Yamaha 2013 FJR1300AS Service Manual

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2013

SERVICE MANUAL

FJR1300AS

1MD-28197-E0

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Troubleshooting

Summary of Contents for Yamaha 2013 FJR1300AS

Page 1 2013 SERVICE MANUAL FJR1300AS 1MD-28197-E0...
Page 2 EAS20040 FJR1300AS 2013 SERVICE MANUAL ©2013 by Yamaha Motor Co., Ltd. First edition, February 2013 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.
Page 3 EAS20071 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 4: How To Use This Manual
EAS20090 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 5: Symbols
EAS20101 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
EAS20110 TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE COOLING SYSTEM FUEL SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING...
Page 9: General Information
MODEL LABEL..................1-1 FEATURES...................... 1-2 OUTLINE OF THE FI SYSTEM..............1-2 FI SYSTEM....................1-3 OUTLINE OF THE YCC-S (Yamaha Chip Controlled-Shift) SYSTEM AND YCC-T (Yamaha Chip Controlled-Throttle) ........1-4 OUTLINE OF THE CRUISE CONTROL SYSTEM........1-9 OUTLINE OF THE UNIFIED BRAKE SYSTEM ........1-17 OUTLINE OF THE ABS................1-19...
Page 10: Identification
IDENTIFICATION EAS20130 IDENTIFICATION EAS20140 VEHICLE IDENTIFICATION NUMBER The vehicle identification number “1” is stamped into the right side of the steering head pipe. EAS20150 MODEL LABEL The model label “1” is affixed to the frame. This information will be needed to order spare parts.
Page 11: Features
FEATURES EAS20170 FEATURES ET2C01025 OUTLINE OF THE FI SYSTEM The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature. In the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the combustion chamber is created by the volume of the intake air and the fuel that is metered by the jet used in the respective carburetor.
Page 12: Fi System
FEATURES ET3P61042 FI SYSTEM The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the fuel pressure that is applied to the fuel injector at only 324 kPa (3.24 kg/cm², 47.0 psi). Accordingly, when the energizing signal from the ECU energizes the fuel injector, the fuel passage opens, causing the fuel to be injected into the intake manifold only during the time the passage remains open.
Page 13: Outline Of The Ycc-S (Yamaha Chip Controlled-Shift) System And Ycc-T (Yamaha Chip Controlled-Throttle)
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 14 FEATURES Mechanism characteristics of the YCC-S YCC-S offers more enjoyable and easy riding by eliminating the need for the user to operate the clutch, which also reduces fatigue during long touring. YCC-S is not an automatic transmission, although it allows the user to shift gears by foot or hand ac- cording to preference.
Page 15 FEATURES 1,2,3 1. YCC-S warning light 2. Stop mode function indicator light 3. Shift down indicator light 4. Hand shift lever switch and stop mode function switch 5. Gear position sensor 6. Neutral switch 7. MCU (motor control unit) 8. Shift actuator 9.
Page 16 FEATURES Shift pattern This vehicle is equipped with a constant-mesh 5-speed transmission. The gears can be shifted using either the shift pedal “1” or the hand shift switch “2”. The gear positions are shown in the illustration. Attention • Do not turn the main switch to “OFF” while the vehicle is moving, otherwise the electrical systems will be switched off, including the YCC-S system, which may result in loss of control or an accident.
Page 17 FEATURES YCC-S and YCC-T system outline 1. Engine speed 2. Vehicle speed 3. Throttle grip 4. Electric throttle valve 5. Gear position sensor 6. Hand shift switch 7. Foot shift sensor 8. Stop mode function switch 9. ECU (engine control unit) 10.
Page 18: Outline Of The Cruise Control System
FEATURES EAS1MC1087 OUTLINE OF THE CRUISE CONTROL SYSTEM This model is equipped with a cruise control system designed to maintain a set cruising speed. Be- cause the vehicle is equipped with the YCC-T system, the cruise control system can be controlled elec- tronically.
Page 19 FEATURES EWA1MC1006 WARNING • Improper use of the cruise control system may result in loss of control, which could lead to an accident. Do not activate the cruise control system in heavy traffic, poor weather conditions, or among winding, slippery, hilly, rough or gravel roads. •...
Page 20 FEATURES Adjusting the set cruising speed While the cruise control system is operating, push the “RES+” side of the cruise control setting switch to increase the set cruising speed or the “SET–” side to decrease the set speed. • Pushing the setting switch once will change the speed in increments of approximately 2.0 km/h (1.2 mph).
Page 21 FEATURES Using the resume function Push the “RES+” side of the cruise control setting switch to reactivate the cruise control system. The traveling speed will return to the previously set cruising speed. The cruise control setting indicator light “SET” will come on. If the “SET–”...
Page 22 Because the automatic deactivation of the cruise control system is stored in the memory of the ECU, the deactivation can be checked using the Yamaha diagnostic tool. In some cases, the cruise control system may not be able to maintain the set cruising speed when the vehicle is traveling uphill or downhill.
Page 23 FEATURES Meter displays during cruise control system operation A. Cruise control system is activated (cruising a. Condition for automatically deactivating cruise speed is set) control system is detected B. Cruise control system is turned off (cruise b. 4 seconds elapse (during this time, input from control system indicator light “...
Page 24 FEATURES ECA1MC1006 NOTICE If the display indicates a fault code, the vehicle should be checked as soon as possible in order to avoid engine damage. • If the cruise control system turned off because a malfunction was detected by the FI self-diagnosis, the cruise control power switch “...
Page 25 FEATURES Meter displays during cruise control system operation A. Cruise control system is activated (cruising E. Cruise control system is turned on (cruising speed is set) speed is not set) B. Cruise control system is turned off (engine F. Malfunction detected by FI self-diagnosis trouble warning light “...
Page 26: Outline Of The Unified Brake System
OUTLINE OF THE UNIFIED BRAKE SYSTEM The Yamaha unified brake system is a system that operates one set of pistons in the front brakes to- gether with the rear brake when the brake pedal is depressed. Compared to conventional brake sys- tems, the ability to slow the vehicle using the simple operation of the brake pedal is improved.
Page 27 FEATURES Brake pedal input force and braking force at each wheel a. Brake force e. Proportioning valve operation b. Brake pedal force f. Metering valve operation c. Rear brake force d. Front brake force (unified brake system) Metering valve This valve prevents the brake fluid pressure that is transmitted to the right front brake caliper from in- creasing until the pressure exceeds a set level.
Page 28: Outline Of The Abs
8. Rear wheel sensor The operation of the Yamaha ABS brakes is the same as conventional brakes on other vehicles, with a brake lever for operating the front brake and a brake pedal for operating the rear brake. However, part of the front brake is operated together with rear brake.
Page 29 FEATURES When the brakes are applied, wheel speed and chassis speed are reduced. However, the chassis travels forward by its inertia even though the wheel speed is reduced. • Brake force: The force applied by braking to reduce the wheel speed. •...
Page 30 FEATURES Wheel slip and hydraulic control The ABS ECU calculates the wheel speed of each wheel according to the rotation signal received from the front and rear wheel sensors. In addition, the ABS ECU calculates the vehicle chassis speed and the rate of speed reduction based on the wheel speed values.
Page 31 Slip ratio (%) b. Brake force Electronic ABS features The Yamaha ABS (anti-lock brake system) has been developed with the most advanced electronic technology. The ABS control is processed with good response under various vehicle travel conditions. The ABS also includes a highly developed self-diagnosis function. The ABS detects any problem con- dition and allows normal braking even if the ABS is not operating properly.
Page 32: Abs Component Functions
FEATURES ABS block diagram 1. Rear brake master cylinder 10. Proportioning valve 2. Hydraulic unit assembly 11. Rear brake caliper 3. Front brake master cylinder 12. Rear wheel sensor 4. Inlet solenoid valve 13. Metering valve 5. ABS motor 14. ABS warning light 6.
Page 33 FEATURES 3. At low speed 7. Voltage 4. At high speed 8. Time 5. Wheel sensor 6. Wheel sensor rotor ABS warning light The ABS warning light “1” comes on to warn the rider if a malfunction in the ABS occurs. When the main switch is turned to “ON”, the ABS warning light comes on during the ABS self-diagnosis to check the electrical circuit of the light.
Page 34 FEATURES GEAR A.TEMP ˚C C.TEMP ˚C TIME TRIP 0:06 • Hydraulic unit assembly The hydraulic unit assembly “1” is composed of hydraulic control valves (each with a outlet solenoid valve and inlet solenoid valve), buffer chambers, hydraulic pumps, an ABS motor, and ABS ECU. The hydraulic unit adjusts the front and rear wheel brake fluid pressure to control the wheel speed accord- ing to signals transmitted from the ABS ECU.
Page 35 FEATURES 3. When the ABS ECU sends a signal to stop reducing the hydraulic pressure, the outlet solenoid valve “2” closes and the brake fluid is pressurized again. The inlet solenoid valve “1” controls the hydraulic pressure difference between the brake fluid in the upper brake lines (brake master cylin- der side) and the brake fluid in the lower brake lines (brake caliper side).
Page 36 FEATURES • ABS ECU The ABS ECU is integrated with the hydraulic unit to achieve a compact and lightweight design. As shown in the block following diagram, the ABS ECU receives wheel sensor signals from the front and rear wheels and also receives signals from other monitor circuits. 20 21 24 25 1.
Page 37 FEATURES ABS control operation The ABS control operation performed in the ABS ECU is divided into the following two parts. • Hydraulic control • Self-diagnosis When a malfunction is detected in the ABS, a fault code is stored in the memory of the ABS ECU for easy problem identification and troubleshooting.
Page 38: Abs Operation
FEATURES ET3P61052 ABS OPERATION The ABS hydraulic circuit consists of two systems: the front wheel, and rear wheel. The following de- scribes the system for the front wheel only, excluding the unified brake system. Normal braking (ABS not activated) When the ABS is not activated, the inlet solenoid valve is open and the outlet solenoid valve is closed because a control signal has not been transmitted from the ABS ECU.
Page 39 FEATURES Emergency braking (ABS activated) 1. Depressurizing phase When the front wheel is about to lock, the outlet solenoid valve is opened by the “depressurization” signal transmitted from the ABS ECU. When this occurs, the inlet solenoid valve compresses the spring and closes the brake line from the brake master cylinder.
Page 40 FEATURES 2. Pressurizing phase The outlet solenoid valve is closed by the “pressurization” signal transmitted from the ABS ECU. At this time, the ABS ECU controls the opening of the inlet solenoid valve. As the inlet solenoid valve opens, the brake line from the brake master cylinder opens, allowing the brake fluid to be sent to the brake caliper.
Page 41: Abs Self-Diagnosis Function
FEATURES ET3P61053 ABS SELF-DIAGNOSIS FUNCTION ABS warning light The ABS warning light “1” comes on when a malfunction is detected by the ABS self-diagnosis. It is located in the multi-function meter center display. GEAR A.TEMP ˚C C.TEMP ˚C TIME TRIP 0:06 Instances when the ABS warning light comes on 1.
Page 42 FEATURES 2. The ABS warning light comes on while the “ ” side of the start/engine stop switch is being pushed. When the engine is being started, the ABS warning light comes on while the “ ” side of the start/en- gine stop switch is being pushed.
Page 43 FEATURES a. ABS warning light d. Unstable ABS ECU input b. Comes on c. Goes off 5. The ABS warning light “1” flashes and a fault code “2” is indicated on the multi-function meter right display when the test coupler adapter “3” is connected to the ABS test coupler “4” for troubleshooting the ABS.
Page 44: Abs Warning Light And Operation
FEATURES ET3P61054 ABS WARNING LIGHT AND OPERATION ABS and UBS function EWA1MC1024 WARNING • When hydraulic control is performed by the ABS, the brake system alerts the rider that the wheels have a tendency to lock by generating a reaction-force pulsating action in the brake lever or brake pedal.
Page 45: Outline Of The Tcs (Traction Control System)
FEATURES EAS1MC1082 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 46 FEATURES 1. Front wheel sensor A. Signal conversion 2. Rear wheel sensor B. Slip amount calculation 3. ABS ECU (electronic control unit) C. Exceeds preset value 4. “TCS” button D. Actuator control 5. ECU (engine control unit) E. Fuel cut-off F.
Page 47 FEATURES Turn the traction control system off to help free the rear wheel if the motorcycle gets stuck in mud, sand, or other soft surfaces. ECA1MC1014 NOTICE Use only the specified tires. Using different sized tires will prevent the traction control system from controlling tire rotation accurately.
Page 48: Multi-Function Meter Unit
FEATURES • a tachometer EAS1MC1030 MULTI-FUNCTION METER UNIT • a clock • a fuel meter 9 10 • a transmission gear display • a drive mode display (which shows the select- ed drive mode) GEAR • a function display (which shows the selected A.TEMP ˚C function)
Page 49 FEATURES Fuel meter • Select the transmission gear that is appropri- ate for the vehicle speed. Transmission gear display GEAR A.TEMP GEAR C.TEMP A.TEMP ˚C C.TEMP ˚C 1. Fuel meter TIME TRIP 0:06 The fuel meter indicates the amount of fuel in the fuel tank.
Page 50 FEATURES Function display Adjusting the grip warmer This vehicle is equipped with grip warmers, which can only be used when the engine is run- ning. There are 4 grip warmer settings. GEAR Setting Display A.TEMP ˚C C.TEMP ˚C TIME TRIP 0:06 Middle 1.
Page 51 FEATURES • an estimated traveling range display • an elapsed time display GEAR • an ambient temperature display • a coolant temperature display • an average fuel consumption display • an instantaneous fuel consumption display The items shown in each information display can be selected.
Page 52 FEATURES The time that has elapsed since the key was turned to “ON” is shown. The maximum time that GEAR can be shown is 99:59. This display is automatically reset when the key is turned to “OFF”. C.TEMP ˚C There are also “TIME-2” and “TIME-3” elapsed time displays, but they cannot be set to the infor- mation display.
Page 53 FEATURES Instantaneous fuel consumption display: Push and hold the menu switch “MENU” for at least 2 seconds to enter the setting mode. To exit the setting mode and return to the normal display, push and hold the menu switch “MENU” again for at least 2 seconds.
Page 54 FEATURES 4. Use the select switch to highlight “Middle” or This function allows you to “Low”, and then change the setting using the “All Reset” reset all items, except the odometer and the clock. same procedure that was used for the high setting.
Page 55 FEATURES Checking and resetting TIME-2 and TIME-3 2. Push the menu switch “MENU”. The unit set- 1. Use the select switch to highlight “Time Trip”. ting display will be shown and “km or mile” (for the UK only) or “km/L or L/100km” (ex- cept for the UK) will flash in the display.
Page 56 FEATURES 4. Use the select switch to select the item to 7. Use the select switch to highlight “ ”, and then push the menu switch “MENU” to return show, and then push the menu switch “MENU”. to the setting mode menu. Unit Display-1 Km or mile...
Page 57 FEATURES 2. Push the menu switch “MENU”. Resetting all of the display items 3. Use the select switch to select the desired 1. Use the select switch to highlight “All Reset”. brightness level, and then push the menu switch “MENU” to return to the setting mode MENU menu.
Page 58 FEATURES The self-diagnosis device also detects problems in the immobilizer system circuits. If a problem is detected in the immobilizer sys- tem circuits, the immobilizer system indicator light will flash and the information display will in- dicate a fault code when the main switch is turned to “ON”.
Page 59: Important Information
5. Keep all parts away from any source of fire. EAS20200 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 60: Bearings And Oil Seals
IMPORTANT INFORMATION EAS20230 EAS1MC1085 BEARINGS AND OIL SEALS RUBBER PARTS Install bearings “1” and oil seals “2” so that the Check rubber parts for deterioration during in- manufacturer’s marks or numbers are visible. spection. Some of the rubber parts are sensitive When installing oil seals, lubricate the oil seal to gasoline, flammable oil, grease, etc.
Page 61: Basic Service Information
BASIC SERVICE INFORMATION EAS30380 BASIC SERVICE INFORMATION EAS30390 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 62: Electrical System
BASIC SERVICE INFORMATION ECA16760 EAS30402 NOTICE ELECTRICAL SYSTEM Be sure to connect the battery leads to the correct battery terminals. Reversing the bat- Electrical parts handling tery lead connections could damage the ECA16600 NOTICE electrical components. Never disconnect a battery lead while the en- gine is running;...
Page 63 BASIC SERVICE INFORMATION ECA16620 Checking the electrical system NOTICE Handle electrical components with special Before checking the electrical system, make care, and do not subject them to strong sure that the battery voltage is at least 12 V. shocks. ECA16630 ECA14371 NOTICE NOTICE...
Page 64 BASIC SERVICE INFORMATION 2. Check: Checking the connections • Lead Check the leads, couplers, and connectors for • Coupler stains, rust, moisture, etc. • Connector 1. Disconnect: Moisture → Dry with an air blower. • Lead Rust/stains → Connect and disconnect sev- •...
Page 65 BASIC SERVICE INFORMATION The resistance values shown were obtained at the standard measuring temperature of 20 °C (68 °F). If the measuring temperature is not 20 °C (68 °F), the specified measuring conditions will be shown. Intake air temperature sensor re- sistance 5.40–6.60 kΩ...
Page 66: Special Tools
SPECIAL TOOLS EAS20260 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country. When placing an order, refer to the list provided below to avoid any mistakes.
Page 67 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Vacuum/pressure pump gauge set 3-13 90890-06756 Mityvac brake bleeding tool YS-42423 Magnet base B 3-14 90890-06844 Magnetic base stand YU-A8438 Dial gauge & stand set 3-14 90890-01252 Dial gauge set YU-03097-B Steering nut wrench 3-22, 4-92 90890-01403 Exhaust flange nut wrench...
Page 68 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Rod holder 4-83, 4-88 90890-01434 Damper rod holder double ended YM-01434 Damper rod holder 4-84, 4-85 90890-01423 Damping rod holder YM-01423 Fork seal driver 4-86, 4-87 90890-01502 Fork seal driver (48) YM-A0948 Fork seal driver attachment 4-86 90890-01503...
Page 69 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Ring gear fix bolt (M14) 4-114 90890-01524 YM-01524 M14×P1.5 Final gear backlash band 4-115 90890-01511 Middle drive gear lash tool YM-01230 Coupling gear/middle shaft tool 4-117, 4-120 90890-01229 Gear holder YM-01229 Bearing retainer wrench 4-117, 4-120 90890-04050 Pinion bearing retainer &...
Page 70 Model 88 Multimeter with tachometer 5-66, 8-274, YU-A1927 8-280 Rotor holding tool 5-15, 5-18 90890-01235 Universal magneto & rotor holder YU-01235 Yamaha bond No. 1215 5-20, 5-35, 90890-85505 5-38, 5-92, (Three Bond No.1215®) 6-13 Valve spring compressor 5-26, 5-31 90890-04019...
Page 71 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Valve guide remover (ø5) 5-28 90890-04097 Valve guide remover (5.0 mm) YM-04097 Valve guide installer (ø5) 5-28 90890-04098 Valve guide installer (5.0 mm) YM-04098 Valve guide reamer (ø5) 5-28 90890-04099 Valve guide reamer (5.0 mm) YM-04099 Sheave holder 5-34, 5-35,...
Page 72 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Test harness- speed sensor (3P) 5-65, 8-279, 90890-03208 8-283 YU-03208 Bearing retainer wrench 5-79, 5-81 90890-04137 Middle drive shaft bearing retainer wrench YM-04137 Damper spring compressor 5-79, 5-80 90890-04090 Middle drive gear damper spring com- pressor YM-33286 Bearing retainer wrench...
Page 73 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Piston ring compressor 5-101 90890-05158 YM-08037 Slide hammer bolt 5-112 90890-01083 Slide hammer bolt 6 mm YU-01083-1 Weight 5-112 90890-01084 YU-01083-3 YU-01083-3 Radiator cap tester 90890-01325 Mityvac cooling system tester kit YU-24460-A YU-24460-A 1-64...
Page 74 Middle drive bearing installer 40 & 50 mm YM-04058 Pressure gauge 7-10 90890-03153 YU-03153 Fuel injector pressure adapter 7-10 90890-03210 YU-03210 Fuel pressure adapter 7-10 90890-03176 YM-03176 Yamaha diagnostic tool 8-41 90890-03215 Ignition checker 8-272 90890-06754 Oppama pet-4000 spark checker YM-34487 1-65...
Page 75 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Test harness- lean angle sensor (6P) 8-273 90890-03209 YU-03209 Test harness S- pressure sensor (3P) 8-280 90890-03207 YU-03207 1-66...
Page 76 SPECIAL TOOLS 1-67...
Page 77: Specifications
SPECIFICATIONS GENERAL SPECIFICATIONS ................ 2-1 ENGINE SPECIFICATIONS ................2-2 CHASSIS SPECIFICATIONS ................2-10 ELECTRICAL SPECIFICATIONS ..............2-13 TIGHTENING TORQUES ................2-16 GENERAL TIGHTENING TORQUE SPECIFICATIONS......2-16 ENGINE TIGHTENING TORQUES............2-17 CHASSIS TIGHTENING TORQUES............2-22 LUBRICATION POINTS AND LUBRICANT TYPES ........2-28 ENGINE....................2-28 CHASSIS....................2-30 LUBRICATION SYSTEM CHART AND DIAGRAMS........
Page 78: General Specifications
GENERAL SPECIFICATIONS EAS20280 GENERAL SPECIFICATIONS Model Model 1MD1 (Europe except (F)) 1MD2 (B) (F) Dimensions Overall length 2230 mm (87.8 in) Overall width 750 mm (29.5 in) Overall height 1325/1455 mm (52.2/57.3 in) Seat height 805/825 mm (31.7/32.5 in) Wheelbase 1545 mm (60.8 in) Ground clearance 123 mm (4.84 in)
Page 79: Engine Specifications
ENGINE SPECIFICATIONS EAS20290 ENGINE SPECIFICATIONS Engine Engine type Liquid cooled 4-stroke, DOHC Displacement 1298.0 cm³ Cylinder arrangement Inline 4-cylinder Bore × stroke 79.0 × 66.2 mm (3.11 × 2.61 in) Compression ratio 10.80 : 1 Standard compression pressure (at sea level) 1600 kPa/400 r/min (16.0 kgf/cm²/400 r/min, 227.6 psi/400 r/min) Minimum-maximum...
Page 80 ENGINE SPECIFICATIONS Relief valve operating pressure 480.0–560.0 kPa (4.80–5.60 kgf/cm², 69.6–81.2 psi) Cooling system Radiator capacity (including all routes) 2.60 L (2.75 US qt, 2.29 Imp.qt) Radiator capacity 0.65 L (0.69 US qt, 0.57 Imp.qt) Coolant reservoir capacity (up to the maximum level mark) 0.25 L (0.26 US qt, 0.22 Imp.qt) Radiator cap opening pressure...
Page 81 ENGINE SPECIFICATIONS Limit 24.897 mm (0.9802 in) Camshaft runout limit 0.030 mm (0.0012 in) Timing chain Tensioning system Automatic Valve, valve seat, valve guide Valve clearance (cold) Intake 0.15–0.22 mm (0.0059–0.0087 in) Exhaust 0.18–0.25 mm (0.0071–0.0098 in) Valve dimensions Valve head diameter A (intake) 29.90–30.10 mm (1.1772–1.1850 in) Valve head diameter A (exhaust) 25.90–26.10 mm (1.0197–1.0276 in)
Page 82 ENGINE SPECIFICATIONS Limit 0.105 mm (0.0041 in) Valve stem runout 0.010 mm (0.0004 in) Cylinder head valve seat width (intake) 0.90–1.10 mm (0.0354–0.0433 in) Cylinder head valve seat width (exhaust) 0.90–1.10 mm (0.0354–0.0433 in) Valve spring Free length (intake) 39.73 mm (1.56 in) Limit 37.74 mm (1.49 in) Free length (exhaust)
Page 83 ENGINE SPECIFICATIONS Height H 5.0 mm (0.20 in) Offset 0.50 mm (0.0197 in) Offset direction Intake side Piston pin bore inside diameter 19.004–19.015 mm (0.7482–0.7486 in) Limit 19.045 mm (0.7498 in) Piston pin outside diameter 18.991–19.000 mm (0.7477–0.7480 in) Limit 18.971 mm (0.7469 in) Piston-pin-to-piston-pin-bore clearance 0.004–0.024 mm (0.00016–0.00094 in)
Page 84 ENGINE SPECIFICATIONS Crankshaft Width A 61.60–63.20 mm (2.425–2.488 in) Width B 325.10–326.30 mm (12.80–12.85 in) Runout limit C 0.030 mm (0.0012 in) Big end side clearance D 0.160–0.262 mm (0.0063–0.0103 in) Journal oil clearance 0.027–0.045 mm (0.0011–0.0018 in) Bearing color code 2.Black 3.Brown 4.Green 5.Yellow 6.Pink 7.Red 8.White Balancer...
Page 85 ENGINE SPECIFICATIONS Shifting mechanism Shift mechanism type Shift drum and guide bar Shift fork guide bar bending limit 0.100 mm (0.0039 in) Air filter Air filter element Dry element Fuel pump Pump type Electrical Maximum consumption amperage 6.0 A Fuel injector Model/quantity 0990/4 12.0 Ω...
Page 86 ENGINE SPECIFICATIONS Ring-gear-to-stopper-bolt clearance 0.30–0.60 mm (0.0118–0.0236 in) Ring-gear-to-thrust-washer clearance 0.20 mm (0.0079 in) Final gear backlash 0.22–0.45 mm (0.0087–0.0177 in)
Page 87: Chassis Specifications
CHASSIS SPECIFICATIONS EAS20300 CHASSIS SPECIFICATIONS Chassis Frame type Diamond Caster angle 26.00° Trail 109.0 mm (4.29 in) Front wheel Wheel type Cast wheel 17M/C × MT3.50 Rim size Rim material Aluminum Wheel travel 135.0 mm (5.31 in) Radial wheel runout limit 1.0 mm (0.04 in) Lateral wheel runout limit 0.5 mm (0.02 in)
Page 88 CHASSIS SPECIFICATIONS Front disc brake Disc outside diameter × thickness 320.0 × 4.5 mm (12.60 × 0.18 in) Brake disc thickness limit 4.0 mm (0.16 in) Brake disc deflection limit 0.10 mm (0.0039 in) Brake pad lining thickness (inner) 5.5 mm (0.22 in) Limit 0.5 mm (0.02 in) Brake pad lining thickness (outer)
Page 89 CHASSIS SPECIFICATIONS Quantity 580.0 cm³ (19.61 US oz, 20.46 Imp.oz) (left side) Quantity 570.0 cm³ (19.27 US oz, 20.10 Imp.oz) (right side) Level 123 mm (4.8 in) Rear suspension Type Swingarm (link suspension) Spring/shock absorber type Coil spring/gas-oil damper Rear shock absorber assembly travel 63.0 mm (2.48 in) Spring free length 181.4 mm (7.14 in)
Page 90: Electrical Specifications
ELECTRICAL SPECIFICATIONS EAS20310 ELECTRICAL SPECIFICATIONS Voltage System voltage 12 V Ignition system Ignition system Ignition timing (B.T.D.C.) 5.0°/1050 r/min Engine control unit Model/manufacturer TBDFH6/DENSO (Europe except (F)) TBDFH9/DENSO (B) (F) Ignition coil Minimum ignition spark gap 6.0 mm (0.24 in) 1.19–1.61 Ω...
Page 91 ELECTRICAL SPECIFICATIONS Engine trouble warning light ABS warning light Cruise control system indicator light Cruise control setting indicator light Immobilizer system indicator light Traction control system indicator/warning light “STOP MODE” indicator light Shift down indicator light YCC-S system warning light Suspension warning light Electric starting system System type...
Page 92 ELECTRICAL SPECIFICATIONS Grip warmer 1.21–1.48 Ω Grip warmer resistance (L) 1.17–1.43 Ω Grip warmer resistance (R) Fuses Main fuse 50.0 A Cooling system fuse 30.0 A Headlight fuse 25.0 A Brake light fuse 1.0 A Signaling system fuse 10.0 A Ignition fuse 20.0 A 10.0 A ×...
Page 93: Tightening Torques
TIGHTENING TORQUES EAS20320 TIGHTENING TORQUES EAS20330 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 94: Engine Tightening Torques
TIGHTENING TORQUES EAS20340 ENGINE TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Spark plug 13 Nm (1.3 m·kg, 9.4 ft·lb) Cylinder head bolt See TIP. Cylinder head bolt 12 Nm (1.2 m·kg, 8.7 ft·lb) Camshaft cap bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Cylinder head cover bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Cylinder head cover plate bolt...
Page 95 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Oil pan bolt 12 Nm (1.2 m·kg, 8.7 ft·lb) Oil pump drive chain guide bolt 12 Nm (1.2 m·kg, 8.7 ft·lb) Oil pump housing cover bolt 12 Nm (1.2 m·kg, 8.7 ft·lb) Oil level switch bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Throttle cable holder bolt...
Page 96 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Upper crankcase damper bolt 12 Nm (1.2 m·kg, 8.7 ft·lb) Damper cover bolt (clutch cover) 12 Nm (1.2 m·kg, 8.7 ft·lb) Stator coil assembly lead holder 10 Nm (1.0 m·kg, 7.2 ft·lb) bolt Main gallery bolt 8 Nm (0.8 m·kg, 5.8 ft·lb)
Page 97 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Radiator bracket bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Coolant reservoir bolt 7 Nm (0.7 m·kg, 5.1 ft·lb) Coolant reservoir bracket bolt 7 Nm (0.7 m·kg, 5.1 ft·lb) Clutch fluid reservoir bolt 7 Nm (0.7 m·kg, 5.1 ft·lb) Clutch actuator bracket bolt 19 Nm (1.9 m·kg, 13 ft·lb)
Page 98 TIGHTENING TORQUES Crankcase bolt Tighten the crankcase bolts to 20 Nm (2.0 m·kg, 14 ft·lb) in the proper tightening sequence, loosen and retighten the bolts to 20 Nm (2.0 m·kg, 14 ft·lb) in the proper tightening sequence, and then tighten them further to reach the specified angle 115–125°...
Page 99: Chassis Tightening Torques
TIGHTENING TORQUES EAS20350 CHASSIS TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Engine mounting bolt (right front 49 Nm (4.9 m·kg, 35 ft·lb) lower side) Engine mounting bolt (right front 49 Nm (4.9 m·kg, 35 ft·lb) upper side) Engine mounting bolt (left front 49 Nm (4.9 m·kg, 35 ft·lb) lower side) Engine mounting bolt (left front...
Page 100 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Rear shock absorber assembly 5 Nm (0.5 m·kg, 3.6 ft·lb) preload adjusting pump bolt Rear shock absorber assembly preload adjusting pump bracket 7 Nm (0.7 m·kg, 5.1 ft·lb) bolt Rear shock absorber assembly 4 Nm (0.4 m·kg, 2.9 ft·lb) DC motor bolt Rear shock absorber assembly...
Page 101 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Fuel pump bolt 4 Nm (0.4 m·kg, 2.9 ft·lb) Front fuel tank bracket and frame 10 Nm (1.0 m·kg, 7.2 ft·lb) bolt Fuel tank and front fuel tank 16 Nm (1.6 m·kg, 11 ft·lb) bracket bolt Fuel tank and rear upper fuel 16 Nm (1.6 m·kg, 11 ft·lb)
Page 102 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Front brake caliper bolt 40 Nm (4.0 m·kg, 29 ft·lb) Front brake hose holder bolt 7 Nm (0.7 m·kg, 5.1 ft·lb) Front brake hose joint bolt See TIP. Front brake caliper bleed screw 6 Nm (0.6 m·kg, 4.3 ft·lb) Front brake pad bolt 17 Nm (1.7 m·kg, 12 ft·lb)
Page 103 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Coupling gear nut 110 Nm (11.0 m·kg, 80 ft·lb) Stake. Ring gear bearing housing bolt 40 Nm (4.0 m·kg, 29 ft·lb) Ring gear bearing housing nut 23 Nm (2.3 m·kg, 17 ft·lb) Final gear case stud bolt 9 Nm (0.9 m·kg, 6.5 ft·lb) Ring gear bearing housing stop-...
Page 104 TIGHTENING TORQUES Front wheel axle pinch bolt 1. Insert the front wheel axle from the right side and tighten it with the front wheel axle bolt from the left side to 91 Nm (9.1 m·kg, 66 ft·lb). 2. In the order pinch bolt “2” → pinch bolt “1” → pinch bolt “2”, tighten each bolt to 21 Nm (2.1 m·kg, 15 ft·lb) without performing temporary tightening.
Page 105: Lubrication Points And Lubricant Types
LUBRICATION POINTS AND LUBRICANT TYPES EAS20360 LUBRICATION POINTS AND LUBRICANT TYPES EAS20370 ENGINE Lubrication point Lubricant Oil seal lips O-rings Bearings Crankshaft pins Piston surfaces Piston pins Connecting rod bolts and nuts Crankshaft journals Camshaft lobes Camshaft journals Balancer dampers, weights, gears and shafts Valve stems and stem end (intake and exhaust) Valve lifter surfaces Water pump impeller shaft...
Page 106 LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant Cylinder head cover mating surface Three Bond 1541C® Yamaha bond No.1215 Cylinder head cover gasket (Three Bond No.1215®) Yamaha bond No.1215 Crankcase mating surface (Three Bond No.1215®) Yamaha bond No.1215 Crankshaft position sensor lead grommet (Three Bond No.1215®)
Page 107: Chassis
LUBRICATION POINTS AND LUBRICANT TYPES EAS20380 CHASSIS Lubrication point Lubricant Steering bearings and upper bearing cover lip Lower bearing dust seal lip Front wheel oil seal lip Rear wheel oil seal lip Rear wheel drive hub mating surface Rear brake pedal pivoting point Footrest assembly pivoting point Passenger footrest pivoting point Shift pedal pivoting point...
Page 108: Lubrication System Chart And Diagrams
LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART 2-31...
Page 109 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil strainer 2. Oil pump 3. Relief valve assembly 4. Oil filter cartridge 5. Oil cooler 6. Main gallery 7. Front balancer shaft 8. Rear balancer shaft 9. Oil nozzle 10. Intake camshaft 11. Exhaust camshaft 12.
Page 110: Lubrication Diagrams
LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20410 LUBRICATION DIAGRAMS 2-33...
Page 111 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Intake camshaft 2. Cylinder head 3. Exhaust camshaft 4. Oil check bolt 5. Main gallery bolt 6. Crankshaft 7. Oil nozzle 2-34...
Page 112 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-35...
Page 113 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Main axle 2. Drive axle 3. Oil delivery pipe 1 2-36...
Page 114 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-37...
Page 115 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil check bolt 2. Crankshaft 3. Oil cooler 4. Oil strainer 5. Oil delivery pipe 3 6. Oil pump 2-38...
Page 116 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-39...
Page 117 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Rear balancer 2. Oil delivery pipe 2 3. Engine oil drain bolt 4. Oil level switch 5. Crankshaft 6. Front balancer 7. Crank pin 8. Oil delivery pipe 3 9. Relief valve assembly 2-40...
Page 118 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-41...
Page 119 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil strainer 2. Oil delivery pipe 2 3. Oil cooler 4. Engine oil drain bolt 5. Oil level switch 6. Oil filter cartridge 7. Oil delivery pipe 3 8. Oil pan 9. Oil pump 2-42...
Page 120: Cooling System Diagrams
COOLING SYSTEM DIAGRAMS EAS20420 COOLING SYSTEM DIAGRAMS 2-43...
Page 121 COOLING SYSTEM DIAGRAMS 1. Thermostat inlet pipe 1 2. Thermostat inlet hose 1 3. Oil cooler outlet hose 4. Radiator 5. Coolant reservoir breather hose 6. Thermostat inlet pipe 2 7. Coolant reservoir hose 8. Radiator inlet hose 9. Thermostat inlet hose 2 10.
Page 122 COOLING SYSTEM DIAGRAMS 2-45...
Page 123 COOLING SYSTEM DIAGRAMS 1. Thermostat inlet pipe 1 2. Thermostat inlet hose 2 3. Radiator inlet hose 4. Radiator 5. Radiator outlet hose 6. Oil cooler outlet hose 7. Water jacket joint inlet hose 8. Water pump outlet pipe 9. Water pump outlet hose 10.
Page 124: Cable Routing
CABLE ROUTING EAS20430 CABLE ROUTING Handlebar (front view) 2-47...
Page 125 CABLE ROUTING 1. Right front fork stepping motor 2. Right grip warmer lead 3. Brake hose (front brake master cylinder to brake pipe/lower joint assembly) 4. Coupler rubber cover 5. Right handlebar switch lead 6. Right front fork stepping motor lead 7.
Page 126 CABLE ROUTING Radiator and battery (right side view) 2-49...
Page 127 8. Radiator fan motor relay 9. Starter relay coupler 10. Front right turn signal light coupler 11. ABS test coupler lead 12. Yamaha diagnostic tool connector 13. Right radiator fan motor coupler 14. Negative battery lead 15. O sensor lead 16.
Page 128 CABLE ROUTING Rear brake hose (right side view) 15 16 8 9 10 11 12 2-51...
Page 129 CABLE ROUTING 1. Rear wheel sensor lead 2. Brake hose (rear brake master cylinder to brake pipe/middle joint assembly) 3. Rear brake fluid reservoir hose 4. Rear brake fluid reservoir 5. Brake pipe (hydraulic unit to metering valve) 6. Hydraulic unit assembly 7.
Page 130 CABLE ROUTING Horn and radiator (left side view) 2-53...
Page 131 CABLE ROUTING 1. Radiator inlet hose 2. Left radiator fan motor 3. Radiator 4. Coolant reservoir breather hose 5. Horn 6. Left radiator fan motor coupler 7. Left radiator fan motor lead 8. Coolant reservoir hose A. After connecting the left radiator fan motor coupler, position the coupler between the left side cowling and the left lower inner panel.
Page 132 CABLE ROUTING Front brake hose and engine (left side view) 10 G 2-55...
Page 133 CABLE ROUTING 1. AC magneto lead O. Fasten the grommet on the brake hose (brake pipe/upper joint assembly to left front brake caliper) 2. Rectifier/regulator lead with the holder. 3. Air filter case breather hose P. Fasten the front wheel sensor lead to the brake 4.
Page 134 CABLE ROUTING Rear fender (left side view) 14 H N 16 2-57...
Page 135 CABLE ROUTING 1. Wire harness O. Route the rear right turn signal light lead under the right tail/brake light bulb socket. 2. Shift actuator motor lead P. Route the rear right turn signal light lead and right 3. Foot shift sensor lead tail/brake light lead over the left tail/brake light bulb 4.
Page 136 CABLE ROUTING Throttle bodies (top view) 2-59...
Page 137 CABLE ROUTING 1. Ignition coil #1 coupler E. Install the immobilizer unit coupler holder so that the end with the bolt is facing forward. 2. Front wheel sensor lead F. Install the positive battery lead terminal so that it is 3.
Page 138 CABLE ROUTING Rear fender (top view) 2-61...
Page 139 C. Route the Yamaha diagnostic tool lead to the rear of the positioning ribs and under the band that is used to secure the MCU (motor control unit). Do not pinch the lead between the positioning ribs and the MCU (motor control unit).
Page 140 CABLE ROUTING Front cowling assembly and electrical components board 17 18 2-63...
Page 141 CABLE ROUTING 1. Right headlight lead O. Insert the projection on left handlebar switch coupler completely into the hole in the electrical 2. Right auxiliary light lead components board. 3. Relay unit lead P. Route the air temperature sensor lead under the 4.
Page 142 CABLE ROUTING Hydraulic unit assembly (top and side view) 2-65...
Page 143 CABLE ROUTING 1. Hydraulic unit assembly 2. Brake pipe/middle joint assembly 3. Brake pipe (hydraulic unit to metering valve) 4. Brake pipe (hydraulic unit to proportioning valve) 5. Brake pipe/upper joint assembly 6. Brake pipe/lower joint assembly 7. Brake pipe (proportioning valve to rear brake hose) 8.
Page 144 CABLE ROUTING 2-67...
Page 145: Periodic Checks And Adjustments
PERIODIC CHECKS AND ADJUSTMENTS PERIODIC MAINTENANCE ................3-1 INTRODUCTION ..................3-1 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM ....................3-1 GENERAL MAINTENANCE AND LUBRICATION CHART .......3-1 CHECKING THE FUEL LINE ..............3-4 CHECKING THE SPARK PLUGS ............. 3-4 ADJUSTING THE VALVE CLEARANCE ..........3-5 CHECKING THE ENGINE IDLING SPEED ..........3-7 SYNCHRONIZING THE THROTTLE BODIES..........
Page 146 MEASURING THE ENGINE OIL PRESSURE ........3-28 CHECKING THE COOLANT LEVEL............3-29 CHECKING THE COOLING SYSTEM ............3-29 CHANGING THE COOLANT..............3-30 CHECKING THE FINAL GEAR OIL LEVEL ..........3-31 CHANGING THE FINAL GEAR OIL............3-32 CHECKING THE BRAKE LIGHT SWITCHES.........3-32 ADJUSTING THE REAR BRAKE LIGHT SWITCH .........3-32 CHECKING AND LUBRICATING THE CABLES ........
Page 148: 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 149: Chassis
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 √ √ √ √ √ √...
Page 150 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) Front and rear √ √ √ √ √ √ 25 * •...
Page 151: Checking The Fuel Line
PERIODIC MAINTENANCE EAS21030 ECA13320 CHECKING THE FUEL LINE NOTICE 1. Remove: Before removing the spark plugs, blow away • Rider seat any dirt accumulated in the spark plug wells Refer to “GENERAL CHASSIS” on page 4-1. with compressed air to prevent it from falling •...
Page 152: Adjusting The Valve Clearance
PERIODIC MAINTENANCE 10.Install: Valve clearance (cold) • T-bar Intake Refer to “GENERAL CHASSIS” on page 4-1. 0.15–0.22 mm (0.0059–0.0087 in) • Fuel tank Exhaust Refer to “FUEL TANK” on page 7-1. 0.18–0.25 mm (0.0071–0.0098 in) • Rider seat Refer to “GENERAL CHASSIS” on page 4-1. ▼...
Page 153 PERIODIC MAINTENANCE • Measure the valve clearance in the following ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remove the valve lifter “1” and the valve pad sequence. “2” with the valve lapper “3”. Valve clearance measuring sequence Valve lapper Cylinder #1 →...
Page 154: Checking The Engine Idling Speed
PERIODIC MAINTENANCE Example: • Install the valve lifter and the valve pad in the If the valve pad is marked “155”, the pad correct place. thickness is 1.55 mm (0.061 in). g. Install the exhaust and intake camshafts, tim- d. Calculate the sum of the values obtained in ing chain and camshaft caps.
Page 155: Synchronizing The Throttle Bodies
▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ 4. Install: a. Connect the Yamaha diagnostic tool. • Vacuum gauge “1” Use the diagnostic code number “67”. Refer to “SELF-DIAGNOSTIC FUNCTION Vacuum gauge AND DIAGNOSTIC CODE TABLE (ECU)” on 90890-03094 page 9-5.
Page 156: Checking The Exhaust System
PERIODIC MAINTENANCE Adjusting the throttle body synchronization • The difference in vacuum pressure between 1. Remove the fuel tank bolts “1” and lift up the the throttle bodies should not exceed 1.33 kPa fuel tank. (10 mmHg). ECA1MC1024 NOTICE Carburetor angle driver 2 When lifting up the fuel tank, be careful not 90890-03173 to pull the fuel tank breather/overflow hose.
Page 157: Adjusting The Exhaust Gas Volume
PERIODIC MAINTENANCE • Exhaust pipe assembly bolts “6” 3. Press the “TCS” button “1” to select ECU in • Exhaust pipe assembly and muffler bolts “7” the multi-function meter right display, and • Muffler bolts “8” then simultaneously press the “TCS” button and “RESET”...
Page 158: Checking The Air Induction System
PERIODIC MAINTENANCE • To increase the selected cylinder number, ECA13450 NOTICE press the “TCS” button. Make sure the crankcase breather hose is 7. After selecting the cylinder number, simulta- routed correctly. neously press the “TCS” button “1” and “RE- SET” button “2” for 2 seconds or more to execute the selection.
Page 159: Checking The Clutch Fluid Level
PERIODIC MAINTENANCE EC3P61043 EWA13370 NOTICE WARNING Never operate the engine without the air filter • Use only the designated clutch fluid. Other element installed. Unfiltered air will cause clutch fluids may cause the rubber seals to deteriorate, causing leakage and poor rapid wear of engine parts and may damage the engine.
Page 160 PERIODIC MAINTENANCE • If bleeding is difficult, it may be necessary to let h. Tighten the bleed screw. the clutch fluid settle for a few hours. Repeat i. Disengage the clutch by turning the manual the bleeding procedure when the tiny bubbles clutch operation bolt “4”...
Page 161: Checking The Vehicle After Bleeding The Hydraulic Clutch System
PERIODIC MAINTENANCE c. Manually engage and disengage the clutch a. 100 mm (3.94 in) using the manual clutch operation bolt “3” five b. 20 mm (0.79 in) times, each time for less than 1 second. c. 1.5 mm (0.06 in) d.
Page 162: Adjusting The Front Disc Brake
PERIODIC MAINTENANCE c. Shift the transmission into neutral, and then rotate the rear wheel by hand. GEAR A.TEMP ˚C C.TEMP ˚C TIME TRIP 0:06 c. Shift the transmission into 1st gear, and then slowly turn the throttle grip and check that the d.
Page 163: Checking The Brake Fluid Level
PERIODIC MAINTENANCE EWA13050 WARNING A soft or spongy feeling in the brake lever can indicate the presence of air in the brake system. Before the vehicle is operated, the air must be removed by bleeding the brake system. Air in the brake system will consid- erably reduce braking performance.
Page 164: Bleeding The Hydraulic Brake System (Abs)
PERIODIC MAINTENANCE EAS22780 BLEEDING THE HYDRAULIC BRAKE SYSTEM (ABS) EWA14000 WARNING Always bleed the brake system when the brake related parts are removed. EC3P61012 NOTICE • Bleed the brake system in the following or- der. • 1st step: Front brake calipers •...
Page 165: Checking The Front Brake Pads
PERIODIC MAINTENANCE j. Check the operation of the hydraulic unit. Refer to “HYDRAULIC UNIT OPERATION TESTS” on page 4-71. EC3P61029 NOTICE Make sure that the main switch is turned to “OFF” before checking the operation of the hydraulic unit. k. After operating the ABS, repeat steps (e) to (i), and then fill the brake master cylinder res- ervoir or brake fluid reservoir to the proper EAS21190...
Page 166: Checking The Rear Brake Pads
PERIODIC MAINTENANCE EAS21280 CHECKING THE BRAKE HOSES The following procedure applies to all of the brake hoses and brake hose holders. 1. Check: • Brake hoses Cracks/damage/wear → Replace. 2. Check: • Brake hose holders Loose → Tighten the holder bolts. 3.
Page 167 PERIODIC MAINTENANCE EWA13180 WARNING • The tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperature. • The tire pressure and the suspension must be adjusted according to the total weight (including cargo, rider, passenger and ac- cessories) and the anticipated riding speed.
Page 168: Checking The Wheel Bearings
1. Measure: en if a tire combination other than one • Swingarm side play approved by Yamaha is used on this vehicle. • Swingarm vertical movement Refer to “REMOVING THE SWINGARM” on Front tire page 4-106.
Page 169: Lubricating The Steering Head
PERIODIC MAINTENANCE f. Install the upper ring nut “2”. g. Finger tighten the upper ring nut, then align the slots of both ring nuts. If necessary, hold the lower ring nut and tighten the upper ring nut until their slots are aligned. h.
Page 170: Checking The Sidestand
PERIODIC MAINTENANCE 3. Hold the vehicle upright and apply the front Recommended lubricant brake. Lithium-soap-based grease 4. Check: • Front fork operation EAS1MC1042 Push down hard on the handlebar several CHECKING THE SIDESTAND times and check if the front fork rebounds 1.
Page 171: Checking The Rear Suspension
PERIODIC MAINTENANCE b. Push the menu switch “MENU” “1” to switch the function display “2” to the damping force GEAR GEAR adjusting function “3”. HARD GEAR HARD ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲...
Page 172 PERIODIC MAINTENANCE • The suspension will still operate as normal, only the preload adjusting function cannot be For solo riding and luggage used. • To reset the electronically adjustable suspen- sion system warning light, wait approximately 6 minutes and then turn the key to “OFF” or immediately turn the key to “OFF”...
Page 173: Lubricating The Rear Suspension
PERIODIC MAINTENANCE GEAR GEAR HARD • If the preload is adjusted repeatedly, the pre- Recommended brand load setting pictogram will flash 4 times and YAMALUBE the preload cannot be adjusted. Wait approx- Type imately 6 minutes for the preload adjusting SAE 10W-40, 10W-50, 15W-40, function motor to cool down, and then try ad- 20W-40 or 20W-50...
Page 174: Engine
PERIODIC MAINTENANCE EAS20780 CHANGING THE ENGINE OIL 1. Start the engine, warm it up for several min- utes, and then turn it off. 2. Place a container under the engine oil drain bolt. 3. Remove: • Engine oil filler cap “1” •...
Page 175: Measuring The Engine Oil Pressure
PERIODIC MAINTENANCE b. Slightly loosen the engine oil check bolt “1”. 4. Remove: • Main gallery bolt EWA12980 WARNING The engine, muffler and engine oil are ex- tremely hot. 5. Install: • Oil pressure gauge set “1” • Oil pressure adapter B “2” Oil pressure gauge set 90890-03120 c.
Page 176: Checking The Coolant Level
PERIODIC MAINTENANCE 8. Install: EAS21120 CHECKING THE COOLING SYSTEM • Right side cowling 1. Remove: Refer to “GENERAL CHASSIS” on page 4-1. • Side cowlings Refer to “GENERAL CHASSIS” on page 4-1. EAS21110 CHECKING THE COOLANT LEVEL • Exhaust pipe assembly 1.
Page 177: Changing The Coolant
PERIODIC MAINTENANCE Place a thick rag or a towel over the radiator cap and slowly turn the radiator cap counter- clockwise toward the detent to allow any re- sidual pressure to escape. When the hissing sound has stopped, press down on the radi- ator cap and turn it counterclockwise to re- move.
Page 178: Cooling System
PERIODIC MAINTENANCE 11.Fill: • Cooling system (with the specified amount of the recom- mended coolant) Recommended antifreeze High-quality ethylene glycol anti- freeze containing corrosion in- hibitors for aluminum engines Mixing ratio 1:1 (antifreeze:water) 14.Install: Radiator capacity (including all • Coolant reservoir cap routes) 15.Start the engine, warm it up for several min- 2.60 L (2.75 US qt, 2.29 Imp.qt)
Page 179: Changing The Final Gear Oil
PERIODIC MAINTENANCE EAS1MC1046 CHECKING THE BRAKE LIGHT SWITCHES Type 1. Check: Shaft drive gear oil (Part No.: • Front brake light switch operation 9079E-SH002–00) • Rear brake light switch operation 4. Install: When operating the brake lever and brake • Final gear oil filler bolt pedal, confirm that the brake light turns on.
Page 180: Checking And Lubricating The Cables
▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect the Yamaha diagnostic tool. Use the diagnostic code number “82”. With the engine stopped, turn the throttle grip Refer to “SELF-DIAGNOSTIC FUNCTION slowly and release it. Make sure that the throttle AND DIAGNOSTIC CODE TABLE (ECU)”...
Page 181: Checking The Switches, Lights And Signals
PERIODIC MAINTENANCE Direction “a” Throttle grip free play is increased. Direction “b” Throttle grip free play is decreased. ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 2. Adjust: • Headlight beam (horizontally) ▼...
Page 182 PERIODIC MAINTENANCE When removing the right headlight bulb cover, it If the ABS test coupler and main fuse holder are is necessary to remove the ABS test coupler “3” removed, it is necessary to install them. and main fuse holder “4”. 9.
Page 183 CHASSIS GENERAL CHASSIS..................4-1 REMOVING THE CENTER REAR COWLING.......... 4-2 INSTALLING THE CENTER REAR COWLING ........4-2 REMOVING THE REAR COWLINGS ............4-2 INSTALLING THE REAR COWLINGS............4-2 REMOVING THE SIDE COVERS ............. 4-3 INSTALLING THE SIDE COVERS............4-3 INSTALLING THE SEATS................. 4-3 ADJUSTING THE SIDE PANELS .............
Page 184 FRONT BRAKE ..................... 4-38 INTRODUCTION ..................4-43 CHECKING THE FRONT BRAKE DISCS..........4-43 REPLACING THE FRONT BRAKE PADS ..........4-44 REMOVING THE FRONT BRAKE CALIPERS ........4-45 DISASSEMBLING THE FRONT BRAKE CALIPERS......4-45 CHECKING THE FRONT BRAKE CALIPERS ........4-46 ASSEMBLING THE FRONT BRAKE CALIPERS........4-46 INSTALLING THE FRONT BRAKE CALIPERS ........
Page 185 STEERING HEAD..................4-90 REMOVING THE LOWER BRACKET.............4-92 CHECKING THE STEERING HEAD ............4-92 INSTALLING THE STEERING HEAD .............4-92 REAR SHOCK ABSORBER ASSEMBLY ............4-94 REMOVING THE REAR FENDER ASSEMBLY........4-99 HANDLING THE REAR SHOCK ABSORBER ........4-99 DISPOSING OF A REAR SHOCK ABSORBER ........4-100 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY....4-100 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY ....4-100 CHECKING THE CONNECTING ARM AND RELAY ARM....4-100...
Page 186: General Chassis
GENERAL CHASSIS EAS21830 GENERAL CHASSIS Removing the seats and covers 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 21 Nm (2.1 m kg, 15 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
Page 187: Removing The Center Rear Cowling
GENERAL CHASSIS EAS1MC1049 REMOVING THE CENTER REAR COWLING 1. Remove: • Center rear cowling “1” ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Unhook the projections on the center rear cowling from the rear fender.
Page 188: Removing The Side Covers
GENERAL CHASSIS b. Make sure that the grommet on the tail/brake EAS1MC1055 INSTALLING THE SEATS light assembly fits into the slot in the rear 1. Install: cowling. • Rider seat height position adjuster • Rider seat The rider seat height can be adjusted to one of two positions to suit the rider’s preference.
Page 189 GENERAL CHASSIS 2. Install: • Passenger seat “1” Insert the projections “a” on the rear of the pas- senger seat into the seat holders “b” as shown, and then push the front of the seat down to lock it in place. ▲...
Page 190 GENERAL CHASSIS Removing the side cowlings Order Job/Parts to remove Q’ty Remarks Open the accessory box lid. Headlight beam adjusting knob Front cowling inner panel Right upper inner panel Right lower inner panel Right side panel Right side cowling Front right turn signal light coupler Disconnect.
Page 191 GENERAL CHASSIS Removing the side cowlings Order Job/Parts to remove Q’ty Remarks Accessory box Accessory box solenoid Auxiliary DC jack Left upper inner panel 2 For installation, reverse the removal proce- dure.
Page 192: Adjusting The Side Panels
GENERAL CHASSIS EAS1MC1056 ADJUSTING THE SIDE PANELS The following procedure applies to both of the side panels. 1. Adjust: • Side panel position The side panel “1” can be opened 20 mm (0.79 in) for added ventilation to suit the riding condi- tions.
Page 193: Installing The Front Cowling Inner Panel
GENERAL CHASSIS 2. Remove: EAS1MC1060 INSTALLING THE FRONT COWLING INNER • Front cowling inner panel “1” PANEL ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Unhook the tabs “a” on the top of the front 1.
Page 194: Removing The Side Cowlings
GENERAL CHASSIS ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect the front left turn signal light coupler, auxiliary DC jack coupler, and accessory box solenoid coupler, and then fasten the front left turn signal light lead “a”, auxiliary DC jack lead “b”, and accessory box solenoid lead “c”...
Page 195 GENERAL CHASSIS Removing the front cowling assembly 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Parts to remove Q’ty Remarks Side cowlings Refer to “Removing the side cowlings”. Windshield bracket outer cover Windshield Windshield bracket Windshield bracket inner cover...
Page 196 GENERAL CHASSIS Removing the front cowling assembly 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Parts to remove Q’ty Remarks Headlight assembly For installation, reverse the removal proce- dure. 4-11...
Page 197: Removing The Windshield Bracket Covers
GENERAL CHASSIS EAS1MC1061 REMOVING THE WINDSHIELD BRACKET COVERS The following procedure applies to both of the windshield bracket covers. 1. Remove: • Windshield bracket outer cover “1” Slide the windshield bracket outer cover upward, and then remove it. EAS1MC1062 REMOVING THE CENTER COVERS 1.
Page 198: Installing The Front Cowling Assembly
GENERAL CHASSIS EAS1MC1080 INSTALLING THE HEADLIGHT BEAM Fit the projections on the upper center cover into ADJUSTING KNOB JOINTS the holes in the lower center cover. The following procedure applies to both of the headlight beam adjusting knob joints. 1. Install: •...
Page 199 GENERAL CHASSIS Removing the meter assembly and electrical components board 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Parts to remove Q’ty Remarks Side cowlings Refer to “Removing the side cowlings”. Refer to “Removing the front cowling assem- Front cowling assembly bly”.
Page 200 GENERAL CHASSIS Removing the windshield drive unit 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 32 Nm (3.2 m kg, 23 ft •...
Page 201: Installing The Windshield Drive Unit
GENERAL CHASSIS EAS1MC1079 INSTALLING THE WINDSHIELD DRIVE UNIT 1. Check: • Windshield drive unit operation After installing the windshield drive unit to the windshield drive unit bracket, check the opera- tion of the drive unit. ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼...
Page 202 GENERAL CHASSIS Removing the electrical components tray 1/2 10 Nm (1.0 m kg, 7.2 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Parts to remove Q’ty Remarks Right side cowling Refer to “Removing the side cowlings”. Negative battery lead Disconnect.
Page 203 GENERAL CHASSIS Removing the electrical components tray 2/2 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
Page 204 GENERAL CHASSIS Removing the T-bar 37 Nm (3.7 m kg, 27 ft • • 37 Nm (3.7 m kg, 27 ft • • Order Job/Parts to remove Q’ty Remarks Rider seat Refer to “Removing the seats and covers”. Fuel tank Refer to “FUEL TANK”...
Page 205 Clutch fluid reservoir Air shroud Air duct Air filter case cover Air filter element Owner’s tool kit MCU (motor control unit) SCU (suspension control unit) Yamaha diagnostic tool coupler Rear lower fuel tank bracket Storage compartment Crankcase breather hose Disconnect. 4-20...
Page 206 GENERAL CHASSIS Removing the air filter case 7 Nm (0.7 m kg, 5.1 ft • • 8 Nm (0.8 m kg, 5.8 ft • • (11) 8 Nm (0.8 m kg, 5.8 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
Page 207: Front Wheel
FRONT WHEEL EAS21880 FRONT WHEEL Removing the front wheel, brake discs, wheel sensor, and sensor housing 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 6 Nm (0.6 m kg, 4.3 ft •...
Page 208 FRONT WHEEL Removing the front wheel, brake discs, wheel sensor, and sensor housing 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 6 Nm (0.6 m kg, 4.3 ft • • 21 Nm (2.1 m kg, 15 ft •...
Page 209 FRONT WHEEL Disassembling the front wheel Order Job/Parts to remove Q’ty Remarks Oil seal Front wheel sensor rotor Wheel bearing Spacer For assembly, reverse the disassembly pro- cedure. 4-24...
Page 210: Removing The Front Wheel
FRONT WHEEL ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ EAS21900 REMOVING THE FRONT WHEEL a. Clean the surface of the front wheel hub. ECA1MC1028 b. Remove the oil seals “1” with a flathead NOTICE screwdriver.
Page 211: Maintenance Of The Front Wheel Sensor And Sensor Rotor
FRONT WHEEL 2. Check: • The front wheel sensor cannot be disas- • Tire sembled. Do not attempt to disassemble it. • Front wheel If faulty, replace with a new one. Damage/wear → Replace. • Keep magnets (including magnetic pick-up Refer to “CHECKING THE TIRES”...
Page 212: Assembling The Front Wheel
FRONT WHEEL EAS21960 ASSEMBLING THE FRONT WHEEL Wheel sensor rotor deflection ECA3P6D003 limit NOTICE 0.14 mm (0.0055 in) • Keep magnets (including magnetic pick-up tools, magnetic screwdrivers, etc.) away ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼...
Page 213: Adjusting The Front Wheel Static Balance
FRONT WHEEL b. When the front wheel stops, put an “X ” mark at the bottom of the wheel. ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 2. Install: c. Turn the front wheel 90° so that the “X ”...
Page 214: 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 215 FRONT WHEEL EC3P61022 NOTICE Distance “a” (between the wheel sensor rotor and wheel sensor Before tightening the wheel axle bolt, push housing) down hard on the handlebars several times 28.82–29.66 mm (1.135–1.168 in) and check if the front fork rebounds smooth- ▼...
Page 216: Rear Wheel
REAR WHEEL EAS22030 REAR WHEEL Removing the rear wheel, brake disc, wheel sensor, and sensor housing 7 Nm (0.7 m kg, 5.1 ft • • 125 Nm (12.5 m kg, 90 ft • • 30 Nm (3.0 m kg, 22 ft •...
Page 217 REAR WHEEL Disassembling the rear wheel Order Job/Parts to remove Q’ty Remarks Dust cover Rear wheel drive hub Dust seal Wheel bearing Rear wheel drive hub damper Oil seal Bearing retainer Left-hand threads Rear wheel sensor rotor Wheel bearing Spacer Spacer Bearing For assembly, reverse the disassembly pro-...
Page 218: Removing The Rear Wheel
REAR WHEEL EAS22050 ET3P6D002 REMOVING THE REAR WHEEL DISASSEMBLING THE REAR WHEEL ECA1MC1029 ECA3P6D003 NOTICE NOTICE Keep magnets (including magnetic pick-up • Keep magnets (including magnetic pick-up tools, magnetic screwdrivers, etc.) away tools, magnetic screwdrivers, etc.) away from the rear wheel hub “1”, otherwise the from the wheel sensor rotor.
Page 219: Checking The Rear Wheel
REAR WHEEL EAS22200 MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR ECA3P6D008 NOTICE • Handle the ABS components with care since they have been accurately adjusted. Keep them away from dirt and do not sub- ject them to shocks. •...
Page 220: Adjusting The Rear Wheel Static Balance
REAR WHEEL Hexagon wrench (41) 90890-01525 YM-01525 Bearing retainer 80 Nm (8.0 m·kg, 58 ft·lb) LOCTITE® ECA3P6D009 NOTICE 2. Rear wheel The bearing retainer has left-handed 2. Install: threads. To tighten the retainer, turn it coun- terclockwise. • Wheel bearings ▼...
Page 221: Installing The Rear Wheel (Rear Brake Disc)
REAR WHEEL EAS22170 ECA14470 INSTALLING THE REAR WHEEL (REAR NOTICE BRAKE DISC) Make sure there are no foreign materials in 1. Install: the wheel hub. Foreign materials cause dam- • Rear brake disc age to the inner sensor rotor and wheel sen- sor.
Page 222 REAR WHEEL Distance “a” (between the wheel sensor rotor and wheel sensor housing) 28.84–29.64 mm (1.135–1.167 in) 7. Install: • Rear wheel sensor Rear wheel sensor bolt 7 Nm (0.7 m·kg, 5.1 ft·lb) ECA1MC1030 NOTICE To route the rear wheel sensor lead, refer to “CABLE ROUTING”...
Page 223: Front Brake
FRONT BRAKE EAS22210 FRONT BRAKE Removing the front brake pads 6 Nm (0.6 m kg, 4.3 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 40 Nm (4.0 m kg, 29 ft • • 6 Nm (0.6 m kg, 4.3 ft •...
Page 224 FRONT BRAKE Removing the front brake master cylinder 10 Nm (1.0 m kg, 7.2 ft • • 30 Nm (3.0 m kg, 22 ft • • Order Job/Parts to remove Q’ty Remarks Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM (ABS)”...
Page 225 FRONT BRAKE Disassembling the front brake master cylinder Order Job/Parts to remove Q’ty Remarks Brake master cylinder push rod Dust boot Circlip Brake master cylinder kit Brake master cylinder body For assembly, reverse the disassembly pro- cedure. 4-40...
Page 226 FRONT BRAKE Removing the front brake calipers 40 Nm (4.0 m kg, 29 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 30 Nm (3.0 m kg, 22 ft • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers.
Page 227 FRONT BRAKE Disassembling the front brake calipers 6 Nm (0.6 m kg, 4.3 ft • • 6 Nm (0.6 m kg, 4.3 ft • • 17 Nm (1.7 m kg, 12 ft • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers.
Page 228: Introduction
FRONT BRAKE e. Measure the deflection 1.5 mm (0.06 in) be- EAS22220 INTRODUCTION low the edge of the brake disc. EWA14100 WARNING Disc brake components rarely require disas- sembly. Therefore, always follow these pre- ventive measures: • Never disassemble brake components un- less absolutely necessary.
Page 229: Replacing The Front Brake Pads
FRONT BRAKE d. Measure the brake disc deflection. 2. Install: e. If out of specification, repeat the adjustment • Brake pads steps until the brake disc deflection is within • Brake pad springs specification. f. If the brake disc deflection cannot be brought Always install new brake pads and new brake within specification, replace the brake disc.
Page 230: Removing The Front Brake Calipers
FRONT BRAKE 3. Install: • Copper washers • Brake pad bolts • Brake hose (brake pipe/upper joint assembly • Brake caliper to right front brake caliper) “3” • Brake hose (metering valve to right front Brake pad bolt brake caliper) “4” 17 Nm (1.7 m·kg, 12 ft·lb) Brake caliper bolt Put the end of the brake hoses into a container...
Page 231: Checking The Front Brake Calipers
FRONT BRAKE EWA13560 EAS22410 ASSEMBLING THE FRONT BRAKE WARNING CALIPERS • Cover the brake caliper pistons with a rag. EWA3P6D002 Be careful not to get injured when the pis- WARNING tons are expelled from the brake caliper. • Before installation, all internal brake com- •...
Page 232: Removing The Front Brake Master Cylinder
FRONT BRAKE ECA13540 NOTICE Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. 5. Bleed: • Brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM (ABS)” on page 3-17. 6. Check: 2.
Page 233: Checking The Front Brake Master Cylinder
FRONT BRAKE • Copper washers “2” EAS22530 INSTALLING THE FRONT BRAKE MASTER • Brake hose (front brake master cylinder to CYLINDER brake pipe/lower joint assembly) “3” 1. Install: • Brake master cylinder “1” To collect any remaining brake fluid, place a •...
Page 234 FRONT BRAKE 3. Fill: • Brake master cylinder reservoir • Brake fluid reservoir (with the specified amount of the specified brake fluid) Specified brake fluid DOT 4 EW3P61008 WARNING A. Front brake • Use only the designated brake fluid. Other B.
Page 235: Rear Brake
REAR BRAKE EAS22550 REAR BRAKE Removing the rear brake pads Order Job/Parts to remove Q’ty Remarks Rear brake caliper bolt Rear brake caliper Brake pad shim Rear brake pad Brake pad spring For installation, reverse the removal proce- dure. 4-50...
Page 236 REAR BRAKE Removing the rear brake master cylinder 30 Nm (3.0 m kg, 22 ft • • 18 Nm (1.8 m kg, 13 ft • • 28 Nm (2.8 m kg, 20 ft • • 28 Nm (2.8 m kg, 20 ft •...
Page 237 REAR BRAKE Removing the rear brake master cylinder 30 Nm (3.0 m kg, 22 ft • • 18 Nm (1.8 m kg, 13 ft • • 28 Nm (2.8 m kg, 20 ft • • 28 Nm (2.8 m kg, 20 ft •...
Page 238 REAR BRAKE Disassembling the rear brake master cylinder 16 Nm (1.6 m kg, 11 ft • • Order Job/Parts to remove Q’ty Remarks Dust boot Circlip Brake master cylinder push rod Brake master cylinder kit Brake master cylinder body For assembly, reverse the disassembly pro- cedure.
Page 239 REAR BRAKE Removing the rear brake caliper Order Job/Parts to remove Q’ty Remarks Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM (ABS)” on page 3-17. Brake hose union bolt Copper washer Brake hose (proportioning valve to rear brake caliper) Rear brake caliper bolt Loosen.
Page 240 REAR BRAKE Disassembling the rear brake caliper Order Job/Parts to remove Q’ty Remarks Rear brake caliper bolt Brake pad shim Rear brake pad Brake pad spring Rear brake caliper bracket Brake caliper piston Brake caliper piston dust seal Brake caliper piston seal Bleed screw For assembly, reverse the disassembly pro- cedure.
Page 241: Introduction
REAR BRAKE EAS22560 INTRODUCTION Brake disc thickness limit EWA14100 4.5 mm (0.18 in) WARNING Disc brake components rarely require disas- 5. Adjust: sembly. Therefore, always follow these pre- • Brake disc deflection ventive measures: Refer to “CHECKING THE FRONT BRAKE •...
Page 242: Removing The Rear Brake Caliper
REAR BRAKE Recommended lubricant Always install new brake pads, brake pad shims, Silicone grease and brake pad springs as a set. ECA3P6D017 ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ NOTICE a.
Page 243: Disassembling The Rear Brake Caliper
REAR BRAKE EAS22640 CHECKING THE REAR BRAKE CALIPER Recommended brake component replace- ment schedule Brake pads If necessary Piston dust seal Every two years Piston seal Every two years Brake hoses Every four years Every two years and Brake fluid whenever the brake EAS22600 DISASSEMBLING THE REAR BRAKE...
Page 244: Installing The Rear Brake Caliper
REAR BRAKE • Never use solvents on internal brake com- ponents as they will cause the brake caliper piston dust seal and brake caliper piston seal to swell and distort. • Whenever a brake caliper is disassembled, replace the brake caliper piston dust seal and brake caliper piston seal.
Page 245: Removing The Rear Brake Master Cylinder
REAR BRAKE 4. Remove: • Rear brake caliper bolts • Rear brake caliper 5. Install: • Brake pad springs • Rear brake pads • Brake pad shims • Rear brake caliper bolts • Rear brake caliper Refer to “REPLACING THE REAR BRAKE PADS”...
Page 246: Assembling The Rear Brake Master Cylinder
REAR BRAKE 2. Check: • Brake master cylinder kit Damage/scratches/wear → Replace. 3. Check: • Brake fluid reservoir Cracks/damage → Replace. • Brake fluid reservoir diaphragm Cracks/damage → Replace. 4. Check: • Brake hose Cracks/damage/wear → Replace. 2. Install: • Rear brake light switch “1” EAS22730 ASSEMBLING THE REAR BRAKE MASTER CYLINDER...
Page 247 REAR BRAKE 4. Bleed: • Brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM (ABS)” on page 3-17. 5. Check: • Brake fluid level Below the minimum level mark “a” → Add the specified brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL”...
Page 248: Abs (Anti-Lock Brake System)
ABS (ANTI-LOCK BRAKE SYSTEM) EAS22760 ABS (ANTI-LOCK BRAKE SYSTEM) ET3P61060 ABS COMPONENTS CHART 12,13 1. Brake hose (metering valve to right front brake caliper) 2. Brake hose (brake pipe/upper joint assembly to front brake calipers) 3. Brake hose (front brake master cylinder to brake pipe/lower joint assembly) 4.
Page 249 ABS (ANTI-LOCK BRAKE SYSTEM) Removing the metering valve, proportioning valve, and brake pipes 7 Nm (0.7 m kg, 5.1 ft • • 30 Nm (3.0 m kg, 22 ft • • 16 Nm (1.6 m kg, 11 ft • • 16 Nm (1.6 m kg, 11 ft 7 Nm (0.7 m...
Page 250 ABS (ANTI-LOCK BRAKE SYSTEM) Removing the metering valve, proportioning valve, and brake pipes 7 Nm (0.7 m kg, 5.1 ft • • 30 Nm (3.0 m kg, 22 ft • • 16 Nm (1.6 m kg, 11 ft • • 16 Nm (1.6 m kg, 11 ft 7 Nm (0.7 m...
Page 251 ABS (ANTI-LOCK BRAKE SYSTEM) Removing the hydraulic unit assembly 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 16 Nm (1.6 m kg, 11 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
Page 252: Removing The Hydraulic Unit Assembly
ABS (ANTI-LOCK BRAKE SYSTEM) 3. Slide the rear fender assembly “1” down. ET3P6D003 REMOVING THE HYDRAULIC UNIT ASSEMBLY ECA3P6D018 NOTICE Unless necessary, avoid removing and in- stalling the brake pipes of the hydraulic unit assembly. EWA13930 WARNING Refill with the same type of brake fluid that is already in the system.
Page 253: Checking The Hydraulic Unit Assembly
ABS (ANTI-LOCK BRAKE SYSTEM) • When using a bolt, do not tighten the bolt until ET3P6D005 INSTALLING THE HYDRAULIC UNIT the bolt head touches the hydraulic unit. Other- ASSEMBLY wise, the brake pipe seating surface could be 1. Install: deformed. •...
Page 254 ABS (ANTI-LOCK BRAKE SYSTEM) 7. Install: ECA3P6D022 NOTICE • Proportioning valve “1” If the brake pipe flare nut does not turn easi- • Brake pipe (hydraulic unit to proportioning ly, replace the hydraulic unit, brake pipes, valve) “2” and related parts as a set. Proportioning valve bolt 7 Nm (0.7 m·kg, 5.1 ft·lb) First tighten the brake pipe/joint assembly flare...
Page 255 ABS (ANTI-LOCK BRAKE SYSTEM) ECA3P6D022 NOTICE Brake pipe flare nut 16 Nm (1.6 m·kg, 11 ft·lb) If the brake pipe flare nut does not turn easi- Metering valve bolt ly, replace the hydraulic unit, brake pipes, 7 Nm (0.7 m·kg, 5.1 ft·lb) and related parts as a set.
Page 256: Hydraulic Unit Operation Tests
ABS (ANTI-LOCK BRAKE SYSTEM) 1. Place the vehicle on the centerstand. ECA13540 NOTICE 2. Turn the main switch to “OFF”. Brake fluid may damage painted surfaces 3. Remove: and plastic parts. Therefore, always clean up • Right upper inner panel any spilt brake fluid immediately.
Page 257 ABS (ANTI-LOCK BRAKE SYSTEM) 6. Turn the main switch to “ON” while operating the brake lever and the brake pedal simulta- neously. • This check cannot be performed unless both the brake lever and the brake pedal are oper- ated simultaneously when the main switch is turned to “ON”.
Page 258 ABS (ANTI-LOCK BRAKE SYSTEM) e. Retract the sidestand. 6. Extend the sidestand. 7. Turn the main switch to “ON”. ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 8. Push the “ ”...
Page 259: Checking The Abs Warning Light
ABS (ANTI-LOCK BRAKE SYSTEM) 11.After the pulsating action has stopped in the 13.Turn the main switch to “OFF”. brake lever, it is generated in the brake pedal 14.Remove the test coupler adapter from the “1” 0.5 second later and continues for approx- ABS test coupler.
Page 260: Handlebars
HANDLEBARS EAS22850 HANDLEBARS Removing the left handlebar 65 Nm (6.5 m kg, 47 ft • • 23 Nm (2.3 m kg, 17 ft • • Order Job/Parts to remove Q’ty Remarks Left handlebar Hand shift switch Left handlebar switch Left handlebar switch holder Grip end Handlebar grip Lead holder...
Page 261 HANDLEBARS Removing the right handlebar 23 Nm (2.3 m kg, 17 ft • • 65 Nm (6.5 m kg, 47 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Front brake master cylinder holder Front brake master cylinder assembly Grip end Throttle cable housing...
Page 262: Adjusting The Handlebar Position
HANDLEBARS EAS1MC1065 ADJUSTING THE HANDLEBAR POSITION 1. Check: • Handlebar position The handlebar position can be adjusted to one of three positions to suit the rider’s preference. a. Front position b. Standard position c. Rear position e. Install the handlebar bolts “3” and nuts “2” temporarily.
Page 263: Checking The Handlebars
HANDLEBARS ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ EAS22890 CHECKING THE HANDLEBARS 3. Install: 1. Check: • Right handlebar switch “1” • Left handlebar • Right handlebar Align the projection “a” on the right handlebar Bends/cracks/damage →...
Page 264 HANDLEBARS • When installing the hand shift switch, route the left grip warmer lead “2” and left handlebar switch lead “3” through the switch as shown in the illustration. • After installing the hand shift switch, check that the left grip warmer lead does not interfere with the movement of the hand shift lever.
Page 265 HANDLEBARS 10.Install: • Front brake master cylinder assembly • Front brake master cylinder holder “1” Front brake master cylinder hold- er bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) • Install the brake master cylinder holder with the “UP” mark facing up. •...
Page 266: Front Fork
FRONT FORK EAS22950 FRONT FORK Removing the front fork legs 26 Nm (2.6 m kg, 19 ft • • 23 Nm (2.3 m kg, 17 ft • • 23 Nm (2.3 m kg, 17 ft • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of...
Page 267 FRONT FORK Disassembling the front fork legs 15 Nm (1.5 m kg, 11 ft • • 23 Nm (2.3 m kg, 17 ft • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front fork legs. Cap bolt (with front fork stepping motor) O-ring Locknut...
Page 268: Removing The Front Fork Legs
FRONT FORK EAS22960 ECA1MD1009 REMOVING THE FRONT FORK LEGS NOTICE The following procedure applies to both of the Because the left and right damper rod as- front fork legs. semblies are different, be sure to install them 1. Stand the vehicle on a level surface. in the correct positions.
Page 269: Checking The Front Fork Legs
FRONT FORK Stroke the damper rod “1” several times while draining the fork oil. A. Left side B. Right side EAS23010 CHECKING THE FRONT FORK LEGS 3. Remove: The following procedure applies to both of the • Dust seal front fork legs. •...
Page 270: Assembling The Front Fork Legs
FRONT FORK 3. Check: • Damper rod assembly The left side (for the compression) damper rod Damage/wear → Replace. assembly has the holes “a” of oil path, unlike the Obstruction → Blow out all of the oil passag- right side. es with compressed air.
Page 271 FRONT FORK 3. Lubricate: 5. Install: • Inner tube outer surface • Outer tube (onto the inner tube) Recommended oil 6. Install: Suspension oil 01 or equivalent • Oil seal “1” (with the fork seal driver “2”) 4. Install: • Dust seal “1” Fork seal driver 90890-01502 •...
Page 272 FRONT FORK Fork seal driver Recommended oil 90890-01502 Suspension oil 01 or equiva- Fork seal driver (48) lent YM-A0948 Quantity 580.0 cm³ (19.61 US oz, 20.46 Imp.oz) (left side) Quantity 570.0 cm³ (19.27 US oz, 20.10 Imp.oz) (right side) ECA14230 NOTICE •...
Page 273 FRONT FORK d. Reinstall the rod puller and rod puller attach- ment. e. Press down in the spacer with the fork spring compressor “1”. f. Pull up the rod puller and install the rod holder “2” between the locknut “3” and the spacer “4”.
Page 274: Installing The Front Fork Legs
FRONT FORK EWA1MD1001 WARNING The fork spring is compressed. ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ EAS23050 INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs.
Page 275: Steering Head
STEERING HEAD EAS23090 STEERING HEAD Removing the lower bracket 7 Nm (0.7 m kg, 5.1 ft • • 115 Nm (11.5 m kg, 85 ft • • 1st 52 Nm (5.2 m kg, 37 ft • • 2nd 18 Nm (1.8 m kg, 13 ft •...
Page 276 STEERING HEAD Removing the lower bracket 7 Nm (0.7 m kg, 5.1 ft • • 115 Nm (11.5 m kg, 85 ft • • 1st 52 Nm (5.2 m kg, 37 ft • • 2nd 18 Nm (1.8 m kg, 13 ft •...
Page 277: Removing The Lower Bracket
STEERING HEAD b. Remove the bearing race from the lower EAS23110 REMOVING THE LOWER BRACKET bracket “3” with a floor chisel “4” and ham- 1. Stand the vehicle on a level surface. mer. EWA13120 c. Install new bearing races. WARNING ECA14270 Securely support the vehicle so that there is NOTICE...
Page 278 STEERING HEAD • Lock washer “4” Refer to “CHECKING AND ADJUSTING THE STEERING HEAD” on page 3-21. 3. Install: • Upper bracket • Steering stem nut Temporarily tighten the steering stem nut. 4. Install: • Front fork legs Refer to “FRONT FORK” on page 4-81. Temporarily tighten the upper and lower bracket pinch bolts.
Page 279: Rear Shock Absorber Assembly
REAR SHOCK ABSORBER ASSEMBLY EAS23160 REAR SHOCK ABSORBER ASSEMBLY Removing the rear fender assembly 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Parts to remove Q’ty Remarks Rear cowlings/Side covers/Storage compart- Refer to “GENERAL CHASSIS”...
Page 280 REAR SHOCK ABSORBER ASSEMBLY Removing the rear fender assembly 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Parts to remove Q’ty Remarks Seat lock cable assembly For installation, reverse the removal proce- dure.
Page 281 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly 7 Nm (0.7 m kg, 5.1 ft 64 Nm (6.4 m kg, 46 ft • • • • 11 9 10 10 40 Nm (4.0 m kg, 29 ft • •...
Page 282 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly 7 Nm (0.7 m kg, 5.1 ft 64 Nm (6.4 m kg, 46 ft • • • • 11 9 10 10 40 Nm (4.0 m kg, 29 ft • •...
Page 283 REAR SHOCK ABSORBER ASSEMBLY Removing the stepping motor and DC motor 0.7 Nm (0.07 m kg, 0.51 ft • • 0.7 Nm (0.07 m kg, 0.51 ft • • 5 Nm (0.5 m kg, 3.6 ft • • 4 Nm (0.4 m kg, 2.9 ft •...
Page 284: Removing The Rear Fender Assembly
REAR SHOCK ABSORBER ASSEMBLY then pull the couplers out through the holes in EAS1MD1055 REMOVING THE REAR FENDER ASSEMBLY the DC motor upper cover and rear fender as- 1. Remove the rear fender bolts “1” and quick sembly. fasteners “2”. Move the rear shock absorber assembly, and then pull the couplers out through the holes in the DC motor upper cover and rear fender as-...
Page 285: Disposing Of A Rear Shock Absorber
REAR SHOCK ABSORBER ASSEMBLY • Spacer “2” EAS23190 DISPOSING OF A REAR SHOCK ABSORBER • Rear shock absorber assembly 1. Gas pressure must be released before dis- posing of a rear shock absorber. To release Partially pull out the rear shock absorber assem- the gas pressure, drill a 2–3 mm (0.08–0.12 bly upper bolt, slide the spacer “2”...
Page 286: Replacing The Stepping Motor
REAR SHOCK ABSORBER ASSEMBLY 3. Check: • Spacers • Make sure that the warning label on the rear Damage/scratches → Replace. shock absorber assembly faces to the right. • When installing the rear shock absorber as- EAS1MD1052 REPLACING THE STEPPING MOTOR sembly, lift up the swingarm.
Page 287: Installing The Rear Fender Assembly
REAR SHOCK ABSORBER ASSEMBLY Installed depth “a” 4.0 mm (0.16 in) Installed depth “b” 1.0 mm (0.04 in) Installed depth “c” 3.5–4.5 mm (0.14–0.18 in) Installed depth “d” 0.5 mm (0.02 in) Installed depth “e” 4.5 mm (0.18 in) EAS1MD1056 INSTALLING THE REAR FENDER ASSEMBLY •...
Page 288 REAR SHOCK ABSORBER ASSEMBLY 4. Place the DC motor upper cover “1” in its orig- inal position, and then install the quick fasten- er “2”. 5. Install the rear fender bolts “1” and quick fas- teners “2”. 4-103...
Page 289: Swingarm
SWINGARM EAS23330 SWINGARM Removing the swingarm 10 Nm (1.0 m kg, 7.2 ft • • 23 Nm (2.3 m kg, 17 ft • • 125 Nm (12.5 m kg, 90 ft • • 115 Nm (11.5 m kg, 85 ft •...
Page 290 SWINGARM Removing the swingarm 10 Nm (1.0 m kg, 7.2 ft • • 23 Nm (2.3 m kg, 17 ft • • 125 Nm (12.5 m kg, 90 ft • • 115 Nm (11.5 m kg, 85 ft • • 28 Nm (2.8 m kg, 20 ft •...
Page 291: Removing The Swingarm
SWINGARM EAS23350 EAS23360 REMOVING THE SWINGARM CHECKING THE SWINGARM 1. Stand the vehicle on a level surface. 1. Check: • Swingarm EWA13120 WARNING Bends/cracks/damage → Replace. Securely support the vehicle so that there is 2. Check: no danger of it falling over. •...
Page 292 SWINGARM 3. Swingarm 4. Connecting arm A. Left side B. Right side 3. Tighten: • Pivot shaft Pivot shaft 23 Nm (2.3 m·kg, 17 ft·lb) • Pivot shaft nut Pivot shaft nut 115 Nm (11.5 m·kg, 85 ft·lb) • Pivot shaft self-lock nut Pivot shaft self-lock nut 125 Nm (12.5 m·kg, 90 ft·lb) 4-107...
Page 293: Shaft Drive
SHAFT DRIVE EAS23550 SHAFT DRIVE Removing the final drive assembly Order Job/Parts to remove Q’ty Remarks Drain. Final gear oil Refer to “CHANGING THE FINAL GEAR OIL” on page 3-32. Rear wheel Refer to “REAR WHEEL” on page 4-31. Final drive assembly For installation, reverse the removal proce- dure.
Page 294 SHAFT DRIVE Removing the universal joint 4 Nm (0.4 m kg, 2.9 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “SHIFT ACTUATOR AND SHIFT Left footrest assembly/Sidestand ROD” on page 5-61. Drain. Refer to “CHANGING THE FINAL GEAR Final gear oil OIL”...
Page 295 SHAFT DRIVE Disassembling the final drive assembly Order Job/Parts to remove Q’ty Remarks Circlip Oil seal Drive shaft Spring Ring gear bearing housing Dust cover Oil seal Stopper bolt Left-hand threads Refer to “ADJUSTING THE RING-GEAR- Stopper bolt shim TO-STOPPER-BOLT CLEARANCE” on page 4-116.
Page 296 SHAFT DRIVE Disassembling the final drive assembly Order Job/Parts to remove Q’ty Remarks Coupling gear nut Coupling gear Bearing retainer Left-hand threads Oil seal Final drive pinion gear Bearing Refer to “ALIGNING THE FINAL DRIVE Final drive pinion gear shim PINION GEAR AND RING GEAR”...
Page 297: Troubleshooting
SHAFT DRIVE EAS23560 TROUBLESHOOTING Symptom Possible cause 1. A pronounced hesitation or jerky movement A. Bearing damage during acceleration, deceleration or sus- B. Improper gear backlash tained speeds (not to be confused with en- C. Damaged gear teeth gine surging or transmission-related D.
Page 298 SHAFT DRIVE Troubleshooting chart When causes (A) or (B) shown in the table at the beginning of the “TROUBLESHOOTING” section ex- ist, check the following points. YES → 1. Place the vehicle on a suitable stand so that the front wheel is ele- •...
Page 299: Checking The Final Drive Oil For Contamination And Checking The Shaft Drive For Leaks
SHAFT DRIVE EAS23570 CHECKING THE FINAL DRIVE OIL FOR CONTAMINATION AND CHECKING THE SHAFT DRIVE FOR LEAKS 1. Drain: • Final gear oil (from the final gear case) Refer to “CHANGING THE FINAL GEAR OIL” on page 3-32. 2. Check: •...
Page 300: Adjusting The Final Gear Backlash
SHAFT DRIVE EAS23590 ADJUSTING THE FINAL GEAR BACKLASH 1. Remove: • Ring gear bearing housing bolts “1” • Ring gear bearing housing nuts “2” Working in a crisscross pattern, loosen each bolt and nut 1/4 of a turn. After all of the bolts and nuts are fully loosened, remove them.
Page 301: Measuring The Ring-Gear-To-Stopper-Bolt Clearance
SHAFT DRIVE EAS23610 ADJUSTING THE RING-GEAR-TO- Ring gear shims STOPPER-BOLT CLEARANCE Thickness (mm) 1. Remove: 0.25 0.30 0.40 0.50 • Ring gear “1” • Stopper bolt “2” Thrust washers • Stopper bolt shim(s) “3” Thickness (mm) • Ring gear bearing housing “4” 1.2 1.4 1.6 1.8 2.0 ▲...
Page 302: Disassembling The Final Drive Assembly
SHAFT DRIVE Ring-gear-to-stopper-bolt clear- Bearing retainer wrench ance 90890-04050 0.30–0.60 mm (0.0118–0.0236 in) Pinion bearing retainer & remov- YM-04050 If the ring-gear-to-stopper-bolt clearance is out ECA14330 of specification, repeat the above procedure. NOTICE The bearing retainer has left-hand threads. EAS23620 To loosen the bearing retainer, turn it clock- DISASSEMBLING THE FINAL DRIVE wise.
Page 303: Aligning The Final Drive Pinion Gear And Ring Gear
SHAFT DRIVE The bearing can be reused, but Yamaha recom- mends installing a new one. 3. Remove: • Bearing “1” ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Heat the final gear case to approximately 150 °C (302 °F).
Page 304 SHAFT DRIVE Final drive pinion gear shims Thickness (mm) 0.30 0.40 0.50 Since the final drive pinion gear shims are only available in 0.10 mm increments, round off to the hundredths digit. Hundredth Rounded value 0, 1, 2 3, 4, 5, 6, 7 8, 9 In the example above, the calculated final drive pinion gear shim thickness is 0.51 mm.
Page 305 SHAFT DRIVE Ring gear bearing thickness 13.00 mm (0.51 in) Example: If the final gear case is marked “51”, the ring gear bearing housing is marked “35”, the ring gear is marked “+ 05”, and “f” is 13.00: 45.51 + 3.35 - 35.45 - 13 0.41 3.
Page 306: Checking The Drive Shaft
SHAFT DRIVE 6. Adjust: Thrust washers • Final gear backlash Thickness (mm) Refer to “MEASURING THE FINAL GEAR 1.2 1.4 1.6 1.8 2.0 BACKLASH” on page 4-114 and “ADJUST- ING THE FINAL GEAR BACKLASH” on i. Repeat the measurement steps until the ring- page 4-115.
Page 307 SHAFT DRIVE Fork seal driver weight 90890-01184 Replacement hammer YM-A9409-7 Fork seal driver attachment 90890-01186 Replacement 27 mm YM-A9409-1 6. Install: • Universal joint • Final drive assembly Align the drive shaft splines with the driven yoke of the universal joint. 7.
Page 308 SHAFT DRIVE 4-123...
Page 309 ENGINE ENGINE INSPECTION ..................5-1 MEASURING THE COMPRESSION PRESSURE........5-1 ENGINE REMOVAL ..................5-3 REMOVING THE GEAR POSITION SENSOR ......... 5-8 REMOVING THE ENGINE ................ 5-8 INSTALLING THE ENGINE............... 5-8 INSTALLING THE GEAR POSITION SENSOR........5-11 ADJUSTING THE GEAR POSITION SENSOR ........5-11 CAMSHAFTS....................5-13 REMOVING THE CAMSHAFTS..............5-15 CHECKING THE CAMSHAFTS ..............5-16...
Page 310 CLUTCH ......................5-44 REMOVING THE CLUTCH ..............5-51 CHECKING THE FRICTION PLATES.............5-51 CHECKING THE CLUTCH PLATES ............5-52 CHECKING THE CLUTCH SPRING PLATE...........5-52 CHECKING THE CLUTCH HOUSING ............5-52 CHECKING THE CLUTCH BOSS............5-53 CHECKING THE PRESSURE PLATE ............5-53 CHECKING THE CLUTCH PUSH RODS ..........5-53 CHECKING THE PRIMARY DRIVEN GEAR ..........5-53 INSTALLING THE CLUTCH..............
Page 311 MIDDLE GEAR ....................5-75 REMOVING THE MIDDLE DRIVE SHAFT ASSEMBLY ......5-79 DISASSEMBLING THE MIDDLE DRIVE SHAFT ASSEMBLY ....5-79 DISASSEMBLING THE MIDDLE DRIVEN SHAFT ASSEMBLY..... 5-79 CHECKING THE MIDDLE DRIVE SHAFT ASSEMBLY......5-80 CHECKING THE MIDDLE DRIVEN SHAFT ASSEMBLY .......5-80 ASSEMBLING THE MIDDLE DRIVE SHAFT ASSEMBLY .....5-80 ASSEMBLING THE MIDDLE DRIVEN SHAFT ASSEMBLY....
Page 312: Engine Inspection
ENGINE INSPECTION EAS1MC1068 ENGINE INSPECTION EAS20710 MEASURING THE COMPRESSION PRESSURE The following procedure applies to all of the cyl- inders. Insufficient compression pressure will result in a loss of performance. 8. Measure: 1. Measure: • Compression pressure Out of specification → Refer to steps (c) and •...
Page 313 ENGINE INSPECTION Compression pressure (with oil applied into the cylinder) Reading Diagnosis Higher than without Piston ring(s) wear or damage → Repair. Pistons, valves, cylin- der head gasket or Same as without oil piston ring(s) possi- bly defective → Re- pair.
Page 314: Engine Removal
ENGINE REMOVAL EAS23710 ENGINE REMOVAL Removing the exhaust pipe assembly and muffler 17 Nm (1.7 m kg, 12 ft • • 25 Nm (2.5 m kg, 18 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 5 Nm (0.5 m kg, 3.6 ft •...
Page 315 ENGINE REMOVAL Disconnecting the leads and hose 10 Nm (1.0 m kg, 7.2 ft 3.5 Nm (0.35 m kg, 2.5 ft 10 Nm (1.0 m kg, 7.2 ft • • • • • • Order Job/Parts to remove Q’ty Remarks Front fender Refer to “FRONT WHEEL”...
Page 316 ENGINE REMOVAL Disconnecting the leads and hose 10 Nm (1.0 m kg, 7.2 ft 3.5 Nm (0.35 m kg, 2.5 ft 10 Nm (1.0 m kg, 7.2 ft • • • • • • Order Job/Parts to remove Q’ty Remarks Clutch release cylinder Dowel pin Crankcase breather hose...
Page 317 ENGINE REMOVAL Removing the engine 8 Nm (0.8 m kg, 5.8 ft 45 Nm (4.5 m kg, 32 ft • • 49 Nm (4.9 m kg, 35 ft • • • • 45 Nm (4.5 m kg, 32 ft • •...
Page 318 ENGINE REMOVAL Removing the engine 8 Nm (0.8 m kg, 5.8 ft 45 Nm (4.5 m kg, 32 ft • • 49 Nm (4.9 m kg, 35 ft • • • • 45 Nm (4.5 m kg, 32 ft • •...
Page 319: Removing The Gear Position Sensor
ENGINE REMOVAL EAS1MD1028 REMOVING THE GEAR POSITION SENSOR 1. Disconnect: • Gear position sensor coupler 2. Remove: • Gear position sensor Remove only the screws “1” when removing the gear position sensor. Do not remove the screws “2”. EAS23720 INSTALLING THE ENGINE 1.
Page 320 ENGINE REMOVAL • Engine mounting bolt (left front upper side) Spacer bolt “5” 18 Nm (1.8 m·kg, 13 ft·lb) • Engine mounting bolt (left front lower side) “6” • Spacers “7” • Engine mounting bolt (right front upper side) • Tighten the spacer bolt “1” to specification with “8”...
Page 321 ENGINE REMOVAL Pinch bolt (rear lower side) 24 Nm (2.4 m·kg, 17 ft·lb) Tighten the pinch bolts (rear lower side) one at a time, making sure to tighten the first bolt again after tightening the second bolt. 12.Tighten: • Engine bracket and engine bolts (top) “13” 14.Install: (temporarily tighten) •...
Page 322: Installing The Gear Position Sensor
ENGINE REMOVAL Align the punch mark “a” on the brake pedal with the punch mark “b” on the brake pedal pivot shaft. 3. Adjust: • Gear position sensor Refer to “ADJUSTING THE GEAR POSI- TION SENSOR” on page 5-11. EAS1MD1030 EAS1MD1029 ADJUSTING THE GEAR POSITION SENSOR INSTALLING THE GEAR POSITION SENSOR...
Page 323 ENGINE REMOVAL c. Turn the main switch to “ON”. d. Measure the gear position sensor voltage. e. Adjust the gear position sensor angle so that the voltage is within the specified range. Output voltage (at neutral posi- tion) 0.71–0.91 V f.
Page 324: Camshafts
CAMSHAFTS EAS23760 CAMSHAFTS Removing the cylinder head cover 10 Nm (1.0 m kg, 7.2 ft • • 13 Nm (1.3 m kg, 9.4 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS”...
Page 325 CAMSHAFTS Removing the camshafts Order Job/Parts to remove Q’ty Remarks Throttle bodies Refer to “THROTTLE BODIES” on page 7-4. Pickup rotor cover Refer to “PICKUP ROTOR” on page 5-37. Timing chain tensioner Timing chain tensioner gasket Intake camshaft cap Exhaust camshaft cap Intake camshaft Exhaust camshaft Intake camshaft sprocket...
Page 326: Removing The Camshafts
CAMSHAFTS EAS23810 REMOVING THE CAMSHAFTS 1. Align: • “T” mark on the pickup rotor (with the crankcase mating surface) ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Turn the crankshaft clockwise. b.
Page 327: Checking The Camshafts
CAMSHAFTS 3. Measure: EAS23850 CHECKING THE CAMSHAFTS • Camshaft runout 1. Check: Out of specification → Replace. • Camshaft lobes Blue discoloration/pitting/scratches → Re- Camshaft runout limit place the camshaft. 0.030 mm (0.0012 in) 2. Measure: • Camshaft lobe dimensions “a” and “b” Out of specification →...
Page 328: Checking The Camshaft Sprockets
CAMSHAFTS • Tighten the camshaft cap bolts in stages and in a crisscross pattern, working from the inner caps out. • Do not turn the camshaft when measuring the camshaft journal-to-camshaft cap clearance with the Plastigauge®. Camshaft cap bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) a.
Page 329: Installing The Camshafts
CAMSHAFTS 2. Install: ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ • Timing chain “1” EAS24010 INSTALLING THE CAMSHAFTS • Exhaust camshaft “2” 1. Install: • Intake camshaft “3” • Exhaust camshaft sprocket (with the camshaft sprockets) •...
Page 330 CAMSHAFTS ECA13730 NOTICE The camshaft cap bolts must be tightened evenly or damage to the cylinder head, cam- shaft caps, and camshafts will result. Tighten the camshaft cap bolts in stages and in a crisscross pattern, working from the inner caps out.
Page 331 • Apply Three Bond 1514C® “1” onto the mating Timing chain tensioner cap bolt surfaces of the cylinder head cover and cylin- 6 Nm (0.6 m·kg, 4.3 ft·lb) der head cover gasket. • Apply Yamaha bond No.1215® “2” onto the ▲ ▲▲▲ ▲ ▲▲▲ ▲...
Page 332 CAMSHAFTS 11.Install: • Cylinder head cover plate “1” Be sure the “UP” mark “a” is facing up. 5-21...
Page 333: Cylinder Head
CYLINDER HEAD EAS24100 CYLINDER HEAD Removing the cylinder head (10) 25 Nm (2.5 m kg, 18 ft • • 2nd 25 Nm (2.5 m kg, 18 ft • • Final Specified angle 175–185˚ 12 Nm (1.2 m kg, 8.7 ft •...
Page 334: Removing The Cylinder Head
CYLINDER HEAD ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ EAS24120 REMOVING THE CYLINDER HEAD a. Place a straightedge “1” and a thickness 1. Remove: gauge “2” across the cylinder head. •...
Page 335 CYLINDER HEAD Cylinder head bolt (M10) 25 Nm (2.5 m·kg, 18 ft·lb) e. Tighten the cylinder head bolts further to reach the specified angle 175–185° in the proper tightening sequence as shown. Cylinder head bolt (M10) Final Specified angle 175–185° ▲...
Page 336 VALVES AND VALVE SPRINGS EAS24270 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 5-22. Valve lifter Valve pad Valve cotter Upper spring seat Intake valve spring Exhaust valve spring Intake valve Exhaust valve...
Page 337: Valves And Valve Springs
VALVES AND VALVE SPRINGS EAS24280 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 338 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) b. Install the new valve guide with the valve 0.010–0.037 mm (0.0004–0.0015 guide installer “2”...
Page 339: Checking The Valve Seats
VALVES AND VALVE SPRINGS Valve guide remover (ø5) Valve stem runout 90890-04097 0.010 mm (0.0004 in) Valve guide remover (5.0 mm) YM-04097 Valve guide installer (ø5) 90890-04098 Valve guide installer (5.0 mm) YM-04098 Valve guide reamer (ø5) 90890-04099 Valve guide reamer (5.0 mm) YM-04099 ▲...
Page 340: Checking The Valve Springs
VALVES AND VALVE SPRINGS For the best lapping results, lightly tap the valve seat while rotating the valve back and forth be- tween your hands. b. Install the valve into the cylinder head. c. Press the valve through the valve guide and onto the valve seat to make a clear impres- sion.
Page 341: Checking The Valve Lifters
VALVES AND VALVE SPRINGS 1. Measure: 3. Measure: • Valve spring free length “a” • Valve spring tilt “a” Out of specification → Replace the valve Out of specification → Replace the valve spring. spring. Free length (intake) Spring tilt (intake) 39.73 mm (1.56 in) 2.5°/1.7 mm (2.5°/0.067 in) Limit...
Page 342 VALVES AND VALVE SPRINGS Valve spring compressor 90890-04019 YM-04019 Valve spring compressor attach- ment 90890-04114 Valve spring compressor adapt- er 19.5 mm YM-04114 3. Install: • Lower spring seat “1” • Valve stem seal “2” • Valve “3” • Valve spring “4” •...
Page 343: Generator And Starter Clutch
GENERATOR AND STARTER CLUTCH EAS24480 GENERATOR AND STARTER CLUTCH Removing the generator rotor and starter clutch Order Job/Parts to remove Q’ty Remarks Fuel tank Refer to “FUEL TANK” on page 7-1. Drain. Engine oil Refer to “CHANGING THE ENGINE OIL” on page 3-27.
Page 344 GENERATOR AND STARTER CLUTCH Removing the stator coil assembly Order Job/Parts to remove Q’ty Remarks Stator coil assembly lead holder Stator coil assembly For installation, reverse the removal proce- dure. 5-33...
Page 345: Removing The Generator
GENERATOR AND STARTER CLUTCH EAS24490 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 EAS24560 REMOVING THE STARTER CLUTCH 90890-01701 1.
Page 346: Installing The Starter Clutch
Sheave holder 90890-01701 Primary clutch holder YS-01880-A 3. Apply: • Sealant (onto the stator coil assembly lead grommet) Yamaha bond No. 1215 90890-85505 (Three Bond No.1215®) EAS24500 INSTALLING THE GENERATOR 1. Install: • Woodruff key • Generator rotor...
Page 347 GENERATOR AND STARTER CLUTCH 4. Install: • Generator cover gasket • Generator cover Generator cover bolt 12 Nm (1.2 m·kg, 8.7 ft·lb) Tighten the generator cover bolts in stages and in a crisscross pattern. 5-36...
Page 348: Pickup Rotor
PICKUP ROTOR EAS24520 PICKUP ROTOR Removing the pickup rotor 12 Nm (1.2 m kg, 8.7 ft • • 65 Nm (6.5 m kg, 47 ft • • 4 Nm (0.4 m kg, 2.9 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS”...
Page 349: Removing The Pickup Rotor
When installing the pickup rotor, align the groove “a” in the crankshaft sprocket with the projection “b” in the pickup rotor. 3. Apply: • Sealant (onto the crankshaft position sensor lead grommet) Yamaha bond No. 1215 90890-85505 (Three Bond No.1215®) 5-38...
Page 350 PICKUP ROTOR 4. Measure: • Gap (between the crankshaft position sensor “1” and pickup rotor “2”) “a” Out of specification → Reinstall or replace. Gap (between the crankshaft po- sition sensor and pickup rotor) 0.5 mm (0.02 in) 5. Install: •...
Page 351: Electric Starter
ELECTRIC STARTER EAS24780 ELECTRIC STARTER Removing the starter motor Order Job/Parts to remove Q’ty Remarks Throttle bodies Refer to “THROTTLE BODIES” on page 7-4. Starter motor lead Disconnect. Starter motor assembly For installation, reverse the removal proce- dure. 5-40...
Page 352 ELECTRIC STARTER Disassembling the starter motor Order Job/Parts to remove Q’ty Remarks O-ring Starter motor front cover Brush Brush seat (along with brushes) Washer Lock washer Oil seal Bearing Starter motor rear cover Collar O-ring Starter motor yoke Armature assembly For assembly, reverse the disassembly pro- cedure.
Page 353: Checking The Starter Motor
ELECTRIC STARTER EAS24790 CHECKING THE STARTER MOTOR Pocket tester 1. Check: 90890-03112 • Commutator Analog pocket tester Dirt → Clean with 600 grit sandpaper. YU-03112-C 2. Measure: • Commutator diameter “1” Armature coil Out of specification → Replace the starter Commutator resistance “1”...
Page 354: Assembling The Starter Motor
ELECTRIC STARTER 7. Check: • Gear teeth Damage/wear → Replace the gear. 8. Check: • Bearing • Oil seal Damage/wear → Replace the defective part(s). EAS24800 ASSEMBLING THE STARTER MOTOR 1. Install: • Brush seat “1” Align the slot “a” on the brush seat with the tab “b”...
Page 355: Clutch
CLUTCH EAS25060 CLUTCH Removing the clutch cover 12 Nm (1.2 m kg, 8.7 ft • • (10) 12 Nm (1.2 m kg, 8.7 ft 12 Nm (1.2 m kg, 8.7 ft • • • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS”...
Page 356 CLUTCH Removing the clutch 90 Nm (9.0 m kg, 65 ft • • 18 17 10 Nm (1.0 m kg, 7.2 ft • • 11 10 9,12 8 Nm (0.8 m kg, 5.8 ft • • Order Job/Parts to remove Q’ty Remarks Rear balancer...
Page 357 CLUTCH Removing the clutch 90 Nm (9.0 m kg, 65 ft • • 18 17 10 Nm (1.0 m kg, 7.2 ft • • 11 10 9,12 8 Nm (0.8 m kg, 5.8 ft • • Order Job/Parts to remove Q’ty Remarks Thrust washer...
Page 358 CLUTCH Removing the clutch actuator and clutch master cylinder 7 Nm (0.7 m kg, 5.1 ft • • 19 Nm (1.9 m kg, 13 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 30 Nm (3.0 m kg, 22 ft •...
Page 359 CLUTCH Removing the clutch actuator and clutch master cylinder 7 Nm (0.7 m kg, 5.1 ft • • 19 Nm (1.9 m kg, 13 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 30 Nm (3.0 m kg, 22 ft •...
Page 360 CLUTCH Disassembling the clutch master cylinder Order Job/Parts to remove Q’ty Remarks Clutch master cylinder kit Clutch master cylinder body For assembly, reverse the disassembly pro- cedure. 5-49...
Page 361 CLUTCH Removing the clutch release cylinder Order Job/Parts to remove Q’ty Remarks Drain. Clutch fluid Refer to “BLEEDING THE HYDRAULIC CLUTCH SYSTEM” on page 3-12. Clutch hose union bolt Copper washer Clutch hose Disconnect. Clutch release cylinder Dowel pin Plate For installation, reverse the removal proce- dure.
Page 362: Removing The Clutch
CLUTCH EAS25080 REMOVING THE CLUTCH • Insert a cross-headed screwdriver into one of 1. Remove: the holes of the clutch housing and primary • Clutch cover “1” driven gear, and then rotate the inner primary driven gear until both primary drive gears are Loosen each bolt 1/4 of a turn at a time, in stag- aligned.
Page 363: Checking The Clutch Plates
CLUTCH EAS25130 CHECKING THE CLUTCH SPRING PLATE 1. Check: • Clutch spring plate retainer Damage → Replace. 2. Check: • Clutch spring plate seat Damage → Replace. 3. Measure: • Clutch spring free height Out of specification → Replace the clutch A.
Page 364: Checking The Clutch Boss
CLUTCH 2. Measure: • Long clutch push rod bending limit Out of specification → Replace the long clutch push rod. Long clutch push rod bending limit 0.370 mm (0.0146 in) EAS25210 CHECKING THE PRIMARY DRIVEN GEAR 2. Check: 1. Check: •...
Page 365 CLUTCH 4. Bend the lock washer tab along a flat side of 2. Install: the nut. • Spacer “1” 5. Install: • Clutch damper spring seat “1” Install the spacer with the two screw holes facing • Clutch damper spring “2” towards the clutch boss.
Page 366: Checking The Clutch Actuator Sensor
CLUTCH Test harness- TPS (4P) Tighten the clutch spring bolts in stages and in a 90890-03205 crisscross pattern. YU-03205 Digital circuit tester 9. Install: 90890-03174 • Rear balancer weight Model 88 Multimeter with ta- Refer to “BALANCERS” on page 5-116. chometer 10.Install: YU-A1927...
Page 367: Breaking In The Friction Plates After Replacement
CLUTCH b. Measure the clutch actuator sensor resis- ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ tance. EAS25280 DISASSEMBLING THE CLUTCH MASTER ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲...
Page 368: Checking The Clutch Master Cylinder
CLUTCH Specified brake and clutch fluid DOT 4 EAS1MD1034 INSTALLING THE CLUTCH MASTER CYLINDER 1. Install: • Copper washers “1” • Clutch hose “2” • Clutch hose union bolt “3” EAS25290 CHECKING THE CLUTCH MASTER Clutch hose union bolt CYLINDER 30 Nm (3.0 m·kg, 22 ft·lb) Recommended clutch component replace- ment schedule...
Page 369: Replacing The Clutch Master Cylinder
CLUTCH • When refilling, be careful that water does 5. Adjust: not enter the clutch fluid reservoir. Water • Clutch engagement point will significantly lower the boiling point of Execute the diagnostic mode. (Code No. Sh_ the clutch fluid and could cause vapor lock. _66) Refer to “SELF-DIAGNOSTIC FUNCTION ECA13420...
Page 370: Removing The Clutch Release Cylinder
CLUTCH 4. Adjust: • Clutch engagement point “1” Execute the diagnostic mode. (Code No. Sh_ _66) Refer to “SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE (MCU)” on page 9-13. Clutch engagement point EAS25330 CHECKING THE CLUTCH RELEASE CYLINDER 1. Check: • Clutch release cylinder body DIAG Cracks/damage →...
Page 371: Checking For Stuck Clutch Actuator
CLUTCH 2. Fill: EAS1MD1037 CHECKING FOR STUCK CLUTCH • Clutch fluid reservoir ACTUATOR (with the specified amount of the specified 1. Check: brake and clutch fluid) • Check whether the clutch actuator is stuck. Clutch actuator is stuck → Reinstall. Specified brake and clutch fluid ▼...
Page 372: Shift Actuator And Shift Rod
SHIFT ACTUATOR AND SHIFT ROD EAS1MD1038 SHIFT ACTUATOR AND SHIFT ROD Removing the shift actuator, shift rod and foot shift sensor 4 Nm (0.4 m kg, 2.9 ft • • 20 Nm (2.0 m kg, 14 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
Page 373 SHIFT ACTUATOR AND SHIFT ROD Removing the shift actuator, shift rod and foot shift sensor 4 Nm (0.4 m kg, 2.9 ft • • 20 Nm (2.0 m kg, 14 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
Page 374: Removing The Shift Actuator
SHIFT ACTUATOR AND SHIFT ROD • Shift pedal pivot EAS1MD1049 REMOVING THE SHIFT ACTUATOR • Spring 1. Remove: • Ball • Shift actuator • Wave washer ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼...
Page 375: Adjusting The Foot Shift Sensor
SHIFT ACTUATOR AND SHIFT ROD d. Measure the foot shift sensor output voltage. e. Adjust the foot shift sensor angle so that the voltage is within the specified range. Output voltage 2.4–2.6 V f. After adjusting the foot shift sensor angle, tighten the foot shift sensor screws “3”...
Page 376: Installing The Shift Actuator
SHIFT ACTUATOR AND SHIFT ROD f. Tighten the shift rod bolts to specification. ET3P66042 INSTALLING THE SHIFT ACTUATOR Shift rod bolt 1. Install: 10 Nm (1.0 m·kg, 7.2 ft·lb) • Shift actuator LOCTITE® ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼...
Page 377: Checking For Stuck Shift Actuator
SHIFT ACTUATOR AND SHIFT ROD ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ • Positive tester probe → a. Shift the transmission into neutral, and then green/yellow “1” turn the main switch to “OFF”. •...
Page 378 SHIFT ACTUATOR AND SHIFT ROD a. High position b. Standard position c. Low position b. Move the shift pedal to the desired position. c. Install the shift pedal bolt, and then tighten it to specification. Shift pedal bolt 7 Nm (0.7 m·kg, 5.1 ft·lb) LOCTITE®...
Page 379: Shift Shaft
SHIFT SHAFT EAS25410 SHIFT SHAFT Removing the shift shaft and stopper lever Order Job/Parts to remove Q’ty Remarks Clutch housing Refer to “CLUTCH” on page 5-44. Refer to “SHIFT ACTUATOR AND SHIFT Shift rod ROD” on page 5-61. Oil baffle plate 1 Shift arm Circlip Shift shaft...
Page 380: Checking The Shift Shaft
SHIFT SHAFT 3. Install: EAS25420 CHECKING THE SHIFT SHAFT • Shift arm “1” 1. Check: • Shift shaft Shift arm pinch bolt Bends/damage/wear → Replace. 10 Nm (1.0 m·kg, 7.2 ft·lb) • Shift shaft spring Damage/wear → Replace. Align the punch mark “a” on the shift arm with the EAS25430 CHECKING THE STOPPER LEVER punch mark “b”...
Page 381: Oil Pump
OIL PUMP EAS24920 OIL PUMP Removing the oil pan and oil pump Order Job/Parts to remove Q’ty Remarks Drain. Engine oil Refer to “CHANGING THE ENGINE OIL” on page 3-27. Throttle bodies Refer to “THROTTLE BODIES” on page 7-4. Exhaust pipe assembly Refer to “ENGINE REMOVAL”...
Page 382 OIL PUMP Removing the oil pan and oil pump Order Job/Parts to remove Q’ty Remarks Oil pump Relief valve assembly sensor lead bracket For installation, reverse the removal proce- dure. 5-71...
Page 383 OIL PUMP Disassembling the oil pump Order Job/Parts to remove Q’ty Remarks Oil pump housing cover Oil pump inner rotor Oil pump outer rotor Washer Oil pump driven sprocket Oil pump housing For assembly, reverse the disassembly pro- cedure. 5-72...
Page 384: Checking The Oil Pump
OIL PUMP EAS24960 CHECKING THE OIL PUMP Inner-rotor-to-outer-rotor-tip 1. Check: clearance • Oil pump driven sprocket Less than 0.12 mm (0.0047 in) Limit • Oil pump housing 0.20 mm (0.0079 in) • Oil pump housing cover Cracks/damage/wear → Replace the defec- Outer-rotor-to-oil-pump-housing clearance tive part(s).
Page 385: Checking The Oil Strainer
OIL PUMP 1. Check: • Oil pan • Oil delivery pipes Oil pan bolt Damage → Replace. 12 Nm (1.2 m·kg, 8.7 ft·lb) Obstruction → Wash and blow out with com- pressed air. EAS24990 Tighten the oil pan bolts in stages and in a criss- CHECKING THE OIL STRAINER cross pattern.
Page 386: Middle Gear
MIDDLE GEAR EAS25710 MIDDLE GEAR Removing the middle gear 160 Nm (16.0 m kg, 115 ft • • Order Job/Parts to remove Q’ty Remarks Engine Refer to “ENGINE REMOVAL” on page 5-3. Oil pan/Oil pump Refer to “OIL PUMP” on page 5-70. Middle gear case cover Middle gear case cover gasket Dowel pin...
Page 387 MIDDLE GEAR Removing the middle gear 160 Nm (16.0 m kg, 115 ft • • Order Job/Parts to remove Q’ty Remarks Spacer Middle driven gear Bearing retainer Bearing Middle drive pinion gear shim Bearing For installation, reverse the removal proce- dure.
Page 388 MIDDLE GEAR Disassembling the middle drive shaft assembly Order Job/Parts to remove Q’ty Remarks Spring retainer Spring seat Damper spring Damper driven cam Damper drive cam Middle drive shaft For assembly, reverse the disassembly pro- cedure. 5-77...
Page 389 MIDDLE GEAR Disassembling the middle driven shaft assembly 110 Nm (11.0 m kg, 80 ft • • 180 Nm (18.0 m kg, 130 ft • • Order Job/Parts to remove Q’ty Remarks Oil seal Middle driven pinion gear nut Middle driven shaft Middle driven pinion gear Bearing retainer Bearing...
Page 390: Removing The Middle Drive Shaft Assembly
MIDDLE GEAR EAS25730 REMOVING THE MIDDLE DRIVE SHAFT ASSEMBLY 1. Remove: • Middle drive pinion gear nut “1” • Lock washer “2” ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a.
Page 391: Checking The Middle Drive Shaft Assembly
MIDDLE GEAR 4. Check: • Bearings Damage/pitting → Replace. EAS25790 CHECKING THE MIDDLE DRIVEN SHAFT ASSEMBLY 1. Check: • Middle driven pinion gear Galling/pitting/wear → Replace. 2. Check: c. Remove the middle driven pinion gear nut. • Bearings Damage/pitting → Replace. ▲...
Page 392: Installing The Middle Drive Shaft Assembly
MIDDLE GEAR c. Tighten the bearing retainer to specification. Bearing retainer 110 Nm (11.0 m·kg, 80 ft·lb) ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ EAS25860 INSTALLING THE MIDDLE DRIVE SHAFT ASSEMBLY 1.
Page 393: Installing The Middle Driven Shaft Assembly
MIDDLE GEAR • Middle drive pinion gear nut “2” • Middle driven shaft end cover ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ • Middle driven shaft bearing housing bolts a.
Page 394: Measuring The Middle Gear Backlash
MIDDLE GEAR EAS25880 EAS25900 MEASURING THE MIDDLE GEAR ADJUSTING THE MIDDLE GEAR BACKLASH BACKLASH 1. Loosen: 1. Measure: • Middle driven shaft bearing housing bolts • Middle gear backlash 2. Remove: Out of specification → Refer to “ADJUSTING • Middle driven pinion gear shim(s) THE MIDDLE GEAR BACKLASH”...
Page 395: Aligning The Middle Gear
MIDDLE GEAR Middle driven shaft bearing hous- While carefully tightening the middle driven shaft ing bolt bearing housing bolts in stages and in a criss- 25 Nm (2.5 m·kg, 18 ft·lb) cross pattern, turn the middle driven shaft back LOCTITE® and forth until the dial gauge reads 0.10–0.20 mm (0.0039–0.0079 in).
Page 396 MIDDLE GEAR ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ “d” = a numeral on the middle driven pinion a. Position the middle gears with the appropri- gear, to be divided by 100 and either added ate shim(s) that has had its respective thick- to or subtracted from “34”...
Page 397 MIDDLE GEAR Middle driven pinion gear shim Thickness (mm) 0.10 0.15 0.20 0.30 0.40 0.50 ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 5-86...
Page 398: Crankcase
CRANKCASE EAS25540 CRANKCASE Separating the crankcase 10 Nm (1.0 m kg, 7.2 ft 20 Nm (2.0 m kg, 14 ft • • • • 2nd 20 Nm (2.0 m kg, 14 ft (10) • • 24 Nm (2.4 m kg, 17 ft •...
Page 399 CRANKCASE Separating the crankcase 10 Nm (1.0 m kg, 7.2 ft 20 Nm (2.0 m kg, 14 ft • • • • 2nd 20 Nm (2.0 m kg, 14 ft • • (10) 24 Nm (2.4 m kg, 17 ft •...
Page 400 CRANKCASE Removing the oil baffle plate and bearings 10 Nm (1.0 m kg, 7.2 ft • • 70 Nm (7.0 m kg, 50 ft • • 8 Nm (0.8 m kg, 5.8 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
Page 401 CRANKCASE Removing the oil baffle plate and bearings 10 Nm (1.0 m kg, 7.2 ft • • 70 Nm (7.0 m kg, 50 ft • • 8 Nm (0.8 m kg, 5.8 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
Page 402: Disassembling The Crankcase
CRANKCASE mating surfaces. Work slowly and carefully EAS25550 DISASSEMBLING THE CRANKCASE and make sure the crankcase halves sepa- 1. Place the engine upside down. rate evenly. 2. Remove: • Crankcase bolts EAS25580 CHECKING THE CRANKCASE 1. Thoroughly wash the crankcase halves in a •...
Page 403: Assembling The Crankcase
Engine oil 2. Apply: • Sealant (onto the crankcase mating surfaces and oil baffle plate 2) 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.
Page 404 CRANKCASE Crankcase bolt “1”–“10” • Lubricate the bolts “1”–“10” thread and wash- ers with engine oil. 20 Nm (2.0 m·kg, 14 ft·lb) • Lubricate the bolts “11”–“31” thread part and mating surface with engine oil. b. Loosen and retighten the crankcase bolts in •...
Page 405: Installing The Oil Pump Drive Sprocket
CRANKCASE 13 21 19 22 EAS1MD1057 INSTALLING THE OIL PUMP DRIVE SPROCKET 1. Install: • Conical spring washer “1” • Collar “2” • Oil pump drive sprocket “3” • Oil pump drive chain Make sure that the white paint mark on the con- ical spring washer is facing outward as shown in ▲...
Page 406 CONNECTING RODS AND PISTONS ET3P61027 CONNECTING RODS AND PISTONS Removing the connecting rods and pistons Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-87. Connecting rod cap Big end lower bearing Piston pin clip Piston pin Piston Connecting rod Big end upper bearing...
Page 407: Connecting Rods And Pistons
CONNECTING RODS AND PISTONS EAS26030 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” Identify the position of each connecting rod so that it can be reinstalled in its original place. 2.
Page 408: Checking The Piston Rings
CONNECTING RODS AND PISTONS ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Measure cylinder bore “C” with the cylinder bore gauge. Measure cylinder bore “C” by taking side-to-side and front-to-back measurements of the cylinder. Then, find the average of the measurements.
Page 409: Checking The Piston Pin
CONNECTING RODS AND PISTONS Piston ring Piston ring Top ring Top ring Ring side clearance End gap (installed) 0.030–0.070 mm (0.0012– 0.20–0.30 mm (0.0079–0.0118 0.0028 in) Limit Limit 0.120 mm (0.0047 in) 0.55 mm (0.0217 in) 2nd ring 2nd ring Ring side clearance End gap (installed) 0.020–0.060 mm (0.0008–...
Page 410: Checking The Connecting Rods
CONNECTING RODS AND PISTONS b. Install the big end upper bearing into the con- Piston pin bore inside diameter necting rod and the big end lower bearing into 19.004–19.015 mm (0.7482– the connecting rod cap. 0.7486 in) Limit Align the projections “a” on the big end bearings 19.045 mm (0.7498 in) with the notches “b”...
Page 411: Installing The Connecting Rods And Pistons
CONNECTING RODS AND PISTONS e. Tighten the connecting rod nuts. Refer to “INSTALLING THE CONNECTING RODS AND PISTONS” on page 5-100. f. Remove the connecting rod and big end bearings. Refer to “REMOVING THE CONNECTING RODS AND PISTONS” on page 5-96. g.
Page 412 CONNECTING RODS AND PISTONS • Piston rings • Cylinder • Apply engine oil onto the piston pin. (with the recommended lubricant) • Make sure that the “Y” mark “a” on the connect- ing rod is facing to the left when the punch Recommended lubricant mark “b”...
Page 413 CONNECTING RODS AND PISTONS c. Tighten the connecting rod nuts further to reach the specified angle 115–125°. Connecting rod nut (final) Specified angle 115–125° EWA13400 WARNING If the connecting rod nut is tightened more than the specified angle, do not loosen the nut and then retighten it.
Page 414: Crankshaft
CRANKSHAFT EAS25950 CRANKSHAFT Removing the crankshaft Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-87. Front balancer weight Refer to “BALANCERS” on page 5-116. Refer to “CONNECTING RODS AND PIS- Connecting rod caps TONS” on page 5-95. Crankshaft Crankshaft journal upper bearing Crankshaft journal lower bearing...
Page 415: Removing The Crankshaft Journal Bearings
CRANKSHAFT EAS26040 REMOVING THE CRANKSHAFT JOURNAL Journal oil clearance BEARINGS 0.027–0.045 mm (0.0011–0.0018 1. Remove: • Crankshaft journal upper bearings ECA13920 (from the upper crankcase) NOTICE • Crankshaft journal lower bearings Do not interchange the crankshaft journal (from the lower crankcase) bearings.
Page 416: Installing The Crankshaft
CRANKSHAFT e. Install the crankshaft journal lower bearings • If J –J are the same, use the same size for all “3” into the lower crankcase and assemble of the bearings. the crankcase halves. • Align the projections “c” of the crankshaft jour- nal lower bearings with the notches “d”...
Page 417 CRANKSHAFT • Align the projections “a” on the crankshaft jour- nal bearings “1” with the notches “b” in the crankcases. • Be sure to install each crankshaft journal bear- ing in its original place. 5-106...
Page 418: Transmission
TRANSMISSION EAS26240 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-87. Stopper lever Refer to “SHIFT SHAFT” on page 5-68. Gear position sensor bracket Oil seal Drive axle assembly Bearing Washer...
Page 419 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks Order Job/Parts to remove Q’ty Remarks Shift fork-C Main axle assembly For installation, reverse the removal proce- dure. 5-108...
Page 420 TRANSMISSION Disassembling the main axle assembly Order Job/Parts to remove Q’ty Remarks 2nd pinion gear Toothed lock washer Toothed lock washer retainer 5th pinion gear Toothed spacer Toothed washer Circlip 3rd pinion gear 4th pinion gear Collar Main axle/1st pinion gear Bearing Washer Main axle bearing housing...
Page 421 TRANSMISSION Disassembling the drive axle assembly Order Job/Parts to remove Q’ty Remarks Middle drive gear Washer 2nd wheel gear Collar Washer 5th wheel gear Circlip Toothed washer 3rd wheel gear Toothed spacer Toothed lock washer Toothed lock washer retainer 4th wheel gear Washer 1st wheel gear Bearing...
Page 422 TRANSMISSION Disassembling the drive axle assembly Order Job/Parts to remove Q’ty Remarks Drive axle For assembly, reverse the disassembly pro- cedure. 5-111...
Page 423: Removing The Transmission
TRANSMISSION EAS26250 REMOVING THE TRANSMISSION 1. Remove: • Main axle assembly Remove the main axle assembly with the slide hammer bolts “1” and weight. Slide hammer bolt 90890-01083 Slide hammer bolt 6 mm 3. Check: YU-01083-1 • Shift fork movement Weight (along the shift fork guide bar) 90890-01084...
Page 424: Assembling The Main Axle And Drive Axle
TRANSMISSION Incorrect → Reassemble the transmission Main axle runout limit axle assemblies. 0.08 mm (0.0032 in) 5. Check: • Transmission gear movement Rough movement → Replace the defective part(s). 6. Check: • Circlips Bends/damage/looseness → Replace. ET3P61030 ASSEMBLING THE MAIN AXLE AND DRIVE AXLE 1.
Page 425: Installing The Transmission
TRANSMISSION • Be sure to align the projection on the toothed lock washer that is between the alignment • When installing the main axle assembly, use a marks “b” with the alignment mark “c” on the re- pin “2” to align the bearing housing hole with tainer.
Page 426 TRANSMISSION 4. Install: • Drive axle assembly • The bearing pin “1” must face towards the rear of the upper crankcase. • Make sure the bearing circlip “2” is inserted into the groove in the upper crankcase. 5. Check: • Transmission Rough movement →...
Page 427 BALANCERS ET3P61031 BALANCERS Removing the front balancer Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-87. Front balancer lever Front balancer shaft Washer Bearing Front balancer gear Damper Front balancer weight For installation, reverse the removal proce- dure.
Page 428 BALANCERS Removing the rear balancer Order Job/Parts to remove Q’ty Remarks Throttle bodies Refer to “THROTTLE BODIES” on page 7-4. Pickup rotor cover Refer to “PICKUP ROTOR” on page 5-37. Clutch cover Refer to “CLUTCH” on page 5-44. Rear balancer cover Rear balancer cover gasket Rear balancer lever Rear balancer shaft...
Page 429: Balancers
BALANCERS 2. Align: EAS26120 CHECKING THE BALANCERS • “T” mark on the pickup rotor 1. Check: (with the crankcase mating surface) • Front balancer gear ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼...
Page 430: Installing The Rear Balancer
BALANCERS • Front balancer shaft pinch bolt “2” Front balancer lever bolt 14 Nm (1.4 m·kg, 10 ft·lb) Front balancer shaft pinch bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Make sure that the balancer shaft does not ro- tate. ▲ ▲▲▲...
Page 431 BALANCERS b. Align the balancer gear punch mark “c” with the primary driven gear point “d” as shown. • Make sure that the rear balancer gear teeth and the primary driven gear teeth mesh cor- rectly. • Make sure that the balancer gear punch mark “c”...
Page 432 BALANCERS • Rear balancer shaft pinch bolt “2” Rear balancer lever bolt 14 Nm (1.4 m·kg, 10 ft·lb) Rear balancer shaft pinch bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Make sure that the balancer shaft does not ro- tate. ▲ ▲▲▲...
Page 433 COOLING SYSTEM RADIATOR ...................... 6-1 REMOVING THE RADIATOR ..............6-3 CHECKING THE RADIATOR..............6-3 INSTALLING THE RADIATOR..............6-3 OIL COOLER....................6-4 CHECKING THE OIL COOLER ..............6-5 INSTALLING THE OIL COOLER .............. 6-5 THERMOSTAT ....................6-6 CHECKING THE THERMOSTAT.............. 6-8 INSTALLING THE THERMOSTAT ASSEMBLY ........6-8 WATER PUMP....................6-10 DISASSEMBLING THE WATER PUMP..........
Page 434: Radiator
RADIATOR EAS26380 RADIATOR Removing the radiator 10 Nm (1.0 m kg, 7.2 ft 10 Nm (1.0 m kg, 7.2 ft • • • • 12 Nm (1.2 m kg, 8.7 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
Page 435 RADIATOR Removing the radiator 10 Nm (1.0 m kg, 7.2 ft 10 Nm (1.0 m kg, 7.2 ft • • • • 12 Nm (1.2 m kg, 8.7 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft 10 Nm (1.0 m...
Page 436: Removing The Radiator
RADIATOR EAS1MC1032 REMOVING THE RADIATOR Radiator cap tester 1. Pull the top of electrical components tray “1” 90890-01325 slightly outward as shown in the illustration Mityvac cooling system tester kit YU-24460-A and then remove the radiator bolt “2”. Radiator cap tester adapter 90890-01352 Pressure tester adapter YU-33984...
Page 437: Oil Cooler
OIL COOLER EAS26410 OIL COOLER Removing the oil cooler Order Job/Parts to remove Q’ty Remarks Drain. Engine oil Refer to “CHANGING THE ENGINE OIL” on page 3-27. Drain. Coolant Refer to “CHANGING THE COOLANT” on page 3-30. Radiator Refer to “RADIATOR” on page 6-1. Exhaust pipe assembly Refer to “ENGINE REMOVAL”...
Page 438: Checking The Oil Cooler
OIL COOLER EAS26420 CHECKING THE OIL COOLER 1. Check: • Oil cooler Cracks/damage → Replace. 2. Check: • Oil cooler inlet hose • Oil cooler outlet hose • Water pump outlet hose • Water pump outlet pipe • Water jacket joint inlet hose Cracks/damage/wear →...
Page 439: Thermostat
THERMOSTAT EAS26440 THERMOSTAT Removing the thermostat assembly 22 Nm (2.2 m kg, 16 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
Page 440 THERMOSTAT Removing the thermostat assembly 22 Nm (2.2 m kg, 16 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 7 Nm (0.7 m kg, 5.1 ft • •...
Page 441: Checking The Thermostat
THERMOSTAT 2. Check: EAS26450 CHECKING THE THERMOSTAT • Thermostat housing 1. Check: Cracks/damage → Replace. • Thermostat 3. Check: Does not open at 69.0–73.0 °C (156.20– • Thermostat hoses 163.40 °F) → Replace. • Thermostat pipes • Radiator inlet hose •...
Page 442 THERMOSTAT 5. Measure: • Radiator cap opening pressure Below the specified pressure → Replace the radiator cap. Refer to “CHECKING THE RADIATOR” on page 6-3.
Page 443: Water Pump
WATER PUMP EAS26500 WATER PUMP Removing the water pump 12 Nm (1.2 m kg, 8.7 ft • • 12 Nm (1.2 m kg, 8.7 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Right side cowling 4-1.
Page 444 WATER PUMP Disassembling the water pump Order Job/Parts to remove Q’ty Remarks Water pump housing cover O-ring Circlip Impeller shaft Rubber damper holder Rubber damper Water pump seal Oil seal Bearing Water pump housing For assembly, reverse the disassembly pro- cedure.
Page 445: Disassembling The Water Pump
• Install the water pump seal with the special tools. • Before installing the water pump seal, apply Yamaha bond No.1215 (Three Bond No.1215®) “2” to the water pump housing “3”. 6-12...
Page 446: Installing The Water Pump
0.15 mm (0.006 in) Water pump seal installer YM-33221-A Middle driven shaft bearing driv- 90890-04058 Middle drive bearing installer 40 & 50 mm YM-04058 Yamaha bond No. 1215 90890-85505 (Three Bond No.1215®) 1. Straightedge 2. Impeller 5. Install: • Impeller “1” • Circlip After installation, check that the impeller shaft ro- tates smoothly.
Page 447 WATER PUMP 2. Fill: • Cooling system (with the specified amount of the recom- mended coolant) Refer to “CHANGING THE COOLANT” on page 3-30. 3. Check: • Cooling system Leaks → Repair or replace any faulty part. 4. Measure: • Radiator cap opening pressure Below the specified pressure →...
Page 448 WATER PUMP 6-15...
Page 449: Fuel System
FUEL SYSTEM FUEL TANK..................... 7-1 REMOVING THE FUEL TANK ..............7-2 REMOVING THE FUEL PUMP ..............7-2 CHECKING THE FUEL PUMP BODY............7-2 INSTALLING THE FUEL PUMP..............7-2 INSTALLING THE FUEL TANK..............7-2 THROTTLE BODIES ..................7-4 CHECKING THE INJECTORS (BEFORE REMOVING) ......7-7 REMOVING THE INJECTORS ..............7-7 CHECKING THE INJECTORS ..............7-7 CHECKING AND CLEANING THE THROTTLE BODIES......7-7 CHECKING THE THROTTLE BODY JOINTS ..........
Page 450: Fuel Tank
FUEL TANK EAS26620 FUEL TANK Removing the fuel tank 10 Nm (1.0 m kg, 7.2 ft 4 Nm (0.4 m kg, 2.9 ft • • 16 Nm (1.6 m kg, 11 ft • • • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS”...
Page 451: Removing The Fuel Tank
FUEL TANK EAS26630 EAS26670 REMOVING THE FUEL TANK CHECKING THE FUEL PUMP BODY 1. Extract the fuel in the fuel tank through the 1. Check: fuel tank cap with a pump. • Fuel pump body Obstruction → Clean. 2. Remove: Cracks/damage →...
Page 452 FUEL TANK 2. Install: • Fuel hose (fuel pump side) • Fuel hose holder EC3P61008 NOTICE When installing the fuel hose, make sure that it is securely connected, and that the fuel hose holder is in the correct position, other- wise the fuel hose will not be properly in- stalled.
Page 453: Throttle Bodies
THROTTLE BODIES EAS26970 THROTTLE BODIES Removing the throttle bodies 3 Nm (0.3 m kg, 2.2 ft • • 4 Nm (0.4 m kg, 2.9 ft • • 3 Nm (0.3 m kg, 2.2 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS”...
Page 454 THROTTLE BODIES Removing the throttle bodies 3 Nm (0.3 m kg, 2.2 ft • • 4 Nm (0.4 m kg, 2.9 ft • • 3 Nm (0.3 m kg, 2.2 ft • • Order Job/Parts to remove Q’ty Remarks Throttle body joint For installation, reverse the removal proce- dure.
Page 455 THROTTLE BODIES Removing the injectors 3.5 Nm (0.35 m kg, 2.5 ft 3.5 Nm (0.35 m kg, 2.5 ft • • • • 5 Nm (0.5 m kg, 3.6 ft • • 5 Nm (0.5 m kg, 3.6 ft • •...
Page 456: Checking The Injectors (Before Removing)
Obstruction → Replace and check the fuel pump/fuel supply system. Recommended cleaning solvent Deposit → Replace. Yamaha Oil & Brake Cleaner Damage → Replace. 2. Check: • Injector resistance Refer to “CHECKING THE FUEL INJEC- TORS” on page 8-281.
Page 457 THROTTLE BODIES • Do not allow any cleaning solvent to enter the opening for the injectors. • Do not apply any cleaning solvent to the por- tions of the throttle valve shafts between the throttle bodies. e. Remove the carbon deposits from the inside of each throttle body in a downward direction, from the air filter case side of the throttle body to the engine side.
Page 458: Checking The Throttle Body Joints
THROTTLE BODIES 5. Adjust: • Be careful not to twist or pinch the O-rings • Throttle bodies synchronizing when installing the injectors. Out of specification → Replace the throttle • If an injector is subject to strong shocks or bodies. excessive force, replace it.
Page 459: Checking The Fuel Pressure
THROTTLE BODIES Pressure gauge 90890-03153 YU-03153 Fuel injector pressure adapter 90890-03210 YU-03210 b. Disconnect the fuel hose “2” from the fuel rail. EWA1MC1018 WARNING Cover fuel hose connections with a cloth when disconnecting them. Residual pres- sure in the fuel lines could cause fuel to spurt out when removing the hose.
Page 460: Adjusting The Throttle Position Sensor
THROTTLE BODIES d. Start the engine. e. Measure the fuel line pressure. All displays on the multi-function meter right dis- play disappear and “DIAG” appears. Fuel line pressure (at idle) 300.0–390.0 kPa (3.00–3.90 f. Simultaneously press the “TCS” button “1” kgf/cm², 43.5–56.6 psi) and “RESET”...
Page 461 THROTTLE BODIES 1. Check: • Accelerator position sensor The diagnostic code number “01” appears on Refer to “CHECKING THE ACCELERATOR the multi-function meter right display. POSITION SENSOR” on page 8-278. h. Diagnostic code number “14” is selected. 2. Adjust: i. Turn the throttle grip to the fully closed posi- •...
Page 462: Air Induction System
AIR INDUCTION SYSTEM EAS27040 AIR INDUCTION SYSTEM 7-13...
Page 463 AIR INDUCTION SYSTEM 1. Reed valve assembly 2. Air induction system hose (3-way joint to reed valve cover) 3. Air induction system hose (air cut-off valve to 3-way joint) 4. Air induction system hose (3-way joint to air cut-off valve) 5.
Page 464 AIR INDUCTION SYSTEM Removing the air cut-off valve Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Rider seat/T-bar 4-1. Fuel tank Refer to “FUEL TANK” on page 7-1. Air induction system solenoid coupler Disconnect. Air induction system hose (air filter case joint assembly to 3-way joint) Air induction system hose (3-way joint to hose plug)
Page 465 AIR INDUCTION SYSTEM Removing the reed valves 14 Nm (1.4 m kg, 10 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Rider seat/T-bar 4-1. Fuel tank Refer to “FUEL TANK” on page 7-1. Air induction system hoses (3-way joint to reed Refer to “Removing the air cut-off valve”.
Page 466: Checking The Air Induction System
AIR INDUCTION SYSTEM • 3-way joint EAS27060 CHECKING THE AIR INDUCTION SYSTEM Cracks/damage → Replace. 2. Check: Air injection • Reed valve The air induction system burns unburned ex- • Reed valve stopper haust gases by injecting fresh air (secondary air) •...
Page 467: Electrical System
CIRCUIT DIAGRAM ................8-23 TROUBLESHOOTING ................8-25 COOLING SYSTEM..................8-31 CIRCUIT DIAGRAM ................8-31 TROUBLESHOOTING ................8-33 FUEL INJECTION SYSTEM................8-35 CIRCUIT DIAGRAM ................8-35 ECU SELF-DIAGNOSTIC FUNCTION............8-37 TROUBLESHOOTING METHOD (ECU)..........8-38 DIAGNOSTIC MODE (ECU) ..............8-40 YAMAHA DIAGNOSTIC TOOL ...............8-41 TROUBLESHOOTING DETAILS (ECU) ..........8-43...
Page 468: General Information
CRUISE CONTROL SYSTEM ............... 8-89 CIRCUIT DIAGRAM ................8-89 CRUISE CONTROL CIRCUIT OPERATION...........8-91 BASIC INSTRUCTIONS FOR TROUBLESHOOTING ......8-93 BASIC PROCESS FOR TROUBLESHOOTING ........8-94 [A] CHECKING THE CRUISE CONTROL SYSTEM INDICATOR LIGHT ................8-95 [B-1] DIAGNOSIS USING THE FAULT CODES ........8-95 [B-2] DIAGNOSIS USING THE MALFUNCTION HISTORY CODES ....................8-104 [B-3] MALFUNCTION HISTORY IS DISPLAYED .........8-104...
Page 469 [C-2] DELETE FUNCTION TEST ............8-162 [C-3] FINAL CHECK ................8-164 GRIP WARMER SYSTEM ................8-165 CIRCUIT DIAGRAM ................8-165 TROUBLESHOOTING ................8-167 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM........8-169 CIRCUIT DIAGRAM ................8-169 TROUBLESHOOTING ................8-171 MAINTENANCE OF THE MCU (motor control unit)......8-174 REPLACING THE MCU (MOTOR CONTROL UNIT)......8-174 MCU (motor control unit) SELF-DIAGNOSTIC FUNCTION ....8-175...
Page 470 ELECTRICAL COMPONENTS..............8-255 CHECKING THE SWITCHES ...............8-259 CHECKING THE BULBS AND BULB SOCKETS .........8-262 CHECKING THE FUSES ..............8-263 REPLACING THE ECU (engine control unit) ........8-264 CHECKING AND CHARGING THE BATTERY........8-264 CHECKING THE RELAYS ..............8-267 CHECKING THE RELAY UNIT (DIODE) ..........8-271 CHECKING THE IGNITION COILS............8-272 CHECKING THE IGNITION SPARK GAP..........8-272 CHECKING THE CRANKSHAFT POSITION SENSOR......8-273 CHECKING THE LEAN ANGLE SENSOR..........8-273...
Page 472: Ignition System
IGNITION SYSTEM EAS27090 IGNITION SYSTEM EAS27110 CIRCUIT DIAGRAM...
Page 473 IGNITION SYSTEM 3. Main switch 4. Main fuse 11.Fuel injection system fuse 16.Ignition fuse 26.Battery 27.Engine ground 31.Joint coupler 34.Relay unit 43.Right handlebar switch 44.Start/engine stop switch 47.Neutral switch 106.Crankshaft position sensor 110.Lean angle sensor 115.ECU (engine control unit) 116.Ignition coil #1 117.Ignition coil #2 118.Ignition coil #3 119.Ignition coil #4...
Page 474 IGNITION SYSTEM ET3P61002 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 475 IGNITION SYSTEM EAS27140 TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). • Before troubleshooting, remove the following part(s): 1. Side cowlings 2. Front cowling assembly 3. Fuel tank 4. T-bar 5. Storage compartment 6. Side covers 7.
Page 476 IGNITION SYSTEM NG → 8. Check the start/engine stop switch. • The start/engine stop switch is faulty. Refer to “CHECKING THE • Replace the right handlebar switch. SWITCHES” on page 8-259. OK ↓ NG → 9. Check the neutral switch. Refer to “CHECKING THE Replace the neutral switch.
Page 477 IGNITION SYSTEM...
Page 478: Electric Starting System
ELECTRIC STARTING SYSTEM EAS27160 ELECTRIC STARTING SYSTEM EAS27170 CIRCUIT DIAGRAM...
Page 479 ELECTRIC STARTING SYSTEM 3. Main switch 4. Main fuse 5. YCC-S motor control fuse 16.Ignition fuse 18.Signaling system fuse 26.Battery 27.Engine ground 29.Starter relay 30.Starter motor 31.Joint coupler 33.Brake light fuse 34.Relay unit 35.Starting circuit cut-off relay 40.Rear brake light switch 42.Front brake light switch 43.Right handlebar switch 44.Start/engine stop switch...
Page 480 ELECTRIC STARTING SYSTEM EAS1MD1001 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the start/engine stop switch is set to “ ” (the switch circuit is closed), the main switch is turned “ON” (the switch circuit is closed), and the brake lever is squeezed (the front brake light switch circuit is open) or the brake pedal is depressed (the rear brake light switch circuit is open), the starter motor can only operate if at least one of the following conditions is met: •...
Page 481 ELECTRIC STARTING SYSTEM a. WHEN THE TRANSMISSION IS IN 10. Sidestand switch NEUTRAL 11. YCC-S control relay b. WHEN THE SIDESTAND IS UP 12. Brake light fuse 1. Battery 13. Rear brake light switch 2. Main fuse 14. Front brake light switch 3.
Page 482 ELECTRIC STARTING SYSTEM EAS27190 TROUBLESHOOTING The starter motor fails to turn. • Before troubleshooting, remove the following part(s): 1. Side cowlings 2. Front cowling assembly 3. Storage compartment 4. Fuel tank 5. T-bar 6. Throttle bodies NG → 1. Check the fuses. (Main, signaling system, brake light, YCC-S motor control and ignition) Replace the fuse(s).
Page 483 ELECTRIC STARTING SYSTEM NG → 8. Check the brake light relay. Refer to “CHECKING THE RE- Replace the brake light relay. LAYS” on page 8-267. OK ↓ NG → 9. Check the brake switch relay. Refer to “CHECKING THE RE- Replace the brake switch relay.
Page 484 ELECTRIC STARTING SYSTEM NG → 17.Check the entire starting system wiring. Properly connect or replace the wire har- Refer to “CIRCUIT DIAGRAM” on ness. page 8-7. OK ↓ Replace the MCU. Refer to “RE- PLACING THE MCU (MOTOR CONTROL UNIT)” on page 8-174. 8-13...
Page 485 ELECTRIC STARTING SYSTEM 8-14...
Page 486: Charging System
CHARGING SYSTEM EAS27200 CHARGING SYSTEM EAS27210 CIRCUIT DIAGRAM 8-15...
Page 487 CHARGING SYSTEM 1. AC magneto 2. Rectifier/regulator 4. Main fuse 26.Battery 27.Engine ground A. Wire harness B. Negative battery sub-wire harness 8-16...
Page 488 CHARGING SYSTEM EAS27230 TROUBLESHOOTING The battery is not being charged. • Before troubleshooting, remove the following part(s): 1. Right upper inner panel 2. Side cowlings NG → 1. Check the fuse. (Main) Replace the fuse. Refer to “CHECKING THE FUS- ES”...
Page 489 CHARGING SYSTEM 8-18...
Page 490: Lighting System
LIGHTING SYSTEM EAS27240 LIGHTING SYSTEM EAS27250 CIRCUIT DIAGRAM 8-19...
Page 491 LIGHTING SYSTEM 3. Main switch 4. Main fuse 8. Hazard lighting fuse 11.Fuel injection system fuse 12.Backup fuse 14.Headlight fuse 16.Ignition fuse 21.Headlight relay (on/off) 26.Battery 27.Engine ground 31.Joint coupler 50.Left handlebar switch 53.Dimmer/pass switch 58.License plate light 59.Tail/brake light assembly 60.Tail/brake light 63.Headlight relay (dimmer) 64.Headlight assembly...
Page 492 LIGHTING SYSTEM EAS27260 TROUBLESHOOTING Any of the following fail to light: headlights, high beam indicator light, taillight, license plate light, auxiliary lights or meter light. • Before troubleshooting, remove the following part(s): 1. Side cowlings 2. Front cowling assembly 3. Fuel tank 4.
Page 493 LIGHTING SYSTEM NG → 8. Check the entire lighting system wiring. Properly connect or replace the wire har- Refer to “CIRCUIT DIAGRAM” on ness. page 8-19. OK ↓ Replace the ECU, meter assembly, or headlight assembly. Refer to “RE- PLACING THE ECU (engine control unit)”...
Page 494: Signaling System
SIGNALING SYSTEM EAS27270 SIGNALING SYSTEM EAS27280 CIRCUIT DIAGRAM 8-23...
Page 495 SIGNALING SYSTEM 3. Main switch 4. Main fuse 5. YCC-S motor control fuse 8. Hazard lighting fuse 11.Fuel injection system fuse 12.Backup fuse 15.ABS ECU fuse 16.Ignition fuse 18.Signaling system fuse 23.Horn 26.Battery 27.Engine ground 31.Joint coupler 33.Brake light fuse 34.Relay unit 40.Rear brake light switch 42.Front brake light switch...
Page 496 SIGNALING SYSTEM EAS27290 TROUBLESHOOTING • Any of the following fail to light: turn signal light, brake light or indicator light. • The horn fails to sound. • The fuel meter fails to come on. • The speedometer fails to operate. •...
Page 497 SIGNALING SYSTEM Checking the signaling system The horn fails to sound. NG → 1. Check the horn switch. • The horn switch is faulty. Refer to “CHECKING THE • Replace the left handlebar switch. SWITCHES” on page 8-259. OK ↓ NG →...
Page 498 SIGNALING SYSTEM The turn signal light, turn signal indicator light or both fail to blink. NG → 1. Check the rear turn signal light bulbs and sockets. Replace the rear turn signal light bulb, Refer to “CHECKING THE BULBS socket or both. AND BULB SOCKETS”...
Page 499 SIGNALING SYSTEM NG → 3. Check the entire signaling system wiring. Properly connect or replace the wire har- Refer to “CIRCUIT DIAGRAM” on ness. page 8-23. OK ↓ Replace the meter assembly. The shift indicator fails to come on. NG → 1.
Page 500 SIGNALING SYSTEM NG → 2. Check the entire signaling system wiring. Properly connect or replace the wire har- Refer to “CIRCUIT DIAGRAM” on ness. page 8-23. OK ↓ Replace the meter assembly. The speedometer fails to operate. NG → 1. Check the rear wheel sensor. Refer to “MAINTENANCE OF THE Replace the rear wheel sensor.
Page 501 SIGNALING SYSTEM 8-30...
Page 502 COOLING SYSTEM EAS27300 COOLING SYSTEM EAS27310 CIRCUIT DIAGRAM 8-31...
Page 503 COOLING SYSTEM 3. Main switch 4. Main fuse 11.Fuel injection system fuse 16.Ignition fuse 19.Left radiator fan motor fuse 20.Right radiator fan motor fuse 22.Radiator fan motor relay 24.Right radiator fan motor 25.Left radiator fan motor 26.Battery 27.Engine ground 28.Cooling system fuse 31.Joint coupler 105.Coolant temperature sensor 115.ECU (engine control unit)
Page 504 COOLING SYSTEM EAS27320 TROUBLESHOOTING The radiator fan motor fails to turn. • Before troubleshooting, remove the following part(s): 1. Side cowlings 2. Fuel tank 3. T-bar NG → 1. Check the fuses. (Main, ignition, cooling system, fuel injection system, left radiator fan Replace the fuse(s).
Page 505 COOLING SYSTEM NG → 7. Check the entire cooling system wiring. Properly connect or replace the wire har- Refer to “CIRCUIT DIAGRAM” on ness. page 8-31. OK ↓ Replace the ECU. Refer to “REPLAC- ING THE ECU (engine control unit)” on page 8-264.
Page 506: Fuel Injection System
FUEL INJECTION SYSTEM EAS27330 FUEL INJECTION SYSTEM EAS27340 CIRCUIT DIAGRAM 8-35...
Page 507 105.Coolant temperature sensor 106.Crankshaft position sensor 107.Intake air pressure sensor 108.Atmospheric pressure sensor 109.Cylinder identification sensor 110.Lean angle sensor 111.Yamaha diagnostic tool coupler 112.ABS ECU (electronic control unit) 113.Front wheel sensor 114.Rear wheel sensor 115.ECU (engine control unit) 116.Ignition coil #1 117.Ignition coil #2...
Page 508 FUEL INJECTION SYSTEM EAS27351 ECU SELF-DIAGNOSTIC FUNCTION The ECU is equipped with a self-diagnostic function in order to ensure that the fuel injection system is operating normally. If this function detects a malfunction in the system, it immediately operates the en- gine under substitute characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the system.
Page 509 FUEL INJECTION SYSTEM 2. Check and repair the probable cause of the EAS1MD1050 TROUBLESHOOTING METHOD (ECU) malfunction. Fault code No. No fault code No. • If there is a malfunction in the fuel injection sys- tem, the windshield adjusting function “1” will Check and repair.
Page 510 FUEL INJECTION SYSTEM The engine operation is not normal, but the engine trouble warning light does not come 1. Check the operation of the following sensors and actuators in the diagnostic mode. Refer to “TROUBLESHOOTING DETAILS (ECU)” on page 8-43. 01: Throttle position sensor signal 1 (throttle angle) 13: Throttle position sensor signal 2 (throttle...
Page 511 SELECT a. FUEL INJECTION SYSTEM c. ELECTRONICALLY ADJUSTABLE SUSPENSION SYSTEM b. YCC-S (Yamaha Chip Controlled-Shift) SYSTEM 6. While “DIAG” is displayed on the multi-function meter right display, simultaneously press the “TCS” button and “RESET” button for 2 seconds or more.
Page 512 EAS1MC1036 YAMAHA DIAGNOSTIC TOOL This model uses the Yamaha diagnostic tool to identify malfunctions. For information about using the Yamaha diagnostic tool, refer to the operation manual that is included with the tool. Yamaha diagnostic tool 90890-03215 Features of the Yamaha diagnostic tool You can use the Yamaha diagnostic tool to identify malfunctions quicker than with conventional methods.
Page 513 Remove the protective cap, and then connect the Yamaha diagnostic tool to the coupler “1”. When the Yamaha diagnostic tool is connected to the vehicle, the operation of the multi-function meter and indicators will be different from the normal operation.
Page 514 FUEL INJECTION SYSTEM EAS1MD1051 TROUBLESHOOTING DETAILS (ECU) This section describes the measures per fault code number displayed on the multi-function meter right display. Check and service the items or components that are the probable cause of the malfunction fol- lowing the order given. After the check and service of the malfunctioning part have been completed, reset the multi-function meter right display according to the “Confirmation of service completion”.
Page 515 FUEL INJECTION SYSTEM Fault code No. Cylinder identification sensor: no normal signals are received Item from the cylinder identification sensor. Open or short circuit → Re- Wire harness continuity. Crank the engine. place the wire harness. Fault code number is not dis- played →...
Page 516 FUEL INJECTION SYSTEM Fault code No. Crankshaft position sensor: no normal signals are received Item from the crankshaft position sensor. Improperly connected → Connection of crankshaft po- Crank the engine. sition sensor coupler. Connect the coupler secure- Fault code number is not dis- played →...
Page 517 FUEL INJECTION SYSTEM Fault code No. Item Intake air pressure sensor: open or short circuit detected. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. Meter display Displays the intake air pressure. Shift the transmission into gear, extend the sidestand, and then Procedure operate the throttle while pushing the “...
Page 518 FUEL INJECTION SYSTEM Fault code No. Item Intake air pressure sensor: open or short circuit detected. Defective intake air pressure Execute the diagnostic Turn the main switch to “ON”. sensor. mode. (Code No. 03) Fault code number is not dis- played →...
Page 519 FUEL INJECTION SYSTEM Fault code No. Intake air pressure sensor: hose system malfunction (clogged Item or detached hose). Condition of intake air pres- Clogged or detached hose Start the engine and let it idle → Repair or replace the sen- sure sensor hose.
Page 520 FUEL INJECTION SYSTEM Fault code No. Item Throttle position sensor: open or short circuit detected. Throttle position sensor signal 2 Meter display • 9–23 (fully closed position) • 94–108 (fully open position) • Check with throttle valves fully closed. Procedure •...
Page 521 FUEL INJECTION SYSTEM Fault code No. Item Throttle position sensor: open or short circuit detected. Defective throttle position Check throttle position sen- Turn the main switch to “ON”. sensor. sor signal 1. Fault code number is not dis- played → Service is finished. Execute the diagnostic mode.
Page 522 FUEL INJECTION SYSTEM Fault code No. Sidestand switch: a break or disconnection of the black/red Item lead of the ECU is detected. Improperly connected → Connection of sidestand Turn the main switch to “ON”, switch coupler. Connect the coupler secure- and then extend and retract Check the locking condition ly or replace the wire har-...
Page 523 FUEL INJECTION SYSTEM Fault code No. Intake air pressure sensor or atmospheric pressure sensor: when the main switch is turned to “ON”, the intake air pres- Item sure sensor voltage and atmospheric pressure sensor voltage differ greatly. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No.
Page 524 FUEL INJECTION SYSTEM Fault code No. Intake air pressure sensor or atmospheric pressure sensor: when the main switch is turned to “ON”, the intake air pres- Item sure sensor voltage and atmospheric pressure sensor voltage differ greatly. Defective atmospheric pres- Execute the diagnostic Turn the main switch to “ON”.
Page 525 FUEL INJECTION SYSTEM Fault code No. Item Coolant temperature sensor: open or short circuit detected. Improperly connected → Connection of wire harness Turn the main switch to “ON”. ECU coupler. Connect the coupler secure- Fault code number is not dis- played →...
Page 526 FUEL INJECTION SYSTEM Fault code No. Item Air temperature sensor: open or short circuit detected. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. Meter display Displays the air temperature. Compare the actually measured air temperature with the meter Procedure display value.
Page 527 FUEL INJECTION SYSTEM Fault code No. Item Air temperature sensor: open or short circuit detected. Defective air temperature Execute the diagnostic Turn the main switch to “ON”. sensor. mode. (Code No. 05) Fault code number is not dis- played → Service is finished. When engine is cold: Displayed temperature is Fault code number is dis-...
Page 528 FUEL INJECTION SYSTEM Fault code No. Item Atmospheric pressure sensor: open or short circuit detected. Open or short circuit → Re- Wire harness continuity. Turn the main switch to “ON”. place the wire harness. Fault code number is not dis- played →...
Page 529 FUEL INJECTION SYSTEM Fault code No. sensor: no normal signals are received from the O sensor. Item Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. — Meter display — Procedure — Probable cause of mal- Confirmation of service Item Maintenance job...
Page 530 FUEL INJECTION SYSTEM Fault code No. sensor: no normal signals are received from the O sensor. Item Check fuel pressure. Refer to “CHECKING THE Start the engine, warm it up, FUEL PRESSURE” on page and then race it, or execute 7-10.
Page 531 FUEL INJECTION SYSTEM Fault code No. Item Latch up detected. Defective lean angle sensor. Execute the diagnostic Turn the main switch to “ON”, mode. (Code No. 08) then to “OFF”, and then back Replace if defective. to “ON”. Refer to “CHECKING THE Fault code number is not dis- played →...
Page 532 FUEL INJECTION SYSTEM Fault code No. Cylinder-#1 ignition coil: open or short circuit detected in the Item primary lead of the cylinder-#1 ignition coil. Installed condition of cylin- Improperly installed ignition Start the engine and let it idle coil → Reinstall or replace der-#1 ignition coil.
Page 533 FUEL INJECTION SYSTEM Fault code No. Cylinder-#2 ignition coil: open or short circuit detected in the Item primary lead of the cylinder-#2 ignition coil. Improperly connected → Connection of wire harness Start the engine and let it idle ECU coupler. Connect the coupler secure- for approximately 5 seconds.
Page 534 FUEL INJECTION SYSTEM Fault code No. Cylinder-#3 ignition coil: open or short circuit detected in the Item primary lead of the cylinder-#3 ignition coil. Probable cause of mal- Confirmation of service Item Maintenance job function and check completion Improperly connected → Connection of cylinder-#3 ig- Start the engine and let it idle nition coil coupler.
Page 535 FUEL INJECTION SYSTEM Fault code No. Cylinder-#4 ignition coil: open or short circuit detected in the Item primary lead of the cylinder-#4 ignition coil. Able to start engine (depending on the number of faulty cylinders) Fail-safe system Able to drive vehicle (depending on the number of faulty cylinders) Diagnostic code No.
Page 536 FUEL INJECTION SYSTEM Fault code No. Cylinder-#4 ignition coil: open or short circuit detected in the Item primary lead of the cylinder-#4 ignition coil. Malfunction in ECU. Execute the diagnostic mode. (Code No. 33) No spark → Replace the ECU. Refer to “REPLACING THE ECU (engine control unit)”...
Page 537 FUEL INJECTION SYSTEM Fault code No. Item Injector: open or short circuit detected. Improperly connected → Connection of injector #1, Execute the diagnostic #2, #3, and/or injector #4 Connect the coupler secure- mode. (Code Nos. 36, 37, coupler. ly or replace the wire har- 38, 39) No operating sound →...
Page 538 FUEL INJECTION SYSTEM Fault code No. Item Lean angle sensor: open or short circuit detected. Unable to start engine Fail-safe system Unable to drive vehicle Diagnostic code No. Lean angle sensor output voltage Meter display • 0.4–1.4 (upright) • 3.7–4.4 (overturned) Remove the lean angle sensor and incline it more than 65 de- Procedure grees.
Page 539 FUEL INJECTION SYSTEM Fault code No. Item Lean angle sensor: open or short circuit detected. Malfunction in ECU. Replace the ECU. Refer to “REPLACING THE ECU (engine control unit)” on page 8-264. Fault code No. Rear wheel sensor: no normal signals are received from the rear wheel sensor.
Page 540 FUEL INJECTION SYSTEM Fault code No. Rear wheel sensor: no normal signals are received from the rear wheel sensor. Item B Neutral switch: open or short circuit is detected. Improperly connected → Connection of ECU coupler. Execute the diagnostic Check the locking condition Connect the coupler secure- mode.
Page 541 FUEL INJECTION SYSTEM Fault code No. Rear wheel sensor: no normal signals are received from the rear wheel sensor. Item B Neutral switch: open or short circuit is detected. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. Neutral Meter display •...
Page 542 FUEL INJECTION SYSTEM Fault code No. Rear wheel sensor: no normal signals are received from the rear wheel sensor. Item B Neutral switch: open or short circuit is detected. Defective relay unit. Check the relay unit. Execute the diagnostic Refer to “CHECKING THE mode.
Page 543 FUEL INJECTION SYSTEM Fault code No. Fuel system voltage: incorrect voltage supplied to the fuel in- Item jector and fuel pump. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. 09, 50 Fuel system voltage (battery voltage) Meter display Approximately 12.0 Set the start/engine stop switch to “...
Page 544 FUEL INJECTION SYSTEM Fault code No. Fuel system voltage: incorrect voltage supplied to the fuel in- Item jector and fuel pump. Open or short circuit → Re- Wire harness continuity. Start the engine and let it idle place the wire harness. for approximately 30 sec- Between relay unit coupler onds.
Page 545 FUEL INJECTION SYSTEM Fault code No. EEPROM fault code number: an error is detected while reading Item or writing on EEPROM. Able/Unable to start engine Fail-safe system Able/Unable to drive vehicle Diagnostic code No. EEPROM fault code display • 00 (no history) •...
Page 546 FUEL INJECTION SYSTEM Fault code No. EEPROM fault code number: an error is detected while reading Item or writing on EEPROM. “02” is indicated in diagnostic Change the CO concentra- Turn the main switch to “ON”. mode (code No. 60). EEP- tion of cylinder #2, and re- Fault code number is not dis- played →...
Page 547 FUEL INJECTION SYSTEM Fault code No. EEPROM fault code number: an error is detected while reading Item or writing on EEPROM. Malfunction in ECU. Replace the ECU. Refer to “REPLACING THE ECU (engine control unit)” on page 8-264. Fault code No. Item Charging voltage is abnormal.
Page 548 FUEL INJECTION SYSTEM Fault code No. Item Accelerator position sensor: open or short circuit detected. Able/Unable to start engine Fail-safe system Able/Unable to drive vehicle Diagnostic code No. 14, 15 Accelerator position sensor signal 1 Meter display • 12–22 (fully closed position) •...
Page 549 FUEL INJECTION SYSTEM Fault code No. Item Accelerator position sensor: open or short circuit detected. Accelerator position sensor Measure the accelerator po- Turn the main switch to “ON”. resistance. sition sensor resistance. Fault code number is not dis- played → Service is finished. black/blue–blue Refer to “CHECKING THE Fault code number is dis-...
Page 550 FUEL INJECTION SYSTEM Fault code No. Item YCC-T drive system: malfunction detected. Improperly connected → Connection of throttle servo Turn the main switch to “ON”. motor coupler. Connect the coupler secure- Fault code number is not dis- played → Service is finished. Check the locking condition ly or replace the wire har- of the coupler.
Page 551 FUEL INJECTION SYSTEM Fault code No. Front wheel sensor: no normal signals are received from the Item front wheel sensor. Front wheel speed pulse Meter display 0–999 Check that the number increases when the front wheel is rotated. Procedure The number is cumulative and does not reset each time the wheel is stopped.
Page 552 FUEL INJECTION SYSTEM Fault code No. Front wheel sensor: no normal signals are received from the Item front wheel sensor. Improperly connected → Connection of wire harness Execute the diagnostic ECU coupler. Connect the coupler secure- mode. (Code No. 16) Check the locking condition ly or replace the wire har- Rotate the front wheel by...
Page 553 The fault code can also be deleted by activating the di- agnostic mode and selecting diagnostic code number “63”. Fault code No. 89 (Yamaha diagnostic tool) Multi-function meter: signals cannot be transmitted between Item the ECU and the multi-function meter. Able to start engine...
Page 554 FUEL INJECTION SYSTEM Fault code No. Err (multi-function meter center display) Abnormal meter assembly communication (meter assembly Item cannot receive CAN communication data). Locate the malfunction. Check the engine trouble — warning light, YCC-S sys- tem warning light, and elec- tronically adjustable suspension system warning light.
Page 555 FUEL INJECTION SYSTEM Fault code No. Err (multi-function meter center display) Abnormal meter assembly communication (meter assembly Item cannot receive CAN communication data). Defective meter assembly. Replace the meter assembly. Turn the main switch to “ON”. Fault code number is not dis- played →...
Page 556 FUEL INJECTION SYSTEM Fault code No. Err (multi-function meter center display) Abnormal ECU communication (CAN communication from the Item meter assembly). Improperly connected → Connection of ECU coupler. Turn the main switch to “ON”. Check the locking condition Connect the coupler secure- Fault code number is not dis- played →...
Page 557 FUEL INJECTION SYSTEM Fault code No. Err (multi-function meter center display) Abnormal MCU communication (CAN communication from the Item meter assembly). Locate the malfunction. Check the engine trouble — warning light, YCC-S sys- tem warning light, and elec- tronically adjustable suspension system warning light.
Page 558 FUEL INJECTION SYSTEM Fault code No. Err (multi-function meter center display) Abnormal SCU communication (CAN communication from the Item meter assembly). Locate the malfunction. Check the engine trouble — warning light, YCC-S sys- tem warning light, and elec- tronically adjustable suspension system warning light.
Page 559 FUEL INJECTION SYSTEM 8-88...
Page 560: Cruise Control System
CRUISE CONTROL SYSTEM EAS1MC1010 CRUISE CONTROL SYSTEM EAS1MC1011 CIRCUIT DIAGRAM 8-89...
Page 561 CRUISE CONTROL SYSTEM 3. Main switch 4. Main fuse 5. YCC-S motor control fuse 11.Fuel injection system fuse 12.Backup fuse 16.Ignition fuse 18.Signaling system fuse 26.Battery 27.Engine ground 31.Joint coupler 32.Cruise control system fuse 33.Brake light fuse 40.Rear brake light switch 41.Grip cancel switch 42.Front brake light switch 48.Brake switch relay...
Page 562 CRUISE CONTROL SYSTEM EAS1MC1012 CRUISE CONTROL CIRCUIT OPERATION 8-91...
Page 563 CRUISE CONTROL SYSTEM 1. Battery 2. Main fuse 3. Main switch 4. Backup fuse 5. Fuel injection system fuse 6. Signaling system fuse 7. Brake light fuse 8. Ignition fuse 9. Cruise control system fuse 10. Cruise control power switch 11.
Page 564 [A] Malfunction check using the cruise control system indicator light. [B] Use the diagnostic mode or Yamaha diagnostic tool to determine the cause of the malfunction for the stored fault code from the condition and place where the malfunction occurred.
Page 565 CRUISE CONTROL SYSTEM EAS1MC1015 BASIC PROCESS FOR TROUBLESHOOTING Push the cruise control Fails to come on The cruise control power switch is • power switch, and check defective. the cruise control system The cruise control system fuse is • indicator light. Flashes blown.
Page 566 CRUISE CONTROL SYSTEM EWA1MC1005 WARNING When maintenance or checks have been performed on components related to the cruise control system, be sure to perform a final check before delivering the vehicle to the customer. (Refer to “[C-2] FINAL CHECK” on page 8-105.) EAS1MC1016 [A] CHECKING THE CRUISE CONTROL SYSTEM INDICATOR LIGHT Turn the main switch to “ON”, and then push the cruise control power switch.
Page 567 CRUISE CONTROL SYSTEM Fault code No. A Front brake light switch: open or short circuit is detected. Item B Rear brake light switch: open or short circuit is detected. Probable cause of mal- Confirmation of service Item Maintenance job function and check completion Locate the malfunction.
Page 568 CRUISE CONTROL SYSTEM Fault code No. A Front brake light switch: open or short circuit is detected. Item B Rear brake light switch: open or short circuit is detected. Abnormality → Replace the Check the fuse. (signaling Turn the main switch to “ON”. system fuse, brake light fuse) fuse.
Page 569 CRUISE CONTROL SYSTEM Fault code No. A Front brake light switch: open or short circuit is detected. Item B Rear brake light switch: open or short circuit is detected. “ON” (when the brakes are applied) Meter display “OFF” (when the brakes are not applied) Procedure Operate the brake pedal.
Page 570 CRUISE CONTROL SYSTEM Fault code No. A Front brake light switch: open or short circuit is detected. Item B Rear brake light switch: open or short circuit is detected. Abnormality → Replace the Check the fuse. (signaling Turn the main switch to “ON”. system fuse, brake light fuse) fuse.
Page 571 CRUISE CONTROL SYSTEM Fault code No. Cruise control setting switch “RES+”: open or short circuit is detected. Item Cruise control setting switch “SET–”: open or short circuit is de- tected. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No.
Page 572 CRUISE CONTROL SYSTEM Fault code No. Cruise control setting switch “RES+”: open or short circuit is detected. Item Cruise control setting switch “SET–”: open or short circuit is de- tected. Improperly connected → Connection of ECU coupler. Turn the main switch to “ON”. Check the locking condition Connect the coupler secure- Push and release the...
Page 573 CRUISE CONTROL SYSTEM Fault code No. Cruise control setting switch “RES+”: open or short circuit is detected. Item Cruise control setting switch “SET–”: open or short circuit is de- tected. Malfunction in ECU. Replace the ECU. Refer to “REPLACING THE ECU (engine control unit)”...
Page 574 CRUISE CONTROL SYSTEM Fault code No. Cruise control setting switch “RES+”: open or short circuit is de- tected. Item Cruise control setting switch “SET–”: open or short circuit is detected. Improperly connected → Connection of main switch Turn the main switch to “ON”. coupler.
Page 575 CRUISE CONTROL SYSTEM Fault code No. Cruise control setting switch “RES+”: open or short circuit is de- tected. Item Cruise control setting switch “SET–”: open or short circuit is detected. Defective cruise control Replace the left handlebar Turn the main switch to “ON”. switch.
Page 576 Refer to “OUTLINE OF THE CRUISE CONTROL SYSTEM” on page 1-9. If you do not have a Yamaha diagnostic tool, the automatic deactivation history cannot be checked. Therefore, explain the automatic deactivation function of the cruise control system to the customer and explain that this is not a malfunction.
Page 577 CRUISE CONTROL SYSTEM 8-106...
Page 578: Fuel Pump System
FUEL PUMP SYSTEM EAS27550 FUEL PUMP SYSTEM EAS27560 CIRCUIT DIAGRAM 8-107...
Page 579 FUEL PUMP SYSTEM 3. Main switch 4. Main fuse 11.Fuel injection system fuse 16.Ignition fuse 26.Battery 27.Engine ground 31.Joint coupler 34.Relay unit 36.Fuel pump relay 43.Right handlebar switch 44.Start/engine stop switch 97.Fuel pump 115.ECU (engine control unit) A. Wire harness B.
Page 580 FUEL PUMP SYSTEM EAS27570 TROUBLESHOOTING If the fuel pump fails to operate. • Before troubleshooting, remove the following part(s): 1. Side cowlings 2. Front cowling assembly 3. Fuel tank 4. T-bar NG → 1. Check the fuses. (Main, ignition, and fuel injection system) Replace the fuse(s).
Page 581 FUEL PUMP SYSTEM 8-110...
Page 582 WINDSHIELD DRIVE SYSTEM EAS27610 WINDSHIELD DRIVE SYSTEM EAS27620 CIRCUIT DIAGRAM 8-111...
Page 583 WINDSHIELD DRIVE SYSTEM 3. Main switch 4. Main fuse 7. Windshield drive system fuse 12.Backup fuse 16.Ignition fuse 18.Signaling system fuse 26.Battery 27.Engine ground 31.Joint coupler 37.Windshield drive unit 38.Windshield drive unit relay (down) 39.Windshield drive unit relay (up) 50.Left handlebar switch 55.Menu switch 56.Select switch 76.Meter assembly...
Page 584 WINDSHIELD DRIVE SYSTEM EAS27630 TROUBLESHOOTING The windshield fails to move. • Before troubleshooting, remove the following part(s): 1. Front cowling assembly 2. Fuel tank 3. T-bar NG → 1. Check that there are no rocks or other foreign material in the wind- Remove the foreign material.
Page 585 WINDSHIELD DRIVE SYSTEM NG → 8. Check the windshield drive unit re- lay (up). Replace the windshield drive unit relay Refer to “CHECKING THE RE- (up). LAYS” on page 8-267. OK ↓ NG → 9. Check the windshield drive unit re- lay (down).
Page 586: Accessory Box System
ACCESSORY BOX SYSTEM ET3P61009 ACCESSORY BOX SYSTEM ET3P61010 CIRCUIT DIAGRAM 8-115...
Page 587 ACCESSORY BOX SYSTEM 3. Main switch 4. Main fuse 18.Signaling system fuse 26.Battery 27.Engine ground 31.Joint coupler 68.Accessory box solenoid A. Wire harness B. Negative battery sub-wire harness D. Accessory box sub-lead 8-116...
Page 588 ACCESSORY BOX SYSTEM ET3P61012 TROUBLESHOOTING The accessory box fails to operate. • Before troubleshooting, remove the following part(s): 1. Right upper inner panel 2. Left side cowling 3. Fuel tank 4. T-bar NG → 1. Check the fuses. (Main and signaling system) Replace the fuse(s).
Page 589 ACCESSORY BOX SYSTEM 8-118...
Page 590: Immobilizer System
IMMOBILIZER SYSTEM EAS27640 IMMOBILIZER SYSTEM EAS27650 CIRCUIT DIAGRAM 8-119...
Page 591 11.Fuel injection system fuse 12.Backup fuse 16.Ignition fuse 26.Battery 27.Engine ground 31.Joint coupler 76.Meter assembly 77.Multi-function meter 79.Immobilizer system indicator light 99.Immobilizer unit 100.Yamaha diagnostic tool connector 115.ECU (engine control unit) A. Wire harness B. Negative battery sub-wire harness 8-120...
Page 592 IMMOBILIZER SYSTEM EAS27670 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 593 IMMOBILIZER SYSTEM Parts to be replaced Main switch/immo- Key registration re- Accesso- bilizer unit Standard quirement ry lock* Main Immobiliz- and key switch er unit √ Standard key is lost New standard key All keys have been Code re-registering √ √...
Page 594 IMMOBILIZER SYSTEM Standby mode a. Main switch “ON” e. Standby mode on b. Main switch “OFF” f. Standby mode off c. LED on d. LED off 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.
Page 595 IMMOBILIZER SYSTEM Standard key registration a. Main switch “ON” B. Immobilizer system indicator light stops flashing when the registration of the second b. Main switch “OFF” standard key is complete. c. LED on d. LED off e. Less than 5.0 s f.
Page 596 IMMOBILIZER SYSTEM EAS27700 TROUBLESHOOTING When the main switch is turned to “ON”, the immobilizer system indicator light does not come on nor flashes. NG → 1. Check the fuses. (Main, ignition, fuel injection sys- tem, and backup) Replace the fuse(s). Refer to “CHECKING THE FUS- ES”...
Page 597 IMMOBILIZER SYSTEM EAS27720 SELF-DIAGNOSIS FAULT CODE INDICATION When a system malfunction occurs, the fault code number is indicated in the multi-function meter right display and the immobilizer system indicator light flashes at the same time. The pattern of flashing also shows the fault code.
Page 598 IMMOBILIZER SYSTEM Fault Part Symptom Cause Action code IMMOBILIZER Key code registra- Same standard key was UNIT tion malfunction. attempted to be regis- Register another tered two consecutive standard key. times. Unidentified code is Noise interference or 1. Check the wire received.
Page 599 IMMOBILIZER SYSTEM 8-128...
Page 600 ABS (ANTI-LOCK BRAKE SYSTEM) EAS28790 ABS (ANTI-LOCK BRAKE SYSTEM) EAS27730 CIRCUIT DIAGRAM 8-129...
Page 601 ABS (ANTI-LOCK BRAKE SYSTEM) 3. Main switch 4. Main fuse 9. ABS motor fuse 10.ABS solenoid fuse 11.Fuel injection system fuse 12.Backup fuse 15.ABS ECU fuse 16.Ignition fuse 18.Signaling system fuse 26.Battery 27.Engine ground 29.Starter relay 31.Joint coupler 33.Brake light fuse 40.Rear brake light switch 42.Front brake light switch 43.Right handlebar switch...
Page 602 ABS (ANTI-LOCK BRAKE SYSTEM) EAS27740 ABS COMPONENTS CHART 12,13 1. ABS test coupler 2. ABS warning light 3. ABS ECU fuse 4. ABS solenoid fuse 5. ABS motor fuse 6. Proportioning valve 7. Hydraulic unit assembly 8. Rear wheel sensor 9.
Page 603 ABS (ANTI-LOCK BRAKE SYSTEM) 8-132...
Page 604 ABS (ANTI-LOCK BRAKE SYSTEM) EAS27750 ABS COUPLER LOCATION CHART Br/Y Br/W Br/B Br/W Br/B R/W W/L W/G W/R G/W L/R L/B G/B Sb/W Y G/R R/G R/G R/G Ch (Gy) W Gy Gy W W Gy W B G/W L/W W/Y L/B B/W Gy W W/L G/Y Sb Br/W...
Page 605 ABS (ANTI-LOCK BRAKE SYSTEM) 1. Meter assembly coupler 2. ABS test coupler 3. Rear wheel sensor coupler 4. ABS ECU coupler 5. Front wheel sensor coupler 8-134...
Page 606 ABS (ANTI-LOCK BRAKE SYSTEM) EAS27770 MAINTENANCE OF THE ABS ECU If the ABS ECU coupler is clogged with mud or dirt, clean with compressed air. Checking the ABS ECU 1. Check: • Terminals “1” of the ABS ECU Cracks/damages → Replace the hydraulic unit assembly and the brake pipes that are connected to the assembly as a set.
Page 607 ABS (ANTI-LOCK BRAKE SYSTEM) The ABS performs a self-diagnosis test for a few seconds each time the vehicle first starts off after the main switch was turned to “ON”. During this test, a “clicking” noise can be heard from under the seat, and if the brake lever or brake pedal are even slightly applied, a vibration can be felt at the lever and pedal, but these do not indicate a malfunction.
Page 608 ABS (ANTI-LOCK BRAKE SYSTEM) EAS27810 BASIC PROCESS FOR TROUBLESHOOTING Fails to Does only the ABS warning [A-1] Turn the main switch to The ABS warning light(LED) is come on • light fail to come on? “ON”, and check the ABS defective.
Page 609 ABS (ANTI-LOCK BRAKE SYSTEM) EWA1MC1004 WARNING When maintenance or checks have been performed on components related to the ABS, be sure to perform a final check before delivering the vehicle to the customer. (Refer to “[C-3] FINAL CHECK” on page 8-164.) EAS27830 [A] CHECKING THE ABS WARNING LIGHT Turn the main switch to “ON”.
Page 610 ABS (ANTI-LOCK BRAKE SYSTEM) • If the T/C terminal is not short-circuited to the ground, check the internal circuit of the meter assem- bly. Turn the main switch to “OFF”. Disconnect the ABS ECU coupler and check that the ABS warning light comes on when the main switch is turned to “ON”.
Page 611 ABS (ANTI-LOCK BRAKE SYSTEM) EAS1MC1005 [B-1] A FAULT CODE NUMBER IS NOT DISPLAYED IN THE MULTI-FUNCTION METER RIGHT DISPLAY 1. The ABS warning light remains on. A malfunction is detected. [B-2] 2. The ABS warning light flashes every 0.5 second for more than 6 seconds. A malfunction is not detected.
Page 612 ABS (ANTI-LOCK BRAKE SYSTEM) • If the ABS warning light does not come on, the ABS ECU is defective. Replace the hydraulic unit assembly. 7. The hydraulic unit assembly is defective. EAS1MC1029 [B-3] DIAGNOSIS USING THE FAULT CODES Connect the test coupler adapter to the ABS test coupler, and then turn the main switch to “ON”. Information for the fault codes from the ABS ECU is contained in the following table.
Page 613 ABS (ANTI-LOCK BRAKE SYSTEM) Fault Symptom Check point code No. Start switch signal is not received prop- • Wire harness ABS_22 erly (start switch circuit or start switch • Connection of the relay unit coupler and monitor circuit). ABS ECU coupler. •...
Page 614 ABS (ANTI-LOCK BRAKE SYSTEM) Fault Symptom Check point code No. • Battery voltage ABS_51 • Battery terminal Power voltage is too high. ABS_52 • Refer to “CHARGING SYSTEM” on page 8-15. • Battery voltage • Connection of the ABS ECU coupler ABS_53 Power voltage is too low.
Page 615 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. ABS_11 Symptom Front wheel sensor signal is not received prop- ABS_25 erly. Order Item/components and probable Check or maintenance job cause Installed condition of wheel sensor. Check for looseness. Properly install or replace the wheel sensor if necessary.
Page 616 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. ABS_13 Symptom Incorrect signal from the front wheel sensor is ABS_26 detected. Order Item/components and probable Check or maintenance job cause Installed condition of wheel sensor. Check for looseness. Properly install or replace the wheel sensor if necessary.
Page 617 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. ABS_14 Symptom Incorrect signal from the rear wheel sensor is ABS_27 detected. Order Item/components and probable Check or maintenance job cause Hydraulic unit assembly internal mal- Replace the hydraulic unit assembly. function. Vehicle possibly ridden on uneven roads. Fault code No.
Page 618 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. ABS_15 Symptom No continuity in the front wheel sensor circuit. Order Item/components and probable Check or maintenance job cause Defective wheel sensor. If the above items were performed and no malfunc- tions were found, connect the ABS ECU coupler and front wheel sensor coupler, and then delete the fault codes.
Page 619 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. ABS_16 Symptom No continuity in the rear wheel sensor circuit. Order Item/components and probable Check or maintenance job cause Wire harness continuity. • Check for continuity between the gray terminal “1” and the gray terminal “3” and between the white terminal “2”...
Page 620 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. ABS_17 Symptom Missing pulses detected in the front wheel sen- ABS_45 sor signal. Order Item/components and probable Check or maintenance job cause Foreign material inside sensor hous- Check the interior of the sensor housing and the ing.
Page 621 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. ABS_22 Symptom Start switch signal is not received properly (start switch circuit or start switch monitor cir- cuit). Order Item/components and probable Check or maintenance job cause Connections • Check the coupler for any pins that may be pulled •...
Page 622 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. ABS_23 Symptom Brake light signal is not received properly when main switch is turned to “ON” (brake light cir- cuit, or front or rear brake light switch circuit). Order Item/components and probable Check or maintenance job cause Open or short circuit in wire harness.
Page 623 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. ABS_24 Symptom Brake light signal is not received properly while vehicle is traveling (brake light circuit, or front or rear brake light switch circuit). Order Item/components and probable Check or maintenance job cause Open or short circuit in wire harness.
Page 624 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. ABS_32 Symptom Hydraulic unit solenoid relay is short-circuited. Order Item/components and probable Check or maintenance job cause Short circuit in solenoid relay. Replace the hydraulic unit assembly. Hydraulic unit assembly internal mal- Replace the hydraulic unit assembly. function.
Page 625 Brake lines • Check the brake lines for kinks and deterioration. EWA3P6D005 WARNING Only use genuine Yamaha parts. Using other brake pipes, hoses and union bolts may close the brake lines. • Check that the connections of the brake lines...
Page 626 ABS (ANTI-LOCK BRAKE SYSTEM) EWA3P6D006 WARNING The front brakes will not function properly if the connections are reversed. • Brake pipe/lower joint assembly “1” and brake pipe “2” inlet: from the front brake master cyl- inder • Brake pipe/upper joint assembly “3” and brake pipe “4” outlet: to the front brake calipers •...
Page 627 (particularly between the hydraulic unit and the rear brake caliper). EWA3P6D005 WARNING Only use genuine Yamaha parts. Using other brake pipes, hoses and union bolts may close the brake lines. • Check that the connections of the brake lines from the brake master cylinder to the hydraulic unit and from the hydraulic unit to the proportion- ing valve are correct.
Page 628 ABS (ANTI-LOCK BRAKE SYSTEM) • If the brake pipes (to the proportioning valve and the metering valve) are switched during assembly, the brakes will continue to operate as normal. However, the reduction of the hydraulic pressure for the rear brake and part of the right front brake will be reversed during the ABS operation when the final check on page “[C-3] FINAL CHECK”...
Page 629 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. ABS_51 Symptom Power voltage is too high. ABS_52 Order Item/components and probable Check or maintenance job cause Battery voltage Replace the battery. Refer to “CHECKING AND CHARGING THE BAT- TERY” on page 8-264. Disconnected battery terminal (fault Check the connection.
Page 630 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. ABS_54 Symptom Power voltage is too low. Order Item/components and probable Check or maintenance job cause Open or short circuit in wire harness. • Replace if there is an open or short circuit. •...
Page 631 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. ABS_63 Symptom Front wheel sensor power is abnormal. Order Item/components and probable Check or maintenance job cause Short circuit in front wheel sensor • Check that there is no short circuit between the lead.
Page 632 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. ABS_64 Symptom Rear wheel sensor power is abnormal. Order Item/components and probable Check or maintenance job cause Short circuit in rear wheel sensor • Check that there is no short circuit between the lead.
Page 633 ABS (ANTI-LOCK BRAKE SYSTEM) EAS1MC1007 5. Push the “ ” side of the start/engine stop [C-1] DELETING THE FAULT CODES switch “1” at least 10 times in 4 seconds to 1. Check: delete the fault codes. • Engine stop due to sidestand operation EWA1MC1021 WARNING •...
Page 634 ABS (ANTI-LOCK BRAKE SYSTEM) 5. Check: • ABS ECU voltage Lower than 12.8 V → Charge or replace the W B G/W L/W W/Y battery. L/B B/W Gy W Br/B W/L G/Y Sb Br/W Battery voltage Higher than 12.8 V R/B R/W ▼...
Page 635 ABS (ANTI-LOCK BRAKE SYSTEM) W B G/W L/W W/Y L/B B/W Gy W Br/B W/L G/Y Sb Br/W b. Shift the transmission into gear and extend the sidestand. c. Push the “ ” side of the start/engine stop switch. d. Measure the ABS ECU voltage. ▲...
Page 636: Grip Warmer System
GRIP WARMER SYSTEM ET3P66016 GRIP WARMER SYSTEM ET3P66017 CIRCUIT DIAGRAM 8-165...
Page 637 GRIP WARMER SYSTEM 3. Main switch 4. Main fuse 11.Fuel injection system fuse 12.Backup fuse 16.Ignition fuse 26.Battery 27.Engine ground 31.Joint coupler 50.Left handlebar switch 55.Menu switch 56.Select switch 76.Meter assembly 77.Multi-function meter 83.Engine trouble warning light 115.ECU (engine control unit) 123.Left grip warmer 124.Right grip warmer A.
Page 638 GRIP WARMER SYSTEM ET3P66019 TROUBLESHOOTING • Before troubleshooting, remove the following part(s): 1. Right upper inner panel 2. Lower center cover 3. Fuel tank 4. T-bar The grip warmers do not become warm at all. NG → 1. Check that the engine trouble warn- Perform the troubleshooting for fault code ing light is on and that “Err”...
Page 639 GRIP WARMER SYSTEM The grip warmers are abnormally hot while the engine is idling. NG → 1. Check that the temperature level of Adjust the temperature levels of the grip the low grip warmer setting is set to warmer settings. “1”.
Page 640 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM EAS1MD1002 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM EAS1MD1003 CIRCUIT DIAGRAM 8-169...
Page 641 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM 3. Main switch 4. Main fuse 5. YCC-S motor control fuse 11.Fuel injection system fuse 12.Backup fuse 15.ABS ECU fuse 16.Ignition fuse 18.Signaling system fuse 26.Battery 27.Engine ground 31.Joint coupler 33.Brake light fuse 34.Relay unit 35.Starting circuit cut-off relay...
Page 642 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM EAS1MD1058 TROUBLESHOOTING • The stop mode function indicator light fails to come on. • The transmission gear display on the right multi-function meter right display fails to indicate the select- ed gear. • Before troubleshooting, remove the following part(s): 1.
Page 643 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Checking the YCC-S system Indication of stop mode function indicator light does not change (indicator light does not come on or go off). 1. Check whether “Err” is displayed in the multi-function meter center display.
Page 644 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM NG → 4. Check the stop mode function switch. The stop mode function switch is faulty. Refer to “CHECKING THE Replace the hand shift switch. SWITCHES” on page 8-259. OK ↓ Replace the MCU (motor control unit).
Page 645 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM NG → 5. Check the installed condition of the • Adjust the gear position sensor again, or gear position sensor. replace the sensor and carry out the Refer to “ADJUSTING THE GEAR learning for each gear position.
Page 646 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM EAS1MD1005 MCU (motor control unit) SELF-DIAGNOSTIC FUNCTION The MCU (motor control unit) is equipped with a self-diagnostic function in order to ensure that the YCC-S system is operating normally. If this function detects a malfunction in the YCC-S system, it im- mediately operates the system under substitute characteristics and lights the YCC-S system warning light to alert the rider that a malfunction has occurred in the system.
Page 647 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM 4. Turn the main switch to “OFF” and back to EAS1MD1019 TROUBLESHOOTING METHOD “ON”, then check that no fault code number is displayed. • If there is a malfunction in the YCC-S system, the windshield adjusting function “1” will be dis-...
Page 648 EAS1MD1026 BASIC INSTRUCTIONS FOR THE DIAGNOSTIC FUNCTION For information about setting the diagnostic mode, refer to “DIAGNOSTIC MODE (ECU)” on page 8-40. For information about using the Yamaha diagnostic tool, refer to “YAMAHA DIAGNOSTIC TOOL” on page 8-41. EAS1MD1007 TROUBLESHOOTING DETAILS (MCU) This section describes the measures per fault code number displayed on the multi-function meter right display.
Page 649 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _12 Malfunction of power cut-off function in the MCU (motor con- Item trol unit). Unable to start Fail-safe system Unable to change the shift Diagnostic code No. — Meter display —...
Page 650 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _13 Item Overcurrent to clutch actuator motor. Improperly connected → Connection of clutch actua- Check the indication of the tor motor coupler. Connect the coupler secure- shift down indicator light Check the locking condition...
Page 651 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _13 Item Overcurrent to clutch actuator motor. Short circuit → Replace the Wire harness continuity. Check the indication of the wire harness. shift down indicator light Between MCU coupler and when the clutch is engaged clutch actuator motor cou- and disengaged.
Page 652 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _13 Item Overcurrent to clutch actuator motor. Defective clutch actuator. Replace the clutch actuator. Check the indication of the Refer to “CLUTCH” on page shift down indicator light 5-44. when the clutch is engaged and disengaged.
Page 653 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _14 Item Overcurrent to shift actuator motor. Improperly connected → Connection of shift actuator Check the indication of the motor coupler. Connect the coupler secure- shift down indicator light Check the locking condition...
Page 654 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _14 Item Overcurrent to shift actuator motor. Stuck shift actuator. Check whether the shift actu- Check the indication of the ator is stuck. shift down indicator light Refer to “CHECKING FOR when the transmission is STUCK SHIFT ACTUATOR”...
Page 655 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _15 Malfunction in portion of MCU (motor control unit) that detects Item the current in the clutch and shift actuator motor circuits. Sh_ _63 Engagement position: Shift down indicator light comes on...
Page 656 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _15 Malfunction in portion of MCU (motor control unit) that detects Item the current in the clutch and shift actuator motor circuits. Improperly connected → Connection of MCU coupler. Check the operation of the...
Page 657 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _15 Malfunction in portion of MCU (motor control unit) that detects Item the current in the clutch and shift actuator motor circuits. Open or short circuit → Re- Wire harness continuity.
Page 658 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _15 Malfunction in portion of MCU (motor control unit) that detects Item the current in the clutch and shift actuator motor circuits. Open or short circuit → Re- Wire harness continuity.
Page 659 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _15 Malfunction in portion of MCU (motor control unit) that detects Item the current in the clutch and shift actuator motor circuits. Open or short circuit → Re- Wire harness continuity.
Page 660 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _15 Malfunction in portion of MCU (motor control unit) that detects Item the current in the clutch and shift actuator motor circuits. Open or short circuit → Re- Wire harness continuity.
Page 661 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _15 Malfunction in portion of MCU (motor control unit) that detects Item the current in the clutch and shift actuator motor circuits. Abnormality → Replace the Check the YCC-S motor con- Check the operation of the trol fuse.
Page 662 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _15 Malfunction in portion of MCU (motor control unit) that detects Item the current in the clutch and shift actuator motor circuits. Defective clutch actuator or Replace the clutch actuator Check the operation of the shift actuator.
Page 663 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM : If any of the following fault codes are detected, do not execute the diagnostic mode “Sh_ _63”. Sh_ _11, Sh_ _12, Sh_ _13, Sh_ _15, Sh_ _16, Sh_ _17, Sh_ _25, Sh_ _26, Sh_ _36, Sh_ _37, and Sh_ _44 : If any of the following fault codes are detected, do not execute the diagnostic mode “Sh_ _64”.
Page 664 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _16 Abnormal current is detected in clutch or shift actuator motor Item drive circuit. Improperly connected → Connection of clutch actua- Check the indication of the tor motor coupler. Connect the coupler secure-...
Page 665 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _16 Abnormal current is detected in clutch or shift actuator motor Item drive circuit. Improperly connected → Connection of MCU coupler. Check the operation of the Check the locking condition Connect the coupler secure- clutch actuator motor and of the coupler.
Page 666 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _16 Abnormal current is detected in clutch or shift actuator motor Item drive circuit. Open or short circuit → Re- Wire harness continuity. Check the operation of the place the wire harness.
Page 667 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _16 Abnormal current is detected in clutch or shift actuator motor Item drive circuit. Open or short circuit → Re- Wire harness continuity. Check the operation of the place the wire harness.
Page 668 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _16 Abnormal current is detected in clutch or shift actuator motor Item drive circuit. Open or short circuit → Re- Wire harness continuity. Check the operation of the place the wire harness.
Page 669 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _16 Abnormal current is detected in clutch or shift actuator motor Item drive circuit. Open or short circuit → Re- Wire harness continuity. Check the operation of the place the wire harness.
Page 670 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _16 Abnormal current is detected in clutch or shift actuator motor Item drive circuit. Abnormality → Replace the Check the YCC-S motor con- Check the operation of the trol fuse. YCC-S motor control fuse.
Page 671 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _16 Abnormal current is detected in clutch or shift actuator motor Item drive circuit. Defective clutch actuator or Replace the clutch actuator Check the operation of the shift actuator. or shift actuator.
Page 672 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM : If any of the following fault codes are detected, do not execute the diagnostic mode “Sh_ _63”. Sh_ _11, Sh_ _12, Sh_ _13, Sh_ _15, Sh_ _16, Sh_ _17, Sh_ _25, Sh_ _26, Sh_ _36, Sh_ _37, and Sh_ _44 : If any of the following fault codes are detected, do not execute the diagnostic mode “Sh_ _64”.
Page 673 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _17 Item Detected clutch actuator position is incorrect. Improperly connected → Connection of MCU coupler. Check the indication of the Check the locking condition Connect the coupler secure- shift down indicator light of the coupler.
Page 674 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _17 Item Detected clutch actuator position is incorrect. Stuck clutch actuator. Check whether the clutch ac- Check the indication of the tuator is stuck. shift down indicator light Refer to “CHECKING FOR...
Page 675 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _18 Item Detected shift actuator position is incorrect. Unable to start Fail-safe system Unable to change the shift Diagnostic code No. Sh_ _64 Correct shifting: Shift down indicator light comes on...
Page 676 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _18 Item Detected shift actuator position is incorrect. Open or short circuit → Re- Wire harness continuity. Check the indication of the place the wire harness. shift down indicator light Between MCU coupler and when the transmission is shift actuator motor coupler.
Page 677 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM : If any of the following fault codes are detected, do not execute the diagnostic mode “Sh_ _64”. Sh_ _11, Sh_ _12, Sh_ _14, Sh_ _15, Sh_ _16, Sh_ _18, Sh_ _19, Sh_ _25, Sh_ _37, and Sh_ _51 Fault code No.
Page 678 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _19 Item Shift actuator sensor: open or short circuit detected. Defective shift actuator sen- 1. Measure the resistance of Turn the main switch to “ON”. sor. the shift actuator sensor. Fault code number is not dis- played →...
Page 679 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Sh_ _20 (this fault code number can be checked only using the Fault code No. Yamaha diagnostic tool) Signals cannot be transmitted between the MCU (motor con- Item trol unit) and the multi-function meter. Locate the malfunction.
Page 680 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _21 Item Gear position sensor: open or short circuit detected. Open or short circuit → Re- Wire harness continuity. Turn the main switch to “ON”. place the wire harness. Fault code number is not dis- played →...
Page 681 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _22 Item Foot shift sensor: open or short circuit detected. Improperly connected → Connection of foot shift sen- Turn the main switch to “ON”. sor coupler. Connect the coupler secure- Fault code number is not dis- played →...
Page 682 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _22 Item Foot shift sensor: open or short circuit detected. Installed condition of foot Refer to “ADJUSTING THE Turn the main switch to “ON”. shift sensor. FOOT SHIFT SENSOR” on Fault code number is not dis- played →...
Page 683 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _23 Item No normal signals are received from the sidestand switch. Open or short circuit → Re- Wire harness continuity. Turn the main switch to “ON”, place the wire harness. and then extend and retract Between MCU coupler and the sidestand.
Page 684 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _26 Abnormal clutch movement is detected during check when Item main switch is turned to “ON”. Unable to start Fail-safe system Unable to change the shift Diagnostic code No. — Meter display —...
Page 685 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _26 Abnormal clutch movement is detected during check when Item main switch is turned to “ON”. Defective clutch actuator. Replace the clutch actuator. Turn the main switch to Refer to “CLUTCH” on page “OFF”.
Page 686 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _31 Item Engine speed signal is abnormal. Open or short circuit → Re- Wire harness continuity. Start the engine and let it run place the wire harness. at idle. Between MCU coupler and Fault code number is not dis- played →...
Page 687 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _32 Item Vehicle speed signal is abnormal. Improperly connected → Malfunction is repaired → Connection of MCU coupler. Check the locking condition Connect the coupler secure- Service is finished. of the coupler.
Page 688 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _35 Item Start switch signal is abnormal. Improperly connected → Connection of right handle- Turn the main switch to “ON”, bar switch coupler. Connect the coupler secure- and then apply the front or...
Page 689 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _35 Item Start switch signal is abnormal. Short circuit → Replace the Wire harness continuity. Turn the main switch to “ON”, wire harness. and then apply the front or Between YCC-S control re- rear brake.
Page 690 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _36 Item Clutch actuator sensor: open or short circuit detected. Improperly connected → Connection of clutch actua- Turn the main switch to “ON”. tor sensor coupler. Connect the coupler secure- Fault code number is not dis- played →...
Page 691 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _36 Item Clutch actuator sensor: open or short circuit detected. Defective clutch actuator 1. Measure the resistance of Turn the main switch to “ON”. sensor. the clutch actuator sen- Fault code number is not dis- played →...
Page 692 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _37 Item Power supply to clutch or shift actuator motor is abnormal. Improperly connected → Connection of clutch actua- Turn the main switch to “ON”. tor motor coupler. Connect the coupler secure- Fault code number is not dis- played →...
Page 693 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _38 Item Malfunction of hand shift lever switch (shift up or shift down). Improperly connected → Connection of hand shift le- Raise the sidestand, and ver switch coupler. Connect the coupler secure-...
Page 694 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _41 Item Coolant temperature sensor: open or short circuit detected. Able to start Fail-safe system Able to change the shift Diagnostic code No. — Meter display — Procedure — Probable cause of mal-...
Page 695 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _42 ECU (engine control unit) data cannot be received and/or ETV Item (electronic throttle valve) is malfunctioning. Improperly connected → Connection of ECU coupler. Turn the main switch to “ON”. Check the locking condition...
Page 696 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _43 Communication between MCU (motor control unit) and ABS Item ECU (electronic control unit) is abnormal. Locate the malfunction. ABS fault code number is — displayed → Refer to “[B-3] DIAGNOSIS USING THE FAULT CODES”...
Page 697 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _44 Item Detected position of clutch actuator sensor is incorrect. Probable cause of mal- Confirmation of service Item Maintenance job function and check completion Defective clutch actuator. Replace the clutch actuator.
Page 698 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _45 Item Shift operation and gear position do not match. Probable cause of mal- Confirmation of service Item Maintenance job function and check completion Malfunction is repaired → Installed condition of gear Refer to “ADJUSTING THE...
Page 699 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _45 Item Shift operation and gear position do not match. Malfunction is repaired → Abnormal clutch stroke. Check the clutch stroke. Refer to “BLEEDING THE Service is finished. HYDRAULIC CLUTCH SYS- Malfunction could not be found →...
Page 700 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _46 Item Detected position of gear position sensor is incorrect. Locate the malfunction. If fuel injection system fault — code No. 12 is displayed → Perform the checks and maintenance jobs for fault code No.
Page 701 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _46 Item Detected position of gear position sensor is incorrect. Open or short circuit → Re- Malfunction is repaired → Wire harness continuity. place the wire harness. Service is finished. Between MCU coupler and Malfunction could not be found →...
Page 702 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _47 Item No brake input during braking. Diagnostic code No. — Meter display — Procedure — Probable cause of mal- Confirmation of service Item Maintenance job function and check completion Refer to the information for —...
Page 703 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _48 Item Engine idling speed is too high. Improperly connected → Connection of throttle servo Start the engine and let it motor coupler. Connect the coupler secure- warm up for several minutes.
Page 704 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _49 Item Engine speed is too high when vehicle is started. Able to start Fail-safe system Able to change the shift Diagnostic code No. Sh_ _65 Sh_ _65 No reading error: The shift down indicator light comes on for 0.5 second.
Page 705 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _49 Item Engine speed is too high when vehicle is started. Malfunction is repaired → Installed condition of gear Refer to “ADJUSTING THE position sensor. GEAR POSITION SEN- Service is finished.
Page 706 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _51 Item Detected position of shift actuator sensor is incorrect. Open or short circuit → Re- Wire harness continuity. Turn the main switch to “ON”. place the wire harness. Fault code number is not dis- played →...
Page 707 YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _52 Item Main switch signal is abnormal. Improperly connected → Connection of MCU coupler. Turn the main switch to Check the locking condition Connect the coupler secure- “OFF” and back to “ON”, and of the coupler.
Page 708 ELECTRONICALLY ADJUSTABLE SUSPENSION SYSTEM EAS1MD1008 ELECTRONICALLY ADJUSTABLE SUSPENSION SYSTEM EAS1MD1009 CIRCUIT DIAGRAM 8-237...
Page 709 ELECTRONICALLY ADJUSTABLE SUSPENSION SYSTEM 3. Main switch 4. Main fuse 6. SCU fuse 11.Fuel injection system fuse 12.Backup fuse 16.Ignition fuse 26.Battery 27.Engine ground 31.Joint coupler 71.SCU (suspension control unit) 72.Left front fork stepping motor 73.Right front fork stepping motor 74.Rear shock absorber assembly stepping motor 75.Rear shock absorber assembly DC motor...
Page 710 ELECTRONICALLY ADJUSTABLE SUSPENSION SYSTEM EAS1MD1053 MAINTENANCE OF THE SCU (suspension control unit) Checking the SCU (suspension control unit) 1. Check: • Terminals “1” of the SCU Cracks/damages → Replace the SCU. • Terminals “2” of the SCU couplers Connection defective, contaminated, come- off →...
Page 711 ELECTRONICALLY ADJUSTABLE SUSPENSION SYSTEM 3. Perform the reinstatement action for the elec- EAS1MD1024 TROUBLESHOOTING METHOD (SCU) tronically adjustable suspension system. Refer to “Confirmation of service completion” • If there is a malfunction in the electronically ad- in the appropriate table in “TROUBLE- justable suspension system, the damping SHOOTING DETAILS (SCU)”...
Page 712 ELECTRONICALLY ADJUSTABLE SUSPENSION SYSTEM EAS1MD1010 BASIC INSTRUCTIONS FOR DIAGNOSTIC FUNCTION For information about setting the diagnostic mode, refer to “DIAGNOSTIC MODE (ECU)” on page 8-40. EAS1MD1025 TROUBLESHOOTING DETAILS (SCU) This section describes the measures per fault code number displayed on the multi-function meter right display.
Page 713 ELECTRONICALLY ADJUSTABLE SUSPENSION SYSTEM Fault code No. EEPROM fault code number: an error is detected while reading Item from or writing on EEPROM. Locate the faulty data (pre- Turn the main switch to Execute the diagnostic load adjustment) in the SCU. “OFF”.
Page 714 ELECTRONICALLY ADJUSTABLE SUSPENSION SYSTEM Fault code No. Item SCU (suspension control unit): open or short circuit detected. When completed successfully “00” is displayed in the multi-function meter right display and the electronically adjustable suspension system warning light goes off. The preload is adjusted to the solo-riding position. When not completed successfully “F0”...
Page 715 ELECTRONICALLY ADJUSTABLE SUSPENSION SYSTEM Fault code No. Signals cannot be transmitted between the SCU and the ECU and between the SCU and the meter assembly. (Fault code No. Item 89 is displayed in the multi-function meter right display only when abnormal ECU communication is detected.) Open or short circuit →...
Page 716 ELECTRONICALLY ADJUSTABLE SUSPENSION SYSTEM Fault code No. Item Stepping motor: open or short circuit detected. Improperly connected → Connection of stepping mo- Turn the main switch to tor coupler. Connect the coupler secure- “OFF” and back to “ON”. Check the locking condition ly or replace the wire har- Fault code number is not dis- played →...
Page 717 ELECTRONICALLY ADJUSTABLE SUSPENSION SYSTEM Fault code No. Item Stepping motor: open or short circuit detected. Open circuit → Replace. Wire harness and/or front Turn the main switch to fork stepping motor sub-lead • Between SCU coupler and “OFF” and back to “ON”. continuity.
Page 718 ELECTRONICALLY ADJUSTABLE SUSPENSION SYSTEM Fault code No. Item Stepping motor: open or short circuit detected. Wire harness and/or front • SCU internal circuit (be- Turn the main switch to fork stepping motor sub-lead tween left front fork step- “OFF” and back to “ON”. continuity.
Page 719 ELECTRONICALLY ADJUSTABLE SUSPENSION SYSTEM Fault code No. Item Stepping motor: open or short circuit detected. Malfunction in stepping mo- Stepping motor operation Turn the main switch to “ON”. tor. confirmation steps: Fault code number is not dis- played → Service is finished. a.
Page 720 ELECTRONICALLY ADJUSTABLE SUSPENSION SYSTEM Fault code No. Preload adjusting motor (rear shock absorber assembly DC motor) is locked, rotary encoder signal is not received, encod- Item er signal is reversed, or motor rotates continuously at a low speed during the diagnostic mode (code No. 84 [preload home position adjustment]).
Page 721 ELECTRONICALLY ADJUSTABLE SUSPENSION SYSTEM Fault code No. Preload adjusting motor (rear shock absorber assembly DC motor) is locked, rotary encoder signal is not received, encod- Item er signal is reversed, or motor rotates continuously at a low speed during the diagnostic mode (code No. 84 [preload home position adjustment]).
Page 722 ELECTRONICALLY ADJUSTABLE SUSPENSION SYSTEM Fault code No. Preload adjusting motor (rear shock absorber assembly DC motor) is locked, rotary encoder signal is not received, encod- Item er signal is reversed, or motor rotates continuously at a low speed during the diagnostic mode (code No. 84 [preload home position adjustment]).
Page 723 ELECTRONICALLY ADJUSTABLE SUSPENSION SYSTEM Fault code No. Preload adjusting motor (rear shock absorber assembly DC motor) is locked, rotary encoder signal is not received, encod- Item er signal is reversed, or motor rotates continuously at a low speed during the diagnostic mode (code No. 84 [preload home position adjustment]).
Page 724 ELECTRONICALLY ADJUSTABLE SUSPENSION SYSTEM Fault code No. Preload adjusting motor (rear shock absorber assembly DC motor) is locked, rotary encoder signal is not received, encod- Item er signal is reversed, or motor rotates continuously at a low speed during the diagnostic mode (code No. 84 [preload home position adjustment]).
Page 725 ELECTRONICALLY ADJUSTABLE SUSPENSION SYSTEM Fault code No. Item Defective preload adjusting motor (DC motor). Wire harness continuity. Refer to “REAR SHOCK AB- Execute the diagnostic SORBER ASSEMBLY” on mode. (Code No. 84) page 4-94. Start the engine, adjust the Short circuit → Replace the preload (solo riding →...
Page 726: Electrical Components
ELECTRICAL COMPONENTS EAS27970 ELECTRICAL COMPONENTS 8-255...
Page 727 ELECTRICAL COMPONENTS 1. Windshield drive unit 2. Battery 3. Starter relay 4. Cooling system fuse 5. Front brake light switch 6. Fuse box 3 7. Fuse box 1 8. Fuse box 2 9. Fuse box 4 10. Cruise control system fuse 11.
Page 728 ELECTRICAL COMPONENTS 8-257...
Page 729 ELECTRICAL COMPONENTS 1. Coolant temperature sensor 2. Accelerator position sensor 3. Throttle position sensor 4. Intake air pressure sensor 5. Atmospheric pressure sensor 6. YCC-S control relay 7. Brake light relay 8. MCU (motor control unit) 9. SCU (suspension control unit) 10.
Page 730: Checking The Switches
ELECTRICAL COMPONENTS EAS27980 CHECKING THE SWITCHES O B/R Br/W W/G W/R O/W Y/B W/B W/Y R/Y Y G/L Br/L L/R DOWN Br/G G/L Y/B Br/L W/G B/W W/R R/B W/L B Br/W B/R Y/B O/W Br/G W/L B/W L/B R/Y Y MENU PASS W/B L/R W/Y...
Page 731 ELECTRICAL COMPONENTS 1. Start/engine stop switch 2. Hazard switch 3. Mode switch 4. Front brake light switch 5. Main switch 6. Rear brake light switch 7. Neutral switch 8. Sidestand switch 9. Horn switch 10. Dimmer/pass switch 11. Cruise control power switch 12.
Page 732 ELECTRICAL COMPONENTS Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. ECA14370 NOTICE Never insert the tester probes into the coupler terminal slots “a”. Always insert the probes from the opposite end of the coupler, taking care not to loosen or damage the leads.
Page 733 ELECTRICAL COMPONENTS EAS27990 EW3P61001 CHECKING THE BULBS AND BULB WARNING SOCKETS Since headlight bulbs get extremely hot, keep flammable products and your hands Do not check any of the lights that use LEDs. away from them until they have cooled down.
Page 734 ELECTRICAL COMPONENTS Checking the condition of the bulb sockets 3. Replace: The following procedure applies to all of the bulb • Blown fuse sockets. ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼...
Page 735 ELECTRICAL COMPONENTS • Skin — Wash with water. EWA13310 WARNING • Eyes — Flush with water for 15 minutes and Never use a fuse with an amperage rating get immediate medical attention. other than that specified. Improvising or us- INTERNAL ing a fuse with the wrong amperage rating •...
Page 736 ELECTRICAL COMPONENTS 3. Remove: A. Open-circuit voltage (V) • Battery B. Charging condition of the battery (%) 4. Check: C. Ambient temperature 20 °C (68 °F) • Battery charge ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼...
Page 737 ELECTRICAL COMPONENTS • If the battery becomes hot to the touch at • Standard charging current is reached any time during the charging process, dis- Battery is good. connect the battery charger and let the bat- • Standard charging current is not reached tery cool before reconnecting it.
Page 738 ELECTRICAL COMPONENTS Starter relay 12.8 V or more --- Charging is complete. 12.7 V or less --- Recharging is required. Under 12.0 V --- Replace the battery. ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲...
Page 739 ELECTRICAL COMPONENTS Relay unit (fuel pump relay) Headlight relay (dimmer) First step: Br/W 1. Positive battery terminal 2. Negative battery terminal 1. Positive tester probe 3. Positive tester probe 2. Negative tester probe 4. Negative tester probe 3. Negative tester probe Result Result Continuity...
Page 740 ELECTRICAL COMPONENTS Brake switch relay 3. Positive tester probe 4. Negative tester probe Result No continuity (between “3” and “4”) Radiator fan motor relay Lg/B 1. Positive battery terminal 2. Negative battery terminal 3. Positive tester probe 4. Negative tester probe Br/B Result Continuity...
Page 741 ELECTRICAL COMPONENTS Second step: Second step: Br/G Br/G 1. Positive battery terminal 1. Positive battery terminal 2. Negative battery terminal 2. Negative battery terminal 3. Positive tester probe 3. Positive tester probe 4. Negative tester probe 4. Negative tester probe 5.
Page 742 ELECTRICAL COMPONENTS YCC-S control relay Continuity First step: Positive tester probe → sky blue “1” Negative tester probe → black/yellow “2” No continuity Positive tester probe → black/yellow “2” Negative tester probe → sky blue “1” Continuity L / R Positive tester probe →...
Page 743 ELECTRICAL COMPONENTS c. Check the relay unit (diode) for continuity. ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect the pocket tester (Ω × 1k) to the ig- d. Check the relay unit (diode) for no continuity. nition coil as shown.
Page 744 ELECTRICAL COMPONENTS B Gy b. Measure the crankshaft position sensor re- 2. Ignition coil sistance. c. Turn the main switch to “ON”. ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ d.
Page 745 ELECTRICAL COMPONENTS EAS28150 CHECKING THE STATOR COIL 1. Disconnect: • Stator coil coupler 65 65 (from the wire harness) 2. Check: • Stator coil resistance Out of specification → Replace the stator coil. Stator coil resistance 0.130–0.190 Ω c. Turn the main switch to “ON”. d.
Page 746 ELECTRICAL COMPONENTS Charging voltage Pocket tester 14 V at 5000 r/min 90890-03112 Analog pocket tester YU-03112-C ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect the pocket tester (DC 20 V) to the battery terminals as shown.
Page 747 ELECTRICAL COMPONENTS • Positive tester probe → green/white “1” • Negative tester probe → black/white “2” GEAR A.TEMP C.TEMP EAS1MC1086 CHECKING THE FRONT TURN SIGNAL LIGHT ASSEMBLIES The following procedure applies to both of the front turn signal light assemblies. b.
Page 748 ELECTRICAL COMPONENTS EAS28250 CHECKING THE RADIATOR FAN MOTORS Pocket tester The following procedure applies to both of the 90890-03112 radiator fan motors. Analog pocket tester YU-03112-C 1. Check: • Radiator fan motor Faulty/rough movement → Replace. b. Immerse the coolant temperature sensor “1” in a container filled with coolant “2”.
Page 749 ELECTRICAL COMPONENTS ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect the pocket tester (Ω × 1k) to the Resistance 1.08–2.52 kΩ throttle position sensor terminals as shown. Pocket tester ▼...
Page 750 ELECTRICAL COMPONENTS ECA1MC1004 • Positive tester probe → NOTICE Air induction system solenoid terminal “1” Do not use a 12 V battery to operate the throt- • Negative tester probe → tle servo motor. Air induction system solenoid terminal “2” Do not use old batteries to operate the throttle servo motor.
Page 751 ELECTRICAL COMPONENTS c. Turn the main switch to “ON”. c. Turn the main switch to “ON”. d. Measure the intake air pressure sensor out- d. Rotate the crankshaft. put voltage. e. Measure the voltage of white/black and black/blue. Turn the crankshaft twice and ▲...
Page 752 ELECTRICAL COMPONENTS c. Turn the main switch to “ON”. d. Heat the water or let it cool down to the spec- d. Measure the atmospheric pressure sensor ified temperatures. output voltage. e. Measure the air temperature sensor resis- tance. ▲ ▲▲▲...
Page 753 ELECTRICAL COMPONENTS EAS1MC1078 CHECKING THE WINDSHIELD DRIVE UNIT Pocket tester 1. Check: 90890-03112 • Windshield drive unit operation Analog pocket tester Faulty/rough movement → Replace. YU-03112-C ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼...
Page 754 ELECTRICAL COMPONENTS e. Measure the voltage of white/yellow and black/blue. With each full rotation of the rear wheel, the voltage reading should cycle from 0.6 V to 4.8 V to 0.6 V to 4.8 V. ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲...
Page 755 ELECTRICAL COMPONENTS b. Measure the foot shift sensor maximum re- sistance. ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 3. Install: • Foot shift sensor Refer to “INSTALLING THE FOOT SHIFT SENSOR”...
Page 756 ELECTRICAL COMPONENTS 8-285...
Page 757: 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 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 ........
Page 758 TROUBLESHOOTING Electrical system EAS28450 TROUBLESHOOTING 1. Battery • Discharged battery EAS28460 • Faulty battery GENERAL INFORMATION 2. Fuse(s) • Blown, damaged or incorrect fuse The following guide for troubleshooting does not • Improperly installed fuse cover all the possible causes of trouble. It should 3.
Page 759 TROUBLESHOOTING Electrical system Shift forks 1. Battery • Worn shift fork • Discharged battery Shift drum • Faulty battery • Incorrect axial play 2. Spark plug(s) • Worn shift drum groove • Incorrect spark plug gap • Incorrect spark plug heat range Transmission •...
Page 760 TROUBLESHOOTING • Incorrect oil viscosity • Damaged brake hose • Inferior oil quality • Oil or grease on the brake disc • Oil or grease on the brake pad Cooling system • Incorrect brake fluid level 1. Coolant EAS28660 • Low coolant level FAULTY FRONT FORK LEGS 2.
Page 761 TROUBLESHOOTING • Faulty rear suspension control stepping motor Turn signal does not come on • Faulty rear shock absorber assembly DC mo- • Faulty turn signal switch • Faulty meter assembly • Faulty front turn signal light Tire(s) • Burnt-out rear turn signal bulb •...
Page 762 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE (ECU) EAS1MD1016 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE (ECU) • If there is a malfunction in the fuel injection system, the windshield adjusting function “1” will be dis- played in the function display, the engine trouble warning light “2” will come on, and a fault code num- ber “3”...
Page 763 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE (ECU) Fault Reference Item code No. pages Cylinder-#2 ignition coil: open or short circuit detected in the primary 8-61 lead of the cylinder-#2 ignition coil. Cylinder-#3 ignition coil: open or short circuit detected in the primary 8-62 lead of the cylinder-#3 ignition coil.
Page 764 Communication error with the meter Reference Fault code No. Item pages Multi-function meter: signals cannot be transmit- 89 (Yamaha diagnostic tool) ted between the ECU and the multi-function 8-82 meter. Abnormal meter assembly communication (meter assembly cannot receive CAN communication da- 8-82 ta).
Page 765 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE (ECU) Diagnostic Item Meter display Procedure code No. Rear wheel vehicle speed Rear wheel speed pulse Check that the number in- pulses 0–999 creases when the rear wheel is rotated. The num- ber is cumulative and does not reset each time the wheel is stopped.
Page 766 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE (ECU) Diagnostic Item Meter display Procedure code No. Neutral switch Shift the transmission. • Transmission is in neu- tral • Transmission is not in neutral EEPROM fault code dis- play • No history — •...
Page 767 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE (ECU) Diagnostic Item Meter display Procedure code No. Malfunction history code erasure • No history — • History exists • Displays the total num- To erase the history, set ber of malfunctions, in- the start/engine stop cluding the current switch from “...
Page 768 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE (ECU) Diagnostic Item Meter display Procedure code No. Cruise control cancel cir- Operate the clutch lever, cuit brake lever, brake pedal, and throttle grip. • Clutch lever is squeezed ON • Clutch lever is released •...
Page 769 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE (ECU) Diagnostic Item Actuation Procedure code No. Injector #1 Actuates the injector #1 Check that injector #1 is five times at one-second actuated five times by lis- intervals. tening for the operating Illuminates the engine sound.
Page 770 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE (MCU) • If there is a malfunction in the YCC-S (Yamaha Chip Controlled-Shift) system, the windshield adjust- ing function “1” will be displayed in the function display, the YCC-S system warning light “2” will come on, and a fault code number “3”...
Page 771 Engine speed is too high when vehicle is started. 8-232 Sh_ _51 Detected position of shift actuator sensor is incorrect. 8-234 Sh_ _52 Main switch signal is abnormal. 8-235 * This fault code number can be checked only using the Yamaha diagnostic tool. 9-14...
Page 772 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE (MCU) Diagnostic code table Diagnos- tic code Item Meter display Procedure Sh_ _61 Malfunction history code display • No history — • History exists Fault codes Sh_ — _11–Sh_ _52 • (If more than one code number is detected, the dis- play alternates ev-...
Page 773 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE (MCU) Diagnos- tic code Item Meter display Procedure Sh_ _63 Clutch actuator oper- Actuates the clutch The clutch actuator can be operated in this ation actuator. mode. Check the shift down indicator light and the operating sound of the clutch actuator.
Page 774 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE (MCU) Diagnos- tic code Item Meter display Procedure Sh_ _65 Gear position setting Carries out the The gear position can be set in this mode. learning for each 1. Make sure that the transmission is in gear position.
Page 775 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE (MCU) Diagnos- tic code Item Meter display Procedure Sh_ _65 Gear position setting Carries out the 12. Operate the brake lever or brake pedal learning for each to write the data on EEPROM. gear position. If all of the data has been written suc- If any of the following cessfully on EEPROM, the shift down...
Page 776 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE (SCU) EAS1MD1020 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE (SCU) • If there is a malfunction in the electronically adjustable suspension system, the damping force adjust- ing function “1” will be displayed in the function display, the electronically adjustable suspension sys- tem warning light “2”...
Page 777 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE (SCU) Diagnostic code table Diagnostic Item Meter display Procedure code No. Monitor voltage Displays the monitor volt- Compare the actually age. measured battery voltage Approximately 12.0 with the meter display val- ue. (If the actually mea- sured battery voltage is low, recharge the battery.) Malfunction history code...
Page 778 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE (SCU) Diagnostic Item Meter display Procedure code No. Preload home position ad- Adjusts the preload home To adjust the preload justment position. home position, simulta- When completed success- neously press the “TCS” fully button and “RESET” but- “00”...
Page 779 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE (SCU) 9-22...
Page 780: Wiring Diagram
58. License plate light 109.Cylinder identification sensor 59. Tail/brake light assembly 110.Lean angle sensor FJR1300AS 2013 60. Tail/brake light 111.Yamaha diagnostic tool cou- 1. AC magneto 61. Rear left turn signal light pler 2. Rectifier/regulator 62. Rear right turn signal light 112.ABS ECU (electronic control...
Page 781 EAS28750 COLOR CODE Black Brown Chocolate Dark green Green Gray Blue Light green Orange Pink Sky blue White Yellow Black/Green Black/Blue Black/Red Black/White Black/Yellow Br/B Brown/Black Br/G Brown/Green Br/L Brown/Blue Br/R Brown/Red Br/W Brown/White Br/Y Brown/Yellow Green/Black Green/Blue Green/Red Green/White Green/Yellow Gy/B Gray/Black...
Page 785 FJR1300AS 2013 FJR1300AS 2013 FJR1300AS 2013 FJR1300AS 2013 FJR1300AS 2013 SCHÉMA DE CÂBLAGE WIRING DIAGRAM SCHALTPLAN SCHEMA ELETTRICO DIAGRAMA ELÉCTRICO Br/B Lg/B Lg/B Br/B (Gy) P/B O/B R/B R/B R/W Br/W O/B Br/R Lg/R Y/R R/L Br/W R/W R Br O R/B Gy/R Y/W Br/L...
Page 786 FJR1300AS 2013 FJR1300AS 2013 FJR1300AS 2013 FJR1300AS 2013 FJR1300AS 2013 SCHÉMA DE CÂBLAGE WIRING DIAGRAM SCHALTPLAN SCHEMA ELETTRICO DIAGRAMA ELÉCTRICO (Gy) D D D D E E E E (Gy) (Gy) (Gy) (Gy) PRESS PULL MODE (Gy) (Gy) (Gy) (Gy) MENU PASS (Gy)

Yamaha 2013 FJR1300AS Service Manual

Table of Contents

Specifications

Periodic Checks and Adjustments

Chassis

General Chassis

Front Wheel

Rear Wheel

Front Brake

Rear Brake

Abs (Anti-Lock Brake System)

Handlebars

Front Fork

Steering Head

Rear Shock Absorber Assembly

Swingarm

Shaft Drive

Engine

Engine Inspection

Engine Removal

Camshafts

Cylinder Head

Valves and Valve Springs

Generator and Starter Clutch

Pickup Rotor

Electric Starter

Clutch

Shift Actuator and Shift Rod

Shift Shaft

Oil Pump

Middle Gear

Crankcase

Connecting Rods and Pistons

Crankshaft

Transmission

Balancers

Quick Links

Chapters

Troubleshooting

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Summary of Contents for Yamaha 2013 FJR1300AS