim size 17M/C x MT3.50 Rim material Aluminum Radial wheel runout limit 1.0 mm (0.04 in) Lateral wheel runout limit 0.5 mm (0.02 in) Rear wheel...
  • Page 45 300.3 mm (11.82 in) Limit 294.2 mm (11.59 in) Inner tube bending limit 0.2 mm (0.01 in) Recommended oil Yamaha Suspension Oil 01 Quantity (left) 458.0 cm³ (15.48 US oz, 16.15 Imp.oz) Quantity (right) 462.0 cm³ (15.62 US oz, 16.29 Imp.oz) Level (left) 148 mm (5.8 in)
  • Page 46 CHASSIS SPECIFICATIONS Unit for adjustment Cam position Adjustment value (Soft) Adjustment value (STD) Adjustment value (Hard) Rebound damping Adjusting system Mechanical adjustable type Unit for adjustment Turn Adjustment value from the start position (Soft) Adjustment value from the start position 1+1/2 (STD) Adjustment value from the start position...

  • Page 47: Electrical Specifications

    ELECTRICAL SPECIFICATIONS EAS20016 ELECTRICAL SPECIFICATIONS Voltage System voltage 12 V Ignition system Ignition system Advancer type Digital 5.0 1200 r/min Ignition timing (B.T.D.C.) Engine control unit Model TBDFZ1 Ignition coil 1.19–1.61  Primary coil resistance Secondary coil resistance 9.35–12.65 k Lean angle sensor output voltage 65 ...
  • Page 48 ELECTRICAL SPECIFICATIONS Starter motor Power output 0.70 kW 0.0050–0.0150  Armature coil resistance Brush overall length 12.0 mm (0.47 in) Limit 6.50 mm (0.26 in) Brush spring force 6.03–6.52 N (615–665 gf, 21.71–23.47 oz) Mica undercut (depth) 0.70 mm (0.03 in) Oil level switch 484.0–536.0 ...

  • Page 49: 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 50: 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) Spark plug 13 N·m (1.3 kgf·m, 9.4 lb·ft) Cylinder head cover bolt 10 N·m (1.0 kgf·m, 7.2 lb·ft) Generator rotor bolt 75 N·m (7.5 kgf·m, 54 lb·ft)
  • Page 51 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Stake. Drive sprocket nut 95 N·m (9.5 kgf·m, 69 lb·ft) Lower ring nut 1. Tighten the ring nut to approximately 52 N·m (5.2 kgf·m, 38 lb·ft) with a torque wrench, then loosen the lower ring nut completely.

  • Page 52: 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 Water or Coolant hose insertion part Bearing Cylinder head cover bolt gasket and timing chain bolt gasket Camshaft lobes and journals (intake and exhaust) Valve stem seals (intake and exhaust) Valve lifter outer surface (intake and exhaust) Valve stems and stem ends (intake and exhaust)

  • Page 53: Chassis

    Shift drum moving surface Shift fork pin Shift forks guide bar outer surface 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.
  • Page 54 LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant Rear wheel drive hub oil seal Rear wheel drive hub mating surface Brake caliper piston seal Master cylinder inside Brake caliper piston dust seal Brake caliper bolts 2-17...
  • Page 55 LUBRICATION POINTS AND LUBRICANT TYPES 2-18...

  • Page 56: Lubrication System Chart And Diagrams

    LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20019 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS30020 ENGINE OIL LUBRICATION CHART 2-19...
  • Page 57 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. Drive axle 8. Main axle 9. Shift fork (upper) 10.Mission shower 11.Crankshaft 12.AC magneto 13.Oil nozzle 14.Balancer shaft 15.Timing chain tensioner 16.Intake camshaft...

  • Page 58: Lubrication Diagrams

    LUBRICATION SYSTEM CHART AND DIAGRAMS EAS30021 LUBRICATION DIAGRAMS 2-21...
  • Page 59 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil level switch 2. Oil filter cartridge union bolt 3. Oil filter cartridge 4. Crankshaft 2-22...
  • Page 60 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-23...
  • Page 61 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Timing chain tensioner 2. Intake camshaft 3. Exhaust camshaft 4. Balancer shaft 5. Crankshaft 6. Oil cooler 7. Oil strainer 8. Oil drain bolt 9. Oil pump driven sprocket 2-24...
  • Page 62 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-25...
  • Page 63 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil cooler 2. Oil filter cartridge 3. Oil level switch 4. Oil strainer 5. Oil pump 6. Main gallery bolt 2-26...
  • Page 64 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-27...
  • Page 65 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Balancer shaft 2. Crankshaft 3. Main axle 4. Shift fork guide bar (shift fork-C side) 5. Drive axle 6. Sub gallery bolt 7. Shift fork 2-28...
  • Page 66 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-29...
  • Page 67 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Cylinder head 2. Exhaust camshaft 3. Intake camshaft 4. Oil passage to the timing chain tensioner 5. Oil passage to the cylinder head 6. Oil passage to the clutch chamber 7. Oil return passage from the cylinder head 8.

  • Page 68: Cooling System Diagrams

    COOLING SYSTEM DIAGRAMS EAS20020 COOLING SYSTEM DIAGRAMS 2-31...
  • Page 69 COOLING SYSTEM DIAGRAMS 1. Water pump 2. Thermostat 3. Radiator 2-32...
  • Page 70 COOLING SYSTEM DIAGRAMS 2-33...
  • Page 71 COOLING SYSTEM DIAGRAMS 1. Water jacket 2. Thermostat 3. Radiator 4. Water pump 5. Oil cooler 6. Coolant reservoir 2-34...

  • Page 72: Cable Routing

    CABLE ROUTING EAS20021 CABLE ROUTING Handlebar (top view) 2-35...
  • Page 73 CABLE ROUTING 1. Front brake master cylinder 2. Throttle cable 3. Rubber cover 4. Handlebar 5. Front brake light switch connector 6. Front brake light switch 7. Front brake hose A. When installing the rubber cover, silicone water or soapy water may be applied to the inside of the rubber cover.
  • Page 74 CABLE ROUTING Handlebar (front view) 2-37...
  • Page 75 CABLE ROUTING 1. Throttle cable 2. Meter 3. Stay 1 4. Brake hose 5. Bracket 1 6. Wire harness 7. Horn 8. Master cylinder 9. Meter lead 10.Headlight lead 11.Meter bracket 12.Headlight coupler A. To headlight B. Clamp the left and right leads of the handle- bar switch to the rounded part of the handle- bar.
  • Page 76 CABLE ROUTING Radiator (front side view and right side view) 2-39...
  • Page 77 CABLE ROUTING 1. Radiator cap 2. Radiator 3. Radiator fan 4. Radiator outlet hose 5. Thermostat assembly 6. Water jacket joint 7. Coolant reservoir 8. Radiator inlet hose A. Install the radiator outlet hose with its white paint mark facing inward. B.
  • Page 78 CABLE ROUTING Fuel tank (left and bottom view) 2-41...
  • Page 79 CABLE ROUTING 1. Frame 2. Fuel tank 3. Fuel pump 4. Fuel tank drain hose 5. Fuel tank breather hose 6. Clip 7. Fuel hose assembly A. Insert the fuel tank drain hose up to the sec- tion where the fuel tank pipe increases in diameter.
  • Page 80 CABLE ROUTING Canister (top view and left side view) 2-43...
  • Page 81 CABLE ROUTING 1. Frame 2. Clamp 3. Canister 4. Canister holder 5. Canister breather hose 6. Fuel tank drain hose 7. Fuel tank breather hose 8. Canister purge hose 9. Fuel tank 10.Rear shock absorber assembly 11.Canister bracket A. Front side of the vehicle B.
  • Page 82 CABLE ROUTING Air filter case and throttle body (top view and left side view) 2-45...
  • Page 83 CABLE ROUTING 1. Air filter case joint clamp 2. ECU (Engine Control Unit) 3. Air filter case 4. Throttle body 5. Clip 6. Cylinder head breather hose 7. Throttle cable (decelerator cable) (white plat- ing) 8. Throttle cable (accelerator cable) (black plat- ing) 9.
  • Page 84 CABLE ROUTING Air cut-off valve (left side view) 2-47...
  • Page 85 CABLE ROUTING 1. Radiator fan cover 2. Air filter case 3. Clip 4. Air induction system hose (air filter case to air cut-off valve) 5. Air induction system hose (air cut-off valve to reed valve cover #1) 6. Air induction system hose (air cut-off valve to reed valve cover #2/#3) 7.
  • Page 86 CABLE ROUTING Frame and engine (right side view) 2-49...
  • Page 87 CABLE ROUTING 1. Clamp 2. Rear brake light switch lead 3. Main switch lead 4. Handlebar switch lead (right) 5. Front brake hose 6. Wire harness 7. O sensor coupler 8. O sensor lead 9. Frame 10.Engine 11.Adapter bracket 12.Bracket A.
  • Page 88 CABLE ROUTING Frame (right side view) 2-51...
  • Page 89 CABLE ROUTING 1. Handlebar switch coupler (right) 2. Front turn signal light coupler (right) 3. Holder 2 4. Front turn signal light lead (right) 5. Cable guide 6. Main switch lead 7. Wire harness 8. Fuse box 9. Clamp 10.Stay 2 11.Frame 12.Coolant reservoir hose A.
  • Page 90 CABLE ROUTING Frame (left side view) 2-53...
  • Page 91 CABLE ROUTING 1. Intake air temperature sensor 2. Grip warmer coupler (OPTION) 3. Front turn signal light coupler 4. Holder 5. Frame 6. Stay 1 7. Clamp 8. Front wheel sensor lead 9. Stay 1 10.Holder 1 11.Bracket 1 A. Install the intake air temperature sensor cou- pler to the rib of stay 1.
  • Page 92 CABLE ROUTING Frame and engine (left side view) 2-55...
  • Page 93 CABLE ROUTING 1. Air induction system hose (air filter case to air cut-off valve) 2. Air filter case 3. Throttle cables 4. Stator coil assembly lead 5. Boots 6. Starter motor lead 7. Clutch cable 8. Clamp 9. Front wheel sensor 10.Wire harness protector 11.Coupler cover 12.Main switch coupler 1...
  • Page 94 CABLE ROUTING Frame and engine (left side view) 2-57...
  • Page 95 CABLE ROUTING 1. License plate light coupler 2. Shift switch lead 3. Drain hose 4. Clamp 5. Shift switch 6. Oil level switch lead 7. Sidestand switch lead 8. Bracket 1 9. License plate light sub-lead A. Insert the clamp of the license plate light sub- lead into the hole in the bracket.
  • Page 96 CABLE ROUTING Frame (top view) 2-59...
  • Page 97 CABLE ROUTING 1. Injector #1 coupler 2. Injector #2 coupler 3. Clamp 4. Ignition coil #1 coupler 5. Ignition coil #2 coupler 6. Air cut-off valve coupler 7. Ignition coil #3 coupler 8. Injector #3 coupler 9. Throttle position sensor coupler 10.Throttle servo motor coupler 11.Cross tube 12.Accelerator position sensor coupler...
  • Page 98 CABLE ROUTING Frame (top view) 2-61...
  • Page 99 CABLE ROUTING 1. Brake hose (front brake master cylinder to hydraulic unit) 2. License plate light sub-lead coupler 3. Rear wheel sensor coupler 4. Brake hose (hydraulic unit to rear brake cali- per) 5. Brake hose (rear brake master cylinder to hydraulic unit) 6.
  • Page 100 CABLE ROUTING Frame (top view) 2-63...
  • Page 101 H. Fasten the wire harness side of the tail/brake light lead to the battery box. I. Insert the rubber bracket of the Yamaha diag- nostic tool coupler to the battery box. J. Instructional drawing for routes in the front of the battery K.
  • Page 102 CABLE ROUTING Front brake (right side view and left side view) 2-65...
  • Page 103 CABLE ROUTING 1. Front brake hose assembly 1 2. Headlight assembly 3. Front wheel sensor lead 4. Clamp 5. Bracket 6. Front brake caliper assembly (right) 7. Brake hose 1 8. Front brake hose assembly 2 9. Horn 10.Front brake caliper assembly (left) 11.Front wheel sensor assembly 12.Front fork sub-assembly 13.Bracket 1...
  • Page 104 CABLE ROUTING Rear brake 2-67...
  • Page 105 CABLE ROUTING 1. Rear frame 2. Rear wheel sensor 3. Rear wheel sensor lead 4. Rear brake caliper 5. Rear brake hose 6. Clamp 7. Swingarm assembly 8. Wire sub-lead 9. Plastic locking tie A. Install the brake pipe so that it contact with the protrusion on the master cylinder at out- side vehicle.
  • Page 106 CABLE ROUTING Hydraulic unit (top view and left side view) 2-69...
  • Page 107 CABLE ROUTING 1. Wire harness 2. Battery box 3. Brake hose (front brake master cylinder to hydraulic unit) 4. Brake hose (hydraulic unit to front brake cali- pers) 5. Brake hose (rear brake master cylinder to hydraulic unit) 6. Brake hose (hydraulic unit to rear brake cali- per) 7.
  • Page 108 CABLE ROUTING 2-71...

  • Page 109: 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 ENGINE IDLING SPEED ..........3-8...
  • Page 110 CHECKING THE ENGINE OIL LEVEL.............3-24 CHANGING THE ENGINE OIL ..............3-24 MEASURING THE ENGINE OIL PRESSURE .........3-25 CHECKING THE COOLANT LEVEL............3-26 CHECKING THE COOLING SYSTEM .............3-27 CHANGING THE COOLANT..............3-27 CHECKING THE FRONT BRAKE LIGHT SWITCH .........3-29 ADJUSTING THE REAR BRAKE LIGHT SWITCH ........3-29 CHECKING AND LUBRICATING THE CABLES ........3-29 CHECKING THE THROTTLE GRIP............3-29 CHECKING AND CHARGING THE BATTERY........3-30...

  • Page 111: 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 112 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 113 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   ...

  • Page 114: 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 115: Checking The Spark Plugs

    PERIODIC MAINTENANCE EAS30620 CHECKING THE SPARK PLUGS The following procedure applies to all of the spark plugs. 1. Remove: • Air scoop Refer to “GENERAL CHASSIS (1)” on page 4-1. • Rider seat Refer to “GENERAL CHASSIS (1)” on page 4-1.
  • Page 116 PERIODIC MAINTENANCE • Fuel tank cover Refer to “GENERAL CHASSIS (1)” on page 4-1. • Fuel tank Refer to “FUEL TANK” on page 7-1. • Air filter case Refer to “GENERAL CHASSIS (2)” on page 4-7. • Air cut-off valve Refer to “AIR INDUCTION SYSTEM”...
  • Page 117 PERIODIC MAINTENANCE d. To measure the valve clearances of the other prevent the valve pad from falling into the cylinders, starting with cylinder #1 at TDC, crankcase. • Make a note of the position of each valve lifter turn the crankshaft counterclockwise as specified in the following table.

  • Page 118: Checking The Engine Idling Speed

    “02”  Clean the throttle bodies. Refer to “CHECKING AND CLEANING THE THROTTLE BODIES” on page 7-8. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the Yamaha diagnostic tool. Use the diagnostic code number “67”. Refer to “SELF-DIAGNOSTIC FUNCTION g. Install the exhaust and intake camshafts, tim- AND DIAGNOSTIC CODE TABLE”...

  • Page 119: 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 120: Checking The Throttle Body Joints

    PERIODIC MAINTENANCE dard. Otherwise, the engine may run roughly 5. Adjust: at idle and the throttle bodies may not oper- • Throttle grip free play ate properly. Refer to “CHECKING THE THROTTLE GRIP” on page 3-29. • Turn the bypass air screw using the carburetor Throttle grip free play angle driver.

  • Page 121: Adjusting The Exhaust Gas Volume

    1. Remove: tion manual of the Yamaha diagnostic tool. • Air scoop Refer to “GENERAL CHASSIS (1)” on page 1. Connect the Yamaha diagnostic tool to the 4-1. coupler. For information about connecting the • Rider seat Yamaha diagnostic tool, refer to “YAMAHA Refer to “GENERAL CHASSIS (1)”...

  • Page 122: Adjusting The Clutch Lever Free Play

    PERIODIC MAINTENANCE 4. Install: 2. Adjust: • Air filter element • Clutch lever free play • Air filter case cover ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • ECU (Engine Control Unit) Handlebar side ECA20710 a. Turn the adjusting bolt “1” in direction “a” or NOTICE “b”...

  • Page 123: Checking The Brake Operation

    PERIODIC MAINTENANCE Clutch cable locknut 7 N·m (0.7 kgf·m, 5.1 lb·ft) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS30801 CHECKING THE BRAKE OPERATION 1. Check: • Brake operation Brake not working properly  Check the brake system. A. Front brake Refer to “FRONT BRAKE” on page 4-25 and B.

  • Page 124: Checking The Front Brake Pads

    PERIODIC MAINTENANCE • While pushing the brake lever forward, turn the adjusting dial “1” until the brake lever is in the desired position. • Be sure to align the setting on the adjusting dial with the arrow mark “2” on the brake lever hold- Position #1 Distance “a”...

  • Page 125: Checking The Rear Brake Pads

    PERIODIC MAINTENANCE EAS30636 CHECKING THE REAR BRAKE HOSE 1. Check: • Brake hose Cracks/damage/wear  Replace. 2. Check: • Brake hose holder Loose Connection  Tighten the holder bolt. 3. Hold the vehicle upright and apply the rear brake several times. 4.

  • Page 126: Checking The Wheels

    PERIODIC MAINTENANCE “OFF” before checking the operation of the ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ hydraulic unit. a. Fill the brake master cylinder reservoir or brake fluid reservoir to the proper level with k. After operating the ABS, repeat steps (e) to (i) the specified brake fluid. , and then fill the brake master cylinder reser- b.
  • Page 127 Tire air pressure (measured on cerning handling characteristics can be giv- cold tires) en if a tire combination other than one 1 person approved by Yamaha is used on this vehicle. Front 250 kPa (2.50 kgf/cm², 36 psi) Front tire Rear Size 290 kPa (2.90 kgf/cm², 42 psi)

  • Page 128: Checking The Wheel Bearings

    PERIODIC MAINTENANCE arm or cause an accident. Therefore, keep the drive chain slack within the specified lim- its. 1. Shift the transmission into the neutral posi- tion. 2. Check: • Drive chain slack “a” Out of specification  Adjust. Drive chain slack (Maintenance stand) 5.0–15.0 mm (0.20–0.59 in) EAS30641...

  • Page 129: Lubricating The Drive Chain

    PERIODIC MAINTENANCE 2. Adjust: and thoroughly lubricate it with engine oil or • Drive chain slack chain lubricant that is suitable for O-ring chains. Do not use any other lubricants on the drive ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ chain since they may contain solvents that could a.

  • Page 130: Lubricating The Steering Head

    PERIODIC MAINTENANCE ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Steering nut wrench 5. Install: 90890-01403 • Upper bracket Exhaust flange nut wrench Refer to “HANDLEBAR” on page 4-58. YU-A9472 EAS30646 LUBRICATING THE STEERING HEAD Lower ring nut (initial tightening 1. Lubricate: torque) • Upper bearing 52 N·m (5.2 kgf·m, 38 lb·ft) •...

  • Page 131: Adjusting The Shift Pedal

    PERIODIC MAINTENANCE EAS30851 ADJUSTING THE SHIFT PEDAL Refer to “ADJUSTING THE SHIFT PEDAL” on page 4-86. EAS30650 CHECKING THE SIDESTAND 1. Check: • Sidestand operation Check that the sidestand moves smoothly. Rough movement  Repair or replace. EAS30651 EAS30806 LUBRICATING THE SIDESTAND ADJUSTING THE FRONT FORK LEGS Lubricate the pivoting point, metal-to-metal mov- The following procedure applies to both of the...
  • Page 132 PERIODIC MAINTENANCE The spring preload setting is determined by Although the total number of clicks of a damping measuring the distance “c” shown in the illustra- force adjusting mechanism may not exactly tion. The shorter distance “c” is, the higher the match the above specifications due to small dif- spring preload;...

  • Page 133: Checking The Rear Shock Absorber Assembly

    PERIODIC MAINTENANCE Spring preload Adjustment value (Soft) Adjustment value (STD) Adjustment value (Hard) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS30808 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 3 2 1 7 6 5 4 Refer to “CHECKING THE REAR SHOCK AB- SORBER ASSEMBLY” on page 4-76. EAS30655 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...

  • Page 134: Checking The Connecting Arm And Relay Arm

    PERIODIC MAINTENANCE production. ECA13361 NOTICE • Engine oil also lubricates the clutch and the wrong oil types or additives could cause clutch slippage. Therefore, do not add any chemical additives or use engine oils with a grade of “CD” or higher and do not use oils labeled “ENERGY CONSERVING II”.

  • Page 135: Engine

    PERIODIC MAINTENANCE 4. Drain: 7. Fill: • Engine oil • Crankcase (completely from the crankcase) (with the specified amount of the recom- 5. If the oil filter cartridge is also to be replaced, mended engine oil) perform the following procedure. Engine oil quantity ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...

  • Page 136: Checking The Coolant Level

    PERIODIC MAINTENANCE 3. Remove: Engine oil pressure Possible causes • Main gallery bolt “1” EWA12980 • Faulty oil pump WARNING • Clogged oil filter Below specification • Leaking oil passage The engine, muffler and engine oil are ex- • Broken or damaged tremely hot.

  • Page 137: Checking The Cooling System

    PERIODIC MAINTENANCE gine is hot. Scalding hot fluid and steam may 4. Check: • Coolant level be blown out, which could cause serious in- jury. When the engine has cooled, open the radiator cap as follows: Before checking the coolant level, wait a few Place a thick rag or a towel over the radiator minutes until it settles.

  • Page 138: Cooling System

    PERIODIC MAINTENANCE 5. Remove: EWA13040 WARNING • Water pump drain bolt “1” • If coolant splashes in your eyes, thorough- • Copper washer “2” ly wash them with water and consult a doc- tor. • If coolant splashes on your clothes, quickly wash it away with water and then with soap and water.

  • Page 139: Checking The Front Brake Light Switch

    PERIODIC MAINTENANCE EL” on page 3-26. EWA13270 WARNING Damaged outer cable may cause the cable to Before checking the coolant level, wait a few corrode and interfere with its movement. Re- minutes until the coolant has settled. place damaged outer cable and inner cables as soon as possible.

  • Page 140: Checking And Charging The Battery

    PERIODIC MAINTENANCE 8-156. EAS30664 ADJUSTING THE HEADLIGHT BEAMS 1. Adjust: • Headlight beam (vertically) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ To adjust the headlight beam (vertically), insert a phillips screwdriver into the hole “a” and turn the adjusting screw. 4. Adjust: a. Turn the adjusting screw “1” in direction “b” or •...
  • Page 141 PERIODIC MAINTENANCE a. Turn the adjusting screw “1” in direction “b” or “c”. Direction “b” Headlight beam moves to the right. Direction “c” Headlight beam moves to the left. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3-31...
  • Page 142 PERIODIC MAINTENANCE 3-32...
  • Page 143 CHASSIS GENERAL CHASSIS (1) ..................4-1 REMOVING THE AIR SCOOPS ..............4-5 INSTALLING THE AIR SCOOPS ...............4-5 INSTALLING THE FUEL TANK MOLES ............4-5 GENERAL CHASSIS (2) ..................4-7 FRONT WHEEL....................4-8 REMOVING THE FRONT WHEEL............4-10 DISASSEMBLING THE FRONT WHEEL..........4-10 CHECKING THE FRONT WHEEL ............4-10 ASSEMBLING THE FRONT WHEEL............4-11 MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR....................4-12...
  • Page 144 REMOVING THE REAR BRAKE CALIPER ..........4-44 DISASSEMBLING THE REAR BRAKE CALIPER ........4-45 CHECKING THE REAR BRAKE CALIPER..........4-45 ASSEMBLING THE REAR BRAKE CALIPER .........4-46 INSTALLING THE REAR BRAKE CALIPER..........4-46 REMOVING THE REAR BRAKE MASTER CYLINDER ......4-47 CHECKING THE REAR BRAKE MASTER CYLINDER ......4-47 ASSEMBLING THE REAR BRAKE MASTER CYLINDER.......4-48 INSTALLING THE REAR BRAKE MASTER CYLINDER ......4-48 ABS (ANTI-LOCK BRAKE SYSTEM)............4-49...
  • Page 145 CHAIN DRIVE....................4-82 REMOVING THE DRIVE CHAIN..............4-83 CHECKING THE DRIVE CHAIN ..............4-83 CHECKING THE DRIVE SPROCKET............4-84 CHECKING THE REAR WHEEL SPROCKET.........4-84 CHECKING THE REAR WHEEL DRIVE HUB .........4-84 INSTALLING THE DRIVE CHAIN ............4-85 ADJUSTING THE SHIFT PEDAL.............4-86...
  • Page 146 GENERAL CHASSIS (1) EAS20026 GENERAL CHASSIS (1) Removing the seat and battery 2.2 N ・ m (0.22 kgf ・ m, 1.6 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Rider seat Battery band Negative battery lead Disconnect. Positive battery lead Disconnect.
  • Page 147 GENERAL CHASSIS (1) Removing the rear cover 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 ・ m (0.15 kgf ・ m, 1.1 lb ・ ft) 4.0 N ・...
  • Page 148 GENERAL CHASSIS (1) Removing the headlight and meter assembly 5 N ・ m (0.5 kgf ・ m, 3.6 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) Order Job/Parts to remove Q’ty...
  • Page 149 GENERAL CHASSIS (1) Removing the air scoop and fuel tank cover 1.5 N ・ m (0.15 kgf ・ m, 1.1 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 150: General Chassis (1)

    GENERAL CHASSIS (1) EAS31332 REMOVING THE AIR SCOOPS 1. Remove: • Air scoop (left) “1” ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the air scoop bolt “2” and quick fas- teners “3”. b. Pull the air scoop off at the areas “a” shown. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2.

  • Page 151: General Chassis (2)

    GENERAL CHASSIS (1) 2. Install: • Fuel tank mole (right) “1” ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Install the hole “a” in the fuel tank mole onto the projection “b” on the air scoop stay. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...
  • Page 152 GENERAL CHASSIS (2) EAS20155 GENERAL CHASSIS (2) Removing the air filter case 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) (10) 1.6 N ・ m (0.16 kgf ・ m, 1.2 lb ・ ft) 2.8 N ・ m (0.28 kgf ・ m, 2.0 lb ・ ft) Order Job/Parts to remove Q’ty...
  • Page 153 FRONT WHEEL EAS20028 FRONT WHEEL Removing the front wheel and brake discs 35 N ・ m (3.5 kgf ・ m, 25 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) 65 N ・ m (6.5 kgf ・ m, 47 lb ・ ft) 23 N ・...
  • Page 154 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...

  • Page 155: Front Wheel

    FRONT WHEEL tor, wipe it off immediately. EAS31148 REMOVING THE FRONT WHEEL 1. Remove: ECA21380 • Oil seals NOTICE • Wheel bearings Keep magnets (including magnetic pick-up tools, magnetic screwdrivers, etc.) away ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ from the front wheel sensor “1”, otherwise a.

  • Page 156: Assembling The Front Wheel

    FRONT WHEEL EAS31150 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 157: Maintenance Of The Front Wheel Sensor And Sensor Rotor

    FRONT WHEEL • 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  Replace. 8 N·m (0.8 kgf·m, 5.8 lb·ft) Iron powder/dust ...

  • Page 158: Adjusting The Front Wheel Static Balance

    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. Release the front wheel. e.

  • Page 159: Installing The Front Wheel (Front Brake Discs)

    FRONT WHEEL c. If the heavy spot does not stay in that posi- 2. Check: tion, install a heavier weight. • Front brake discs d. Repeat steps (b) and (c) until the front wheel Refer to “CHECKING THE FRONT BRAKE is balanced.
  • Page 160 FRONT WHEEL sor rotor and the front wheel sensor. Thickness gauge 90890-03180 Feeler gauge set YU-26900-9 6. Install: • Front wheel sensor • Front wheel sensor bracket Front wheel sensor bolt 7 N·m (0.7 kgf·m, 5.1 lb·ft) ECA21020 NOTICE Make sure there are no foreign materials in the front wheel sensor rotor and front wheel sensor.
  • Page 161 REAR WHEEL EAS20029 REAR WHEEL Removing the rear wheel 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) 16 N ・ m (1.6 kgf ・ m, 12 lb ・ ft) 16 N ・...
  • Page 162 REAR WHEEL Disassembling the mudguard 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) 22 N ・...
  • Page 163 REAR WHEEL Removing the brake disc and rear wheel sprocket 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) 80 N ・ m (8.0 kgf ・ m, 58 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Rear brake disc Bracket Rear wheel sprocket...
  • Page 164 REAR WHEEL Disassembling the rear wheel 8 N ・ m (0.8 kgf ・ m, 5.8 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Rear wheel sensor rotor Oil seal Wheel bearing Spacer Wheel bearing 4-19...

  • Page 165: Rear Wheel

    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. 4. Remove: •...

  • Page 166: Checking The Rear Wheel

    REAR WHEEL EAS30159 CHECKING THE REAR WHEEL 1. Check: • Wheel axle • Wheel bearings • Oil seals Refer to “CHECKING THE FRONT WHEEL” on page 4-10. 2. Check: • Tire • Rear wheel Damage/wear  Replace. b. Correct Refer to “CHECKING THE TIRES” on page 1.

  • Page 167: Maintenance Of The Rear Wheel Sensor And Sensor Rotor

    REAR WHEEL • Oil seal EAS31157 INSTALLING THE REAR WHEEL (REAR Refer to “ASSEMBLING THE FRONT BRAKE DISC) WHEEL” on page 4-11. 1. Install: • Rear brake disc EAS31156 MAINTENANCE OF THE REAR WHEEL Rear brake disc bolt SENSOR AND SENSOR ROTOR 30 N·m (3.0 kgf·m, 22 lb·ft) ECA21060 LOCTITE®...
  • Page 168 REAR WHEEL ing block (left side: chain puller) “1” and adjust- ing bolt “2”. A. Right side 5. Install: • Rear brake caliper A. Left side • Rear brake caliper bolts B. Right side 6. Adjust: 8. Install: • Drive chain slack •...
  • Page 169 REAR WHEEL vice and caught foreign materials). If there is any defective part, repair or replace the de- fective part. Distance “a” (between the wheel sensor rotor and rear wheel sen- sor) 0.7–1.4 mm (0.03–0.06 in) Measure the distance between the rear wheel sensor rotor and rear wheel sensor in several places in one rotation of the rear wheel.

  • Page 170: Front Brake

    FRONT BRAKE EAS20030 FRONT BRAKE Removing the front brake pads 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 Remarks The following procedure applies to both of the front brake calipers.
  • Page 171 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 172 FRONT BRAKE Disassembling the front brake master cylinder Order Job/Parts to remove Q’ty Remarks Brake master cylinder kit Brake master cylinder body 4-27...
  • Page 173 FRONT BRAKE Removing the front brake calipers 35 N ・ m (3.5 kgf ・ m, 25 lb ・ ft) 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers.
  • Page 174 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 175: Introduction

    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 176: Replacing The Front Brake Pads

    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 177: Removing The Front Brake Calipers

    FRONT BRAKE 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 178: Disassembling The Front Brake Calipers

    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 179: Installing The Front Brake Calipers

    FRONT BRAKE replace the brake caliper piston dust seals 2. Remove: and brake caliper piston seals. • Front brake caliper 3. Install: Specified brake fluid • Brake pads DOT 4 • Brake pad spring • Brake pad pin • Brake pad clips EAS30175 INSTALLING THE FRONT BRAKE CALIPERS •...

  • Page 180: Removing The Front Brake Master Cylinder

    FRONT BRAKE (brake master cylinder body) Obstruction  Blow out with compressed air. 2. Check: • Brake master cylinder kit Damage/scratches/wear  Replace. 3. Check: • Brake master cylinder reservoir “1” • Brake master cylinder reservoir diaphragm holder “2” Cracks/damage  Replace. •...
  • Page 181 FRONT BRAKE • Align the end of the front brake master cylinder (with the specified amount of the specified holder with the punch mark “b” on the handle- brake fluid) bar. Specified brake fluid • First, tighten the upper bolt, then the lower bolt. DOT 4 •...

  • Page 182: Rear Brake

    REAR BRAKE EAS20031 REAR BRAKE Removing the rear brake pads 5 N ・ m (0.5 kgf ・ m, 3.6 lb ・ ft) 27 N ・ m (2.7 kgf ・ m, 20 lb ・ ft) 22 N ・ m (2.2 kgf ・ m, 16 lb ・ ft) 17 N ・...
  • Page 183 REAR BRAKE Removing the rear brake master cylinder 3.8 N ・ m (0.38 kgf ・ m, 2.8 lb ・ ft) 110 N ・ m (11 kgf ・ m, 80 lb ・ ft) 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) 30 N ・...
  • Page 184 REAR BRAKE Removing the rear brake master cylinder 3.8 N ・ m (0.38 kgf ・ m, 2.8 lb ・ ft) 110 N ・ m (11 kgf ・ m, 80 lb ・ ft) 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) 30 N ・...
  • Page 185 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 4-40...
  • Page 186 REAR BRAKE Removing the rear brake caliper 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) 22 N ・ m (2.2 kgf ・ m, 16 lb ・ ft) 27 N ・ m (2.7 kgf ・ m, 20 lb ・ ft) Order Job/Parts to remove Q’ty...
  • Page 187 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 188: Introduction

    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 189: Removing The Rear Brake Caliper

    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 190: Disassembling The Rear Brake Caliper

    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 191: Assembling The Rear Brake Caliper

    REAR BRAKE 2. Check: EWA13531 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 4-16. ECA19080 NOTICE When installing the brake hose onto the brake caliper “1”, make sure the brake pipe “a”...

  • Page 192: Removing The Rear Brake Master Cylinder

    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 193: Assembling The Rear Brake Master Cylinder

    REAR BRAKE EAS30195 EWA13090 ASSEMBLING THE REAR BRAKE MASTER WARNING CYLINDER • Use only the designated brake fluid. Other EWA13520 brake fluids may cause the rubber seals to WARNING deteriorate, causing leakage and poor • Before installation, all internal brake com- brake performance.

  • Page 194: Abs (Anti-Lock Brake System)

    ABS (ANTI-LOCK BRAKE SYSTEM) EAS20032 ABS (ANTI-LOCK BRAKE SYSTEM) Removing the hydraulic unit assembly 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) 7 N ・...
  • Page 195 ABS (ANTI-LOCK BRAKE SYSTEM) Removing the hydraulic unit assembly 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) 7 N ・...

  • Page 196: Abs Components Chart

    ABS (ANTI-LOCK BRAKE SYSTEM) EAS30728 ABS COMPONENTS CHART 1. Hydraulic unit assembly 2. Fuse box 2 3. Yamaha diagnostic tool coupler 4. Rear wheel sensor 5. Rear wheel sensor rotor 6. Front wheel sensor 7. Front wheel sensor rotor 8. ABS warning light 9.

  • Page 197: Removing The Hydraulic Unit Assembly

    ABS (ANTI-LOCK BRAKE SYSTEM) EAS30197 REMOVING THE HYDRAULIC UNIT Do not operate the brake lever and brake pedal ASSEMBLY while removing the brake hoses. ECA21091 NOTICE ECA18251 NOTICE Unless necessary, avoid removing and in- When removing the brake hoses, cover the stalling the brake hoses of the hydraulic unit area around the hydraulic unit assembly to assembly.
  • Page 198 ABS (ANTI-LOCK BRAKE SYSTEM) Do not allow any foreign materials to enter the hydraulic unit assembly or the brake hoses when installing the hydraulic unit assembly. 2. Remove: • Rubber plugs or bolts (M10  1.0) 3. Install: • Front brake hose (front brake master cylinder to hydraulic unit) “1”...

  • Page 199: Hydraulic Unit Operation Tests

    Securely support the vehicle so that there is no danger of it falling over. • For the brake line routing confirmation, use the 6. Start the Yamaha diagnostic tool and display diagnosis of function of the Yamaha diagnostic the diagnosis of function screen.
  • Page 200 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 201 • Be sure to continue operating the brake lever and brake pedal even after the pulsating action has stopped. 6. Start the Yamaha diagnostic tool and display • “ON” and “OFF” on the tool screen indicate the diagnosis of function screen.

  • Page 202: Checking The Abs Warning Light

    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 203: Handlebar

    HANDLEBAR EAS20033 HANDLEBAR Removing the handlebar 3.8 N ・ m (0.38 kgf ・ m, 2.8 lb ・ ft) 17 N ・ m (1.7 kgf ・ m, 12 lb ・ ft) 26 N ・ m (2.6 kgf ・ m, 19 lb ・ ft) 11 N ・...

  • Page 204: Removing The Handlebar

    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 handlebar EAS30205 (left) and the handlebar grip, and gradually push INSTALLING THE HANDLEBAR...
  • Page 205 HANDLEBAR • Clutch cable Lower handlebar holder nut 40 N·m (4.0 kgf·m, 29 lb·ft) Clutch lever holder pinch bolt 11 N·m (1.1 kgf·m, 8.0 lb·ft) 4. Install: • Throttle grip “1” • Throttle cables Align the center of slit on the clutch lever holder •...
  • Page 206 HANDLEBAR 9. Install: • Handlebar switch screw (left) Handlebar switch screw 1.8 N·m (0.18 kgf·m, 1.3 lb·ft) Align the projection “a” on the handlebar switch (left) with the hole “b” in the handlebar. 10.Adjust: • Throttle grip free play Refer to “CHECKING THE THROTTLE GRIP”...

  • Page 207: Front Fork

    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) 23 N ・ m (2.3 kgf ・ m, 17 lb ・ ft) 10 N ・...
  • Page 208 FRONT FORK Disassembling the front fork leg 23 N ・ m (2.3 kgf ・ m, 17 lb ・ ft) 15 N ・ m (1.5 kgf ・ m, 11 lb ・ ft) 23 N ・ m (2.3 kgf ・ m, 17 lb ・ ft) Order Job/Parts to remove Q’ty...

  • Page 209: Removing The Front Fork Legs

    FRONT FORK • Spacer “3” EAS30206 REMOVING THE FRONT FORK LEGS • Locknut “4” The following procedure applies to both of the ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ front fork legs. a. Press down on the spacer with the fork spring compressor “5”. Each front fork leg is equipped with a spring pre- b.

  • Page 210: Checking The Front Fork Legs

    FRONT FORK • Oil seal clip “2” (with a flat-head screwdriver) ECA19100 NOTICE Do not scratch the outer tube. EAS30208 CHECKING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Check: • Inner tube “1” 4.

  • Page 211: Assembling The Front Fork Legs

    –Copper washer • Inner tube’s outer surface –O-ring Recommended oil • Before assembling the front fork leg, make Yamaha Suspension Oil 01 sure all of the components are clean. 1. Install: 4. Install: • Damper rod assembly “1” • Dust seal “1”...
  • Page 212 FRONT FORK • Oil seal clip “2” • Oil seal “3” • Washer “4” • Outer tube bushing “5” • Inner tube bushing “6” ECA19170 NOTICE Make sure the numbered side of the oil seal faces bottom side. 7. Install: •...
  • Page 213 FRONT FORK Fork seal driver Recommended oil 90890-01442 Yamaha Suspension Oil 01 Adjustable fork seal driver (36–46 Quantity (left) 458.0 cm³ (15.48 US oz, 16.15 YM-01442 Imp.oz) Quantity (right) 462.0 cm³ (15.62 US oz, 16.29 Imp.oz) ECA14230 NOTICE • Be sure to use the recommended fork oil.
  • Page 214 FRONT FORK compressor “1”. h. Pull up the rod puller and install the rod holder “2” between the locknut “3” and the spacer “4”. Rod puller 90890-01437 Universal damping rod bleeding tool set YM-A8703 Rod puller attachment (M10 long) 90890-01578 15.Install: Universal damping rod bleeding •...

  • Page 215: Installing The Front Fork Legs

    FRONT FORK 1. Install: Distance “c” • Front fork leg 13 mm (0.51 in) Temporarily tighten the upper and lower bracket pinch bolts. Make sure the outer tube is flush with the top of the upper bracket. 2. Tighten: • Lower bracket pinch bolts “1” Lower bracket pinch bolt 23 N·m (2.3 kgf·m, 17 lb·ft) •...

  • Page 216: Steering Head

    STEERING HEAD EAS20035 STEERING HEAD Removing the lower bracket 110 N ・ m (11 kgf ・ m, 80 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) 52 N ・ m (5.2 kgf ・ m, 38 lb ・ ft) 18 N ・...
  • Page 217 STEERING HEAD Removing the lower bracket 110 N ・ m (11 kgf ・ m, 80 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) 52 N ・ m (5.2 kgf ・ m, 38 lb ・ ft) 18 N ・...

  • Page 218: Removing The Lower Bracket

    STEERING HEAD • Bearing race “2” EAS30213 REMOVING THE LOWER BRACKET Damage/pitting  Replace the bearings and 1. Stand the vehicle on a level surface. bearing races as a set. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over.

  • Page 219: Installing The Steering Head

    STEERING HEAD ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 4. Check: • Upper bracket • Lower bracket (along with the steering stem) Bends/cracks/damage  Replace. EAS30216 INSTALLING THE STEERING HEAD 1. Lubricate: • Upper bearing • Lower bearing Recommended lubricant Lithium-soap-based grease 2. Install: • Lower ring nut “1” •...
  • Page 220 REAR SHOCK ABSORBER ASSEMBLY EAS20036 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly 44 N ・ m (4.4 kgf ・ m, 32 lb ・ ft) 61 N ・ m (6.1 kgf ・ m, 44 lb ・ ft) 44 N ・ m (4.4 kgf ・ m, 32 lb ・ ft) 55 N ・...

  • Page 221: Rear Shock Absorber Assembly

    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 lower nut “1” the rear shock absorber, read and make sure •...

  • Page 222: Installing The Relay Arm

    REAR SHOCK ABSORBER ASSEMBLY 2. Check: • Bearing • Oil seals Damage/pitting  Replace. 3. Check: • Collars Damage/scratches  Replace. EAS30222 INSTALLING THE RELAY ARM 1. Lubricate: • Collars 3. Relay arm • Oil seals 4. Connecting arm 5. Rear shock absorber assembly Recommended lubricant Lithium-soap-based grease A.
  • Page 223 REAR SHOCK ABSORBER ASSEMBLY Rear shock absorber assembly nut (upper) 44 N·m (4.4 kgf·m, 32 lb·ft) Relay arm nut 61 N·m (6.1 kgf·m, 44 lb·ft) Connecting arm lower nut 55 N·m (5.5 kgf·m, 40 lb·ft) 4-78...

  • Page 224: Swingarm

    SWINGARM EAS20037 SWINGARM Removing the swingarm 110 N ・ m (11 kgf ・ m, 80 lb ・ ft) 55 N ・ m (5.5 kgf ・ m, 40 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) 7 N ・...

  • Page 225: Removing The Swingarm

    SWINGARM EAS30226 REMOVING THE SWINGARM 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. Place the vehicle on a maintenance stand so that the rear wheel is elevated. 2.

  • Page 226: Installing The Swingarm

    SWINGARM • Collars “3” Damage/scratches  Replace. • Bearing “4” Damage/pitting  Replace. A. Left side B. Right side 3. Install: • Swingarm EAS30228 • Pivot shaft INSTALLING THE SWINGARM 1. Lubricate: Pivot shaft nut • Dust covers 110 N·m (11 kgf·m, 80 lb·ft) •...

  • Page 227: Chain Drive

    CHAIN DRIVE EAS20038 CHAIN DRIVE Removing the drive chain 95 N ・ m (9.5 kgf ・ m, 69 lb ・ ft) 8 N ・ m (0.8 kgf ・ m, 5.8 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) 10 N ・...

  • Page 228: Removing The Drive Chain

    CHAIN DRIVE lowing formula. EAS30229 REMOVING THE DRIVE CHAIN Drive chain 15-link section length “a” = 1. Stand the vehicle on a level surface. (length “b” between pin inner sides + length EWA13120 “c” between pin outer sides)/2 WARNING Securely support the vehicle so that there is •...

  • Page 229: Checking The Drive Sprocket

    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 230: Installing The Drive Chain

    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 231: Adjusting The Shift Pedal

    CHAIN DRIVE 7. Adjust: • Drive chain slack Refer to “DRIVE CHAIN SLACK” on page 3-18. Drive chain slack (Maintenance stand) 5.0–15.0 mm (0.20–0.59 in) Drive chain slack (Sidestand) 5.0–15.0 mm (0.20–0.59 in) 5. Install: ECA13550 NOTICE • Shift rod joint “1” A drive chain that is too tight will overload •...
  • Page 232 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 233 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 CAMSHAFTS....................5-9 REMOVING THE CAMSHAFTS...............5-11 CHECKING THE CAMSHAFTS ...............5-12 CHECKING THE TIMING CHAIN AND CAMSHAFT SPROCKET ..5-13 CHECKING THE TIMING CHAIN GUIDES..........5-13 CHECKING THE TIMING CHAIN TENSIONER........5-13 INSTALLING THE CAMSHAFTS .............5-14 CYLINDER HEAD...................5-19 REMOVING THE CYLINDER HEAD............5-20...
  • Page 234 CHECKING THE CLUTCH HOUSING .............5-44 CHECKING THE CLUTCH BOSS............5-45 CHECKING THE PRESSURE PLATE .............5-45 CHECKING THE PRIMARY DRIVE GEAR..........5-45 CHECKING THE PRIMARY DRIVEN GEAR ...........5-45 CHECKING THE PULL LEVER SHAFT AND PULL ROD .......5-45 INSTALLING THE CLUTCH..............5-46 SHIFT SHAFT....................5-49 CHECKING THE SHIFT SHAFT ..............5-50 CHECKING THE STOPPER LEVER ............5-50 INSTALLING THE SHIFT SHAFT ............5-50 OIL PUMP.......................5-51...
  • Page 235 CHECKING THE SHIFT DRUM ASSEMBLY...........5-82 CHECKING THE TRANSMISSION ............5-82 ASSEMBLING THE MAIN AXLE AND DRIVE AXLE .......5-82 INSTALLING THE TRANSMISSION ............5-83...

  • Page 236: Engine Inspection

    ENGINE INSPECTION EAS20041 ENGINE INSPECTION Compression gauge 90890-03081 Engine compression tester EAS30249 MEASURE THE COMPRESSION PRESSURE YU-33223 The following procedure applies to all of the cyl- Extension inders. 90890-04136 Insufficient compression pressure will result in a loss of performance. 1. Measure: •...
  • Page 237 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) 7.

  • Page 238: Engine Removal

    ENGINE REMOVAL EAS20042 ENGINE REMOVAL Removing the muffler and exhaust pipe 20 N ・ m (2.0 kgf ・ m, 14 lb ・ ft) 20 N ・ m (2.0 kgf ・ m, 14 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) 12 N ・...
  • Page 239 ENGINE REMOVAL Disconnecting the leads and hoses 12 N ・ m (1.2 kgf ・ m, 8.7 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 (1)” on page Rider seat 4-1.
  • Page 240 ENGINE REMOVAL Disconnecting the leads and hoses 12 N ・ m (1.2 kgf ・ m, 8.7 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Oil level switch coupler Disconnect.
  • Page 241 ENGINE REMOVAL Removing the engine 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) 45 N ・ m (4.5 kgf ・ m, 33 lb ・ ft) 45 N ・ m (4.5 kgf ・ m, 33 lb ・ ft) 12 N ・...

  • Page 242: Removing The Engine

    ENGINE REMOVAL EAS30250 REMOVING THE ENGINE 1. Loosen: • Engine mounting adjust bolt (front) Loosen the engine mounting adjust bolt with the pivot shaft wrench “1”. Pivot shaft wrench 90890-01485 Frame mount insert wrench YM-01485 EAS30251 INSTALLING THE ENGINE 1. Install: •...
  • Page 243 ENGINE REMOVAL 7. Tighten: • Engine mounting adjust bolts (rear) “2” • Tighten the engine mounting adjust bolts to specification with the pivot shaft wrench and pivot shaft wrench adapter. • Make sure that the flange on the engine mounting adjust bolt contacts the engine. Engine mounting adjust bolt (rear) 7 N·m (0.7 kgf·m, 5.1 lb·ft)

  • Page 244: Camshafts

    CAMSHAFTS EAS20043 CAMSHAFTS Removing the cylinder head cover 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) 13 N ・ m (1.3 kgf ・ m, 9.4 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS (1)” on page Rider seat 4-1.
  • Page 245 CAMSHAFTS Removing the camshafts 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) 24 N ・...

  • Page 246: Removing The Camshafts

    CAMSHAFTS 4. Remove: EAS30256 REMOVING THE CAMSHAFTS • Camshaft cap “1” 1. Remove: • Intake camshaft cap “2” • Timing mark accessing bolt “1” • Exhaust camshaft cap “3” • Crankshaft end cover “2” ECA13720 NOTICE To prevent damage to the cylinder head, camshafts or camshaft caps, loosen the camshaft cap bolts in stages and in a criss- cross pattern, working from the outside in.

  • Page 247: Checking The Camshafts

    CAMSHAFTS Camshaft wrench 90890-04162 Camshaft wrench YM-04162 4. Measure: • Camshaft-journal-to-camshaft-cap clearance Out of specification  Measure the camshaft journal diameter. Camshaft-journal-to-camshaft- cap clearance EAS30257 0.028–0.062 mm (0.0011–0.0024 CHECKING THE CAMSHAFTS 1. Check: Limit • Camshaft lobes 0.080 mm (0.0032 in) Blue discoloration/pitting/scratches ...

  • Page 248: Checking The Timing Chain And Camshaft Sprocket

    CAMSHAFTS a. 1/4 tooth ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ b. Correct 5. Measure: • Camshaft journal diameter “a” 1. Timing chain Out of specification  Replace the camshaft. 2. Camshaft sprocket Within specification  Replace the cylinder head and the camshaft caps as a set. EAS30265 CHECKING THE TIMING CHAIN GUIDES Camshaft journal diameter...

  • Page 249: Installing The Camshafts

    CAMSHAFTS b. Make sure that the timing chain tensioner rod ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ moves in and out of the timing chain tension- 3. Install: er housing smoothly. If there is rough move- • Intake camshaft sprocket “1” ment, replace the timing chain tensioner. •...
  • Page 250 CAMSHAFTS shaft faces up. • When installing the camshaft, no need to align Tighten the camshaft cap bolts in the tightening the mark “b” on the camshaft sprocket. sequence as shown. ECA17430 NOTICE • Lubricate the camshaft cap bolts with the engine oil.
  • Page 251 CAMSHAFTS 8. Check: c. Tighten the timing chain tensioner bolts to the • Camshaft punch mark “a” specified torque. Make sure the camshaft punch mark “a” on Timing chain tensioner bolt the camshaft is aligned with the camshaft cap 10 N·m (1.0 kgf·m, 7.2 lb·ft) alignment mark “b”.
  • Page 252 CAMSHAFTS 10.Turn: • Crankshaft (several turns counterclockwise) 11.Check: • Mark “a” Make sure the mark “a” on the generator rotor is aligned with the generator rotor cover mark “b”. • Camshaft punch mark “c” Make sure the camshaft punch mark “c” on the camshaft is aligned with the camshaft cap 14.Install: alignment mark “d”.
  • Page 253 CAMSHAFTS Install the ignition coils “1” in the direction shown in the illustration. 5-18...

  • Page 254: Cylinder Head

    CYLINDER HEAD EAS20044 CYLINDER HEAD Removing the cylinder head 20 N ・ m (2.0 kgf ・ m, 14 lb ・ ft) 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) 17 N ・ m (1.7 kgf ・ m, 12 lb ・ ft) 10 N ・...

  • Page 255: Removing The Cylinder Head

    CYLINDER HEAD 2. Check: EAS30276 REMOVING THE CYLINDER HEAD • Cylinder head 1. Remove: Damage/scratches  Replace. • Intake camshaft • Cylinder head water jacket • Exhaust camshaft Mineral deposits/rust  Eliminate. Refer to “REMOVING THE CAMSHAFTS” 3. Measure: on page 5-11. •...

  • Page 256: Installing The Cylinder Head

    CYLINDER HEAD 4. Install: EAS30282 INSTALLING THE CYLINDER HEAD • Exhaust camshaft 1. Install: • Intake camshaft • Timing chain guide (exhaust side) “1” Refer to “INSTALLING THE CAMSHAFTS” • Cylinder head gasket “2” on page 5-14. • Dowel pins “3” 2.
  • Page 257 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 5-19. Intake valve lifter Intake valve pad Intake valve cotter Intake valve spring retainer Intake valve spring Intake valve Intake valve stem seal...

  • Page 258: Valves And Valve Springs

    VALVES AND VALVE SPRINGS EAS30283 REMOVING THE VALVES Remove the valve cotters by compressing the The following procedure applies to all of the valve spring with the valve spring compressor valves and related components. “1” and the valve spring compressor attachment “2”.
  • Page 259 VALVES AND VALVE SPRINGS 1. Measure: • Valve-stem-to-valve-guide clearance Out of specification  Replace the valve guide. • 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 b. Install the new valve guide with the valve guide installer “2”...

  • Page 260: Checking The Valve Seats

    VALVES AND VALVE SPRINGS 2. Check: Valve guide remover (ø4.5) • Valve seat 90890-04116 Pitting/wear  Replace the cylinder head. Valve guide remover (4.5 mm) 3. Measure: YM-04116 • Valve seat contact width “a” Valve guide installer (ø4.5) Out of specification  Replace the cylinder 90890-04117 head.

  • Page 261: Checking The Valve Springs

    VALVES AND VALVE SPRINGS After replacing the cylinder head or replacing the valve and valve guide, the valve seat and valve face should be lapped. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Apply a coarse lapping compound “a” to the valve face. ECA13790 NOTICE Do not let the lapping compound enter the h.

  • Page 262: Checking The Valve Lifters

    VALVES AND VALVE SPRINGS (with an oil stone) 2. Measure: • Valve spring tilt “a” 2. Lubricate: Out of specification  Replace the valve • Valve stem “1” • Valve stem seal “2” spring. (with the recommended lubricant) Spring tilt (intake) 1.7 mm (0.07 in) Recommended lubricant Spring tilt (exhaust)
  • Page 263 VALVES AND VALVE SPRINGS 6. Lubricate: b. Smaller pitch • Valve pad 4. Install: (with the recommended lubricant) • Valve cotters “1” Recommended lubricant Molybdenum disulfide oil Install the valve cotters by compressing the valve spring with the valve spring compressor •...
  • Page 264 GENERATOR AND STARTER CLUTCH EAS20140 GENERATOR AND STARTER CLUTCH Removing the stator coil, generator rotor and starter clutch 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) 32 N ・ m (3.2 kgf ・ m, 23 lb ・ ft) 14 N ・...
  • Page 265 GENERATOR AND STARTER CLUTCH Removing the stator coil, generator rotor and starter clutch 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) 32 N ・ m (3.2 kgf ・ m, 23 lb ・ ft) 14 N ・ m (1.4 kgf ・ m, 10 lb ・ ft) 75 N ・...

  • Page 266: Generator And Starter Clutch

    GENERATOR AND STARTER CLUTCH EAS30867 REMOVING THE GENERATOR 1. Remove: • Generator rotor bolt “1” • Washer While holding the generator rotor “2” with the sheave holder “3”, loosen the generator rotor bolt. Sheave holder EAS30868 90890-01701 REMOVING THE STARTER CLUTCH Primary clutch holder 1.

  • Page 267: Installing The Starter Clutch

    GENERATOR AND STARTER CLUTCH erator rotor “2” and hold the generator rotor. b. When turning the starter clutch gear clock- wise “A”, the starter clutch and the starter clutch gear should engage, otherwise the starter clutch is faulty and must be replaced. c.
  • Page 268 GENERATOR AND STARTER CLUTCH 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 “1” 12 N·m (1.2 kgf·m, 8.7 lb·ft) LOCTITE®...

  • Page 269: Electric Starter

    ELECTRIC STARTER EAS20052 ELECTRIC STARTER Removing the starter motor 12 N ・ m (1.2 kgf ・ m, 8.7 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 (1)” on page Rider seat 4-1.
  • Page 270 ELECTRIC STARTER Disassembling the starter motor 11 N ・ m (1.1 kgf ・ m, 8.0 lb ・ ft) 5 N ・ m (0.5 kgf ・ m, 3.6 lb ・ ft) Order Job/Parts to remove Q’ty Remarks O-ring Starter motor front cover Starter motor yoke Armature assembly Gasket...

  • Page 271: 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 272: Assembling The Starter Motor

    ELECTRIC STARTER 6. Check: Starter motor bolt • Gear teeth 12 N·m (1.2 kgf·m, 8.7 lb·ft) Damage/wear  Replace the starter motor. 7. Check: 2. Connect: • Bearing • Starter motor lead • Oil seal Damage/wear  Replace the starter motor. EAS30326 ASSEMBLING THE STARTER MOTOR 1.

  • Page 273: Clutch

    CLUTCH EAS20055 CLUTCH Removing the clutch cover 12 N ・ m (1.2 kgf ・ m, 8.7 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) 12 N ・ m (1.2 kgf ・ m, 8.7 lb ・ ft) 1.5 N ・...
  • Page 274 CLUTCH Removing the pull lever shaft 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 Install the clutch cover damper plate with its Clutch cover damper plate folded-up side facing upward.
  • Page 275 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 Oil pump driven sprocket Refer to “OIL PUMP” on page 5-51. Pressure plate 1 Clutch spring Absorber...
  • Page 276 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 Thrust plate Clutch housing Oil pump drive chain Bearing Spacer Thrust plate...

  • Page 277: Removing The Clutch

    CLUTCH 4. Remove: EAS30346 REMOVING THE CLUTCH • Friction plates 1 “1” 1. Remove: • Cover “1” • Clutch cover “2” • 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 278: Checking The Friction Plates

    CLUTCH 8. Remove: A. Friction plate 1 • Clutch boss nut B. Friction plate 2 • Conical spring washer EAS30349 • Washer CHECKING THE CLUTCH PLATES • Clutch boss The following procedure applies to all of the • Thrust plate clutch plates.

  • Page 279: Checking The Clutch Springs

    CLUTCH Out of specification  Adjust. Assembly width 42.7–43.5 mm (1.68–1.71 in) • Perform the thickness measurement without applying the oil. • This step should be performed only if the fric- tion plates and clutch plates were replaced. • To measure the total width of the friction plates and clutch plates, combine 9 friction plates and ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...

  • Page 280: Checking The Clutch Boss

    CLUTCH Cracks/damage  Replace. • Bearing “3” Damage/wear  Replace. 2. Check: • Oil pump drive sprocket “1” Cracks/damage/wear  Replace. EAS30356 CHECKING THE PRIMARY DRIVE GEAR 1. Check: • Primary drive gear Damage/wear  Replace the crankshaft and clutch housing as a set. Excessive noise during operation ...

  • Page 281: Installing The Clutch

    CLUTCH Universal clutch holder 90890-04086 Universal clutch holder YM-91042 2. Check: • Pull rod bearing Damage/wear  Replace. EAS30363 INSTALLING THE CLUTCH 1. Install: • Oil pump drive chain “1” • Clutch housing “2” Install the oil pump drive chain onto the oil pump drive sprocket “a”.
  • Page 282 CLUTCH • Clutch springs a crisscross pattern. • Pressure plate 1 6. Install: • Clutch spring bolts “1” • Pull lever Clutch spring bolt • Install the pull lever with the “O” mark facing to- 10 N·m (1.0 kgf·m, 7.2 lb·ft) ward lower side.
  • Page 283 CLUTCH 8. Adjust: • Clutch lever free play Refer to “ADJUSTING THE CLUTCH LEVER FREE PLAY” on page 3-12. Clutch lever free play 10.0–15.0 mm (0.39–0.59 in) 5-48...

  • Page 284: 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 5-38. Shift arm Refer to “CHAIN DRIVE”...

  • Page 285: Checking The Shift Shaft

    SHIFT SHAFT 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” • Lubricate the oil seal lips with lithium-soap- based grease.

  • Page 286: Oil Pump

    OIL PUMP EAS20054 OIL PUMP Removing the oil pump 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) 15 N ・ m (1.5 kgf ・ m, 11 lb ・ ft) Order Job/Parts to remove Q’ty...
  • Page 287 OIL PUMP Disassembling the oil pump 3.8 N ・ m (0.38 kgf ・ m, 2.8 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Oil pump cover Oil pump shaft Oil pump inner rotor Oil pump outer rotor Hold down the washer when removing the Circlip circlip.

  • Page 288: Checking The Sprocket And Chain

    OIL PUMP EAS30336 CHECKING THE SPROCKET AND CHAIN Inner-rotor-to-outer-rotor-tip clearance 1. Check: Less than 0.120 mm (0.0047 in) • Oil pump drive sprocket Limit Refer to “CHECKING THE CLUTCH HOUS- 0.20 mm (0.0079 in) ING” on page 5-44. Outer-rotor-to-oil-pump-housing 2. Check: clearance •...

  • Page 289: Assembling The Oil Pump

    OIL PUMP Oil pump bolt 10 N·m (1.0 kgf·m, 7.2 lb·ft) • Oil pump driven sprocket “3” Oil pump driven sprocket bolt 15 N·m (1.5 kgf·m, 11 lb·ft) LOCTITE® ECA20940 NOTICE EAS30342 After installing the oil pump drive chain and ASSEMBLING THE OIL PUMP driven sprocket, make sure the oil pump 1.

  • Page 290: Oil Pan

    OIL PAN EAS20177 OIL PAN Removing the oil pan 43 N ・ m (4.3 kgf ・ m, 31 lb ・ ft) (13) 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 291: Removing The Oil Pan

    OIL PAN EAS31068 EWA12820 REMOVING THE OIL PAN WARNING 1. Remove: Always use new copper washers. • Oil level switch “1” • Oil pan “2” • Tighten the oil pan bolts in stages and in a • Oil pan gasket crisscross pattern.

  • Page 292: Crankcase

    CRANKCASE EAS20059 CRANKCASE Separating the crankcase 24 N ・ m (2.4 kgf ・ m, 17 lb ・ ft) 25 N ・ m (2.5 kgf ・ m, 18 lb ・ ft) 18 N ・ m (1.8 kgf ・ m, 13 lb ・ ft) 10 N ・...

  • Page 293: 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 294 CRANKCASE 4. Set the shift drum assembly and transmission gears in the neutral position. 5. Install: 19 20 • Lower crankcase “1” 21 22 23 24 (onto the upper crankcase “2”) ECA13980 NOTICE Before tightening the crankcase bolts, make sure the transmission gears shift correctly when the shift drum assembly is turned by hand.
  • Page 295 CRANKCASE 8. Tighten: • Crankcase bolts “9”–“30” Crankcase bolts “9”–“14” 24 N·m (2.4 kgf·m, 17 lb·ft) Crankcase bolts “15”–“30” 10 N·m (1.0 kgf·m, 7.2 lb·ft) Tighten the bolts in the tightening sequence cast on the crankcase. 19 20 23 24 5-60...
  • Page 296 CONNECTING RODS AND PISTONS EAS20132 CONNECTING RODS AND PISTONS Removing the connecting rods and pistons 20 N ・ m (2.0 kgf ・ m, 14 lb ・ ft) Specified angle 175–185˚ Order Job/Parts to remove Q’ty Remarks Lower crankcase Refer to “CRANKCASE” on page 5-57. Connecting rod cap Big end lower bearing Piston pin clip...

  • Page 297: 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 298: Checking The Piston Rings

    CONNECTING RODS AND PISTONS Piston-to-cylinder clearance Measure cylinder bore “C” by taking side-to-side 0.010–0.035 mm (0.0004–0.0014 and front-to-back measurements of the cylinder. Bore f. If out of specification, replace the cylinder, 78.000–78.010 mm (3.0709– and replace the piston and piston rings as a 3.0713 in) set.

  • Page 299: Checking The Piston Pin

    CONNECTING RODS AND PISTONS Out of specification  Replace the piston ring. The oil ring expander spacer’s end gap cannot be measured. If the oil ring rail’s gap is exces- sive, replace all three piston rings. Top ring End gap (installed) 0.15–0.25 mm (0.0059–0.0098 in) End gap limit 3.
  • Page 300 CONNECTING RODS AND PISTONS • Make sure that the projection “a” on the con- ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ necting rod cap faces the same direction as the The following procedure applies to all of the “Y” mark “b” on the connecting rod. connecting rods. •...
  • Page 301 CONNECTING RODS AND PISTONS tighten it. Instead, replace the bolt with a new necting rod cap faces the same direction as the “Y” mark “b” on the connecting rod. one and perform the procedure again. • Make sure the “Y” marks “b” on the connecting ECA20890 rods face towards the left side of the crank- NOTICE...

  • Page 302: Installing The Connecting Rod And Piston

    CONNECTING RODS AND PISTONS ings with the notches “b” in the connecting rods Bearing color code and connecting rod caps. Code 1 • Make sure that the projection “c” on the con- Blue necting rod cap faces the same direction as the Code 2 “Y”...
  • Page 303 CONNECTING RODS AND PISTONS • Install the piston pin clips, so that the clip ends are 3 mm (0.12 in) “c” or more from the cutout To install the big end bearing, care should be taken not to install it at an angle and the position in the piston.
  • Page 304 CONNECTING RODS AND PISTONS 7. Lubricate: • Crankshaft pins • Connecting rod big end bearing inner surface (with the recommended lubricant) Recommended lubricant Engine oil 8. Install: • Piston assemblies “1” (into the cylinder “2” and onto the crankshaft 10.Tighten: pin) •...
  • Page 305 CONNECTING RODS AND PISTONS 180˚ EWA16610 WARNING If the bolt is tightened more than the speci- fied angle, do not loosen the bolt and then re- tighten it. Instead, replace the bolt with a new one and perform the procedure again. ECA20890 NOTICE Do not use a torque wrench to tighten the...
  • Page 306 CRANKSHAFT AND BALANCER SHAFT EAS20178 CRANKSHAFT AND BALANCER SHAFT Removing the crankshaft and balancer shaft Order Job/Parts to remove Q’ty Remarks Lower crankcase Refer to “CRANKCASE” on page 5-57. Refer to “REMOVING THE CONNECTING Connecting rod RODS AND PISTONS” on page 5-62. Balancer shaft Balancer shaft journal lower bearing Balancer shaft journal upper bearing...

  • Page 307: 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 that it can be reinstalled in its original place.
  • Page 308 CRANKSHAFT AND BALANCER SHAFT 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. 4.

  • Page 309: Checking The Balancer Shaft

    CRANKSHAFT AND BALANCER SHAFT Balancer shaft journal to balancer shaft bearing clearance 0.024–0.048 mm (0.0009–0.0019 ECA18400 NOTICE Do not interchange the balancer shaft jour- nal bearings. To obtain the correct balancer shaft-journal-to-balancer shaft-journal-bear- ing clearance and prevent engine damage, the balancer shaft journal bearings must be installed in their original positions.

  • Page 310: Installing The Crankshaft

    CRANKSHAFT AND BALANCER SHAFT e. Install the balancer shaft journal lower bear- ancer shaft web “J ” numbers are 5 and 2 re- ings “1” into the lower crankcase and assem- spectively, then the bearing size for “J ” is: ble the crankcase halves.

  • Page 311: Installing The Balancer Assembly

    CRANKSHAFT AND BALANCER SHAFT (into the lower crankcase) • Crankshaft • Align the projections “a” on the crankshaft jour- nal bearings “1” with the notches “b” in the crankcase. • Be sure to install each crankshaft journal bear- ings in its original place. EAS31172 INSTALLING THE BALANCER ASSEMBLY 1.

  • Page 312: 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 313 TRANSMISSION Disassembling the main axle assembly Order Job/Parts to remove Q’ty Remarks 2nd pinion gear Toothed lock washer Toothed lock washer retainer 6th pinion gear Collar Washer Circlip 3rd pinion gear Circlip Washer 5th pinion gear Collar Bearing housing Bearing Main axle 5-78...
  • Page 314 TRANSMISSION Disassembling the drive axle assembly Order Job/Parts to remove Q’ty Remarks 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 Washer...
  • Page 315 TRANSMISSION Disassembling the drive axle assembly Order Job/Parts to remove Q’ty Remarks Collar Bearing Circlip Drive axle 5-80...

  • Page 316: 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 317 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 318 TRANSMISSION positioned opposite side to the toothed washer and gear. • Align the opening between the ends “b” of the circlip with a groove “c” in the axle. • Install the circlip so that a spline “d” is in the center of the gap between the circlip ends “e”...
  • Page 319 TRANSMISSION • Touch the protrusion “d” on the shift fork guide bar to the side of the shift drum retainer. • Make sure that the drive axle bearing circlip “4” is inserted into the grooves “e” in the upper crankcase. 3.
  • Page 320 TRANSMISSION 5-85...
  • Page 321 COOLING SYSTEM RADIATOR......................6-1 CHECKING THE RADIATOR..............6-2 INSTALLING THE RADIATOR..............6-2 OIL COOLER....................6-4 CHECKING THE OIL COOLER ..............6-5 INSTALLING THE OIL COOLER ...............6-5 THERMOSTAT....................6-6 CHECKING THE THERMOSTAT...............6-7 INSTALLING THE THERMOSTAT ASSEMBLY ........6-7 WATER PUMP ....................6-8 DISASSEMBLING THE WATER PUMP...........6-10 CHECKING THE WATER PUMP .............6-10 ASSEMBLING THE WATER PUMP............6-10...

  • Page 322: Radiator

    RADIATOR EAS20063 RADIATOR Removing the radiator 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) 5 N ・ m (0.5 kgf ・ m, 3.6 lb ・ ft) 0.5 N ・ m (0.05 kgf ・ m, 0.36 lb ・ ft) 9 N ・...

  • Page 323: Checking The Radiator

    RADIATOR EAS30439 CHECKING THE RADIATOR 1. Check: • Radiator fins Obstruction  Clean. Apply compressed air to the rear of the radia- tor. Damage  Repair or replace. Straighten any flattened fins with a thin, flat-head screwdriver. b. Apply the specified pressure for ten seconds and make sure there is no drop in pressure.
  • Page 324 RADIATOR pressure. c. Measure the indicated pressure with the gauge. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Measure: • Radiator cap valve opening pressure Below the specified pressure  Replace the radiator cap. Refer to “CHECKING THE RADIATOR” on page 6-2.

  • Page 325: 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) Order Job/Parts to remove Q’ty Remarks Coolant reservoir Refer to “RADIATOR”...

  • Page 326: Checking The Oil Cooler

    OIL COOLER 5. Measure: EAS30441 CHECKING THE OIL COOLER • Radiator cap valve opening pressure 1. Check: Below the specified pressure  Replace the • Oil cooler radiator cap. Cracks/damage  Replace. Refer to “CHECKING THE RADIATOR” on 2. Check: page 6-2.

  • Page 327: Thermostat

    THERMOSTAT EAS20065 THERMOSTAT Removing the thermostat assembly 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Muffler assembly Refer to “ENGINE REMOVAL” on page 5-3. Drain. Coolant Refer to “CHANGING THE COOLANT” on page 3-27.

  • Page 328: Checking The Thermostat

    THERMOSTAT EAS30443 CHECKING THE THERMOSTAT 1. Check: • Thermostat assembly “1” Cracks/damage  Replace. EAS30445 INSTALLING THE THERMOSTAT ASSEMBLY 1. Install: • Thermostat assembly 2. Fill: • Cooling system (with the specified amount of the recom- mended coolant) Refer to “CHANGING THE COOLANT” on page 3-27.

  • Page 329: Water Pump

    WATER PUMP EAS20066 WATER PUMP Removing the water pump 12 N ・ m (1.2 kgf ・ m, 8.7 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Drain. Coolant Refer to “CHANGING THE COOLANT” on page 3-27. Water pump inlet hose Disconnect.
  • Page 330 WATER PUMP Disassembling the water pump 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 Water pump driven gear Washer Impeller shaft Mechanical seal Bearing Oil seal...

  • Page 331: 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 332 WATER PUMP 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. touches the water pump housing.

  • Page 333: 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 334 FUEL TANK EAS20067 FUEL TANK Removing the fuel tank 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) 4.0 N ・...
  • Page 335 FUEL TANK Removing the canister 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS (1)” on page Rider seat 4-1. Refer to “GENERAL CHASSIS (2)” on page Air scoop/Fuel tank cover 4-7.

  • Page 336: 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/Fuel tank cover Refer to “GENERAL CHASSIS (1)” on page 4-1.

  • Page 337: Installing The Fuel Pump

    FUEL TANK EAS30456 INSTALLING THE FUEL PUMP 1. Install: • Fuel pump gasket • Fuel pump • Fuel pump bracket • Fuel pump bolts Fuel pump bolt 4.0 N·m (0.40 kgf·m, 2.9 lb·ft) 2. Connect: • Do not damage the installation surfaces of the •...

  • Page 338: Throttle Bodies

    THROTTLE BODIES EAS20070 THROTTLE BODIES Removing the throttle bodies 4.5 N ・ m (0.45 kgf ・ m, 3.3 lb ・ ft) 3.0 N ・ m (0.30 kgf ・ m, 2.2 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS (1)” on page Rider seat 4-1.
  • Page 339 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) Order Job/Parts to remove Q’ty Remarks Negative pressure hose Hose joint Canister purge hose Hose joint Intake air pressure sensor 2...
  • Page 340 THROTTLE BODIES Removing the injectors 5 N ・ m (0.5 kgf ・ m, 3.6 lb ・ ft) 12 N ・ m (1.2 kgf ・ m, 8.7 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Throttle bodies/Throttle body joint Refer to “THROTTLE BODIES” on page 7-5. Fuel rail Injector Injector coupler...

  • Page 341: Checking The Injectors (Before Removing)

    THROTTLE BODIES hose may cause the fuel to spray out. Place EAS30475 CHECKING THE INJECTORS (BEFORE a container or rag under the hose to catch REMOVING) any fuel that spills. Always clean up any 1. Check: spilt fuel immediately. • Injectors •...
  • Page 342 • Do not turn the bypass air screws “a”; oth- erwise, the throttle body synchronization will be affected. Recommended cleaning solvent Yamaha Oil & Brake Cleaner d. Apply the recommended cleaning solvent to the throttle valves and the inside of the throt- tle bodies to remove any carbon deposits.

  • Page 343: Replacing The Throttle Bodies

    THROTTLE BODIES • Do not allow carbon deposits or other for- 5. Place the vehicle on a maintenance stand so eign materials to enter any of the passages that the rear wheel is elevated. in each throttle body or in the space be- 6.

  • Page 344: Checking The Fuel Pressure

    THROTTLE BODIES to the fuel rail joint “2”, and then connect an ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ air compressor “3” to the adapter. a. Remove the rider seat, air scoop and fuel b. Connect the pressure gauge “4” to the fuel in- tank cover. jector pressure adapter “1”.

  • Page 345: Installing The Fuel Hose (Fuel Rail Side)

    Remove the protective cap “1”, and then con- When installing the fuel hose, make sure that nect the Yamaha diagnostic tool to coupler. it is securely connected, and that the fuel hose connector cover on the fuel hose is in...

  • Page 346: Adjusting The Accelerator Position Sensor

    Check the Yamaha diagnostic tool screen value. If the Yamaha diagnostic tool screen value is not 95–109, 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. 7-13...
  • Page 347 THROTTLE BODIES r. If the Yamaha diagnostic tool screen values are not within the specified ranges after re- peating steps (f) to (p) several times, replace the accelerator position sensor. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 7-14...

  • Page 348: Air Induction System

    AIR INDUCTION SYSTEM EAS20071 AIR INDUCTION SYSTEM 7-15...
  • Page 349 AIR INDUCTION SYSTEM 1. Air filter case 2. Air induction system hose (air filter case to air cut-off valve) 3. Air cut-off valve 4. Air induction system hose (air cut-off valve to reed valve cover) 7-16...
  • Page 350 AIR INDUCTION SYSTEM Removing the air cut-off valve assembly and reed valves 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 Refer to “GENERAL CHASSIS (1)”...
  • Page 351 AIR INDUCTION SYSTEM Removing the air cut-off valve assembly and reed valves 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 Reed valve assembly 2...

  • Page 352: Checking The Air Induction System

    AIR INDUCTION SYSTEM Cracks/damage  Replace the reed valve EAS30488 CHECKING THE AIR INDUCTION SYSTEM assembly. Air injection 3. Measure: The air induction system burns unburned ex- • Reed valve bending limit “a” haust gases by injecting fresh air (secondary air) Out of specification ...
  • Page 353 AIR INDUCTION SYSTEM 2. Install: • Reed valve assembly 1 • Reed valve assembly 2 • Install the reed valve assembly 1 so that the open side turns to the exhaust side of the en- gine. • Install the reed valve assembly 2 so that the open side turns to the intake side of the engine.
  • Page 354 AIR INDUCTION SYSTEM 7-21...

  • Page 355: Electrical System

    COOLING SYSTEM..................8-29 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 FUEL PUMP SYSTEM..................8-105 CIRCUIT DIAGRAM ................8-105 TROUBLESHOOTING ................8-107 IMMOBILIZER SYSTEM................8-109 CIRCUIT DIAGRAM ................8-109 GENERAL INFORMATION ..............8-111...
  • Page 356 ABS (ANTI-LOCK BRAKE SYSTEM)............8-117 CIRCUIT DIAGRAM ................8-117 ABS COMPONENTS CHART ..............8-119 ABS COUPLER LOCATION CHART .............8-121 MAINTENANCE OF THE ABS ECU ............8-123 ABS TROUBLESHOOTING OUTLINE...........8-123 BASIC INSTRUCTIONS FOR TROUBLESHOOTING ......8-124 BASIC PROCESS FOR TROUBLESHOOTING ........8-125 [A] CHECKING THE ABS WARNING LIGHT.........8-126 [A-1] ONLY THE ABS WARNING LIGHT FAILS TO COME ON....8-126 [A-2] THE ABS WARNING LIGHT AND OTHER INDICATOR LIGHTS FAIL TO COME ON ..............8-126...

  • Page 358: Ignition System

    IGNITION SYSTEM EAS20072 IGNITION SYSTEM EAS30490 CIRCUIT DIAGRAM...
  • Page 359 IGNITION SYSTEM 3. Main switch 4. Main fuse 13.Ignition fuse 18.Battery 19.Engine ground 20.Fuel injection system fuse 23.Joint connector 24.Joint coupler 25.Relay unit 30.ECU (Engine Control Unit) 31.Ignition coil #1 32.Ignition coil #2 33.Ignition coil #3 34.Spark plug 40.Crankshaft position sensor 45.Lean angle sensor 70.Gear position switch 73.Sidestand switch...

  • Page 360: 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 ignition coils does not flow to the ECU when both the gear position switch (neutral circuit) and sidestand switch are set to “OFF”, thereby preventing the spark plugs from producing a spark.
  • Page 361 IGNITION SYSTEM 1. Battery 2. Main fuse 3. Main switch 4. Ignition fuse 5. Start/engine stop switch 6. Ignition coil 7. Spark plug 8. ECU (Engine Control Unit) 9. Sidestand switch 10.Relay unit (diode) 11.Gear position switch (neutral circuit) 12.Battery negative lead...

  • Page 362: 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 2. Air scoop 3. Front side panel 4. Fuel tank cover 5. Fuel tank 6. Air filter case 1.
  • Page 363 IGNITION SYSTEM 9. Check the gear position switch. Refer to “CHECKING THE GEAR Replace the gear position switch. POSITION SWITCH” on page NG 8-173. OK 10.Check the sidestand switch. Refer to “CHECKING THE Replace the sidestand switch. NG SWITCHES” on page 8-153. OK...

  • Page 364: Electric Starting System

    ELECTRIC STARTING SYSTEM EAS20073 ELECTRIC STARTING SYSTEM EAS30493 CIRCUIT DIAGRAM...
  • Page 365 ELECTRIC STARTING SYSTEM 3. Main switch 4. Main fuse 13.Ignition fuse 18.Battery 19.Engine ground 20.Fuel injection system fuse 21.Starter relay 22.Starter motor 23.Joint connector 24.Joint coupler 25.Relay unit 26.Starting circuit cut-off relay 70.Gear position switch 73.Sidestand switch 74.Handlebar switch (right) 76.Start/engine stop switch 81.Handlebar switch (left) 82.Clutch switch...

  • Page 366: 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 367 ELECTRIC STARTING SYSTEM a. WHEN THE TRANSMISSION IS IN NEU- TRAL b. WHEN THE SIDESTAND IS UP AND THE CLUTCH LEVER IS PULLED TO THE HAN- DLEBAR 1. Battery 2. Main fuse 3. Main switch 4. Ignition fuse 5. Start/engine stop switch 6.

  • Page 368: Troubleshooting

    ELECTRIC STARTING SYSTEM EAS30495 TROUBLESHOOTING The starter motor fails to turn. • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Air scoop 3. Fuel tank cover 4. Fuel tank 5. Air filter case 6. Throttle bodies 1. Check the fuses. (Main, ignition and fuel injection system) Replace the fuse(s).
  • Page 369 ELECTRIC STARTING SYSTEM 9. Check the gear position switch. Refer to “CHECKING THE GEAR Replace the gear position switch. POSITION SWITCH” on page NG 8-173. OK 10.Check the sidestand switch. Refer to “CHECKING THE Replace the sidestand switch. NG SWITCHES” on page 8-153. OK...

  • Page 370: Charging System

    CHARGING SYSTEM EAS20074 CHARGING SYSTEM EAS30496 CIRCUIT DIAGRAM 8-13...
  • Page 371 CHARGING SYSTEM 1. AC magneto 2. Rectifier/regulator 4. Main fuse 18.Battery 19.Engine ground A. Wire harness D. Negative battery sub-wire harness 8-14...

  • Page 372: Troubleshooting

    CHARGING SYSTEM EAS30497 TROUBLESHOOTING The battery is not being charged. • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Rear side cover 1. Check the fuse. (Main) Replace the fuse. Refer to “CHECKING THE FUSES” NG on page 8-156. OK...
  • Page 373 CHARGING SYSTEM 8-16...

  • Page 374: Lighting System

    LIGHTING SYSTEM EAS20075 LIGHTING SYSTEM EAS30498 CIRCUIT DIAGRAM 8-17...
  • Page 375 LIGHTING SYSTEM 3. Main switch 4. Main fuse 13.Ignition fuse 15.Signaling system fuse 16.Headlight fuse 18.Battery 19.Engine ground 23.Joint connector 24.Joint coupler 30.ECU (Engine Control Unit) 53.Meter assembly 56.Meter light 57.High beam indicator light 81.Handlebar switch (left) 86.Pass switch 87.Dimmer switch 93.Headlight assembly 94.Headlight control unit 95.Headlight (high beam)

  • Page 376: Troubleshooting

    LIGHTING SYSTEM EAS30499 TROUBLESHOOTING Any of the following fail to light: headlight, high beam indicator light, taillight, license light or meter light. • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Air scoop 3. Fuel tank cover 4. Fuel tank 5.
  • Page 377 LIGHTING SYSTEM 7. Check the entire lighting system’s wiring. Properly connect or repair the lighting sys- Refer to “CIRCUIT DIAGRAM” on tem’s wiring. NG page 8-17. OK Replace the ECU, meter assembly, headlight assembly or tail/brake light. Refer to “REPLACING THE ECU (Engine Control Unit)”...

  • Page 378: Signaling System

    SIGNALING SYSTEM EAS20076 SIGNALING SYSTEM EAS30500 CIRCUIT DIAGRAM 8-21...
  • Page 379 SIGNALING SYSTEM 3. Main switch 4. Main fuse 11.Parking lighting fuse 13.Ignition fuse 15.Signaling system fuse 18.Battery 19.Engine ground 23.Joint connector 24.Joint coupler 25.Relay unit 29.Shift switch 30.ECU (Engine Control Unit) 42.Coolant temperature sensor 47.Rear wheel sensor 48.ABS ECU (electronic control unit) 53.Meter assembly 55.Neutral indicator light 58.Tachometer...

  • Page 380: 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 381 SIGNALING SYSTEM 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. OK This circuit is OK. The tail/brake light fails to come on. 1. Check the front brake light switch. Refer to “CHECKING THE Replace the front brake light switch.
  • Page 382 SIGNALING SYSTEM 5. 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. OK Replace the meter assembly. The neutral indicator light fails to come on. 1. Check the gear position switch. Refer to “CHECKING THE GEAR Replace the gear position switch.
  • Page 383 SIGNALING SYSTEM 2. 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. OK Replace the ECU or meter assembly. Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-157. QS (Quick Shift System) does not operate.
  • Page 384 SIGNALING SYSTEM The speedometer fails to operate. 1. Check the rear wheel sensor. Refer to “MAINTENANCE OF THE Replace the rear wheel sensor. REAR WHEEL SENSOR AND NG SENSOR ROTOR” on page 4-22. OK 2. Check the entire wheel sensor wir- Properly connect or repair the wheel sen- ing.
  • Page 385 SIGNALING SYSTEM 8-28...

  • Page 386: Cooling System

    COOLING SYSTEM EAS20077 COOLING SYSTEM EAS30502 CIRCUIT DIAGRAM 8-29...
  • Page 387 COOLING SYSTEM 3. Main switch 4. Main fuse 9. Radiator fan motor fuse 13.Ignition fuse 18.Battery 19.Engine ground 23.Joint connector 24.Joint coupler 30.ECU (Engine Control Unit) 42.Coolant temperature sensor 100.Radiator fan motor relay 101.Radiator fan motor A. Wire harness C. Sub-wire harness (Coolant temperature sen- sor) D.

  • Page 388: Troubleshooting

    COOLING SYSTEM EAS30503 TROUBLESHOOTING • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Air scoop 3. Front side panel 4. Fuel tank cover 5. Fuel tank 6. Air filter case 7. Throttle bodies 1. Check the fuses. (Main, ignition and radiator fan mo- tor) Replace the fuse(s).
  • Page 389 COOLING SYSTEM 8-32...

  • Page 390: Fuel Injection System

    FUEL INJECTION SYSTEM EAS20078 FUEL INJECTION SYSTEM EAS30504 CIRCUIT DIAGRAM 8-33...
  • Page 391 45.Lean angle sensor 47.Rear wheel sensor 48.ABS ECU (electronic control unit) 49.Throttle servo motor 50.Accelerator position sensor 51.Throttle position sensor 52.Yamaha diagnostic tool coupler 53.Meter assembly 59.Multi-function meter 62.Engine trouble warning light 64.Traction control system indicator light 70.Gear position switch 72.Fuel pump...

  • Page 392: 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 393: 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 USB 90890-03250 Yamaha diagnostic tool (A/I) 90890-03252 A generic scan tool can also be used to identify malfunctions.

  • Page 394: 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 395 FUEL INJECTION SYSTEM Parts connected to the ECU The following parts are connected to the ECU. When checking for a power short circuit, the couplers must be disconnected from all of the following parts beforehand. • Crankshaft position sensor • Intake air temperature sensor •...
  • Page 396 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 397 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 398 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 399 FUEL INJECTION SYSTEM Fault code No. P0107, P0108 [P0107] Intake air pressure sensor 1: ground short circuit detected. Item [P0108] Intake air pressure sensor 1: open or power short circuit detected. [For P0108] Open circuit Between intake air pressure sensor 1 coupler and ECU coupler: blue–blue If there is no continuity, replace the wire harness.
  • Page 400 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 401 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 402 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 403 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 404 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 405 Yamaha diagnostic tool. Condition is “Recovered”  Go to item 7 and finish the service. Condition is “Detected”  Go to item 4.
  • Page 406 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 407 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 408 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 409 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 410 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 411 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 412 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 413 1. and then check the condition of Execute the diagnostic mode. the fault code using the mal- function mode of the Yamaha (Code No. 01) When the throttle valves are diagnostic tool. Condition is “Recovered”  Go fully closed: A value of 11–21 is indicated.
  • Page 414 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 415 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 416 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 417 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 418 5 seconds. light goes off. 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. Fault code No. P0335 Fault code No. P0335 Crankshaft position sensor: no normal signals are received from Item the crankshaft position sensor.
  • Page 419 Crank the engine, and then the wire harness. check the condition of the fault Between crankshaft position code using the malfunction sensor coupler and ECU cou- mode of the Yamaha diagnostic pler. tool. Condition is “Recovered”  Go gray–gray Between crankshaft position to item 7 and finish the service.
  • Page 420 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 421 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 422 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 423 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 424 Check the condition of the fault Replace if out of specification. code using the malfunction Refer to “CHECKING THE mode of the Yamaha diagnostic IGNITION COILS” on page tool. Condition is “Recovered”  Go 8-163. to item 7 and finish the service.
  • Page 425 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 426 (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 427 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 428 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 429 (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 430 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 431 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 432 (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 433 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 434 EEPROM data error for adjust- EEPROM. the fault code using the mal- ment of CO concentration of cyl- Refer to “ADJUSTING THE function mode of the Yamaha inder #1. EXHAUST GAS VOLUME” on diagnostic tool. Condition is “Recovered”  Go page 3-11.
  • Page 435 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 436 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 437 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 438 (Code No. 03) and then check the condition of When engine is stopped: the fault code using the mal- Atmospheric pressure at the function mode of the Yamaha current altitude and weather diagnostic tool. Condition is “Recovered”  Go conditions is indicated.
  • Page 439 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 440 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 441 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 442 ECU coupler. Check the condition of the fault black/red–black/red 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 443 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 444 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 445 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 446 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 447 “OFF”, and then back to page 8-165. “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 448 Turn the main switch to “ON”, the wire harness. and then check the condition of the fault code using the mal- function mode of the Yamaha diagnostic tool. Condition is “Recovered”  Go to item 7 and finish the service.
  • Page 449 FUEL INJECTION SYSTEM Fault code No. P1606, P1607 [P1606] Intake air pressure sensor 2: ground short circuit detected. Item [P1607] Intake air pressure sensor 2: open or power short circuit detected. [For P1607] Open circuit Between Intake air pressure sensor 2 coupler and ECU coupler: blue–blue If there is no continuity, replace the wire harness.
  • Page 450 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 451 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 452 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 453 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 454 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 455 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 456 1. and then check the condition of Execute the diagnostic mode. the fault code using the mal- (Code No. 14) function mode of the Yamaha When the throttle grip is fully diagnostic tool. Condition is “Recovered”  Go closed: A value of 12–22 is indicated.
  • Page 457 FUEL INJECTION SYSTEM Fault code No. P2158 Front wheel sensor: no normal signals are received from the front Item wheel sensor. Locate the malfunction. If the ABS warning light is on, refer to “BASIC INSTRUC- TIONS FOR TROUBLESHOOT- ING” on page 8-124. If the ABS warning light is off, perform the following procedure.
  • Page 458 (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 459 Improperly installed sensor  Check the condition of the fault Reinstall or replace the sensor. code using the malfunction mode of the Yamaha diagnostic tool. Condition is “Recovered”  Go to item 8 and finish the service. Condition is “Detected”  Go to item 2.
  • Page 460 FUEL PRESSURE” on page approximately 10 seconds. 7-11. Check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool. Condition is “Recovered”  Go to item 8 and finish the service. Condition is “Detected”  Go to item 6.
  • Page 461 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 462 FUEL PUMP SYSTEM EAS20081 FUEL PUMP SYSTEM EAS30513 CIRCUIT DIAGRAM 8-105...
  • Page 463 FUEL PUMP SYSTEM 3. Main switch 4. Main fuse 13.Ignition fuse 18.Battery 19.Engine ground 20.Fuel injection system fuse 23.Joint connector 24.Joint coupler 25.Relay unit 27.Fuel pump relay 30.ECU (Engine Control Unit) 72.Fuel pump 74.Handlebar switch (right) 76.Start/engine stop switch A. Wire harness D.
  • Page 464 FUEL PUMP SYSTEM EAS30514 TROUBLESHOOTING If the fuel pump fails to operate. • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Air scoop 3. Fuel tank cover 4. Fuel tank 1. Check the fuses. (Main, ignition and fuel injection system) Replace the fuse(s).
  • Page 465 FUEL PUMP SYSTEM 8-108...
  • Page 466 IMMOBILIZER SYSTEM EAS20084 IMMOBILIZER SYSTEM EAS30519 CIRCUIT DIAGRAM 8-109...
  • Page 467 IMMOBILIZER SYSTEM 3. Main switch 4. Main fuse 8. Backup fuse 13.Ignition fuse 18.Battery 19.Engine ground 23.Joint connector 24.Joint coupler 28.Immobilizer unit 30.ECU (Engine Control Unit) 53.Meter assembly 54.Immobilizer system indicator light 59.Multi-function meter A. Wire harness D. Negative battery sub-wire harness 8-110...
  • Page 468 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 469 IMMOBILIZER SYSTEM Parts to be replaced Main switch/ Key registration immobilizer unit Acces- requirement Standard sory lock* and key Main Immobi- switch lizer unit  Standard key is lost New standard key All keys have been lost Code re-registering  ...
  • Page 470 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 471 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 472 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 8-156.
  • Page 473 IMMOBILIZER SYSTEM Fault Part Symptom Cause Action code IMMOBILIZER Codes cannot be Noise interference or dis- 1. Check the wire UNIT transmitted between connected lead/cable. harness and con- the ECU and the 1. Interference due to nector. immobilizer unit. radio wave noise. 2.
  • Page 474 ABS (ANTI-LOCK BRAKE SYSTEM) EAS20085 ABS (ANTI-LOCK BRAKE SYSTEM) EAS30843 CIRCUIT DIAGRAM 8-117...
  • Page 475 25.Relay unit 26.Starting circuit cut-off relay 30.ECU (Engine Control Unit) 46.Front wheel sensor 47.Rear wheel sensor 48.ABS ECU (electronic control unit) 52.Yamaha diagnostic tool coupler 53.Meter assembly 59.Multi-function meter 68.ABS warning light 74.Handlebar switch (right) 76.Start/engine stop switch 78.Front brake light switch 79.Rear brake light switch...
  • Page 476 ABS (ANTI-LOCK BRAKE SYSTEM) EAS30525 ABS COMPONENTS CHART 8-119...
  • Page 477 ABS (ANTI-LOCK BRAKE SYSTEM) 1. Hydraulic unit assembly 2. Fuse box 2 3. Yamaha diagnostic tool coupler 4. Rear wheel sensor 5. Rear wheel sensor rotor 6. Front wheel sensor 7. Front wheel sensor rotor 8. ABS warning light 9. Fuse box 1...
  • Page 478 ABS (ANTI-LOCK BRAKE SYSTEM) EAS30844 ABS COUPLER LOCATION CHART 8-121...
  • Page 479 ABS (ANTI-LOCK BRAKE SYSTEM) 1. Meter assembly coupler 2. Rear wheel sensor coupler 3. ABS ECU coupler 4. Yamaha diagnostic tool coupler 5. Front wheel sensor coupler 8-122...
  • Page 480 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 8-127. For troubleshooting items other than the following items, follow the normal service method.
  • Page 481 Previous malfunctions can be checked since the ABS ECU also stores the mal- function history. 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 482 • Can the tool communicate with is defective. the ABS ECU? 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 wire harness is defective.
  • Page 483 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 484 Check for continuity between black/yellow 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 485 Removing the rider seat. Refer to “GENERAL CHASSIS (1)” on page 4-1. Removing the protective cap “1”, and then connect the Yamaha diagnostic tool to the coupler. Details about the displayed fault codes are shown in the following chart. Refer to this chart and check the vehicle.
  • Page 486 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 487 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code Item Symptom Check point Brake light switch or Brake light signal is not • Defective signaling system tail/brake light received properly while the (tail/brake light or brake vehicle is traveling. (Brake light switch) • Defective coupler between light circuit, or front or rear brake light switch circuit.) the signaling system...
  • Page 488 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code Item Symptom Check point Rear wheel ABS (intermit- • Pulses from the rear wheel • Incorrect installation of the tent wheel speed pulses or sensor are received inter- rear wheel sensor (for fault incorrect depressurization) mittently while the vehicle code No.
  • Page 489 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code Item Symptom Check point Hydraulic unit assembly Abnormal data is detected in • Defective hydraulic unit (defective ABS ECU) the hydraulic unit assembly. assembly Hydraulic unit assembly Abnormality is detected in • Defective hydraulic unit (abnormal internal power the power supply circuit in assembly...
  • Page 490 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 491 ABS (ANTI-LOCK BRAKE SYSTEM) • Vehicle possibly ridden on uneven roads. Fault code No. 14, 27 Fault code No. Item Rear wheel sensor (abnormal pulse period) Rear wheel sensor signal is not received properly. (The pulse period Symptom is abnormal while the vehicle is traveling.) Order Item/components and probable cause Check or maintenance job Foreign material adhered around the rear...
  • Page 492 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 493 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 494 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Item Front wheel sensor (missing pulses) Front wheel sensor signal is not received properly. (Missing pulses Symptom are detected in the signal while the vehicle is traveling.) Order Item/components and probable cause Check or maintenance job Defective sensor rotor or incorrect instal- Check the surface of the sensor rotor for damage.
  • Page 495 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. 21 Fault code No. Item Hydraulic unit assembly (defective solenoid drive circuit) Solenoid drive circuit in the hydraulic unit assembly is open or Symptom short-circuited. Order Item/components and probable cause Check or maintenance job Defective hydraulic unit assembly Replace the hydraulic unit assembly.
  • Page 496 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Item Hydraulic unit assembly (abnormal ABS solenoid power supply) Power is not supplied to the solenoid circuit in the hydraulic unit Symptom assembly. Order Item/components and probable cause Check or maintenance job Defective coupler between the battery •...
  • Page 497 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Item Hydraulic unit assembly (abnormal ABS motor power supply) Power is not supplied to the motor circuit in the hydraulic unit Symptom assembly. Order Item/components and probable cause Check or maintenance job Open or short circuit in the wire harness •...
  • Page 498 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Front wheel ABS (intermittent wheel speed pulses or incorrect Item depressurization) • Pulses from the front wheel sensor are received intermittently while the vehicle is traveling. Symptom • Front wheel will not recover from the locking tendency even though the signal is transmitted from the ABS ECU to reduce the hydraulic pressure.
  • Page 499 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. 43 Fault code No. Item Front wheel sensor (missing pulses) Front wheel sensor signal is not received properly. (Missing pulses Symptom are detected in the signal while the vehicle is traveling.) Order Item/components and probable cause Check or maintenance job Foreign material adhered around the front Check the surface of the sensor rotor and wheel sensor...
  • Page 500 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. 51, 52 Fault code No. • Vehicle system power supply (voltage of ABS ECU power supply is high) (for fault code No. 51) Item • Vehicle system power supply (voltage of wheel sensor power sup- ply is high) (for fault code No.
  • Page 501 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. 54 Fault code No. Hydraulic unit assembly (defective ABS solenoid and ABS motor Item power supply circuits) Abnormality is detected in the solenoid or motor power supply cir- Symptom cuit in the hydraulic unit assembly. Order Item/components and probable cause Check or maintenance job Defective battery...
  • Page 502 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. 56 Fault code No. Item Hydraulic unit assembly (abnormal internal power supply) Abnormality is detected in the power supply circuit in the hydraulic Symptom unit assembly. Order Item/components and probable cause Check or maintenance job Defective hydraulic unit assembly Replace the hydraulic unit assembly.
  • Page 503 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Item Front wheel sensor power supply (voltage of power supply is low) Power voltage supplied from the ABS ECU to the front wheel sensor Symptom is too low. Order Item/components and probable cause Check or maintenance job Defective hydraulic unit assembly Replace the hydraulic unit assembly.
  • Page 504 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 505 ABS (ANTI-LOCK BRAKE SYSTEM) Check for continuity between green/red terminal of the ABS ECU coupler and green/red terminal of the meter assembly coupler. • Malfunction in the meter assembly circuit. • Malfunction in the ABS warning light circuit in the hydraulic unit assembly. 8-148...
  • Page 506 ELECTRICAL COMPONENTS EAS20089 ELECTRICAL COMPONENTS 8-149...
  • Page 507 ELECTRICAL COMPONENTS 1. Main switch/Immobilizer unit 2. Clutch switch 3. Front brake light switch 4. Hydraulic unit assembly 5. Battery 6. Fuse box 2 7. Main fuse 8. Fuel injection system fuse 9. Starter relay 10.Rectifier/regulator 11.Rear wheel sensor 12.Rear brake light switch 13.Gear position switch 14.Sidestand switch 15.O...
  • Page 508 ELECTRICAL COMPONENTS 8-151...
  • Page 509 ELECTRICAL COMPONENTS 1. Intake air temperature sensor 2. ECU (Engine Control Unit) 3. Fuel pump 4. Lean angle sensor 5. Radiator fan motor relay 6. Turn signal/hazard relay 7. Relay unit 8. Shift switch 9. Stator coil 10.Crankshaft position sensor 11.Coolant temperature sensor 12.Throttle servo motor 13.Accelerator position sensor...
  • Page 510 ELECTRICAL COMPONENTS EAS30549 CHECKING THE SWITCHES 8-153...
  • Page 511 ELECTRICAL COMPONENTS 1. Dimmer switch 2. Pass switch 3. Turn signal switch 4. Horn switch 5. Traction control system switch 6. Clutch switch 7. Oil level switch 8. Sidestand switch 9. Hazard switch 10.Start/engine stop switch 11.Drive mode switch 12.Front brake light switch 13.Main switch 14.Rear brake light switch 15.Shift switch...
  • Page 512 ELECTRICAL COMPONENTS Check each switch for continuity with the digital circuit 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 513 ELECTRICAL COMPONENTS EAS30550 CHECKING THE BULBS AND BULB SOCKETS Check each bulb and bulb socket for damage or wear, proper connections, and also for continuity between the terminals. Damage/wear  Repair or replace the bulb, bulb socket or both. Improperly connected  Properly connect. No continuity ...
  • Page 514 ELECTRICAL COMPONENTS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Amperage Fuses Q’ty a. Connect the digital circuit tester to the fuse rating and check the continuity. Main 50 A Set the digital circuit tester selector to “  ”. Headlight 10 A Signaling system 7.5 A Digital circuit tester (CD732) 90890-03243 Ignition...
  • Page 515 ELECTRICAL COMPONENTS be charged according to the appropriate Refer to “CHECKING AND CLEANING THE THROTTLE BODIES” on page 7-8. charging method. If the battery is over- charged, the electrolyte level will drop con- 4. Check: • Engine idling speed siderably. Therefore, take special care when charging the battery.
  • Page 516 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 517 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 518 ELECTRICAL COMPONENTS Relay unit (starting circuit cut-off relay) 10.Install: • Rider seat Refer to “GENERAL CHASSIS (1)” on page 4-1. EAS30553 CHECKING THE RELAYS Check each switch for continuity with the digital circuit tester. If the continuity reading is incor- rect, replace the relay.
  • Page 519 ELECTRICAL COMPONENTS Radiator fan motor relay b. Turn the main switch to “ON”. 1. Positive battery terminal c. Measure the turn signal/hazard relay input 2. Negative battery terminal voltage. 3. Positive tester probe ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 4. Negative tester probe 2. Check: •...
  • Page 520 ELECTRICAL COMPONENTS EAS30795 CHECKING THE RELAY UNIT (DIODE) 1. Check: • Relay unit (diode) Out of specification  Replace. Digital circuit tester (CD732) 90890-03243 Model 88 Multimeter with tachom- eter YU-A1927 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the relay unit coupler from the The digital circuit tester readings are shown in wire harness.
  • Page 521 ELECTRICAL COMPONENTS Minimum ignition spark gap 6.0 mm (0.24 in) If the ignition spark gap is within specification, the ignition system circuit is operating normally. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the ignition coil from the spark plug. b. Connect the ignition checker “1” as shown. c.
  • Page 522 ELECTRICAL COMPONENTS Digital circuit tester (CD732) Digital circuit tester (CD732) 90890-03243 90890-03243 Model 88 Multimeter with tachom- Model 88 Multimeter with tachom- eter eter YU-A1927 YU-A1927 Test harness– lean angle sensor (6P) • Positive tester probe 90890-03209 gray “1” Test harness– lean angle sensor •...
  • Page 523 ELECTRICAL COMPONENTS fluid is in the vicinity. b. Measure the stator coil resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ b. Check the starter motor operation. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS30680 CHECKING THE RECTIFIER/REGULATOR EAS30566 1. Check: CHECKING THE STATOR COIL • Rectifier/regulator input voltage 1. Disconnect: Out of specification  Correct the stator coil •...
  • Page 524 ELECTRICAL COMPONENTS EAS30569 CHECKING THE HORN 1. Check: • Horn resistance Out of specification  Replace. Horn Coil resistance 1.07–1.11  ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the horn leads from the horn ter- c. Start the engine and let it run at approximate- minals.
  • Page 525 ELECTRICAL COMPONENTS Out of specification  Replace the fuel pump Oil level switch assembly. Oil level switch resistance (maxi- mum level position) Sender unit resistance (full) 484.0–536.0  9.0–11.0  Oil level switch resistance (mini- Sender unit resistance (empty) mum level position) 213.0–219.0 ...
  • Page 526 ELECTRICAL COMPONENTS Warning light comes on for a few seconds, b. Connect the battery (DC 12 V) as shown. then goes off  Warning light is OK. • Positive tester probe Warning light does not come on  Replace blue “1” the meter assembly.
  • Page 527 ELECTRICAL COMPONENTS b. Immerse the coolant temperature sensor “1” Digital circuit tester (CD732) in a container filled with coolant “2”. 90890-03243 Model 88 Multimeter with tachom- Make sure the coolant temperature sensor ter- eter minals do not get wet. YU-A1927 c.
  • Page 528 ELECTRICAL COMPONENTS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Do not use old batteries to operate the throttle a. Connect the digital circuit tester () to the ac- servo motor. celerator position sensor terminals as shown. Digital circuit tester (CD732) 90890-03243 Model 88 Multimeter with tachom- eter YU-A1927 •...
  • Page 529 ELECTRICAL COMPONENTS c. Measure the air induction system solenoid re- sistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS30593 CHECKING THE INTAKE AIR PRESSURE SENSOR 1. Check: • Intake air pressure sensor output voltage Out of specification  Replace. A. Intake air pressure sensor 1 Intake air pressure sensor output B.
  • Page 530 ELECTRICAL COMPONENTS take air temperature sensor terminal as Result shown. Neutral position Continuity Digital circuit tester (CD732) Positive tester probe 90890-03243 sky blue “1” Model 88 Multimeter with tachom- Negative tester probe eter Sensor terminal “a” YU-A1927 1st position Continuity b.
  • Page 531 ELECTRICAL COMPONENTS EAS30681 CHECKING THE FUEL INJECTORS The following procedure applies to all of the fuel injectors. 1. Remove: • Fuel injector Refer to “THROTTLE BODIES” on page 7-5. 2. Check: • Fuel injector resistance Out of specification  Replace the fuel injec- tor.
  • Page 532 ELECTRICAL COMPONENTS 8-175...

  • Page 533: 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 534 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 535 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 536 TROUBLESHOOTING • Damaged pipe • Incorrect oil viscosity • Improperly connected pipe • Incorrect oil level Fuel system EAS30611 1. Throttle body (-ies) UNSTABLE HANDLING • Damaged or loose throttle body joint Handlebar 2. Air filter • Bent or improperly installed handlebar •...
  • Page 537 TROUBLESHOOTING • Faulty tail/brake light assembly Turn signal does not come on • Faulty turn signal switch • Faulty turn signal/hazard relay • Burnt-out turn signal bulb • Incorrect connection • Damaged or faulty wire harness • Improperly grounded circuit •...
  • Page 538 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 539 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 540 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Fault Probable cause of Fail-safe system Item Vehicle symptom code No. malfunction operation P0132 sensor (short cir- [P0132] High voltage Increased exhaust feedback is not of the O sensor cir- emissions. cuit detected (power carried out.
  • Page 541 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Fault Probable cause of Fail-safe system Item Vehicle symptom code No. malfunction operation P0351 [P0351] Cylinder-#1 • Defective coupler Engine stops. Injection to the appli- P0352 ignition coil (open or between ignition coil Loss of engine power. cable cylinder group is P0353 short circuit detected...
  • Page 542 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Fault Probable cause of Fail-safe system Item Vehicle symptom code No. malfunction operation P0601 Internal malfunction in • Malfunction in ECU. Engine cannot be Engine cannot be ECU (ROM data started. started. error) (When this mal- function is detected in the ECU, the fault code number might...
  • Page 543 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Fault Probable cause of Fail-safe system Item Vehicle symptom code No. malfunction operation P1004 Intake air pressure • Malfunction in ECU. Engine is difficult to Intake air pressure is • Hose of intake air sensor 1 or intake air start.
  • Page 544 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Fault Probable cause of Fail-safe system Item Vehicle symptom code No. malfunction operation P1602 Malfunction in ECU • Open or short cir- Engine idling speed is feedback learning internal circuit (mal- cuit in wire harness unstable.
  • Page 545 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 546 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 547 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Diagnostic Item Tool display Procedure code No. Air temperature Displays the air temperature. Compare the actually mea- sured air temperature with the tool display value. Coolant temperature When engine is cold: Dis- Compare the actually mea- plays temperature closer to sured coolant temperature air temperature.
  • Page 548 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Diagnostic Item Tool display Procedure code No. Sidestand switch Extend and retract the sides- tand (with the transmission in • Stand retracted gear). • Stand extended gear position switch and Operate the transmission, clutch switch clutch lever, and sidestand.
  • Page 549 • Connect an ignition The “check” indicator on the checker. Yamaha diagnostic tool screen come on each time the ignition coil is actuated. Cylinder-#2 ignition coil Actuates the cylinder-#2 igni- Check that a spark is gener- tion coil five times at one- ated five times.
  • Page 550 Check that injector #3 is The “check” indicator on the actuated five times by listen- Yamaha diagnostic tool ing for the operating sound. screen come on each time the injector is actuated. Air induction system solenoid Actuates the air induction...
  • Page 551 EVENT CODE TABLE EAS20164 EVENT CODE TABLE Item Symptom Possible causes Note Intake air pres- Brief abnormality Same as for fault code Perform the checks and sure sensor 1 detected in the intake number P0107 and maintenance jobs for fault air pressure sensor 1 P0108 code number P0107 and...
  • Page 552 EVENT CODE TABLE Item Symptom Possible causes Note During idling, the Idling engine speed is • Implement diagnosis (Stuck at the adjustment is main- slow mode (diagnostic code • Clogged throttle body upper limit for tained at the upper number 67), and check •...
  • Page 553 EVENT CODE TABLE EAS32023 TROUBLESHOOTING DETAILS (EVENT CODE) Event code No. 30 Event code No. Item Latch up detected. Unable to start engine Fail-safe system Unable to drive vehicle Diagnostic code No. Lean angle sensor output voltage Tool display • 0.4–1.4 (upright) •...
  • Page 554 EVENT CODE TABLE Event code No. 70 If another error code is displayed at the same time, check the other error code first and repair it. Event code No. Engine forcibly stops when the vehicle is left idling for a long period Item of time.
  • Page 555 TION) 49. Throttle servo motor 104.Auxiliary DC connector 2 (OP- 50. Accelerator position sensor TION) 51. Throttle position sensor 52. Yamaha diagnostic tool cou- A. Wire harness pler B. Sub-wire harness (Injector #2) 53. Meter assembly C. Sub-wire harness (Coolant 54.
  • Page 556 EAS30613 COLOR CODE Black Brown Chocolate Dark green Gray Blue Light green Orange Pink Sky blue Violet White Yellow Black/Blue Black/Red Black/White Black/Yellow Br/L Brown/Blue Br/R Brown/Red Br/W Brown/White Br/Y Brown/Yellow Green/Black Green/Red Green/White Green/Yellow Gy/G Gray/Green Gy/R Gray/Red Blue/Black Blue/Red Blue/White Blue/Yellow...
  • Page 559 MTN850-A/MTN850-AH 2017 MTN850-A/MTN850-AH 2017 MTN850-A/MTN850-AH 2017 MTN850-A/MTN850-AH 2017 MTN850-A/MTN850-AH 2017 SCHÉMA DE CÂBLAGE SCHEMA ELETTRICO WIRING DIAGRAM SCHALTPLAN DIAGRAMA ELÉCTRICO...
  • Page 560 MTN850-A/MTN850-AH 2017 MTN850-A/MTN850-AH 2017 MTN850-A/MTN850-AH 2017 MTN850-A/MTN850-AH 2017 MTN850-A/MTN850-AH 2017 SCHÉMA DE CÂBLAGE SCHEMA ELETTRICO WIRING DIAGRAM SCHALTPLAN DIAGRAMA ELÉCTRICO...

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