Yamaha 2014 MT-07 Service Manual
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Yamaha 2014 MT-07 Service Manual

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Table of Contents

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2014
SERVICE MANUAL
MT07A
1XB-28197-E0

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Summary of Contents for Yamaha 2014 MT-07

  • Page 1 2014 SERVICE MANUAL MT07A 1XB-28197-E0...
  • Page 2 EAS20002 MT07A 2014 SERVICE MANUAL ©2014 by Yamaha Motor Co., Ltd. First edition, October 2014 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.
  • Page 3 EAS20003 IMPORTANT This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one man- ual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles.

  • Page 4: How To Use This Manual

    EAS20004 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. •...

  • Page 5: Symbols

    EAS20005 SYMBOLS The following symbols are used in this manual for easier understanding. The following symbols are not relevant to every vehicle. SYMBOL DEFINITION SYMBOL DEFINITION Serviceable with engine mounted Gear oil Filling fluid Molybdenum disulfide oil Lubricant Brake fluid Special tool Wheel bearing grease Tightening torque...

  • Page 7: Table Of Contents

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

  • Page 9: General Information

    GENERAL INFORMATION IDENTIFICATION .................... 1-1 VEHICLE IDENTIFICATION NUMBER .............1-1 MODEL LABEL..................1-1 FEATURES...................... 1-2 OUTLINE OF THE FI SYSTEM..............1-2 FI SYSTEM....................1-3 OUTLINE OF THE ABS................1-4 ABS COMPONENT FUNCTIONS ............. 1-8 ABS OPERATION ...................1-13 ABS WARNING LIGHT AND OPERATION..........1-16 MULTI-FUNCTION METER UNIT ............1-18 IMPORTANT INFORMATION ...............

  • Page 10: Identification

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

  • Page 11: Features

    FEATURES EAS20008 FEATURES EAS30005 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 EAS30617 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 a certain level. 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: Abs Layout

    EAS30683 OUTLINE OF THE ABS 1. The Yamaha ABS (anti-lock brake system) features an electronic control system, which acts on the front and rear brakes independently. 2. The ABS features a compact and lightweight design to help maintain the basic maneuverability of the vehicle.
  • Page 14 FEATURES 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. When wheel lock is detected during emergency braking, hydraulic control is performed by the hydraulic system on the front and rear brakes independently.
  • Page 15 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 16 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 17: Abs Component Functions

    FEATURES ABS block diagram 1. Rear brake master cylinder 9. Buffer chamber 2. Hydraulic unit assembly 10. Rear brake caliper 3. Front brake master cylinder 11. Rear wheel sensor 4. Inlet solenoid valve 12. ABS warning light 5. ABS motor 13.
  • Page 18 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 to check the electrical circuit and the system function (ABS self-diagnosis), and goes off when the vehicle is operated (the function check is properly completed at a speed of about 6 to 10 km/h [3.8 to 6.3 mi/h]).
  • Page 19 FEATURES 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 according to signals transmitted from the ABS ECU.
  • Page 20 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 cylinder side) and the brake fluid in the lower brake lines (brake caliper side).
  • Page 21 25. ECU (engine control unit) 12. Tail/brake light 26. Front wheel sensor 13. Yamaha diagnostic tool coupler 27. Rear wheel sensor 14. Hydraulic unit assembly The necessary actions are confirmed using the monitor circuit and control signals are transmitted to the hydraulic unit assembly.

  • Page 22: Abs Operation

    FEATURES • The ABS performs a self-diagnosis test for a few seconds each time the vehicle first starts off after the main switch was turned on. During this test, a “clicking” noise can be heard from under the seat, and if the brake lever or brake pedal is even slightly operated, a vibration can be felt at the lever and pedal, but these do not indicate a malfunction.
  • Page 23 FEATURES 1. Brake master cylinder 8. Brake caliper 2. Brake light switch 9. Wheel sensor 3. ABS motor 10. ABS ECU 4. Hydraulic pump 11. ABS warning light 5. Buffer chamber 12. Brake fluid pressure 6. Outlet solenoid valve 13. Time 7.
  • Page 24 FEATURES 1. Brake master cylinder 8. Brake caliper 2. Brake light switch 9. Wheel sensor 3. ABS motor 10. ABS ECU 4. Hydraulic pump 11. ABS warning light 5. Buffer chamber 12. Brake fluid pressure 6. Outlet solenoid valve 13. Time 7.

  • Page 25: Abs Warning Light And Operation

    FEATURES 1. Brake master cylinder 8. Brake caliper 2. Brake light switch 9. Wheel sensor 3. ABS motor 10. ABS ECU 4. Hydraulic pump 11. ABS warning light 5. Buffer chamber 12. Brake fluid pressure 6. Outlet solenoid valve 13. Time 7.
  • Page 26 FEATURES ABS function EWA16520 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. When the ABS is activated, the grip between the road surface and tires is close to the limit.

  • Page 27: Multi-Function Meter Unit

    FEATURES EAS30982 MULTI-FUNCTION METER UNIT • Be sure to turn the key to “ON” before using the left and right set buttons except for setting the brightness control mode. • For the U.K. only: To switch the speedometer and multi-function display between kilometers and miles, set the multi-function display to the odometer mode or a tripmeter mode, and then press the left set button for at least three sec-...
  • Page 28 FEATURES The clock displays when the key is turned to Eco indicator “ON”. In addition, the clock can be displayed for 10 seconds by pushing the left set button when the main switch is in the “OFF”, “LOCK” or “ ”...
  • Page 29 FEATURES Multi-function display If the fuel level warning indicator “ ” and left segment of the fuel meter start flashing, the dis- play automatically changes to the fuel reserve tripmeter mode “TRIP F” and starts counting the distance traveled from that point. In that case, push the left set button to switch the display be- tween the various tripmeter, odometer, instanta- neous fuel consumption and average fuel...
  • Page 30 FEATURES To switch between the instantaneous fuel con- Coolant temperature display sumption displays, push the left set button for one second when one of the displays is shown. If traveling at speeds under 20 km/h (12 mi/h), “_ _._” is displayed. Average fuel consumption mode 1.
  • Page 31 FEATURES Self-diagnosis device 2. If the engine starts, turn it off and try starting the engine with the standard keys. 3. If one or both of the standard keys do not start the engine, take the vehicle, the code re-reg- istering key and both standard keys.

  • Page 32: Important Information

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

  • Page 33: Bearings And Oil Seals

    IMPORTANT INFORMATION EAS30010 EAS30012 BEARINGS AND OIL SEALS RUBBER PARTS Install bearings “1” and oil seals “2” so that the Check rubber parts for deterioration during in- manufacturer 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 34: Basic Service Information

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

  • Page 35: Electrical System

    BASIC SERVICE INFORMATION ECA16760 EAS30014 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 36 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 37 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 38 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 39: Special Tools

    8-134, 8-135, 8-135, 8-137, 8-137, 8-138, 8-139, 8-140, 8-140, 8-141, 8-141 Thickness gauge 3-6, 4-25, 4-34, 90890-03180 5-55 Feeler gauge set YU-26900-9 Valve lapper 90890-04101 Valve lapping tool YM-A8998 Yamaha diagnostic tool 3-8, 4-67, 4-68, 90890-03231 5-2, 8-36, 8-95, 8-116 1-30...
  • Page 40 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Vacuum gauge 90890-03094 Vacuummate YU-44456 YU-44456 Carburetor angle driver 2 90890-03173 Steering nut wrench 3-19, 4-89 90890-01403 Exhaust flange nut wrench YU-A9472 Oil filter wrench 3-22 90890-01426 Oil filter wrench YU-38411 Pressure gauge 3-23, 7-16, 7-17 90890-03153 Pressure gauge...
  • Page 41 90890-03081 Engine compression tester YU-33223 YU-33223 Rotor holding tool 5-17, 5-21 90890-01235 Universal magneto and rotor holder YU-01235 Yamaha bond No. 1215 5-24, 5-44, 5-71, 90890-85505 5-73 (Three bond No.1215®) Valve spring compressor 5-32, 5-37 90890-04019 Valve spring compressor YM-04019...
  • Page 42 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Valve spring compressor attachment 5-32, 5-37 90890-01243 Valve spring compressor adapter (26 mm) YM-01253-1 Valve guide remover (ø4.5) 5-34 90890-04116 Valve guide remover (4.5 mm) YM-04116 Valve guide installer (ø4.5) 5-34 90890-04117 Valve guide installer (4.5 mm) YM-04117 Valve guide reamer (ø4.5)
  • Page 43 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Piston pin puller set 5-77 90890-01304 Piston pin puller YU-01304 YU-01304 Piston ring compressor 5-84 90890-05158 Piston ring compressor YM-08037 Radiator cap tester 90890-01325 Mityvac cooling system tester kit YU-24460-A YU-24460-A Radiator cap tester adapter 90890-01352 Pressure tester adapter YU-33984...
  • Page 44 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Middle driven shaft bearing driver 6-12 90890-04058 Middle drive bearing installer 40 & 50 mm YM-04058 Vacuum/pressure pump gauge set 90890-06756 Mityvac brake bleeding tool YS-42423 Fuel injector pressure adapter 7-16 90890-03210 Fuel injector pressure adapter YU-03210 Fuel pressure adapter...

  • Page 45: Specifications

    SPECIFICATIONS GENERAL SPECIFICATIONS ................ 2-1 ENGINE SPECIFICATIONS ................2-2 CHASSIS SPECIFICATIONS ................2-8 ELECTRICAL SPECIFICATIONS ..............2-11 TIGHTENING TORQUES ................2-14 GENERAL TIGHTENING TORQUE SPECIFICATIONS......2-14 ENGINE TIGHTENING TORQUES............2-15 CHASSIS TIGHTENING TORQUES............2-20 LUBRICATION POINTS AND LUBRICANT TYPES ........2-24 ENGINE....................2-24 LUBRICATION SYSTEM CHART AND DIAGRAMS........2-25 ENGINE OIL LUBRICATION CHART .............2-25 LUBRICATION DIAGRAMS ..............

  • Page 46: General Specifications

    GENERAL SPECIFICATIONS EAS20013 GENERAL SPECIFICATIONS Model Model 1XB1 (BEL)(CHE)(CZE)(DNK)(FIN)(GBR)(GRC)(HU N)(IRL)(NLD)(NOR)(POL)(PRT)(SVK)(SVN)(S WE)(TUR)(ZAF) 1XB2 (BEL)(CHE)(CZE)(DNK)(FIN)(GBR)(GRC)(HU N)(IRL)(NLD)(NOR)(POL)(PRT)(SVK)(SVN)(S WE)(TUR)(ZAF) 1XB5 (BEL)(CHE)(CZE)(DNK)(FIN)(GBR)(GRC)(HU N)(IRL)(NLD)(NOR)(POL)(PRT)(SVK)(SVN)(S WE)(TUR)(ZAF) 1XB6 (BEL)(CHE)(CZE)(DNK)(FIN)(GBR)(GRC)(HU N)(IRL)(NLD)(NOR)(POL)(PRT)(SVK)(SVN)(S WE)(TUR)(ZAF) 1XB7 (BEL)(CHE)(CZE)(DNK)(FIN)(GBR)(GRC)(HU N)(IRL)(NLD)(NOR)(POL)(PRT)(SVK)(SVN)(S WE)(TUR)(ZAF) 1XB8 (BEL)(CHE)(CZE)(DNK)(FIN)(GBR)(GRC)(HU N)(IRL)(NLD)(NOR)(POL)(PRT)(SVK)(SVN)(S WE)(TUR)(ZAF) Dimensions Overall length 2085 mm (82.1 in) Overall width 745 mm (29.3 in) Overall height 1090 mm (42.9 in)

  • Page 47: Engine Specifications

    ENGINE SPECIFICATIONS EAS20014 ENGINE SPECIFICATIONS Engine Engine type Liquid cooled 4-stroke, DOHC Displacement 689 cm³ Cylinder arrangement Inline 2-cylinder Bore × stroke 80.0 × 68.6 mm (3.15 × 2.70 in) Compression ratio 11.5 : 1 Standard compression pressure (at sea level) #1 880 kPa/355 r/min (8.8 kgf/cm²/355 r/min, 125.2 psi/355 r/min) #2 790 kPa/355 r/min (7.9 kgf/cm²/355 r/min,...
  • Page 48 ENGINE SPECIFICATIONS Relief valve operating pressure 630.0–810.0 kPa (6.30–8.10 kgf/cm², 91.4– 117.5 psi) Cooling system Radiator capacity (including all routes) 1.60 L (1.69 US qt, 1.41 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 108.0–137.4 kPa (1.08–1.37 kgf/cm², 15.7–19.9 psi)
  • Page 49 ENGINE SPECIFICATIONS Valve dimensions Valve head diameter (intake) 31.40–31.60 mm (1.2362–1.2441 in) Valve head diameter (exhaust) 26.40–26.60 mm (1.0394–1.0472 in) Valve seat contact width (intake) 0.90–1.10 mm (0.0354–0.0433 in) Valve seat contact width (exhaust) 0.90–1.10 mm (0.0354–0.0433 in) Valve stem diameter (intake) 4.475–4.490 mm (0.1762–0.1768 in) Limit 4.445 mm (0.1750 in)
  • Page 50 ENGINE SPECIFICATIONS Piston-pin-to-piston-pin-bore clearance 0.009–0.025 mm (0.0004–0.0010 in) Limit 0.075 mm (0.0030 in) Piston ring Top ring Ring type Barrel End gap (installed) 0.15–0.25 mm (0.0059–0.0098 in) Limit 0.50 mm (0.0197 in) Ring side clearance 0.030–0.065 mm (0.0012–0.0026 in) Limit 0.115 mm (0.0045 in) 2nd ring Ring type...
  • Page 51 ENGINE SPECIFICATIONS Transmission Transmission type Constant mesh 6-speed Primary reduction ratio 1.925 (77/40) Final drive Chain Secondary reduction ratio 2.688 (43/16) Operation Left foot operation Gear ratio 2.846 (37/13) 2.125 (34/16) 1.632 (31/19) 1.300 (26/20) 1.091 (24/22) 0.964 (27/28) Main axle runout limit 0.08 mm (0.0032 in) Drive axle runout limit 0.08 mm (0.0032 in)
  • Page 52 ENGINE SPECIFICATIONS Intake vacuum 29.8–32.4 kPa (224–243 mmHg, 8.8–9.6 inHg) Water temperature 85.0–105.0 °C (185.00–221.00 °F) Oil temperature 60.0–80.0 °C (140.00–176.00 °F) Throttle grip free play 3.0–5.0 mm (0.12–0.20 in)

  • Page 53: Chassis Specifications

    CHASSIS SPECIFICATIONS EAS20015 CHASSIS SPECIFICATIONS Chassis Frame type Diamond Caster angle 24.80 ° Trail 90 mm (3.5 in) Front wheel Wheel type Cast wheel Rim size 17M/C x MT3.50 Rim material Aluminum Wheel travel 130 mm (5.1 in) Radial wheel runout limit 1.0 mm (0.04 in) Lateral wheel runout limit 0.5 mm (0.02 in)
  • Page 54 CHASSIS SPECIFICATIONS Brake pad lining thickness (inner) 4.5 mm (0.18 in) Limit 0.5 mm (0.02 in) Brake pad lining thickness (outer) 4.5 mm (0.18 in) Limit 0.5 mm (0.02 in) Master cylinder inside diameter 15.00 mm (0.59 in) Caliper cylinder inside diameter 30.23 mm (1.19 in) Caliper cylinder inside diameter 27.00 mm (1.06 in)
  • Page 55 CHASSIS SPECIFICATIONS Enclosed gas/air pressure (STD) 980 kPa (9.8 kgf/cm², 139.4 psi) Spring preload adjusting positions Minimum Standard Maximum Drive chain Type/manufacturer 525VAZ/DAIDO Number of links 15-link length limit 239.3 mm (9.42 in) Drive chain slack 51.0–56.0 mm (2.01–2.20 in) Limit 58.0 mm (2.28 in) 2-10...

  • Page 56: Electrical Specifications

    ELECTRICAL SPECIFICATIONS EAS20016 ELECTRICAL SPECIFICATIONS Voltage System voltage 12 V Ignition system Ignition system Ignition timing (B.T.D.C.) 10.0 °/1200 r/min Engine control unit Model/manufacturer TBDFH8/DENSO Ignition coil Minimum ignition spark gap 6.0 mm (0.24 in) 1.19–1.61 Ω Primary coil resistance Secondary coil resistance 8.50–11.50 kΩ...
  • Page 57 ELECTRICAL SPECIFICATIONS Oil pressure warning light High beam indicator light Coolant temperature warning light Engine trouble warning light ABS warning light Immobilizer system indicator light Electric starting system System type Constant mesh Starter motor Power output 0.50 kW 0.0150–0.0250 Ω Armature coil resistance Brush overall length 12.0 mm (0.47 in)
  • Page 58 ELECTRICAL SPECIFICATIONS Spare fuse 2.0 A 2-13...

  • Page 59: Tightening Torques

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

  • Page 60: Engine Tightening Torques

    TIGHTENING TORQUES EAS30016 ENGINE TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Exhaust pipe nut 20 Nm (2.0 m·kgf, 14 ft·lbf) Cylinder head stud bolt (exhaust 15 Nm (1.5 m·kgf, 11 ft·lbf) pipe) Muffler bracket bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Muffler bracket bolt 20 Nm (2.0 m·kgf, 14 ft·lbf) Muffler cover bolt...
  • Page 61 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Stake. Clutch boss nut 95 Nm (9.5 m·kgf, 69 ft·lbf) Clutch spring bolt 8 Nm (0.8 m·kgf, 5.8 ft·lbf) Clutch cover bolt 12 Nm (1.2 m·kgf, 8.7 ft·lbf) Clutch cable holder bolt 12 Nm (1.2 m·kgf, 8.7 ft·lbf) Oil pump drive chain guide bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
  • Page 62 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Shift drum retainer bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Radiator cap bolt 1.0 Nm (0.10 m·kgf, 0.72 ft·lbf) Coolant reservoir bolt 5 Nm (0.5 m·kgf, 3.6 ft·lbf) Radiator side cover bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Radiator fan motor bolt 8 Nm (0.8 m·kgf, 5.8 ft·lbf)
  • Page 63 TIGHTENING TORQUES 4. Loosen and retighten the cylinder head bolts “1”–“6” to 20 Nm (2.0 m·kgf, 14 ft·lbf) in the proper tight- ening sequence, and then tighten them further to reach the specified angle 90° in the proper tight- ening sequence. 5.
  • Page 64 TIGHTENING TORQUES ×8 ×2 ×3 ×2 ×6 ×6 26 27 Connecting rod bolt Tighten the connecting rod bolts to 20 Nm (2.0 m·kgf, 14 ft·lbf), and then tighten them further to reach the specified angle 175–185°. 2-19...

  • Page 65: Chassis Tightening Torques

    TIGHTENING TORQUES EAS30017 CHASSIS TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Engine mounting nut (rear upper 55 Nm (5.5 m·kgf, 40 ft·lbf) side) Engine mounting nut (rear lower 55 Nm (5.5 m·kgf, 40 ft·lbf) side) Engine mounting bolt (left front side) 75 Nm (7.5 m·kgf, 54 ft·lbf) Engine mounting bolt (left upper 55 Nm (5.5 m·kgf, 40 ft·lbf)
  • Page 66 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Rectifier/regulator bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Electrical components tray 2 nut 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Electrical components tray 2 bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Hydraulic unit assembly bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Front brake hose guide bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
  • Page 67 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Rearview mirror 17 Nm (1.7 m·kgf, 12 ft·lbf) Handlebar switch screw (right) 2.0 Nm (0.20 m·kgf, 1.4 ft·lbf) Throttle cable housing bolt 3.8 Nm (0.38 m·kgf, 2.8 ft·lbf) Handlebar switch screw (left) 2.0 Nm (0.20 m·kgf, 1.4 ft·lbf) Grip end 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
  • Page 68 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Connecting arm nut (frame side) 52 Nm (5.2 m·kgf, 38 ft·lbf) Drive sprocket cover bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Stake Drive sprocket nut 95 Nm (9.5 m·kgf, 69 ft·lbf) Shift rod locknut (shift arm side) 9 Nm (0.9 m·kgf, 6.5 ft·lbf) Left-hand...

  • Page 69: Lubrication Points And Lubricant Types

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

  • Page 70: Lubrication System Chart And Diagrams

    LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20019 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS30020 ENGINE OIL LUBRICATION CHART 2-25...
  • Page 71 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil strainer 2. Oil pump 3. Relief valve 4. Oil cooler 5. Oil filter cartridge 6. Main gallery 7. Oil pressure switch 8. Crankshaft 9. Oil nozzle 10. Balancer shaft assembly 11. Timing chain tensioner 12.

  • Page 72: Lubrication Diagrams

    LUBRICATION SYSTEM CHART AND DIAGRAMS EAS30021 LUBRICATION DIAGRAMS Crankcase, cylinder, and cylinder head (right side view) 2-27...
  • Page 73 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Timing chain tensioner 2. Intake camshaft 3. Exhaust camshaft 4. Crankshaft 5. Oil filter cartridge 6. Oil cooler 7. Oil drain bolt 8. Oil strainer 9. Oil pump 2-28...
  • Page 74 LUBRICATION SYSTEM CHART AND DIAGRAMS Crankcase and cylinder (left side view) 2-29...
  • Page 75 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Crankshaft 2. Balancer shaft assembly 3. Connecting rod 4. Oil cooler 5. Oil filter cartridge 2-30...
  • Page 76 LUBRICATION SYSTEM CHART AND DIAGRAMS Oil pump (bottom view) 2-31...
  • Page 77 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil pump 2. Oil pressure switch 3. Oil filter cartridge 4. Oil cooler 5. Oil strainer 2-32...
  • Page 78 LUBRICATION SYSTEM CHART AND DIAGRAMS Camshaft (top view) 2-33...
  • Page 79 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Intake camshaft 2. Cylinder head 3. Exhaust camshaft 2-34...
  • Page 80 LUBRICATION SYSTEM CHART AND DIAGRAMS Crankshaft (front view) 2-35...
  • Page 81 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil nozzle 2. Piston 3. Crankshaft 4. Main gallery 2-36...
  • Page 82 LUBRICATION SYSTEM CHART AND DIAGRAMS Crankshaft and transmission (top view) 2-37...
  • Page 83 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Balancer shaft assembly 2. Crankshaft 3. Main axle 4. Drive axle 2-38...

  • Page 84: Cooling System Diagrams

    COOLING SYSTEM DIAGRAMS EAS20020 COOLING SYSTEM DIAGRAMS 2-39...
  • Page 85 COOLING SYSTEM DIAGRAMS 1. Thermostat 2. Oil cooler inlet hose 3. Oil cooler 4. Oil cooler outlet hose 5. Water jacket joint inlet hose 6. Water pump outlet pipe 7. Water pump inlet pipe 8. Radiator outlet hose 9. Water jacket joint 10.

  • Page 86: Cable Routing

    CABLE ROUTING EAS20021 CABLE ROUTING Handlebar (front view) 2-41...
  • Page 87 CABLE ROUTING 1. Throttle cable (decelerator cable) L. Face the damper on the holder toward the front brake master cylinder and face the catch 2. Throttle cable (accelerator cable) of the holder downward. 3. Clutch cable M. Connect the auxiliary light coupler. 4.
  • Page 88 CABLE ROUTING Clutch cable (right side view) 2-43...
  • Page 89 CABLE ROUTING 1. Fuel tank breather hose K. Make sure that there is no slack in the fuel tank breather hose or fuel tank overflow hose. 2. Fuel tank overflow hose 3. Intake solenoid coupler 4. Brake hose (hydraulic unit to left front brake caliper) 5.
  • Page 90 CABLE ROUTING Rectifier/regulator (left side view) J 14 2-45...
  • Page 91 CABLE ROUTING 1. Wire harness I. Make sure that the throttle cables do not twist between the throttle body assembly and the 2. Intake air temperature sensor coupler steering head pipe. 3. Fuel pump coupler J. Route the headlight lead to the rear of the 4.
  • Page 92 CABLE ROUTING Engine (left side view) I 10 2-47...
  • Page 93 2. Tail/brake light assembly coupler M. Insert the projection on the coupler into the 3. Yamaha diagnostic tool coupler hole in the bracket. 4. License plate light coupler N. Fit the starter motor lead between the bottom 5.
  • Page 94 CABLE ROUTING Frame (top view) 35 N 33 L 2-49...
  • Page 95 36. Rectifier/regulator bracket 37. Battery 38. Battery box 39. Lean angle sensor lead 40. Yamaha diagnostic tool coupler lead 41. Rear left turn signal light lead 42. Rear right turn signal light lead 43. Seat lock cable 44. License plate light lead 45.
  • Page 96 CABLE ROUTING Rear fender (top view) 2-51...
  • Page 97 CABLE ROUTING 1. Battery band 2. Wire harness 3. Positive battery lead 4. Negative battery lead 5. Fuse box 1 6. Fuse box 2 7. Lean angle sensor 8. Rear turn signal light lead (left turn signal light) 9. Rear turn signal light lead (right turn signal light) 10.
  • Page 98 CABLE ROUTING Rear fender (left side view) 2-53...
  • Page 99 CABLE ROUTING 1. Seat lock cable 2. License plate light lead 3. Rear turn signal light lead (right turn signal light) 4. Tail/brake light assembly lead 5. Tail/brake light assembly 6. Rear turn signal light lead (left turn signal light) 7.
  • Page 100 CABLE ROUTING Rear brake hose (right side view) 2-55...
  • Page 101 CABLE ROUTING 1. Rear wheel sensor lead 2. Rear brake fluid reservoir hose 3. Brake hose (rear brake master cylinder to hydraulic unit) 4. Brake hose (hydraulic unit to rear brake caliper) 5. O sensor lead 6. Rear brake light switch lead A.
  • Page 102 CABLE ROUTING Front brake hose (left and right side view) 2-57...
  • Page 103 CABLE ROUTING 1. Brake hose (hydraulic unit to left front brake caliper) 2. Front wheel sensor lead 3. Brake hose (left front brake caliper to right front brake caliper) 4. Brake hose (front brake master cylinder to hydraulic unit) A. Make sure that there is no slack in the front wheel sensor lead and that the lead is not pinched between the headlight unit side cover (right) and the brake hose (hydraulic unit to...
  • Page 104 CABLE ROUTING Hydraulic unit assembly (top and right side view) 2-59...
  • Page 105 CABLE ROUTING 1. Brake hose (rear brake master cylinder to hydraulic unit) 2. Brake hose (front brake master cylinder to hydraulic unit) 3. Brake hose (hydraulic unit to left front brake caliper) 4. Brake hose (hydraulic unit to rear brake caliper) A.
  • Page 106 CABLE ROUTING Fuel tank (left side view) 2-61...
  • Page 107 CABLE ROUTING 1. Fuel tank 2. Fuel hose 3. Fuel tank breather hose 4. Fuel tank overflow hose A. Face the blue paint mark on the fuel tank breather hose to the right. Install the hose up to the wide portion of the pipe. B.
  • Page 108 CABLE ROUTING Throttle bodies (top view) 2-63...
  • Page 109 CABLE ROUTING 1. Air filter case 2. Fuel hose 3. Surge tank hose 4. Surge tank 5. Intake solenoid 6. Intake solenoid vacuum hose (one-way valve to intake solenoid) 7. One-way valve 8. Intake solenoid vacuum hose (throttle body to one-way valve) 9.
  • Page 110 CABLE ROUTING Air filter case (left and right side view) 2-65...
  • Page 111 CABLE ROUTING 1. Throttle cable (accelerator cable) N. Face the blue paint mark on the surge tank hose downward. 2. Throttle cable (decelerator cable) O. Install the hose up to the bend in the hose 3. Intake air pressure sensor fitting.
  • Page 112 CABLE ROUTING Radiator (front view) 2-67...
  • Page 113 CABLE ROUTING 1. Radiator 2. Radiator cap 3. Coolant reservoir hose 4. Radiator inlet hose 5. Coolant reservoir 6. Radiator outlet hose A. Connect the end of the coolant reservoir hose that is identified by the white paint mark to the radiator.
  • Page 114 CABLE ROUTING Radiator (left side view) 2-69...
  • Page 115 CABLE ROUTING 1. Coolant reservoir hose 2. Radiator inlet hose 3. Thermostat housing 4. Oil cooler inlet hose 5. Coolant reservoir breather hose 6. Coolant reservoir 7. Coolant reservoir cap 8. Radiator 9. Radiator cap 10. AC magneto lead 11. Horn lead A.
  • Page 116 CABLE ROUTING Radiator (right side view) 2-71...
  • Page 117 CABLE ROUTING 1. Radiator inlet hose 2. Coolant reservoir hose 3. Radiator cap 4. Radiator 5. Coolant reservoir 6. Coolant reservoir breather hose 7. Radiator outlet hose 8. Oil cooler inlet hose A. Align the plastic locking tie with the white paint marks on the radiator inlet hose and coolant reservoir hose.
  • Page 118 CABLE ROUTING 2-73...

  • Page 119: 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 ..........3-8 SYNCHRONIZING THE THROTTLE BODIES..........
  • Page 120 CHECKING AND LUBRICATING THE CABLES ........3-27 CHECKING THE THROTTLE GRIP OPERATION .........3-27 CHECKING AND CHARGING THE BATTERY........3-28 CHECKING THE FUSES ................3-28 REPLACING THE HEADLIGHT BULB............3-28 ADJUSTING THE HEADLIGHT BEAM ...........3-29...

  • Page 122: 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 123 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 for cracks or damage. √ √ √ √ √...
  • Page 124 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) Moving parts and √ √ √ √ √ • Lubricate. cables •...

  • Page 125: Checking The Fuel Line

    PERIODIC MAINTENANCE EAS30619 CHECKING THE FUEL LINE The following procedure applies to all of the fuel, vacuum and breather hoses. 1. Remove: • Rider seat Refer to “GENERAL CHASSIS (1)” on page 4-1. • Fuel tank top cover • Fuel tank cover (left) •...

  • Page 126: Adjusting The Valve Clearance

    PERIODIC MAINTENANCE 3. Check: • Fuel tank top cover • Spark plug type Refer to “GENERAL CHASSIS (4)” on page Incorrect → Change. 4-11. • Rider seat Manufacturer/model Refer to “GENERAL CHASSIS (1)” on page NGK/LMAR8A-9 4-1. 4. Check: EAS30622 ADJUSTING THE VALVE CLEARANCE •...
  • Page 127 PERIODIC MAINTENANCE 5. Measure: • Valve clearance Out of specification → Adjust. Valve clearance (cold) Intake 0.11–0.20 mm (0.0043–0.0079 in) Exhaust 0.24–0.30 mm (0.0094–0.0118 in) ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼...
  • Page 128 PERIODIC MAINTENANCE d. Calculate the sum of the values obtained in Valve lapper steps (b) and (c) to determine the required 90890-04101 valve pad thickness and the valve pad num- Valve lapping tool ber. YM-A8998 Example: 1.58 mm (0.0622 in) + 0.05 mm (0.0020 in) = 1.63 mm (0.0641 in) •...

  • Page 129: Checking The Engine Idling Speed

    ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect the Yamaha diagnostic tool. ing chain and camshaft caps. Use the diagnostic code number “67”. Exhaust camshaft cap bolt Refer to “SELF-DIAGNOSTIC FUNCTION 10 Nm (1.0 m·kgf, 7.2 ft·lbf) AND DIAGNOSTIC CODE TABLE” on page Intake camshaft cap bolt 9-5.
  • Page 130 PERIODIC MAINTENANCE • Fuel tank Engine idling speed Refer to “FUEL TANK” on page 7-1. 1100–1300 r/min 3. Disconnect: • Intake solenoid vacuum hose (throttle body to b. Check the vacuum pressure. one way valve) • Intake air pressure sensor hose The difference in vacuum pres- Refer to “THROTTLE BODIES”...

  • Page 131: Checking The Throttle Body Joints

    PERIODIC MAINTENANCE EAS30798 CHECKING THE THROTTLE BODY JOINTS 1. Remove: • Rider seat Refer to “GENERAL CHASSIS (1)” on page 4-1. • Fuel tank top cover • Fuel tank cover (left) • Fuel tank cover (right) • Fuel tank center cover •...

  • Page 132: Replacing The Air Filter Element And

    PERIODIC MAINTENANCE EAS31130 REPLACING THE AIR FILTER ELEMENT AND CLEANING THE CHECK HOSE There is an air filter check hose “1” at the bottom of the air filter case. If dust and/or water collects in this hose, clean the air filter check hose and replace the air filter element.

  • Page 133: Adjusting The Clutch Lever Free Play

    PERIODIC MAINTENANCE b. Turn the adjusting nut “2” in direction “a” or “b” EAS30629 ADJUSTING THE CLUTCH LEVER FREE until the specified clutch lever free play is ob- PLAY tained. 1. Check: • Clutch lever free play “a” Direction “a” Out of specification →...

  • Page 134: Checking The Front Brake Pads

    PERIODIC MAINTENANCE Position #1 Distance “a” is the largest. Position #5 Distance “a” is the smallest. EAS30631 ADJUSTING THE REAR DISC BRAKE 1. Adjust: • Brake pedal position ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼...

  • Page 135: Checking The Rear Brake Pads

    PERIODIC MAINTENANCE Refer to “FRONT BRAKE” on page 4-35, “REAR BRAKE” on page 4-49 and “ABS (AN- TI-LOCK BRAKE SYSTEM )” on page 4-62. EAS30893 BLEEDING THE HYDRAULIC BRAKE SYSTEM (ABS) EWA14000 WARNING Always bleed the brake system when the brake related parts are removed.

  • Page 136: Checking The Brake Fluid Level

    PERIODIC MAINTENANCE Brake caliper bleed screw 5 Nm (0.5 m·kgf, 3.6 ft·lbf) m. Fill the brake master cylinder reservoir or brake fluid reservoir to the proper level with the specified brake fluid. Refer to “CHECKING THE BRAKE FLUID LEVEL” on page 3-15. EWA13110 WARNING After bleeding the hydraulic brake system,...

  • Page 137: Checking The Wheels

    PERIODIC MAINTENANCE EWA13090 WARNING • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. • Refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake performance.

  • Page 138: Checking The Wheel Bearings

    1. Check: en if a tire combination other than one • Swingarm operation Swingarm not working properly → Check the approved by Yamaha is used on this vehicle. swingarm. Front tire Refer to “SWINGARM” on page 4-95. Size 2.
  • Page 139 PERIODIC MAINTENANCE arm or cause an accident. Therefore, keep the drive chain slack within the specified lim- its. 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. Place the vehicle on a suitable stand so that the 5.

  • Page 140: Lubricating The Drive Chain

    PERIODIC MAINTENANCE EAS30803 LUBRICATING THE DRIVE CHAIN The drive chain consists of many interacting parts. If the drive chain is not maintained proper- ly, it will wear out quickly. Therefore, the drive chain should be serviced, especially when the vehicle is used in dusty areas. This vehicle has a drive chain with small rubber O-rings between each side plate.

  • Page 141: Checking The Fasteners

    PERIODIC MAINTENANCE EAS30647 EAS30653 CHECKING THE FASTENERS CHECKING THE FRONT FORK 1. Check: 1. Stand the vehicle on a level surface. • Fasteners EWA13120 WARNING Damage/pitting → Replace. Securely support the vehicle so that there is Refer to “GENERAL CHASSIS (1)” on page no danger of it falling over.

  • Page 142: Checking The Connecting Arm And Relay Arm

    PERIODIC MAINTENANCE ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ 2. Start the engine, warm it up for several min- a. Adjust the spring preload with the special utes, and then turn it off. wrench “1”...

  • Page 143: Changing The Engine Oil

    PERIODIC MAINTENANCE 4. Start the engine, warm it up for several min- utes, and then turn it off. 5. Check the engine oil level again. Before checking the engine oil level, wait a few minutes until the oil has settled. EAS30657 CHANGING THE ENGINE OIL 1.

  • Page 144: Measuring The Engine Oil Pressure

    PERIODIC MAINTENANCE 8. Install: • Engine oil filler cap (along with the O-ring 9. Start the engine, warm it up for several min- utes, and then turn it off. 10.Check: • Engine (for engine oil leaks) 11.Check: • Engine oil level 5.

  • Page 145: Checking The Coolant Level

    PERIODIC MAINTENANCE EAS30812 CHECKING THE COOLING SYSTEM Main gallery bolt 1. Check: 8 Nm (0.8 m·kgf, 5.8 ft·lbf) • Radiator “1” • Radiator inlet hose “2” • Radiator outlet hose “3” Lubricate the O-ring with a thin coat of lithium- •...
  • Page 146 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 147: Checking The Front Brake Light Switch

    PERIODIC MAINTENANCE EWA13040 WARNING • If coolant splashes in your eyes, thorough- ly wash them with water and consult a doc- tor. • If coolant splashes on your clothes, quickly wash it away with water and then with soap and water. •...

  • Page 148: Checking And Lubricating The Cables

    PERIODIC MAINTENANCE Recommended lubricant Suitable cable lubricant With the engine stopped, turn the throttle grip slowly and release it. Make sure that the throttle grip turns smoothly and returns properly when released. Repeat this check with the handlebar turned all the way to the left and right.

  • Page 149: Checking And Charging The Battery

    PERIODIC MAINTENANCE EAS30816 CHECKING AND CHARGING THE BATTERY Refer to “CHECKING AND CHARGING THE BATTERY” on page 8-128. EAS30662 CHECKING THE FUSES Refer to “CHECKING THE FUSES” on page 8-127. EAS30665 REPLACING THE HEADLIGHT BULB 1. Remove: • Headlight assembly bolts “1” If the specified throttle grip free play cannot be obtained on the throttle body side of the cable, use the adjusting nut on the handlebar side.

  • Page 150: Adjusting The Headlight Beam

    PERIODIC MAINTENANCE 4. Unhook: 10.Install: • Headlight bulb holder “1” • Headlight assembly “1” 5. Remove: • Headlight bulb “2” Fit the projections “a” on the headlight bracket into the holes “b” in the headlight assembly. EWA13320 WARNING 11.Install: Since the headlight bulb gets extremely hot, •...
  • Page 151 PERIODIC MAINTENANCE ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Turn the adjusting screw “1” in direction “b” or “c”. To adjust the headlight beam (vertically), insert Direction “b” a crosshead screwdriver into the hole “a”...
  • Page 152 PERIODIC MAINTENANCE 3-31...

  • Page 153: Chassis

    CHASSIS GENERAL CHASSIS (1) ................. 4-1 INSTALLING THE RIDER SEAT............... 4-2 INSTALLING THE PASSENGER SEAT............ 4-2 GENERAL CHASSIS (2) ................. 4-3 REMOVING THE CENTER COVER ............4-5 INSTALLING THE CENTER COVER............4-5 REMOVING THE UPPER TAIL COVER ........... 4-5 INSTALLING THE UPPER TAIL COVER..........4-5 REMOVING THE REAR SIDE COVERS ..........
  • Page 154 REAR WHEEL ....................4-26 REMOVING THE REAR WHEEL (DISC BRAKE)........4-30 DISASSEMBLING THE REAR WHEEL ..........4-30 CHECKING THE REAR WHEEL............. 4-30 CHECKING THE REAR WHEEL DRIVE HUB ........4-30 CHECKING AND REPLACING THE REAR WHEEL SPROCKET ..4-31 MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR ..................
  • Page 155 FRONT FORK....................4-75 REMOVING THE FRONT FENDER SIDE COVERS AND FRONT FORK LEGS................4-80 DISASSEMBLING THE FRONT FORK LEGS ........4-80 CHECKING THE FRONT FORK LEGS ..........4-81 ASSEMBLING THE FRONT FORK LEGS ..........4-81 INSTALLING THE FRONT FORK LEGS AND FRONT FENDER SIDE COVERS ............

  • Page 156: General Chassis (1)

    GENERAL CHASSIS (1) EAS20026 GENERAL CHASSIS (1) Removing the seats and battery 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 2.2 Nm (0.22 m kgf, 1.6 ft Ibf) •...

  • Page 157: Installing The Rider Seat

    GENERAL CHASSIS (1) EAS31125 INSTALLING THE RIDER SEAT 1. Install: • Rider seat “1” Rider seat bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Fit the slot “a” in the rider seat onto the projection “b” on the rider seat bracket as shown, and then place the seat in the original position.

  • Page 158: General Chassis (2)

    GENERAL CHASSIS (2) EAS20155 GENERAL CHASSIS (2) Removing the covers, tail/brake light assembly, and mudguard 1.5 Nm (0.15 m kgf, 1.1 ft Ibf) 16 Nm (1.6 m kgf, 12 ft Ibf) • • • • 3.3 Nm (0.33 m kgf, 2.4 ft Ibf) •...
  • Page 159 GENERAL CHASSIS (2) Removing the covers, tail/brake light assembly, and mudguard 1.5 Nm (0.15 m kgf, 1.1 ft Ibf) 16 Nm (1.6 m kgf, 12 ft Ibf) • • • • 3.3 Nm (0.33 m kgf, 2.4 ft Ibf) • •...

  • Page 160: Removing The Center Cover

    GENERAL CHASSIS (2) EAS31094 REMOVING THE CENTER COVER 1. Remove: • Center cover “1” ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remove the center cover screws “2”. b. Unhook the projections “a” on the center cov- er from the rear side covers.

  • Page 161: Installing The Rear Side Covers

    GENERAL CHASSIS (2) ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ EAS31099 EAS31127 INSTALLING THE REAR SIDE COVERS INSTALLING THE LOWER TAIL COVER...

  • Page 162: General Chassis (3)

    GENERAL CHASSIS (2) ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Fit the projections “a” on the lower fender cover into the holes “b” in the battery box. b. Install the quick fastener. ▲...
  • Page 163 GENERAL CHASSIS (3) EAS20156 GENERAL CHASSIS (3) Removing the headlight and meter assembly 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 1.3 Nm (0.13 m kgf, 0.94 ft Ibf) • • 0.8 Nm (0.08 m kgf, 0.58 ft Ibf) •...
  • Page 164 GENERAL CHASSIS (3) Removing the headlight and meter assembly 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 1.3 Nm (0.13 m kgf, 0.94 ft Ibf) • • 0.8 Nm (0.08 m kgf, 0.58 ft Ibf) • • 0.8 Nm (0.08 m kgf, 0.58 ft Ibf) •...

  • Page 165: Installing The Headlight Assembly

    GENERAL CHASSIS (3) EAS31128 INSTALLING THE HEADLIGHT ASSEMBLY 1. Install: • Headlight assembly “1” • Headlight assembly bolts “2” Headlight assembly bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) • Fit the projections “a” on the headlight bracket into the holes “b” in the headlight assembly. •...
  • Page 166 GENERAL CHASSIS (4) EAS20157 GENERAL CHASSIS (4) Removing the fuel tank covers and air scoops 1.5 Nm (0.15 m kgf, 1.1 ft Ibf) • • 4.0 Nm (0.40 m kgf, 2.9 ft Ibf) • • 1.5 Nm (0.15 m kgf, 1.1 ft Ibf) •...

  • Page 167: Removing The Fuel Tank Top Cover

    GENERAL CHASSIS (4) EAS31102 REMOVING THE FUEL TANK TOP COVER 1. Remove: • Fuel tank top cover “1” ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remove the fuel tank top cover bolt “2”. b.

  • Page 168: Removing The Fuel Tank Center Cover

    GENERAL CHASSIS (4) b. Fit the projections “e” on the fuel tank cover ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ into the holes “f” in the fuel tank center cover. EAS31107 INSTALLING THE FUEL TANK CENTER COVER...

  • Page 169: General Chassis (5)

    GENERAL CHASSIS (5) EAS20158 GENERAL CHASSIS (5) Removing the electrical components tray 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 3.8 Nm (0.38 m kgf, 2.8 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...
  • Page 170 GENERAL CHASSIS (5) Removing the electrical components tray 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 3.8 Nm (0.38 m kgf, 2.8 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...
  • Page 171 GENERAL CHASSIS (5) Removing the electrical components tray 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 3.8 Nm (0.38 m kgf, 2.8 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...

  • Page 172: Removing The Ecu (Engine Control Unit)

    GENERAL CHASSIS (5) EAS31108 REMOVING THE ECU (engine control unit) 1. Disconnect: • ECU coupler “1” While pushing the portion “a” of the ECU cou- pler, move the lock lever “b” in the direction of the arrow shown to disconnect the coupler. 2.

  • Page 173: Front Wheel

    FRONT WHEEL EAS20028 FRONT WHEEL Removing the front wheel and brake discs 40 Nm (4.0 m kgf, 29 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...
  • Page 174 FRONT WHEEL Disassembling the front wheel Order Job/Parts to remove Q’ty Remarks Oil seal Wheel bearing Spacer 4-19...

  • Page 175: Removing The Front Wheel

    FRONT WHEEL EAS30145 REMOVING THE FRONT WHEEL ECA20981 NOTICE • Keep any type of magnets (including mag- netic pick-up tools, magnetic screwdrivers, etc.) away from the front wheel sensor or front wheel sensor rotor; otherwise, the sensor or rotor may be damaged, resulting in improper performance of the ABS sys- tem.

  • Page 176: Maintenance Of The Front Wheel Sensor And Sensor Rotor

    FRONT WHEEL • Lateral wheel runout “2” 1. Check: Over the specified limits → Replace. • Front wheel sensor “1” Cracks/bends/distortion → Replace. Radial wheel runout limit Iron powder/dust → Clean. 1.0 mm (0.04 in) Lateral wheel runout limit 0.5 mm (0.02 in) 2.

  • Page 177: Assembling The Front Wheel

    FRONT WHEEL EAS30151 ASSEMBLING THE FRONT WHEEL Do not touch the surface of the wheel sensor ro- 1. Install: tor with a sharp object. • Wheel bearings • Oil seals ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼...

  • Page 178: Installing The Front Wheel (Disc Brake)

    FRONT WHEEL • Adjust the front wheel static balance with the brake disc installed. Start with the lightest weight. 1. Remove: • Balancing weight(s) 2. Find: • Front wheel’s heavy spot Place the front wheel on a suitable balancing stand. ▼...
  • Page 179 FRONT WHEEL • Front brake discs 4. Install: • Collars Front wheel sensor rotor bolt • Front wheel 8 Nm (0.8 m·kgf, 5.8 ft·lbf) • Front wheel axle LOCTITE® Front brake disc bolt Install the front wheel with the mark “a” on the 18 Nm (1.8 m·kgf, 13 ft·lbf) front tire pointing in the direction of wheel rota- LOCTITE®...
  • Page 180 FRONT WHEEL • To route the front wheel sensor lead, refer to Front brake caliper bolt “CABLE ROUTING” on page 2-41. 40 Nm (4.0 m·kgf, 29 ft·lbf) 7. Measure: Front brake hose/lead holder bolt • Distance “a” 7 Nm (0.7 m·kgf, 5.1 ft·lbf) (between the front wheel sensor rotor “1”...

  • Page 181: Rear Wheel

    REAR WHEEL EAS20029 REAR WHEEL Removing the rear wheel 105 Nm (10.5 m kgf, 76 ft lbf) 16 Nm (1.6 m kgf, 12 ft Ibf) • • • • 16 Nm (1.6 m kgf, 12 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) 22 Nm (2.2 m...
  • Page 182 REAR WHEEL Removing the rear wheel 105 Nm (10.5 m kgf, 76 ft lbf) 16 Nm (1.6 m kgf, 12 ft Ibf) • • • • 16 Nm (1.6 m kgf, 12 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) 22 Nm (2.2 m...
  • Page 183 REAR WHEEL Removing the rear brake disc and rear wheel sprocket 80 Nm (8.0 m kgf, 58 ft Ibf) • • 30 Nm (3.0 m kgf, 22 ft Ibf) • • 8 Nm (0.8 m kgf, 5.8 ft Ibf) • •...
  • Page 184 REAR WHEEL Disassembling the rear wheel Order Job/Parts to remove Q’ty Remarks Oil seal Wheel bearing Spacer 4-29...

  • Page 185: Removing The Rear Wheel (Disc Brake)

    REAR WHEEL • Rear wheel EAS30156 REMOVING THE REAR WHEEL (DISC BRAKE) Push the rear wheel forward and remove the ECA21030 NOTICE drive chain from the rear wheel sprocket. • Keep any type of magnets (including mag- netic pick-up tools, magnetic screwdrivers, etc.) away from the rear wheel sensor or rear wheel sensor rotor;...

  • Page 186: Checking And Replacing The Rear Wheel Sprocket

    REAR WHEEL ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ EAS30161 CHECKING AND REPLACING THE REAR EAS30167 WHEEL SPROCKET MAINTENANCE OF THE REAR WHEEL 1. Check: SENSOR AND SENSOR ROTOR •...

  • Page 187: Assembling The Rear Wheel

    REAR WHEEL • Install the brake disc so that the recessed por- EAS30163 ASSEMBLING THE REAR WHEEL tions of the bolt holes “b” face away from the ECA21050 hub. NOTICE • Tighten the brake disc bolts in stages and in a •...
  • Page 188 REAR WHEEL • Rear brake caliper retaining bolt • Rear brake caliper bolt • Install the rear wheel with the mark “a” on the 7. Fit the space “a” between the side plates of rear tire pointing in the direction of wheel rota- the drive chain “1”...
  • Page 189 REAR WHEEL To route the rear wheel sensor lead, refer to “CABLE ROUTING” on page 2-41. 11.Measure: • Distance “a” (between the rear wheel sensor rotor “1” and rear wheel sensor “2”) Out of specification → Check the wheel bear- ing for looseness, and the rear wheel sensor and sensor rotor installation conditions (warpage caused by overtorque, wrong in-...

  • Page 190: Front Brake

    FRONT BRAKE EAS20030 FRONT BRAKE Removing the front brake pads 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • 40 Nm (4.0 m kgf, 29 ft Ibf) • • 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • Order Job/Parts to remove Q’ty...
  • Page 191 FRONT BRAKE Removing the front brake master cylinder 1.5 Nm (0.15 m kgf, 1.1 ft Ibf) • • 1.0 Nm (0.10 m kgf, 0.72 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 6 Nm (0.6 m kgf, 4.3 ft Ibf) •...
  • Page 192 FRONT BRAKE Removing the front brake master cylinder 1.5 Nm (0.15 m kgf, 1.1 ft Ibf) • • 1.0 Nm (0.10 m kgf, 0.72 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 6 Nm (0.6 m kgf, 4.3 ft Ibf) •...
  • Page 193 FRONT BRAKE Disassembling the front brake master cylinder Order Job/Parts to remove Q’ty Remarks Brake master cylinder kit Brake master cylinder body 4-38...
  • Page 194 FRONT BRAKE Removing the front brake calipers 40 Nm (4.0 m kgf, 29 ft Ibf) • • 30 Nm (3.0 m kgf, 22 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers.
  • Page 195 FRONT BRAKE Disassembling the front brake calipers 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers. Brake pad clip Brake pad pin Brake pad spring Brake pad Brake caliper piston...

  • Page 196: Introduction

    FRONT BRAKE d. Hold the dial gauge at a right angle against EAS30168 INTRODUCTION the brake disc surface. EWA14101 e. Measure the deflection 1.5 mm (0.06 in) be- WARNING low the edge of the brake disc. Disc brake components rarely require disas- sembly.

  • Page 197: Replacing The Front Brake Pads

    FRONT BRAKE d. Measure the brake disc deflection. 3. Measure: e. If out of specification, repeat the adjustment • Brake pad wear limit “a” Out of specification → Replace the brake steps until the brake disc deflection is within specification. pads as a set.

  • Page 198: Removing The Front Brake Calipers

    FRONT BRAKE c. Tighten the bleed screw. 7. Check: • Brake lever operation Brake caliper bleed screw Soft or spongy feeling → Bleed the brake sys- 5 Nm (0.5 m·kgf, 3.6 ft·lbf) tem. Refer to “BLEEDING THE HYDRAULIC d. Install the new brake pads and a new brake BRAKE SYSTEM (ABS)”...

  • Page 199: Disassembling The Front Brake Calipers

    FRONT BRAKE c. Remove the brake caliper piston dust seals and brake caliper piston seals. d. Repeat the previous steps to force out the right side pistons from the brake caliper. ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲...

  • Page 200: Assembling The Front Brake Calipers

    FRONT BRAKE EAS30174 ASSEMBLING THE FRONT BRAKE CALIPERS EWA13621 WARNING • Before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. • Never use solvents on internal brake com- ponents as they will cause the brake caliper piston dust seals and brake caliper piston seals to swell and distort.

  • Page 201: 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. 4. Bleed: • Brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM (ABS)” on page 3-14. 5. Check: •...

  • Page 202: Installing The Front Brake Master Cylinder

    FRONT BRAKE • Attach the brake hose so that its angle is 15° to Specified brake fluid 25° against the straight line in parallel with the DOT 4 ceiling plane of the master cylinder. • While holding the brake hose, tighten the union EAS30182 bolt as shown.
  • Page 203 FRONT BRAKE 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” on page 3-15. 6. Check: • Brake lever operation Soft or spongy feeling →...

  • Page 204: Rear Brake

    REAR BRAKE EAS20031 REAR BRAKE Removing the rear brake pads 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • 27 Nm (2.7 m kgf, 20 ft Ibf) • • 22 Nm (2.2 m kgf, 16 ft Ibf) • • 17 Nm (1.7 m kgf, 12 ft Ibf)
  • Page 205 REAR BRAKE Removing the rear brake master cylinder 7 Nm (0.7 m kgf, 5.1 ft Ibf) 3.8 Nm (0.38 m kgf, 2.8 ft Ibf) 30 Nm (3.0 m kgf, 22 ft Ibf) • • • • • • 5 Nm (0.5 m kgf, 3.6 ft Ibf) •...
  • Page 206 REAR BRAKE Removing the rear brake master cylinder 7 Nm (0.7 m kgf, 5.1 ft Ibf) 3.8 Nm (0.38 m kgf, 2.8 ft Ibf) 30 Nm (3.0 m kgf, 22 ft Ibf) • • • • • • 5 Nm (0.5 m kgf, 3.6 ft Ibf) •...
  • Page 207 REAR BRAKE Disassembling the rear brake master cylinder 18 Nm (1.8 m kgf, 13 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Brake master cylinder yoke Brake master cylinder kit Hose joint Bushing Brake master cylinder body 4-52...
  • Page 208 REAR BRAKE Removing the rear brake caliper 30 Nm (3.0 m kgf, 22 ft Ibf) • • 22 Nm (2.2 m kgf, 16 ft Ibf) • • 27 Nm (2.7 m kgf, 20 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Drain.
  • Page 209 REAR BRAKE Disassembling the rear brake caliper 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • 17 Nm (1.7 m kgf, 12 ft Ibf) • • 2.5 Nm (0.25 m kgf, 1.8 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Screw plug...

  • Page 210: Introduction

    REAR BRAKE EAS30183 INTRODUCTION Brake disc thickness limit EWA14101 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 211 REAR BRAKE • Brake pad spring (into the rear brake caliper) • Brake pads Always install new brake pads, brake pad insu- lators, brake pad shims, and brake pad spring as a set. ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼...

  • Page 212: Removing The Rear Brake Caliper

    REAR BRAKE 6. Check: ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Blow compressed air into the brake hose joint • Brake pedal operation opening “a” to force out the piston from the Soft or spongy feeling →...

  • Page 213: Assembling The Rear Brake Caliper

    REAR BRAKE • Brake caliper cylinder “2” Specified brake fluid Scratches/wear → Replace the brake caliper DOT 4 assembly. • Brake caliper body “3” Cracks/damage → Replace the brake caliper EAS30190 INSTALLING THE REAR BRAKE CALIPER assembly. 1. Install: • Brake fluid delivery passages •...

  • Page 214: Removing The Rear Brake Master Cylinder

    REAR BRAKE • Brake pad shims Refer to “CHECKING THE BRAKE FLUID (onto the brake pads) LEVEL” on page 3-15. • Brake pad spring (into the rear brake caliper) • Brake pads • Rear brake caliper Refer to “REPLACING THE REAR BRAKE PADS”...

  • Page 215: Assembling The Rear Brake Master Cylinder

    REAR BRAKE 3. Check: Rear brake hose/lead guide bolt • Brake fluid reservoir “1” 7 Nm (0.7 m·kgf, 5.1 ft·lbf) • Brake fluid reservoir diaphragm holder “2” Rear brake hose/lead holder bolt Cracks/damage → Replace. 5 Nm (0.5 m·kgf, 3.6 ft·lbf) •...
  • Page 216 REAR BRAKE 6. Adjust: 3. Fill: • Brake pedal position • Brake fluid reservoir Refer to “ADJUSTING THE REAR DISC (with the specified amount of the specified BRAKE” on page 3-13. brake fluid) 7. Adjust: Specified brake fluid • Rear brake light operation timing DOT 4 Refer to “ADJUSTING THE REAR BRAKE LIGHT SWITCH”...

  • Page 217: Abs (Anti-Lock Brake System)

    ABS (ANTI-LOCK BRAKE SYSTEM) EAS20170 ABS (ANTI-LOCK BRAKE SYSTEM) Removing the hydraulic unit assembly 30 Nm (3.0 m kgf, 22 ft Ibf) • • 30 Nm (3.0 m kgf, 22 ft Ibf) • • 30 Nm (3.0 m kgf, 22 ft Ibf) •...
  • Page 218 ABS (ANTI-LOCK BRAKE SYSTEM) Removing the hydraulic unit assembly 30 Nm (3.0 m kgf, 22 ft Ibf) • • 30 Nm (3.0 m kgf, 22 ft Ibf) • • 30 Nm (3.0 m kgf, 22 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...

  • Page 219: Removing The Hydraulic Unit Assembly

    ABS (ANTI-LOCK BRAKE SYSTEM) EAS31036 REMOVING THE HYDRAULIC UNIT Do not operate the brake lever and brake pedal ASSEMBLY while removing the brake hoses. ECA21090 NOTICE ECA14530 Unless necessary, avoid removing and in- NOTICE stalling the brake hoses of the hydraulic unit When removing the brake hoses, cover the assembly.
  • Page 220 ABS (ANTI-LOCK BRAKE SYSTEM) ter cylinder to hydraulic unit) “2”, and then temporarily tighten the union bolt for the Do not allow any foreign materials to enter the brake hose (hydraulic unit to left front brake hydraulic unit assembly or the brake hoses caliper).

  • Page 221: Hydraulic Unit Operation Tests

    NOTICE • For the brake line routing confirmation, use the Brake fluid may damage painted surfaces diagnosis mode of the Yamaha diagnostic tool. and plastic parts. Therefore, always clean up • Before performing the brake line routing confir- any spilt brake fluid immediately.
  • Page 222 “1”, brake pedal “2”, and again in the brake lever “1”, in this order. 6. Start the Yamaha diagnostic tool and display the diagnosis mode screen. 7. Select code No. 2, “Brake line routing confir- “ON”...
  • Page 223 • For the ABS reaction-force confirmation, use the diagnosis mode of the Yamaha diagnostic tool. For more information, refer to the opera- 6. Start the Yamaha diagnostic tool and display tion manual of the Yamaha diagnostic tool. the diagnosis mode screen.

  • Page 224: Checking The Abs Warning Light

    10.After the pulsating action has stopped in the 12.Turn the main switch to “OFF”. brake lever, it is generated in the brake pedal 13.Remove the Yamaha diagnostic tool from the “1” and continues for a few seconds. Yamaha diagnostic tool coupler, and then in- stall the protective cap.

  • Page 225: Handlebar

    HANDLEBAR EAS20033 HANDLEBAR Removing the handlebar 17 Nm (1.7 m kgf, 12 ft Ibf) • • 17 Nm (1.7 m kgf, 12 ft Ibf) • • 28 Nm (2.8 m kgf, 20 ft Ibf) • • 2.0 Nm (0.20 m kgf, 1.4 ft Ibf) •...
  • Page 226 HANDLEBAR Removing the handlebar 17 Nm (1.7 m kgf, 12 ft Ibf) • • 17 Nm (1.7 m kgf, 12 ft Ibf) • • 28 Nm (2.8 m kgf, 20 ft Ibf) • • 2.0 Nm (0.20 m kgf, 1.4 ft Ibf) •...

  • Page 227: Removing The Handlebar

    HANDLEBAR EAS30203 EAS30205 REMOVING THE HANDLEBAR INSTALLING THE HANDLEBAR 1. Stand the vehicle on a level surface. 1. Stand the vehicle on a level surface. EWA13120 EWA13120 WARNING WARNING Securely support the vehicle so that there is Securely support the vehicle so that there is no danger of it falling over.
  • Page 228 HANDLEBAR • Fit the projection “b” on the bottom of the bolt EWA13700 WARNING head into the slot “c” in the bolt hole in the Do not touch the handlebar grip until the rub- clutch lever holder. ber adhesive has fully dried. •...
  • Page 229 HANDLEBAR • There should be 1–3 mm (0.04–0.12 in) of clearance “c” between the throttle grip and the grip end. 9. Install: • Front brake master cylinder assembly Refer to “INSTALLING THE FRONT BRAKE MASTER CYLINDER” on page 4-47. 7. Install: 10.Adjust: •...

  • Page 230: Front Fork

    FRONT FORK EAS20034 FRONT FORK Removing the front fork legs 26 Nm (2.6 m kgf, 19 ft Ibf) • • 21 Nm (2.1 m kgf, 15 ft Ibf) • • 23 Nm (2.3 m kgf, 17 ft Ibf) • • 26 Nm (2.6 m kgf, 19 ft Ibf)
  • Page 231 FRONT FORK Removing the front fork legs 26 Nm (2.6 m kgf, 19 ft Ibf) • • 21 Nm (2.1 m kgf, 15 ft Ibf) • • 23 Nm (2.3 m kgf, 17 ft Ibf) • • 26 Nm (2.6 m kgf, 19 ft Ibf) •...
  • Page 232 FRONT FORK Removing the front fork legs 26 Nm (2.6 m kgf, 19 ft Ibf) • • 21 Nm (2.1 m kgf, 15 ft Ibf) • • 23 Nm (2.3 m kgf, 17 ft Ibf) • • 26 Nm (2.6 m kgf, 19 ft Ibf) •...
  • Page 233 FRONT FORK Disassembling the front fork legs 30 Nm (3.0 m kgf, 22 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front fork legs. Protector Front fork cap bolt O-ring Spacer Spring seat Fork spring...
  • Page 234 FRONT FORK Disassembling the front fork legs 30 Nm (3.0 m kgf, 22 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Damper rod Damper rod ring Rebound spring Inner tube Oil seal Washer Outer tube bushing Inner tube bushing Oil flow stopper spring Oil flow stopper Outer tube...

  • Page 235: Removing The Front Fender Side Covers And Front Fork Legs

    FRONT FORK EAS31110 REMOVING THE FRONT FENDER SIDE COVERS AND FRONT FORK LEGS The following procedure applies to both of the front fender side covers and front fork legs. 1. Remove: • Front fender side cover “1” • Front fender “2” •...

  • Page 236: Checking The Front Fork Legs

    FRONT FORK 3. Remove: EAS30208 CHECKING THE FRONT FORK LEGS • Front fork damper rod bolt “1” The following procedure applies to both of the • Copper washer front fork legs. 1. Check: While holding the damper rod with the damper •...
  • Page 237 • Inner tube’s outer surface b. Install the damper rod ring onto the damper Recommended oil rod. Yamaha fork oil 10WT Fit the damper rod ring into the damper rod 3. Install: groove so that the side of the ring with the pro- •...
  • Page 238 FRONT FORK 5. Tighten: 7. Install: • Front fork damper rod bolt “1” • Oil seal “1” (with the fork seal driver attachment “2” and Front fork damper rod bolt fork seal driver weight “3”) 30 Nm (3.0 m·kgf, 22 ft·lbf) ECA14220 LOCTITE®...

  • Page 239: Installing The Front Fork Legs And Front Fender Side Covers

    FRONT FORK 9. Install: 12.Install: • Fork spring • Dust seal “1” • Spring seat (with the fork seal driver weight “2”) • Spacer • Front fork cap bolt Fork seal driver weight 90890-01367 (along with the O-ring Replacement hammer YM-A9409-7 •...
  • Page 240 FRONT FORK Lower bracket pinch bolt Make sure that the O-ring contacts the top of the 23 Nm (2.3 m·kgf, 17 ft·lbf) lower bracket “3”. Upper bracket pinch bolt (center) 21 Nm (2.1 m·kgf, 15 ft·lbf) Upper bracket pinch bolt (left and right) 26 Nm (2.6 m·kgf, 19 ft·lbf) Front fork cap bolt...
  • Page 241 FRONT FORK ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 4-86...
  • Page 242 STEERING HEAD EAS20035 STEERING HEAD Removing the lower bracket 1st 52 Nm (5.2 m kgf, 38 ft lbf) • • 2nd 18 Nm (1.8 m kgf, 13 ft Ibf) • • 3.8 Nm (0.38 m kgf, 2.8 ft Ibf) • •...
  • Page 243 STEERING HEAD Removing the lower bracket 1st 52 Nm (5.2 m kgf, 38 ft lbf) • • 2nd 18 Nm (1.8 m kgf, 13 ft Ibf) • • 3.8 Nm (0.38 m kgf, 2.8 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...

  • Page 244: Steering Head

    STEERING HEAD b. Remove the bearing race “3” from the lower EAS30213 REMOVING THE LOWER BRACKET bracket with a floor chisel “4” and hammer. 1. Stand the vehicle on a level surface. c. Install a new dust seal and new bearing rac- EWA13120 WARNING ECA14270...
  • Page 245 STEERING HEAD • Make sure that the projection “b” on the front brake hose lower holder fits into the hole in the Face the holes “a” in the lower bracket cap rear- front brake hose upper holder. ward. 3. Install: •...

  • Page 246: Rear Shock Absorber Assembly

    REAR SHOCK ABSORBER ASSEMBLY EAS20036 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 44 Nm (4.4 m kgf, 32 ft Ibf) • • 40 Nm (4.0 m kgf, 29 ft Ibf) •...
  • Page 247 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 44 Nm (4.4 m kgf, 32 ft Ibf) • • 40 Nm (4.0 m kgf, 29 ft Ibf) • • 40 Nm (4.0 m kgf, 29 ft Ibf)

  • Page 248: Handling The Rear Shock Absorber

    REAR SHOCK ABSORBER ASSEMBLY EAS30826 HANDLING THE REAR SHOCK ABSORBER Place the vehicle on a suitable stand so that the EWA13740 WARNING rear wheel is elevated. This rear shock absorber contains highly compressed nitrogen gas. Before handling EAS30220 CHECKING THE REAR SHOCK ABSORBER the rear shock absorber, read and make sure ASSEMBLY you understand the following information.

  • Page 249: Installing The Rear Shock Absorber Assembly

    REAR SHOCK ABSORBER ASSEMBLY When installing the oil seals to the relay arm, face the character stamps of the oil seals out- side. 4. Tighten: • Connecting arm nut • Relay arm nut Connecting arm nut (relay arm side) 40 Nm (4.0 m·kgf, 29 ft·lbf) Relay arm nut 40 Nm (4.0 m·kgf, 29 ft·lbf) EAS30225...

  • Page 250: Swingarm

    SWINGARM EAS20037 SWINGARM Removing the swingarm 10 Nm (1.0 m kgf, 7.2 ft Ibf) 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 52 Nm (5.2 m kgf, 38 ft Ibf) •...
  • Page 251 SWINGARM Removing the swingarm 10 Nm (1.0 m kgf, 7.2 ft Ibf) 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 52 Nm (5.2 m kgf, 38 ft Ibf) •...
  • Page 252 SWINGARM Removing the swingarm 10 Nm (1.0 m kgf, 7.2 ft Ibf) 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 52 Nm (5.2 m kgf, 38 ft Ibf) •...

  • Page 253: Removing The Swingarm

    SWINGARM EAS30226 EWA13770 REMOVING THE SWINGARM WARNING 1. Stand the vehicle on a level surface. Do not attempt to straighten a bent pivot EWA13120 shaft. WARNING Securely support the vehicle so that there is no danger of it falling over. Place the vehicle on a suitable stand so that the rear wheel is elevated.

  • Page 254: Installing The Connecting Arm

    SWINGARM 3. Check: • Collar Damage/scratches → Replace. EAS31114 INSTALLING THE CONNECTING ARM 1. Lubricate: • Spacers • Bearings Recommended lubricant Lithium-soap-based grease EAS30228 INSTALLING THE SWINGARM 2. Install: 1. Lubricate: • Bearings “1” • Spacers • Pivot shaft • Oil seals “2” •...
  • Page 255 SWINGARM A. Left side B. Right side 3. Adjust: • Drive chain slack Refer to “ADJUSTING THE DRIVE CHAIN SLACK” on page 3-17. Drive chain slack 51.0–56.0 mm (2.01–2.20 in) 4-100...

  • Page 256: Chain Drive

    CHAIN DRIVE EAS20038 CHAIN DRIVE Removing the drive chain 14 Nm (1.4 m kgf, 10 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 110 Nm (11 m kgf, 80 ft lbf) • • 9 Nm (0.9 m kgf, 6.5 ft Ibf) •...
  • Page 257 CHAIN DRIVE Removing the drive chain 14 Nm (1.4 m kgf, 10 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 110 Nm (11 m kgf, 80 ft lbf) • • 9 Nm (0.9 m kgf, 6.5 ft Ibf) •...

  • Page 258: Removing The Drive Chain

    CHAIN DRIVE EAS30229 REMOVING THE DRIVE CHAIN 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. Place the vehicle on a suitable stand so that the rear wheel is elevated.
  • Page 259 CHAIN DRIVE • Perform this procedure 2–3 times, at a different clean the drive chain. High-pressure meth- location each time. ods could force dirt or water into the drive chain’s internals, and solvents will deterio- rate the O-rings. A coarse brush can also damage the O-rings.

  • Page 260: Checking The Drive Sprocket

    CHAIN DRIVE • Stake the drive sprocket nut at cutouts “b” in Recommended lubricant the drive axle. Chain lubricant suitable for O- ring chains EAS30231 CHECKING THE DRIVE SPROCKET 1. Check: • Drive sprocket More than 1/4 tooth “a” wear → Replace the drive chain sprocket, drive chain, and rear wheel sprocket as a set.
  • Page 261 CHAIN DRIVE 4. Fit the space “a” between the side plates of the drive chain “1” onto the rib “b” on the drive chain guide “2”. 7. Adjust: • Installed shift rod length ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼...
  • Page 262 CHAIN DRIVE 90˚ ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 8. Adjust: • Drive chain slack Refer to“ADJUSTING THE DRIVE CHAIN SLACK” on page 3-17. Drive chain slack 51.0–56.0 mm (2.01–2.20 in) ECA13550 NOTICE A drive chain that is too tight will overload...

  • Page 263: Engine

    ENGINE ENGINE INSPECTION ..................5-1 MEASURE THE COMPRESSION PRESSURE........5-1 ADJUSTING THE EXHAUST GAS VOLUME ...........5-2 CHECKING THE CYLINDER HEAD BREATHER HOSE ......5-2 ENGINE REMOVAL ..................5-4 REMOVING THE ENGINE ..............5-10 INSTALLING THE ENGINE..............5-10 CAMSHAFTS....................5-13 REMOVING THE CAMSHAFTS..............5-17 CHECKING THE CAMSHAFTS ..............5-18 CHECKING THE CAMSHAFT SPROCKETS .........5-19 CHECKING THE TIMING CHAIN TENSIONER........
  • Page 264 CLUTCH ......................5-50 REMOVING THE CLUTCH ..............5-54 CHECKING THE FRICTION PLATES.............5-55 CHECKING THE CLUTCH PLATES ............5-55 CHECKING THE CLUTCH SPRINGS.............5-55 CHECKING THE CLUTCH HOUSING ............5-56 CHECKING THE CLUTCH BOSS............5-56 CHECKING THE PRESSURE PLATE ............5-56 CHECKING THE PRIMARY DRIVE GEAR..........5-56 CHECKING THE PRIMARY DRIVEN GEAR ..........5-56 CHECKING THE PULL LEVER SHAFT AND PULL ROD ......5-56 INSTALLING THE CLUTCH..............
  • Page 265 CRANKSHAFT AND BALANCER SHAFT ...........5-86 REMOVING THE BALANCER SHAFT JOURNAL BEARINGS ....5-87 REMOVING THE CRANKSHAFT JOURNAL BEARINGS ......5-87 CHECKING THE BALANCER SHAFT ASSEMBLY........5-87 CHECKING THE CRANKSHAFT ............5-89 INSTALLING THE CRANKSHAFT ............5-91 INSTALLING THE BALANCER SHAFT ASSEMBLY......5-91 TRANSMISSION.................... 5-92 REMOVING THE TRANSMISSION ............

  • Page 266: Engine Inspection

    ENGINE INSPECTION 7. Install: EAS20041 ENGINE INSPECTION • Extension “1” • Compression gauge “2” EAS30249 MEASURE THE COMPRESSION PRESSURE Extension The following procedure applies to all of the cyl- 90890-04136 inders. Compression gauge 90890-03081 Insufficient compression pressure will result in a Engine compression tester YU-33223 loss of performance.

  • Page 267: Adjusting The Exhaust Gas Volume

    14 psi). tion manual of the Yamaha diagnostic tool. c. If the compression pressure is above the 1. Connect the Yamaha diagnostic tool to the maximum specification, check the cylinder coupler. For information about connecting the head, valve surfaces and piston crown for Yamaha diagnostic tool, refer to “YAMAHA...
  • Page 268 ENGINE INSPECTION 3. Install: • Fuel tank Refer to “FUEL TANK” on page 7-1. • Fuel tank front cover • Fuel tank center cover • Fuel tank cover (left) • Fuel tank cover (right) • Fuel tank top cover Refer to “GENERAL CHASSIS (4)” on page 4-11.

  • Page 269: Engine Removal

    ENGINE REMOVAL EAS20042 ENGINE REMOVAL Removing the muffler and exhaust pipe 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 20 Nm (2.0 m kgf, 14 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • •...
  • Page 270 ENGINE REMOVAL Disconnecting the leads and hoses 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 2.2 Nm (0.22 m kgf, 1.6 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS (1)”...
  • Page 271 ENGINE REMOVAL Disconnecting the leads and hoses 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 2.2 Nm (0.22 m kgf, 1.6 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Drain.
  • Page 272 ENGINE REMOVAL Disconnecting the leads and hoses 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 2.2 Nm (0.22 m kgf, 1.6 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Fuel tank overflow hose...
  • Page 273 ENGINE REMOVAL Removing the engine 7 Nm (0.7 m kgf, 5.1 ft Ibf) 55 Nm (5.5 m kgf, 40 ft Ibf) • • • • 25 Nm (2.5 m kgf, 18 ft Ibf) • • 55 Nm (5.5 m kgf, 40 ft Ibf) •...
  • Page 274 ENGINE REMOVAL Removing the engine 7 Nm (0.7 m kgf, 5.1 ft Ibf) 55 Nm (5.5 m kgf, 40 ft Ibf) • • • • 25 Nm (2.5 m kgf, 18 ft Ibf) • • 55 Nm (5.5 m kgf, 40 ft Ibf) •...

  • Page 275: Removing The Engine

    ENGINE REMOVAL b. Move the rear brake hose joint bracket “3” EAS30250 REMOVING THE ENGINE slightly rearward, and then remove the en- gine mounting bolt (rear upper side). Pass a suitable rod “1” through the holes in the ECA21181 NOTICE brackets of the passenger footrests “2”...
  • Page 276 ENGINE REMOVAL Temporarily tighten the bolts and nuts. 4. Tighten: • Engine mounting nut (rear upper side) “4” • Engine mounting nut (rear lower side) “6” • Engine mounting bolt (left front side) “7” Engine mounting nut (rear upper side) 55 Nm (5.5 m·kgf, 40 ft·lbf) Engine mounting nut (rear lower side)
  • Page 277 ENGINE REMOVAL 5-12...

  • Page 278: Camshafts

    CAMSHAFTS EAS20043 CAMSHAFTS Removing the cylinder head cover 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 13 Nm (1.3 m kgf, 9.4 ft Ibf) • • 13 Nm (1.3 m kgf, 9.4 ft Ibf) • • 4.0 Nm (0.40 m kgf, 2.9 ft Ibf) •...
  • Page 279 CAMSHAFTS Removing the cylinder head cover 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 13 Nm (1.3 m kgf, 9.4 ft Ibf) • • 13 Nm (1.3 m kgf, 9.4 ft Ibf) • • 4.0 Nm (0.40 m kgf, 2.9 ft Ibf) •...
  • Page 280 CAMSHAFTS Removing the camshafts 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...
  • Page 281 CAMSHAFTS Removing the camshafts 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...

  • Page 282: Removing The Camshafts

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

  • Page 283: Checking The Camshafts

    CAMSHAFTS Camshaft lobe dimensions Lobe height (Intake) 35.610–35.710 mm (1.4020– 1.4059 in) Limit 35.510 mm (1.3980 in) Base circle diameter (Intake) 27.950–28.050 mm (1.1004– 1.1043 in) Limit 7. Remove: 27.850 mm (1.0965 in) Lobe height (Exhaust) • Exhaust camshaft sprocket “1” 35.710–35.810 mm (1.4059–...

  • Page 284: Checking The Camshaft Sprockets

    CAMSHAFTS 4. Measure: ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ • Camshaft-journal-to-camshaft-cap clearance 5. Measure: Out of specification → Measure the camshaft • Camshaft journal diameter “a” journal diameter. Out of specification →...

  • Page 285: Checking The Timing Chain Tensioner

    CAMSHAFTS EAS30266 CHECKING THE TIMING CHAIN TENSIONER 1. Check: • Timing chain tensioner Cracks/damage/rough movement → Re- place. ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Lightly press the timing chain tensioner rod into the timing chain tensioner housing by hand.
  • Page 286 CAMSHAFTS ECA19980 NOTICE Rotor holding tool 90890-01235 Be sure to tighten the camshaft sprocket Universal magneto and rotor bolts to the specified torque to avoid the holder possibility of the bolts coming loose and YU-01235 damaging the engine. • Make sure that the mark “a” on the exhaust camshaft sprocket is aligned with cam lobe #1 “b”...
  • Page 287 CAMSHAFTS • When installing the timing chain, start with the exhaust camshaft and be sure to keep the tim- ing chain as tight as possible on the exhaust side. • Make sure that the match marks “a” on the ex- haust camshaft sprocket and cam lobe #1 “b”...
  • Page 288 CAMSHAFTS c. Install a new timing chain tensioner gasket 8. Turn: “3”, the timing chain tensioner “4”, and the • Crankshaft timing chain tensioner bolts “5” on the cylin- (several turns counterclockwise) der block. 9. Check: • Mark “a” Make sure the mark “a” on the generator rotor Be sure to install the timing chain tensioner gas- is aligned with the slot “b”...

  • Page 289: Installing The Cylinder Head Cover

    10 Nm (1.0 m·kgf, 7.2 ft·lbf) Install the ignition coils “1” in the direction shown in the illustration. • Apply Yamaha bond No.1215 “3” onto the mat- ing surfaces of the cylinder head cover gasket and cylinder head. • After installing the cylinder head cover gasket “1”...

  • Page 290: Cylinder Head

    CYLINDER HEAD EAS20044 CYLINDER HEAD Removing the cylinder head 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 40 Nm (4.0 m kgf, 29 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 20 Nm (2.0 m kgf, 14 ft Ibf) •...
  • Page 291 CYLINDER HEAD Removing the cylinder head 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 40 Nm (4.0 m kgf, 29 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 20 Nm (2.0 m kgf, 14 ft Ibf) •...
  • Page 292 CYLINDER HEAD Removing the cylinder head 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 40 Nm (4.0 m kgf, 29 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 20 Nm (2.0 m kgf, 14 ft Ibf) •...
  • Page 293 CYLINDER HEAD Removing the cylinder head 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 40 Nm (4.0 m kgf, 29 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 20 Nm (2.0 m kgf, 14 ft Ibf) •...

  • Page 294: Removing The Cylinder Head

    CYLINDER HEAD EAS30276 REMOVING THE CYLINDER HEAD 1. Remove: The following procedure applies to both of the engine bracket. ×2 • Engine bracket bolts “1” • Engine mounting bolt “2” ×6 • Engine bracket “3” • Place a suitable stand under the engine. •...

  • Page 295: Installing The Cylinder Head

    CYLINDER HEAD Cylinder head bolt (“1”–“6”) 1st: 10 Nm (1.0 m·kgf, 7.2 ft·lbf) 2nd: 40 Nm (4.0 m·kgf, 29 ft·lbf) *3rd: 20 Nm (2.0 m·kgf, 14 ft·lbf) Specified angle 90° Cylinder head bolt (“7”, “8”) 10 Nm (1.0 m·kgf, 7.2 ft·lbf) * Following the tightening order, loosen the bolt one by one, and then retighten it to the ▼...
  • Page 296 VALVES AND VALVE SPRINGS EAS20045 VALVES AND VALVE SPRINGS Removing the valves and valve springs Order Job/Parts to remove Q’ty Remarks Cylinder head Refer to “CYLINDER HEAD” on page 5-25. Valve lifter Valve pad Valve cotter Valve spring retainer Valve spring Exhaust valve Intake valve Valve stem seal...

  • Page 297: Valves And Valve Springs

    VALVES AND VALVE SPRINGS EAS30283 REMOVING THE VALVES Remove the valve cotters by compressing the The following procedure applies to all of the valve spring with the valve spring compressor valves and related components. “1” and the valve spring compressor attachment “2”.
  • Page 298 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 299: Checking The Valve Seats

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

  • Page 300: Checking The Valve Springs

    VALVES AND VALVE SPRINGS After replacing the cylinder head or replacing the valve and valve guide, the valve seat and valve face should be lapped. ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼...

  • Page 301: Checking The Valve Lifters

    VALVES AND VALVE SPRINGS 2. Measure: EAS30287 CHECKING THE VALVE LIFTERS • Compressed valve spring force “a” Out of specification → Replace the valve The following procedure applies to all of the valve lifters. spring. 1. Check: Installed compression spring •...
  • Page 302 VALVES AND VALVE SPRINGS Valve spring compressor 90890-04019 Valve spring compressor YM-04019 Valve spring compressor attach- ment 90890-01243 Valve spring compressor adapt- er (26 mm) YM-01253-1 4. Install: • Valve spring seat “1” (into the cylinder head) • Valve stem seal “2” •...
  • Page 303 VALVES AND VALVE SPRINGS • Each valve lifter and valve pad must be rein- stalled in their original position. 5-38...

  • Page 304: Generator And Starter Clutch

    GENERATOR AND STARTER CLUTCH EAS20140 GENERATOR AND STARTER CLUTCH Removing the stator coil, generator rotor and starter clutch 32 Nm (3.2 m kgf, 23 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 70 Nm (7.0 m kgf, 51 ft Ibf) •...
  • Page 305 GENERATOR AND STARTER CLUTCH Removing the stator coil, generator rotor and starter clutch 32 Nm (3.2 m kgf, 23 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 70 Nm (7.0 m kgf, 51 ft Ibf) •...
  • Page 306 GENERATOR AND STARTER CLUTCH Removing the stator coil, generator rotor and starter clutch 17 13 32 Nm (3.2 m kgf, 23 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 70 Nm (7.0 m kgf, 51 ft Ibf) •...

  • Page 307: Removing The Generator

    GENERATOR AND STARTER CLUTCH EAS30867 REMOVING THE GENERATOR 1. Remove: • Generator rotor bolt “1” • Washer While holding the generator rotor “2” with the ro- tor holding tool “3”, loosen the generator rotor bolt. Rotor holding tool EAS30868 REMOVING THE STARTER CLUTCH 90890-04166 1.

  • Page 308: Checking The Torque Limiter

    GENERATOR AND STARTER CLUTCH b. When turning the starter clutch gear clock- wise “A”, the starter clutch and the starter clutch gear should engage, otherwise the starter clutch is faulty and must be replaced. c. When turning the starter clutch gear counter- clockwise “B”, it should turn freely, otherwise the starter clutch is faulty and must be re- placed.
  • Page 309 • Apply LOCTITE® to the threads of only the generator cover bolts “1” shown in the illustra- tion. 4. Apply: • Sealant (onto the stator coil lead grommet) Yamaha bond No. 1215 90890-85505 (Three bond No.1215®) 7. Connect: • Stator coil coupler • Crankshaft position sensor coupler To route the stator coil lead, refer to “CABLE...

  • Page 310: Electric Starter

    ELECTRIC STARTER EAS20052 ELECTRIC STARTER Removing the starter motor 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks...
  • Page 311 ELECTRIC STARTER Removing the starter motor 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Gear position switch coupler...
  • Page 312 ELECTRIC STARTER Disassembling the starter motor 11 Nm (1.1 m kgf, 8.0 ft Ibf) • • 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks O-ring Starter motor front cover Starter motor yoke Armature assembly Gasket Brush holder set...

  • Page 313: Checking The Starter Motor

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

  • Page 314: Assembling The Starter Motor

    ELECTRIC STARTER 7. Check: • Bearing • Oil seal Damage/wear → Replace the starter motor front cover. EAS30326 ASSEMBLING THE STARTER MOTOR 1. Install: • Lead guide “1” Make sure that the slot “a” in the lead guide is facing in the direction shown in the illustration. 2.

  • Page 315: Clutch

    CLUTCH EAS20055 CLUTCH Removing the clutch cover and pull lever shaft 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) • •...
  • Page 316 CLUTCH Removing the clutch cover and pull lever shaft 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks...
  • Page 317 CLUTCH Removing the clutch 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 95 Nm (9.5 m kgf, 69 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Compression spring Pressure plate Pull rod...
  • Page 318 CLUTCH Removing the clutch 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 95 Nm (9.5 m kgf, 69 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Thrust plate Spacer Bearing...

  • Page 319: Removing The Clutch

    CLUTCH 5. Loosen: EAS30346 REMOVING THE CLUTCH • Clutch boss nut “1” 1. Remove: • Clutch cover “1” While holding the clutch boss “2” with the univer- • Gasket sal clutch holder “3”, loosen the clutch boss nut. Loosen each bolt 1/4 of a turn at a time, in stag- Universal clutch holder es and in a crisscross pattern.

  • Page 320: Checking The Friction Plates

    CLUTCH 1. Check: EAS30348 CHECKING THE FRICTION PLATES • Clutch plate The following procedure applies to all of the fric- Damage → Replace the clutch plates as a tion plates. set. 1. Check: 2. Measure: • Friction plate • Clutch plate warpage Damage/wear →...

  • Page 321: Checking The Clutch Housing

    CLUTCH • Bearing “2” Damage/wear → Replace. EAS30352 CHECKING THE CLUTCH HOUSING 1. Check: EAS30356 CHECKING THE PRIMARY DRIVE GEAR • Clutch housing dogs 1. Check: Damage/pitting/wear → Deburr the clutch • Primary drive gear housing dogs or replace the clutch housing. Damage/wear →...

  • Page 322: Installing The Clutch

    CLUTCH • Stake the clutch boss nut at a cutout “a” in the main axle. Universal clutch holder 90890-04086 Universal clutch holder YM-91042 2. Check: • Pull rod bearing Damage/wear → Replace. EAS30363 INSTALLING THE CLUTCH 1. Install: • Oil pump drive chain “1” •...
  • Page 323 CLUTCH • Clutch springs • Clutch spring bolts “3” Clutch spring bolt 8 Nm (0.8 m·kgf, 5.8 ft·lbf) • Apply lithium-soap-based grease onto the pull rod. • Tighten the clutch spring bolts in stages and in a crisscross pattern. 6. Install: 5.
  • Page 324 CLUTCH • After installing the clutch cable, bend the pro- • Clutch cover gasket “2” jection “b” on the pull lever. • Clutch cover “3” • Clutch cable holder “4” Clutch cover bolt 12 Nm (1.2 m·kgf, 8.7 ft·lbf) Clutch cable holder bolt 12 Nm (1.2 m·kgf, 8.7 ft·lbf) LOCTITE®...

  • Page 325: Shift Shaft

    SHIFT SHAFT EAS20057 SHIFT SHAFT Removing the shift shaft and stopper lever 22 Nm (2.2 m kgf, 16 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Clutch housing Refer to “CLUTCH” on page 5-50. Circlip Washer Shift shaft Washer Circlip Washer...
  • Page 326 SHIFT SHAFT Removing the shift shaft and stopper lever 12 13 22 Nm (2.2 m kgf, 16 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Shift shaft spring Shift shaft spring stopper Oil seal Bearing 5-61...

  • Page 327: Checking The Shift Shaft

    SHIFT SHAFT EAS30377 CHECKING THE SHIFT SHAFT 1. Check: • Shift shaft “1” Bends/damage/wear → Replace. • Shift shaft spring “2” • Collar Damage/wear → Replace. 2. Install: • Shift shaft spring stopper • Washer • Shift shaft assembly • Stopper lever spring Shift shaft spring stopper 22 Nm (2.2 m·kgf, 16 ft·lbf) LOCTITE®...

  • Page 328: Oil Pump

    OIL PUMP EAS20054 OIL PUMP Removing the oil pump 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks...
  • Page 329 OIL PUMP Disassembling the oil pump 3.8 Nm (0.38 m kgf, 2.8 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Oil pump cover Oil pump rotor assembly Oil pump inner rotor Oil pump outer rotor Oil pump driven sprocket Hold down the washer when removing the Circlip circlip.

  • Page 330: Checking The Sprocket And Chain

    OIL PUMP EAS30336 CHECKING THE SPROCKET AND CHAIN 1. Check: • Oil pump drive sprocket Refer to “CHECKING THE CLUTCH HOUS- ING” on page 5-56. • Oil pump driven sprocket Refer to “CHECKING THE OIL PUMP” on page 5-65. 2. Check: •...

  • Page 331: Installing The Oil Pump

    OIL PUMP 2. Lubricate: ECA20940 NOTICE • Oil pump driven sprocket After installing the oil pump drive chain and (with the recommended lubricant) driven sprocket, make sure the oil pump Recommended lubricant turns smoothly. Engine oil 3. Install: • Oil pump driven sprocket “1” •...

  • Page 332: Oil Pan

    OIL PAN EAS20177 OIL PAN Removing the oil pan 43 Nm (4.3 m kgf, 31 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) (11) • • • • Order Job/Parts to remove Q’ty...

  • Page 333: Removing The Oil Pan

    OIL PAN EAS31068 REMOVING THE OIL PAN 1. Remove: • Oil pan “1” • Oil pan gasket • Loosen each bolt 1/4 of a turn at a time, in stag- es and in a crisscross pattern. After all of the bolts are fully loosened, remove them.

  • Page 334: Crankcase

    CRANKCASE EAS20059 CRANKCASE Separating the crankcase 24 Nm (2.4 m kgf, 17 ft Ibf) • • 24 Nm (2.4 m kgf, 17 ft Ibf) • • 17 Nm (1.7 m kgf, 12 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...
  • Page 335 CRANKCASE Separating the crankcase 24 Nm (2.4 m kgf, 17 ft Ibf) 24 Nm (2.4 m kgf, 17 ft Ibf) • • • • 17 Nm (1.7 m kgf, 12 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...

  • Page 336: Disassembling The Crankcase

    ×3 ×2 • Sealant ×2 ×6 ×6 (onto the crankcase mating surfaces) Yamaha bond No. 1215 90890-85505 (Three bond No.1215®) ECA20880 NOTICE Do not allow any sealant to come into con- tact with the oil gallery, crankshaft journal bearings, or balancer shaft journal bearings.
  • Page 337 CRANKCASE • Lubricate the bolts “13”–“27” threads and mat- ing surfaces with engine oil. • M9 × 80 mm bolt (×6) (bolts with washers): “1”–“6” • M8 × 70 mm bolt (×6) (bolts with new O- rings): “7”–“12” • M8 × 65 mm bolt (×2): “13”, “14” •...

  • Page 338: Installing The Oil Pressure Switch

    24 Nm (2.4 m·kgf, 17 ft·lbf) (onto the oil pressure switch threads) Crankcase bolts “15”–“27” 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Yamaha bond No. 1215 90890-85505 (Three bond No.1215®) • Tighten the bolts “7”–“16” in the tightening se- quence cast on the crankcase.
  • Page 339 CRANKCASE 10˚ 45˚ 5-74...

  • Page 340: Connecting Rods And Pistons

    CONNECTING RODS AND PISTONS EAS20132 CONNECTING RODS AND PISTONS Removing the connecting rods and pistons 1st 20 Nm (2.0 m kgf, 14 ft Ibf) • • 2nd Specified angle 180˚ Order Job/Parts to remove Q’ty Remarks The following procedure applies to all of the connecting rods and pistons.
  • Page 341 CONNECTING RODS AND PISTONS Removing the connecting rods and pistons 1st 20 Nm (2.0 m kgf, 14 ft Ibf) • • 2nd Specified angle 180˚ Order Job/Parts to remove Q’ty Remarks Top ring 2nd ring Oil ring 5-76...

  • Page 342: Removing The Connecting Rods And Pistons

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

  • Page 343: Checking The Piston Rings

    CONNECTING RODS AND PISTONS ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Measure cylinder bore with the cylinder bore gauge. Measure cylinder bore by taking side-to-side and front-to-back measurements of the cylinder. Then, find the average of the measurements.

  • Page 344: Checking The Piston Pin

    CONNECTING RODS AND PISTONS EAS30749 CHECKING THE PISTON PIN The following procedure applies to all of the pis- ton pins. 1. Check: • Piston pin Blue discoloration/grooves → Replace the piston pin, and then check the lubrication sys- tem. 2. Measure: •...

  • Page 345: Checking The Connecting Rods

    CONNECTING RODS AND PISTONS c. Put a piece of Plastigauge® “1” on the crank- Piston-pin-to-piston-pin-bore clearance = shaft pin. Piston pin bore inside diameter “b” – Piston pin outside diameter “a” Piston-pin-to-piston-pin-bore clearance 0.009–0.025 mm (0.0004–0.0010 Limit 0.075 mm (0.0030 in) EAS30750 CHECKING THE CONNECTING RODS d.
  • Page 346 CONNECTING RODS AND PISTONS To install the big end bearing, care should be taken not to install it at an angle and the position should not be out of alignment. i. Tighten the connecting rod bolts further to reach the specified angle 175–185°. Connecting rod bolt (final) Specified angle 180°...

  • Page 347: Installing The Connecting Rod And Piston

    CONNECTING RODS AND PISTONS l. Measure the compressed Plastigauge® width on the crankshaft pin. If the crankshaft- pin-to-big-end-bearing clearance is out of specification, select replacement big end bearings. For example, if the connecting rod “P ” and the crankshaft web “P ”...
  • Page 348 CONNECTING RODS AND PISTONS a. Side machined face 2. Tighten: b. Thrusting faces • Connecting rod bolts ECA18390 e. Loosen the connecting rod bolt, remove the NOTICE connecting rod and connecting rod cap and Tighten the connecting rod bolts using the install these parts to the crankshaft with the plastic-region tightening angle method.
  • Page 349 CONNECTING RODS AND PISTONS • Reinstall each piston into its original cylinder. Recommended lubricant Engine oil 8. Install: • Connecting rod assemblies “1” (into the cylinder and onto the crankshaft pin) • Connecting rod caps (onto the connecting rod) • While compressing the piston ring with piston ring compressor “2”, install the connecting rod assembly into the cylinder with the other hand.
  • Page 350 CONNECTING RODS AND PISTONS EWA16610 WARNING If the bolt is tightened more than the speci- fied angle, do not loosen the bolt and then re- tighten it. Instead, replace the bolt with a new one and perform the procedure again. ECA20890 NOTICE Do not use a torque wrench to tighten the...

  • Page 351: Crankshaft And Balancer Shaft

    CRANKSHAFT AND BALANCER SHAFT EAS20178 CRANKSHAFT AND BALANCER SHAFT Removing the crankshaft and balancer shaft Order Job/Parts to remove Q’ty Remarks Crankcase Refer to “CRANKCASE” on page 5-69. Refer to “CONNECTING RODS AND PIS- Connecting rod TONS” on page 5-75. Balancer shaft assembly Balancer shaft journal lower bearing Balancer shaft journal upper bearing...

  • Page 352: Removing The Balancer Shaft Journal Bearings

    CRANKSHAFT AND BALANCER SHAFT 3. Check: EAS31072 REMOVING THE BALANCER SHAFT • Balancer shaft assembly JOURNAL BEARINGS Cracks/damage/wear → Replace the balanc- 1. Remove: er shaft assembly and journal bearings. • Balancer shaft journal lower bearings Dirt → Clean. (from the crankcase) •...
  • Page 353 CRANKSHAFT AND BALANCER SHAFT Do not put the Plastigauge® over the oil hole in the balancer shaft journal. ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 5. Select: • Balancer shaft journal bearings (J –J d.

  • Page 354: Checking The Crankshaft

    CRANKSHAFT AND BALANCER SHAFT 4. Measure: • Crankshaft-journal-to-crankshaft-journal- J1 J2 J3 bearing clearance Out of specification → Replace the crank- shaft journal bearings. Journal oil clearance 0.018–0.042 mm (0.0007–0.0017 ECA13920 NOTICE For example, if the crankcase J and balanc- Do not interchange the crankshaft journal er shaft web J numbers are 6 and 5 respec- bearings.
  • Page 355 CRANKSHAFT AND BALANCER SHAFT 5. Select: • Crankshaft journal bearings (J –J • The numbers “A” stamped into the crankcase and the numbers “B” stamped into the crank- shaft web are used to determine the replace- ment crankshaft journal bearing sizes. •...

  • Page 356: Installing The Crankshaft

    CRANKSHAFT AND BALANCER SHAFT Bearing color code • Align the projections “a” on the balancer shaft -1.Violet-Pink 0.White-Pink journal bearings “1” with the notches “b” in the 1.Blue-Pink 2.Black-Pink crankcase. 3.Brown-Pink • Be sure to install each balancer shaft journal bearing in its original place.

  • Page 357: Transmission

    TRANSMISSION EAS20062 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Crankcase Refer to “CRANKCASE” on page 5-69. Drive axle assembly Shift drum retainer Shift fork guide bar...
  • Page 358 TRANSMISSION Disassembling the main axle assembly Order Job/Parts to remove Q’ty Remarks 2nd pinion gear Toothed lock washer Toothed lock washer retainer 6th pinion gear Collar Washer Circlip 3rd pinion gear Circlip Washer 5th pinion gear Collar 5-93...
  • Page 359 TRANSMISSION Disassembling the main axle assembly Order Job/Parts to remove Q’ty Remarks Main axle 5-94...
  • Page 360 TRANSMISSION Disassembling the drive axle assembly Order Job/Parts to remove Q’ty Remarks 1st wheel gear Collar 5th wheel gear Circlip Washer 3rd wheel gear Collar Toothed lock washer Toothed lock washer retainer 4th wheel gear Collar Washer 5-95...
  • Page 361 TRANSMISSION Disassembling the drive axle assembly Order Job/Parts to remove Q’ty Remarks Circlip 6th wheel gear Circlip Washer Collar 2nd wheel gear Oil seal Circlip Bearing Collar Drive axle 5-96...

  • Page 362: Removing The Transmission

    TRANSMISSION EAS30430 REMOVING THE TRANSMISSION 1. Remove: • Drive axle assembly “1” • Shift drum retainer “2” • Shift fork guide bars • Shift fork “L” and “R” • Shift drum assembly • Shift fork “C” 2. Check: • Shift fork guide bar Roll the shift fork guide bar on a flat surface.

  • Page 363: Checking The Transmission

    TRANSMISSION • Transmission gear dogs Cracks/damage/rounded edges → Replace the defective gear(s). EAS30433 CHECKING THE TRANSMISSION 1. Measure: • Main axle runout 4. Check: (with a centering device and dial gauge “1”) • Transmission gear engagement Out of specification → Replace the main axle. (each pinion gear to its respective wheel gear) Main axle runout limit...

  • Page 364: Installing The Transmission

    TRANSMISSION • Bearing retainer Bearing retainer bolt 12 Nm (1.2 m·kgf, 8.7 ft·lbf) LOCTITE® Use a suitable pin “a” to position the bearing housing, and then install the housing until it con- tacts the cylinder. 2. Install: A. Main axle •...
  • Page 365 TRANSMISSION 4. Check: • Transmission Rough movement → Repair. Oil each gear, shaft, and bearing thoroughly. 5-100...
  • Page 366 TRANSMISSION 5-101...

  • Page 367: Cooling System

    COOLING SYSTEM RADIATOR ...................... 6-1 CHECKING THE RADIATOR..............6-3 INSTALLING THE RADIATOR..............6-3 OIL COOLER....................6-4 CHECKING THE OIL COOLER ..............6-6 CHECKING THE WATER JACKET JOINT ..........6-6 INSTALLING THE OIL COOLER .............. 6-6 THERMOSTAT ....................6-7 CHECKING THE THERMOSTAT.............. 6-8 INSTALLING THE THERMOSTAT............6-8 WATER PUMP....................6-9 DISASSEMBLING THE WATER PUMP..........

  • Page 368: Radiator

    RADIATOR EAS20063 RADIATOR Removing the radiator 2.0 Nm (0.20 m kgf, 1.4 ft Ibf) • • 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 1.0 Nm (0.10 m kgf, 0.72 ft Ibf) •...
  • Page 369 RADIATOR Removing the radiator 2.0 Nm (0.20 m kgf, 1.4 ft Ibf) • • 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 1.0 Nm (0.10 m kgf, 0.72 ft Ibf) •...

  • Page 370: Checking The Radiator

    RADIATOR EAS30439 CHECKING THE RADIATOR 1. Check: • Radiator fins Obstruction → Clean. Apply compressed air to the rear of the radia- tor. Damage → Repair or replace. Straighten any flattened fins with a thin, flat-head screwdriver. b. Apply the specified pressure for ten seconds and make sure there is no drop in pressure.

  • Page 371: Oil Cooler

    OIL COOLER EAS20064 OIL COOLER Removing the oil cooler 2.0 Nm (0.20 m kgf, 1.4 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 17 Nm (1.7 m kgf, 12 ft Ibf) 40 Nm (4.0 m kgf, 29 ft Ibf) •...
  • Page 372 OIL COOLER Removing the oil cooler 2.0 Nm (0.20 m kgf, 1.4 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 17 Nm (1.7 m kgf, 12 ft Ibf) 40 Nm (4.0 m kgf, 29 ft Ibf) •...

  • Page 373: Checking The Oil Cooler

    OIL COOLER • Crankcase EAS30441 CHECKING THE OIL COOLER (with the specified amount of the recom- 1. Check: mended engine oil) • Oil cooler Refer to “CHANGING THE ENGINE OIL” on Cracks/damage → Replace. page 3-22. 2. Check: 4. Check: •...

  • Page 374: Thermostat

    THERMOSTAT EAS20065 THERMOSTAT Removing the thermostat 2.0 Nm (0.20 m kgf, 1.4 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 16 Nm (1.6 m kgf, 12 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Drain.

  • Page 375: Checking The Thermostat

    THERMOSTAT 2. Check: EAS30443 CHECKING THE THERMOSTAT • Thermostat cover 1. Check: Cracks/damage → Replace. • Thermostat Does not open at 80–84 °C (176–183.2 °F) → EAS30939 INSTALLING THE THERMOSTAT Replace. 1. Install: • Thermostat Install the thermostat with its breather valve “a” facing inward.

  • Page 376: Water Pump

    WATER PUMP EAS20066 WATER PUMP Removing the water pump 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • • • (10) 7 Nm (0.7 m kgf, 5.1 ft Ibf)
  • Page 377 WATER PUMP Removing the water pump 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • • • (10) 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...

  • Page 378: Disassembling The Water Pump

    WATER PUMP EAS30446 EAS30447 DISASSEMBLING THE WATER PUMP CHECKING THE WATER PUMP 1. Remove: 1. Check: • Mechanical seal (impeller side) “1” • Water pump housing (from the impeller, with a thin, flat-head • Clutch cover screwdriver) • Impeller shaft Cracks/damage/wear →...
  • Page 379 WATER PUMP Mechanical seal installer If the surface “a” of the mechanical seal (impeller 90890-04132 side) that contacts the mechanical seal (housing Water pump seal installer side) is dirty, clean it. YM-33221-A Middle driven shaft bearing driv- Mechanical seal (impeller side) 90890-04058 0.15 mm (0.006 in) Middle drive bearing installer 40...

  • Page 380: Installing The Clutch Cover

    WATER PUMP 3. Check: EAS31117 INSTALLING THE CLUTCH COVER • Cooling system 1. Install: Leaks → Repair or replace the faulty part. • Dowel pins “1” 4. Measure: • Clutch cover gasket “2” • Radiator cap opening pressure Below the specified pressure → Replace the •...

  • Page 381: Fuel System

    FUEL SYSTEM FUEL TANK..................... 7-1 REMOVING THE FUEL TANK ..............7-3 REMOVING THE FUEL PUMP ..............7-3 CHECKING THE FUEL PUMP BODY............7-3 INSTALLING THE FUEL PUMP..............7-3 INSTALLING THE FUEL TANK BRACKET..........7-4 INSTALLING THE FUEL TANK..............7-4 AIR FILTER CASE VALVE ................7-6 CHECKING THE AIR FILTER CASE VALVE..........7-8 INSTALING THE AIR FILTER CASE VALVE..........7-8 THROTTLE BODIES ..................7-9 CHECKING THE INJECTORS (BEFORE REMOVING) ......

  • Page 382: Fuel Tank

    FUEL TANK EAS20067 FUEL TANK Removing the fuel tank and fuel pump 30 Nm (3.0 m kgf, 22 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...
  • Page 383 FUEL TANK Removing the fuel tank and fuel pump 30 Nm (3.0 m kgf, 22 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 3.8 Nm (0.38 m kgf, 2.8 ft Ibf) •...

  • Page 384: Removing The Fuel Tank

    FUEL TANK EAS30450 ECA14720 REMOVING THE FUEL TANK NOTICE 1. Extract the fuel in the fuel tank through the • Do not drop the fuel pump or give it a fuel tank cap with a pump. strong shock. 2. Remove: •...

  • Page 385: Installing The Fuel Tank Bracket

    FUEL TANK Make sure that the arrow mark “a” on the rear fuel tank bracket points toward the punch mark “b” on the fuel tank. EAS30457 INSTALLING THE FUEL TANK 1. Tighten: • Front fuel tank bracket bolt (temporarily) EAS31081 INSTALLING THE FUEL TANK BRACKET Temporarily tighten the front fuel tank bracket 1.
  • Page 386 FUEL TANK • Intake air temperature sensor 4. Tighten: • Rear fuel tank bracket bolts Rear fuel tank bracket bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) 5. Tighten: • Front fuel tank bracket bolt Front fuel tank bracket bolt 30 Nm (3.0 m·kgf, 22 ft·lbf)

  • Page 387: Air Filter Case Valve

    AIR FILTER CASE VALVE EAS20179 AIR FILTER CASE VALVE Removing the air filter case valve and air filter element 1.6 Nm (0.16 m kgf, 1.2 ft Ibf) • • 1.6 Nm (0.16 m kgf, 1.2 ft Ibf) • • A: 1XB1, 1XB5, 1XB6 B: 1XB2, 1XB7, 1XB8 Order Job/Parts to remove...
  • Page 388 AIR FILTER CASE VALVE Removing the air filter case valve and air filter element 1.6 Nm (0.16 m kgf, 1.2 ft Ibf) • • 1.6 Nm (0.16 m kgf, 1.2 ft Ibf) • • A: 1XB1, 1XB5, 1XB6 B: 1XB2, 1XB7, 1XB8 Order Job/Parts to remove Q’ty...

  • Page 389: Checking The Air Filter Case Valve

    AIR FILTER CASE VALVE EAS31090 CHECKING THE AIR FILTER CASE VALVE 1. Check: • Air filter case valve operation ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remove the air duct bracket (with the air filter case valve).

  • Page 390: Throttle Bodies

    THROTTLE BODIES EAS20070 THROTTLE BODIES Removing the air filter case and throttle bodies 3.0 Nm (0.30 m kgf, 2.2 ft Ibf) 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • • • 3.0 Nm (0.30 m kgf, 2.2 ft Ibf) •...
  • Page 391 THROTTLE BODIES Removing the air filter case and throttle bodies 3.0 Nm (0.30 m kgf, 2.2 ft Ibf) 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • • • 3.0 Nm (0.30 m kgf, 2.2 ft Ibf) • • 3.0 Nm (0.30 m kgf, 2.2 ft Ibf)
  • Page 392 THROTTLE BODIES Removing the fuel injectors 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • 3.5 Nm (0.35 m kgf, 2.5 ft Ibf) • • 3.5 Nm (0.35 m kgf, 2.5 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks ISC (idle speed control) valve plate...

  • Page 393: Checking The Injectors (Before Removing)

    THROTTLE BODIES EAS30475 EAS30479 CHECKING THE INJECTORS (BEFORE CHECKING THE THROTTLE BODIES REMOVING) 1. Check: Before checking the throttle bodies, check the • Injectors following items: Use the diagnostic code numbers “36–37”. • Valve clearance Refer to “SELF-DIAGNOSTIC FUNCTION • Spark plugs AND DIAGNOSTIC CODE TABLE”...
  • Page 394 THROTTLE BODIES • Do not turn the bypass air screws “a”; oth- d. Apply a petroleum-based solvent to the throt- erwise, the throttle body synchronization tle valves and the inside of the throttle bodies will be affected. to remove any carbon deposits. •...

  • Page 395: Checking The Throttle Body Joints

    THROTTLE BODIES • ISC (idle speed control) valve Recommended cleaning agent: • ISC (idle speed control) valve plate Yamaha oil & brake cleaner ISC (idle speed control) valve ECA21230 plate screw NOTICE 5 Nm (0.5 m·kgf, 3.6 ft·lbf) • Be sure to use the recommended cleaning agent.

  • Page 396: Adjusting The Throttle Position Sensor

    • If an injector is subject to strong shocks or d. Remove the protective cap, and then connect excessive force, replace it. the Yamaha diagnostic tool to coupler “1”. • If installing the original fuel rail and screws, remove the white paint marks using a For information about using the Yamaha diag- cleaning solvent.

  • Page 397: Checking The Injector Pressure

    THROTTLE BODIES Pressure drops → Check the pressure gauge EAS30481 CHECKING THE INJECTOR PRESSURE and adapter. Check the seals and O-rings, and then rein- • After installing the fuel injectors, perform the stall. following steps to check the injector pressure. Replace the fuel injectors.

  • Page 398: Installing The Throttle Body Joints

    THROTTLE BODIES • Fuel tank top cover Refer to “GENERAL CHASSIS (4)” on page 4-11. • Rider seat Refer to “GENERAL CHASSIS (1)” on page 4-1. EAS30937 INSTALLING THE THROTTLE BODY JOINTS 1. Install: • Throttle body joints “1” c. Connect the pressure gauge “3” and adapter “4”...
  • Page 399 THROTTLE BODIES 7-18...
  • Page 400 INTAKE SOLENOID EAS20181 INTAKE SOLENOID Removing the intake solenoid 3.8 Nm (0.38 m kgf, 2.8 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS (1)” on page Rider seat 4-1. Fuel tank top cover/Fuel tank covers/Fuel tank Refer to “GENERAL CHASSIS (4)”...
  • Page 401 INTAKE SOLENOID Removing the intake solenoid 3.8 Nm (0.38 m kgf, 2.8 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks One-way valve Intake solenoid vacuum hose (one-way valve to intake solenoid) Surge tank hose Intake solenoid Surge tank 7-20...

  • Page 402: Intake Solenoid

    INTAKE SOLENOID EAS31093 CHECKING THE VACUUM LINE 1. Check: • Hoses Loose connections → Connect properly. Cracks/damage → Replace. 2. Check: • Surge tank Cracks/damage → Replace. 3. Check: • One-way valve Cracks/damage/faulty → Replace. Check that air flows smoothly only in the direc- tion of the arrow shown in the illustration.

  • Page 403: Electrical System

    CIRCUIT DIAGRAM ................8-29 TROUBLESHOOTING ................8-31 FUEL INJECTION SYSTEM................8-33 CIRCUIT DIAGRAM ................8-33 ECU SELF-DIAGNOSTIC FUNCTION............8-35 TROUBLESHOOTING METHOD............8-35 YAMAHA DIAGNOSTIC TOOL ...............8-36 TROUBLESHOOTING DETAILS ............8-39 FUEL PUMP SYSTEM...................8-73 CIRCUIT DIAGRAM ................8-73 TROUBLESHOOTING ................8-75 IMMOBILIZER SYSTEM................8-77 CIRCUIT DIAGRAM ................8-77 GENERAL INFORMATION ..............
  • Page 404 ABS (ANTI-LOCK BRAKE SYSTEM)............8-87 CIRCUIT DIAGRAM ................8-87 ABS COUPLER LOCATION CHART ............8-89 MAINTENANCE OF THE ABS ECU ............8-91 ABS TROUBLESHOOTING OUTLINE............8-91 BASIC INSTRUCTIONS FOR TROUBLESHOOTING ......8-92 BASIC PROCESS FOR TROUBLESHOOTING ........8-93 [A] CHECKING THE ABS WARNING LIGHT..........8-94 [A-1] ONLY THE ABS WARNING LIGHT FAILS TO COME ON.....

  • Page 406: Ignition System

    IGNITION SYSTEM EAS20072 IGNITION SYSTEM EAS30490 CIRCUIT DIAGRAM...
  • Page 407 IGNITION SYSTEM 1. Main switch 7. Ignition fuse 10.Fuel injection system fuse 15.Battery 16.Engine ground 18.Main fuse 22.Relay unit 25.Joint coupler 26.Sidestand switch 27.Crankshaft position sensor 30.Ignition coil #1 31.Ignition coil #2 32.Spark plug 37.ECU (engine control unit) 41.Lean angle sensor 63.Gear position switch 64.Handlebar switch (right) 67.Start/engine stop switch...

  • Page 408: Engine Stopping Due To Sidestand Operation

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

  • Page 409: Troubleshooting

    IGNITION SYSTEM EAS30492 TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Passenger seat 3. Center cover 4. Fuel tank side covers 5. Fuel tank 6. Drive sprocket cover 7.
  • Page 410 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 8-123. OK ↓ NG → 9. Check the gear position switch. Refer to “CHECKING THE GEAR Replace the gear position switch.
  • Page 411 IGNITION SYSTEM...

  • Page 412: Electric Starting System

    ELECTRIC STARTING SYSTEM EAS20073 ELECTRIC STARTING SYSTEM EAS30493 CIRCUIT DIAGRAM...
  • Page 413 ELECTRIC STARTING SYSTEM 1. Main switch 7. Ignition fuse 10.Fuel injection system fuse 15.Battery 16.Engine ground 18.Main fuse 19.Starter relay 20.Starter motor 22.Relay unit 23.Starting circuit cut-off relay 25.Joint coupler 26.Sidestand switch 37.ECU (engine control unit) 63.Gear position switch 64.Handlebar switch (right) 67.Start/engine stop switch 69.Handlebar switch (left) 70.Clutch switch...

  • Page 414: Starting Circuit Cut-Off System Operation

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

  • Page 415: Troubleshooting

    ELECTRIC STARTING SYSTEM EAS30495 TROUBLESHOOTING The starter motor fails to turn. • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Passenger seat 3. Center cover 4. Fuel tank side covers 5. Fuel tank 6. Drive sprocket cover 7. Headlight assembly NG →...
  • Page 416 ELECTRIC STARTING SYSTEM NG → 8. Check the main switch. Refer to “CHECKING THE Replace the main switch/immobilizer unit. SWITCHES” on page 8-123. OK ↓ NG → 9. Check the gear position switch. Refer to “CHECKING THE GEAR Replace the gear position switch. POSITION SWITCH”...
  • Page 417 ELECTRIC STARTING SYSTEM 8-12...

  • Page 418: Charging System

    CHARGING SYSTEM EAS20074 CHARGING SYSTEM EAS30496 CIRCUIT DIAGRAM 8-13...
  • Page 419 CHARGING SYSTEM 13.AC magneto 14.Rectifier/regulator 15.Battery 16.Engine ground 18.Main fuse 8-14...

  • Page 420: Troubleshooting

    CHARGING SYSTEM EAS30497 TROUBLESHOOTING The battery is not being charged. • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Passenger seat 3. Center cover 4. Fuel tank cover (left) NG → 1. Check the fuse. (Main) Replace the fuse. Refer to “CHECKING THE FUS- ES”...
  • Page 421 CHARGING SYSTEM 8-16...

  • Page 422: Lighting System

    LIGHTING SYSTEM EAS20075 LIGHTING SYSTEM EAS30498 CIRCUIT DIAGRAM 8-17...
  • Page 423 LIGHTING SYSTEM 1. Main switch 7. Ignition fuse 8. Signaling system fuse 9. Headlight fuse 10.Fuel injection system fuse 15.Battery 16.Engine ground 18.Main fuse 25.Joint coupler 37.ECU (engine control unit) 49.Meter assembly 52.Meter light 58.High beam indicator light 69.Handlebar switch (left) 71.Dimmer switch 72.Pass switch 79.Headlight assembly...

  • Page 424: Troubleshooting

    LIGHTING SYSTEM EAS30499 TROUBLESHOOTING Any of the following fail to light: headlight, high beam indicator light, taillight, license plate light or meter light. • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Passenger seat 3. Center cover 4. Fuel tank side covers 5.
  • Page 425 LIGHTING SYSTEM NG → 7. Check the headlight relay. Refer to “CHECKING THE RE- Replace the headlight relay. LAYS” on page 8-131. OK ↓ NG → 8. Check the entire lighting system wiring. Properly connect or replace the wiring har- Refer to “CIRCUIT DIAGRAM”...

  • Page 426: Signaling System

    SIGNALING SYSTEM EAS20076 SIGNALING SYSTEM EAS30500 CIRCUIT DIAGRAM 8-21...
  • Page 427 SIGNALING SYSTEM 1. Main switch 4. Parking lighting fuse 5. ABS control unit fuse 7. Ignition fuse 8. Signaling system fuse 10.Fuel injection system fuse 11.Backup fuse 15.Battery 16.Engine ground 18.Main fuse 21.Rear brake light switch 22.Relay unit 25.Joint coupler 37.ECU (engine control unit) 39.Coolant temperature sensor 43.Rear wheel sensor...

  • Page 428: Troubleshooting

    SIGNALING SYSTEM EAS30501 TROUBLESHOOTING • Any of the following fail to light: turn signal light, brake light or an indicator light. • The horn fails to sound. • The fuel meter fails to come on. • The speedometer fails to operate. •...
  • Page 429 SIGNALING SYSTEM NG → 2. Check the entire signaling system wiring. Properly connect or replace the wiring har- Refer to “CIRCUIT DIAGRAM” on ness. page 8-21. OK ↓ Replace the horn. The tail/brake light fails to come on. NG → 1.
  • Page 430 SIGNALING SYSTEM NG → 5. Check the entire signaling system wiring. Properly connect or replace the wiring har- Refer to “CIRCUIT DIAGRAM” on ness. page 8-21. OK ↓ Replace the meter assembly. The neutral indicator light fails to come on. NG →...
  • Page 431 SIGNALING SYSTEM The oil pressure warning light remains on after the engine is started. NG → 1. Check the entire signaling system wiring. Properly connect or replace the wiring har- Refer to “CIRCUIT DIAGRAM” on ness. page 8-21. OK ↓ NG →...
  • Page 432 SIGNALING SYSTEM The speedometer fails to operate. NG → 1. Check the rear wheel sensor. Refer to “MAINTENANCE OF THE Replace the rear wheel sensor. REAR WHEEL SENSOR AND SENSOR ROTOR” on page 4-31. OK ↓ NG → 2. Check the entire rear wheel sensor Properly connect or replace the wiring har- wiring.
  • Page 433 SIGNALING SYSTEM 8-28...

  • Page 434: Cooling System

    COOLING SYSTEM EAS20077 COOLING SYSTEM EAS30502 CIRCUIT DIAGRAM 8-29...
  • Page 435 COOLING SYSTEM 1. Main switch 7. Ignition fuse 10.Fuel injection system fuse 12.Radiator fan motor fuse 15.Battery 16.Engine ground 18.Main fuse 25.Joint coupler 37.ECU (engine control unit) 39.Coolant temperature sensor 85.Radiator fan motor 86.Radiator fan motor relay A. Wire harness C.

  • Page 436: Troubleshooting

    COOLING SYSTEM EAS30503 TROUBLESHOOTING The radiator fan motor fails to turn. • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Passenger seat 3. Center cover 4. Fuel tank side covers 5. Fuel tank NG → 1. Check the fuses. (Ignition, fuel injection system, radi- ator fan motor, and main) Replace the fuse(s).
  • Page 437 COOLING SYSTEM NG → 7. Check the entire cooling system wiring. Properly connect or replace the wiring har- Refer to “CIRCUIT DIAGRAM” on ness. page 8-29. OK ↓ Replace the ECU. Refer to “REPLAC- ING THE ECU (engine control unit)” on page 8-128.

  • Page 438: Fuel Injection System

    FUEL INJECTION SYSTEM EAS20078 FUEL INJECTION SYSTEM EAS30504 CIRCUIT DIAGRAM 8-33...
  • Page 439 38.Intake air temperature sensor 39.Coolant temperature sensor 40.Intake air pressure sensor 41.Lean angle sensor 43.Rear wheel sensor 44.ABS ECU (electronic control unit) 45.Yamaha diagnostic tool coupler 47.Fuel pump 49.Meter assembly 54.Multi-function meter 56.Engine trouble warning light 63.Gear position switch 64.Handlebar switch (right) 67.Start/engine stop switch...

  • Page 440: Ecu Self-Diagnostic Function

    FUEL INJECTION SYSTEM EAS30505 ECU SELF-DIAGNOSTIC FUNCTION The ECU is equipped with a self-diagnostic function in order to ensure that the fuel injection system is operating normally. If this function detects a malfunction in the system, it immediately operates the en- gine under substitute characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the system.

  • Page 441: Yamaha Diagnostic Tool

    EAS30951 YAMAHA DIAGNOSTIC TOOL This model uses the Yamaha diagnostic tool to identify malfunctions. For information about using the Yamaha diagnostic tool, refer to the operation manual that is included with the tool. Yamaha diagnostic tool 90890-03231 Features of the Yamaha diagnostic tool You can use the Yamaha diagnostic tool to identify malfunctions quicker than with conventional meth- ods.
  • Page 442 Connecting the Yamaha diagnostic tool Remove the protective cap “1”, and then connect the Yamaha diagnostic tool to the coupler. Operation of the Yamaha diagnostic tool (Malfunction mode) Malfunction results are displayed in the top part of the window area.
  • Page 443 FUEL INJECTION SYSTEM 1. Recovered The item list of the malfunction detected in the past (already recovered) are displayed. 2. Detected The item list of the malfunction currently occurred are displayed. 3. Code The following icons and the fault code numbers for the detected malfunctions are displayed. A.

  • Page 444: Troubleshooting Details

    FUEL INJECTION SYSTEM 6. Condition The current conditions are displayed. (Detected/Recovered) 7. Symptom The symptoms of the detected malfunction are displayed. 8. Diagnosis code The diagnosis codes related to the detected malfunction are displayed. 9. FFD (only for models that can display freeze frame data) The mark “...

  • Page 445: Fault Code 13

    FUEL INJECTION SYSTEM Fault code No. Crankshaft position sensor: no normal signals are received from the Item crankshaft position sensor. Improperly connected → Con- Connection of ECU coupler. Crank the engine. Check the locking condition of nect the coupler securely or re- Fault code number is not dis- played →...
  • Page 446 FUEL INJECTION SYSTEM Fault code No. Item Intake air pressure sensor: open or short circuit detected. Probable cause of malfunc- Confirmation of service com- Item Maintenance job tion and check pletion Improperly connected → Con- Connection of intake air pres- Turn the main switch to “ON”.
  • Page 447 FUEL INJECTION SYSTEM Fault code No. Item Intake air pressure sensor: open or short circuit detected. Defective intake air pressure Execute the diagnostic mode. Turn the main switch to “ON”. sensor. (Code No. 03) Fault code number is not dis- played →...
  • Page 448 FUEL INJECTION SYSTEM Fault code No. Intake air pressure sensor: hose system malfunction (clogged or de- Item tached hose). Clogged or detached hose → Condition of intake air pressure Start the engine and let it idle for sensor hose. Repair or replace the sensor approximately 5 seconds.
  • Page 449 FUEL INJECTION SYSTEM Fault code No. Item Throttle position sensor: open or short circuit detected. Improperly connected → Con- Connection of throttle position Turn the main switch to “ON”. sensor coupler. nect the coupler securely or re- Fault code number is not dis- played →...
  • Page 450 FUEL INJECTION SYSTEM Fault code No. Item Throttle position sensor: open or short circuit detected. Malfunction in ECU. Replace the ECU. Refer to “REPLACING THE ECU (engine control unit)” on page 8-128. Fault code No. 19 Fault code No. Sidestand switch: a break or disconnection of the black/red lead of Item the ECU is detected.
  • Page 451 FUEL INJECTION SYSTEM Fault code No. Sidestand switch: a break or disconnection of the black/red lead of Item the ECU is detected. Defective sidestand switch. Execute the diagnostic mode. Turn the main switch to “ON”, (Code No. 20) and then extend and retract the Shift the transmission into gear.
  • Page 452 FUEL INJECTION SYSTEM Fault code No. Item Coolant temperature sensor: open or short circuit detected. Open or short circuit → Replace Wire harness continuity. Turn the main switch to “ON”. the wire harness. Fault code number is not dis- played → Service is finished. Between coolant temperature sensor coupler and sub-wire Fault code number is displayed...
  • Page 453 FUEL INJECTION SYSTEM Fault code No. Item Intake air temperature sensor: open or short circuit detected. Improperly connected → Con- Connection of intake air temper- Turn the main switch to “ON”. ature sensor coupler. nect the coupler securely or re- Fault code number is not dis- played →...
  • Page 454 FUEL INJECTION SYSTEM Fault code No. 24 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 malfunc- Confirmation of service com- Item...
  • Page 455 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 the 7-16.
  • Page 456 Actuates the cylinder-#1 ignition coil five times at one-second intervals. Actuation The “CHECK” indicator and “ ” on the Yamaha diagnostic tool screen comes on each time the ignition coil is actuated. Check that a spark is generated five times.
  • Page 457 Actuates the cylinder-#2 ignition coil five times at one-second intervals. Actuation The “CHECK” indicator and “ ” on the Yamaha diagnostic tool screen comes on each time the ignition coil is actuated. Check that a spark is generated five times.
  • Page 458 Fully closes the ISC valve, and then opens the valve. This operation is performed 3 times and takes approximately 6 seconds each time. The Actuation “CHECK” indicator and “ ” on the Yamaha diagnostic tool screen comes on during the operation. Procedure The ISC unit vibrates when the ISC valve operates.
  • Page 459 Fully closes the ISC valve, and then opens the valve. This operation is performed 3 times and takes approximately 6 seconds each time. The Actuation “CHECK” indicator and “ ” on the Yamaha diagnostic tool screen comes on during the operation. Procedure The ISC unit vibrates when the ISC valve operates.
  • Page 460 FUEL INJECTION SYSTEM Fault code No. Component other than ISC (idle speed control) unit is defec- tive (ISC operating sound is heard). Item Defective ISC (idle speed control) unit (ISC operating sound is not heard). ISC operating sound is heard → Locate the malfunction.
  • Page 461 Actuates fuel injector #1 five times at one-second intervals. Actuation The “CHECK” indicator and “ ” on the Yamaha diagnostic tool screen comes on each time the fuel injector is actuated. Check that fuel injector #1 is actuated five times by listening for the oper- Procedure ating sound.
  • Page 462 FUEL INJECTION SYSTEM Fault code No. Item Fuel injector: open or short circuit detected. Defective fuel injector #1 and/or Measure the fuel injector resis- Execute the diagnostic mode. fuel injector #2. tance. (Code Nos. 36, 37) No operating sound → Go to Replace if out of specification.
  • Page 463 FUEL INJECTION SYSTEM Fault code No. Item Lean angle sensor: open or short circuit detected. Improperly connected → Con- Connection of lean angle sensor Turn the main switch to “ON”, coupler. nect the coupler securely or re- then to “OFF”, and then back to Check the locking condition of place the wire harness.
  • Page 464 FUEL INJECTION SYSTEM Fault code No. Rear wheel sensor: no normal signals are received from the rear wheel sensor. Item Gear position switch: open or short circuit is detected. Clutch switch: open or short circuit is detected. Check that the number increases when the rear wheel is rotated. The Procedure number is cumulative and does not reset each time the wheel is stopped.
  • Page 465 FUEL INJECTION SYSTEM Fault code No. Rear wheel sensor: no normal signals are received from the rear wheel sensor. Item Gear position switch: open or short circuit is detected. Clutch switch: open or short circuit is detected. Open or short circuit → Replace Wire harness continuity.
  • Page 466 FUEL INJECTION SYSTEM Fault code No. Rear wheel sensor: no normal signals are received from the rear wheel sensor. Item Gear position switch: open or short circuit is detected. Clutch switch: open or short circuit is detected. Value does not increase → Go Locate the malfunction.
  • Page 467 FUEL INJECTION SYSTEM Fault code No. Rear wheel sensor: no normal signals are received from the rear wheel sensor. Item Gear position switch: open or short circuit is detected. Clutch switch: open or short circuit is detected. Open or short circuit → Replace Wire harness continuity.
  • Page 468 FUEL INJECTION SYSTEM Fault code No. Rear wheel sensor: no normal signals are received from the rear wheel sensor. Item Gear position switch: open or short circuit is detected. Clutch switch: open or short circuit is detected. Delete the fault code. Turn the main switch to “ON”, and then rotate the rear wheel by hand.
  • Page 469 FUEL INJECTION SYSTEM Fault code No. Rear wheel sensor: no normal signals are received from the rear wheel sensor. Item Gear position switch: open or short circuit is detected. Clutch switch: open or short circuit is detected. Clutch lever adjustment. Refer to “ADJUSTING THE Execute the diagnostic mode.
  • Page 470 FUEL INJECTION SYSTEM Fault code No. Rear wheel sensor: no normal signals are received from the rear wheel sensor. Item Gear position switch: open or short circuit is detected. Clutch switch: open or short circuit is detected. Open or short circuit → Replace Wire harness continuity.
  • Page 471 When the relay is off, the “CHECK” indica- tor and “ ” on the Yamaha diagnostic tool screen come on.) Check that the relay unit is actuated five times by listening for the operat- Procedure ing sound.
  • Page 472 FUEL INJECTION SYSTEM Fault code No. Fuel system voltage: incorrect voltage supplied to the fuel injector Item and fuel pump. Improperly connected → Con- Connection of ECU coupler. Start the engine and let it idle for Check the locking condition of nect the coupler securely or re- approximately 5 seconds.
  • Page 473 FUEL INJECTION SYSTEM Fault code No. EEPROM fault code number: an error is detected while reading or Item writing on EEPROM. EEPROM fault code display • 00 (no history) • 01–02: Cylinder fault code number (history exists) If more than one cylinder is defective, the display switches every two Meter display seconds to show the cylinder fault code numbers of all defective cylin- ders in a repeating cycle.
  • Page 474 Check that the fault code num- ECU (engine control unit)” on ber is not displayed. page 8-128. Fault code No. 89 (Yamaha diagnostic tool) Fault code No. 89 (Yamaha diagnostic tool) Multi-function meter: signals cannot be transmitted between the Item ECU and the multi-function meter.
  • Page 475 FUEL INJECTION SYSTEM Fault code No. 89 (Yamaha diagnostic tool) Multi-function meter: signals cannot be transmitted between the Item ECU and the multi-function meter. Improperly connected → Con- Connection of meter assembly Turn the main switch to “ON”. coupler. nect the coupler securely or re- Fault code number is not dis- played →...
  • Page 476 FUEL INJECTION SYSTEM Fault code No. Err (meter display) Multi-function meter: signals cannot be transmitted between the Item ECU and the multi-function meter. Improperly connected → Con- Connection of meter assembly Turn the main switch to “ON”. coupler. nect the coupler securely or re- Fault code number is not dis- played →...
  • Page 477 FUEL INJECTION SYSTEM 8-72...

  • Page 478: Fuel Pump System

    FUEL PUMP SYSTEM EAS20081 FUEL PUMP SYSTEM EAS30513 CIRCUIT DIAGRAM 8-73...
  • Page 479 FUEL PUMP SYSTEM 1. Main switch 7. Ignition fuse 10.Fuel injection system fuse 15.Battery 16.Engine ground 18.Main fuse 22.Relay unit 24.Fuel pump relay 25.Joint coupler 37.ECU (engine control unit) 47.Fuel pump 64.Handlebar switch (right) 67.Start/engine stop switch 8-74...

  • Page 480: Troubleshooting

    FUEL PUMP SYSTEM EAS30514 TROUBLESHOOTING If the fuel pump fails to operate. • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Passenger seat 3. Center cover 4. Fuel tank side covers 5. Fuel tank 6. Headlight assembly NG → 1.
  • Page 481 FUEL PUMP SYSTEM NG → 7. Check the entire fuel pump system wiring. Properly connect or replace the wiring har- Refer to “CIRCUIT DIAGRAM” on ness. page 8-73. OK ↓ Replace the ECU. Refer to “REPLAC- ING THE ECU (engine control unit)” on page 8-128.

  • Page 482: Immobilizer System

    IMMOBILIZER SYSTEM EAS20084 IMMOBILIZER SYSTEM EAS30519 CIRCUIT DIAGRAM 8-77...
  • Page 483 IMMOBILIZER SYSTEM 1. Main switch 7. Ignition fuse 10.Fuel injection system fuse 11.Backup fuse 15.Battery 16.Engine ground 17.Immobilizer unit 18.Main fuse 25.Joint coupler 37.ECU (engine control unit) 49.Meter assembly 50.Immobilizer system indicator light 54.Multi-function meter 8-78...

  • Page 484: General Information

    IMMOBILIZER SYSTEM EAS30520 GENERAL INFORMATION This vehicle is equipped with an immobilizer system to help prevent theft by re-registering codes in the standard keys. This system consists of the following: • a code re-registering key (with a red bow) • two standard keys (with a black bow) that can be re-registered with new codes •...
  • Page 485 IMMOBILIZER SYSTEM Parts to be replaced Main switch/immobi- Key registration re- Accessory lizer unit Standard quirement lock* and Main Immobilizer switch unit √ Standard key is lost New standard key All keys have been lost Code re-registering √ √ √ √...
  • Page 486 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 487 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 488: Troubleshooting

    IMMOBILIZER SYSTEM EAS30522 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. (Ignition, fuel injection system, backup, and main) Replace the fuse(s). Refer to “CHECKING THE FUS- ES”...
  • Page 489 IMMOBILIZER SYSTEM Fault code Part Symptom Cause Action IMMOBILIZER Codes between the 1. Signal received from 1. Place the immobi- UNIT key and immobilizer other transponder lizer unit at least unit do not match. (failed to recognize 50 mm away from code after ten consecu- the transponder of tive attempts).
  • Page 490 IMMOBILIZER SYSTEM a. Light on b. Light off 8-85...
  • Page 491 IMMOBILIZER SYSTEM 8-86...

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

    ABS (ANTI-LOCK BRAKE SYSTEM) EAS20166 ABS (ANTI-LOCK BRAKE SYSTEM) EAS30988 CIRCUIT DIAGRAM 8-87...
  • Page 493 21.Rear brake light switch 25.Joint coupler 37.ECU (engine control unit) 42.Front wheel sensor 43.Rear wheel sensor 44.ABS ECU (electronic control unit) 45.Yamaha diagnostic tool coupler 49.Meter assembly 54.Multi-function meter 61.ABS warning light 64.Handlebar switch (right) 65.Front brake light switch 83.Tail/brake light assembly 84.Tail/brake light...

  • Page 494: Abs Coupler Location Chart

    ABS (ANTI-LOCK BRAKE SYSTEM) EAS30990 ABS COUPLER LOCATION CHART W B B W G G/R W/Y Y G G Br/W L/R L/B B/L G/R G/W L/R L/B Sb/W Y Dg Ch G/R Gy O W/R Y/W P W R/W R/G G/B B/W (Gy) L/R L/B...
  • Page 495 ABS (ANTI-LOCK BRAKE SYSTEM) 1. ABS ECU coupler 2. Rear wheel sensor coupler 3. Yamaha diagnostic tool coupler 4. Meter assembly coupler 5. Front wheel sensor coupler 8-90...

  • Page 496: Maintenance Of The Abs Ecu

    The following troubleshooting describes the problem identification and service method using the Yamaha diagnostic tool. For information about using the Yamaha diagnostic tool, refer to “[B-2] DIAG- NOSIS USING THE FAULT CODES” on page 8-95. For troubleshooting items other than the following items, follow the normal service method.

  • Page 497: Basic Instructions For Troubleshooting

    Previous malfunctions can be checked since the ABS ECU also stores the mal- function history. The fault codes recorded in the ABS ECU can be checked using the Yamaha diagnostic tool. When the service is finished, check the normal operation of the vehicle, and then delete the fault code(s). For in- formation about deleting the fault codes, refer to “[B-3] DELETING THE FAULT CODES”...

  • Page 498: Basic Process For Troubleshooting

    The hydraulic unit assembly Can the tool communicate with is defective. the ABS ECU? Can communicate [A-5] ABS ECU and FI ECU The connection with the Yamaha • Return to [A]. fail to communicate. diagnostic tool is defective. The wire harness is defective.

  • Page 499: [A] Checking The Abs Warning Light

    EAS31134 [A-3] THE ABS WARNING LIGHT COMES ON Connect the Yamaha diagnostic tool to the Yamaha diagnostic tool coupler and execute functional di- agnosis. (For information about how to execute functional diagnosis, refer to the operation manual that is included with the tool.) Check that communication with the ABS ECU is possible.

  • Page 500: [A-4] Only The Abs Ecu Fails To Communicate (The Select Unit Screen Does Not Appear.)

    ABS ECU coupler and ground. If there is no continuity, the wire harness is defective. Replace the wire harness. • Open circuit in the wire harness between the ABS ECU coupler and the Yamaha diagnostic tool cou- pler.
  • Page 501 ABS (ANTI-LOCK BRAKE SYSTEM) Removing the protective cap “1”, and then connect the Yamaha diagnostic tool to the coupler. Details about the displayed fault codes are shown in the following chart. Refer to this chart and check the vehicle. Once all the work is complete, delete the fault codes. [B-3] Check the inspection points after terminating the connection with the Yamaha diagnostic tool and turn- ing the main switch off.
  • Page 502 ABS (ANTI-LOCK BRAKE SYSTEM) A. Detected malfunction B. Recovered malfunction 4. ECU The types of the control units are displayed. (e.g., FI, ABS) 5. Item The item names of the detected malfunction are displayed. 6. Condition The current conditions are displayed. (Detected/Recovered) 7.
  • Page 503 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Item Symptom Check point Front wheel sensor (abnor- Front wheel sensor signal is • Foreign material adhered mal pulse period) not received properly. (The around the front wheel sen- pulse period is abnormal while the vehicle is traveling.) •...
  • Page 504 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Item Symptom Check point Rear wheel sensor (missing Rear wheel sensor signal is • Foreign material adhered pulses) not received properly. (Miss- around the rear wheel sen- ing pulses are detected in the signal while the vehicle is •...
  • Page 505 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Item Symptom Check point Front wheel ABS (intermit- • Pulses from the front wheel • Incorrect installation of the tent wheel speed pulses or sensor are received inter- front wheel sensor incorrect depressurization) mittently while the vehicle •...
  • Page 506 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Item Symptom Check point Vehicle system power supply Power voltage supplied to • Defective battery (voltage of ABS ECU power the ABS ECU in the hydrau- • Defective coupler between supply is low) lic unit assembly is too low.
  • Page 507 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Item Front wheel sensor (intermittent pulses or no pulses) Front wheel sensor signal is not received properly. (Pulses are not re- Symptom ceived or are received intermittently while the vehicle is traveling.) Order Item/components and probable cause Check or maintenance job Foreign material adhered around the front Check the surface of the sensor rotor and wheel sensor...
  • Page 508 ABS (ANTI-LOCK BRAKE SYSTEM) • Vehicle possibly ridden on uneven roads. Fault code No. Item Front wheel sensor (abnormal pulse period) Front wheel sensor signal is not received properly. (The pulse period Symptom is abnormal while the vehicle is traveling.) Order Item/components and probable cause Check or maintenance job Foreign material adhered around the front...
  • Page 509 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Item Rear wheel sensor (abnormal pulse period) Rear wheel sensor signal is not received properly. (The pulse period Symptom is abnormal while the vehicle is traveling.) Order Item/components and probable cause Check or maintenance job Defective rear wheel sensor or incorrect Check the wheel sensor for damage and the installed installation of the sensor...
  • Page 510 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Item Front wheel sensor (open or short circuit) Symptom Open or short circuit is detected in the front wheel sensor. Order Item/components and probable cause Check or maintenance job Defective front wheel sensor or hydraulic If the above items were performed and no malfunctions unit assembly were found, the wheel sensor or hydraulic unit assembly...
  • Page 511 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Item Rear wheel sensor (open or short circuit) Symptom Open or short circuit is detected in the rear wheel sensor. Order Item/components and probable cause Check or maintenance job Defective rear wheel sensor or hydraulic If the above items were performed and no malfunctions unit assembly were found, the wheel sensor or hydraulic unit assembly...
  • Page 512 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Item Rear wheel sensor (missing pulses) Rear wheel sensor signal is not received properly. (Missing pulses are Symptom detected in the signal while the vehicle is traveling.) Order Item/components and probable cause Check or maintenance job Foreign material adhered around the rear Check the surface of the sensor rotor and wheel sensor wheel sensor...
  • Page 513 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Item Brake light switch or tail/brake light Brake light signal is not received properly while the vehicle is travel- Symptom ing (Brake light circuit, or front or rear brake light switch circuit). Order Item/components and probable cause Check or maintenance job Open or short circuit in the wire harness •...
  • Page 514 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. 32 Fault code No. Hydraulic unit assembly (short circuit in ABS solenoid power supply Item circuit) Short circuit is detected in the solenoid power supply circuit in the hy- Symptom draulic unit assembly. Order Item/components and probable cause Check or maintenance job Defective hydraulic unit assembly...
  • Page 515 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. 41 Fault code No. Front wheel ABS (intermittent wheel speed pulses or incorrect de- Item pressurization) • Pulses from the front wheel sensor are received intermittently while the vehicle is traveling. Symptom • Front wheel will not recover from the locking tendency even though the signal is transmitted from the ABS ECU to reduce the hydraulic pressure.
  • Page 516 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Rear wheel ABS (intermittent wheel speed pulses or incorrect depres- Item surization) • Pulses from the rear wheel sensor are received intermittently while the vehicle is traveling. (for fault code No. 42) Symptom •...
  • Page 517 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. 44 Fault code No. Item Rear wheel sensor (missing pulses) Rear wheel sensor signal is not received properly. (Missing pulses are Symptom detected in the signal while the vehicle is traveling.) Order Item/components and probable cause Check or maintenance job Foreign material adhered around the rear Check the surface of the sensor rotor and wheel sensor...
  • Page 518 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Vehicle system power supply (voltage of ABS ECU power supply is Item low) Power voltage supplied to the ABS ECU in the hydraulic unit assem- Symptom bly is too low. Order Item/components and probable cause Check or maintenance job Defective battery Recharge or replace the battery.
  • Page 519 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. 55 Fault code No. Item Hydraulic unit assembly (defective ABS ECU) Symptom Abnormal data is detected in the hydraulic unit assembly. Order Item/components and probable cause Check or maintenance job Defective hydraulic unit assembly Replace the hydraulic unit assembly.
  • Page 520 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Item Front wheel sensor power supply (voltage of power supply is low) Power voltage supplied from the ABS ECU to the front wheel sensor is Symptom too low. Order Item/components and probable cause Check or maintenance job Defective front wheel sensor •...

  • Page 521: [B-3] Deleting The Fault Codes

    EAS31139 [B-3] DELETING THE FAULT CODES To delete the fault codes, use the Yamaha diagnostic tool. For information about deleting the fault codes, refer to the operation manual of the Yamaha diagnostic tool. Check that all the displayed fault codes are deleted.
  • Page 522 ABS (ANTI-LOCK BRAKE SYSTEM) Checking procedures 1. Check the brake fluid level in the brake master cylinder reservoir and brake fluid reservoir. Refer to “CHECKING THE BRAKE FLUID LEVEL” on page 3-15. 2. Check the wheel sensors for proper installation. Refer to “INSTALLING THE FRONT WHEEL (DISC BRAKE)”...
  • Page 523 ABS (ANTI-LOCK BRAKE SYSTEM) 8-118...

  • Page 524: Electrical Components

    ELECTRICAL COMPONENTS EAS20089 ELECTRICAL COMPONENTS 8-119...
  • Page 525 ELECTRICAL COMPONENTS 1. Main switch 2. Front brake light switch 3. Clutch switch 4. Rectifier/regulator 5. Ignition coil 6. Battery 7. Fuse box 1 8. Fuse box 2 9. Main fuse 10. Starter relay 11. Rear brake light switch 12. Sidestand switch 13.
  • Page 526 ELECTRICAL COMPONENTS 8-121...
  • Page 527 ELECTRICAL COMPONENTS 1. Intake air temperature sensor 2. Hydraulic unit assembly 3. Intake solenoid 4. Intake air pressure sensor 5. Fuel pump 6. Lean angle sensor 7. Rear wheel sensor 8. Coolant temperature sensor 9. Crankshaft position sensor 10. Fuel injector 11.

  • Page 528: Checking The Switches

    ELECTRICAL COMPONENTS EAS30549 CHECKING THE SWITCHES Dg Br/W L/B Y L/B G R/W L/W Br/W L/B Y Br/W Br/W Br B/W B/L B/L Br/R R/W Br/L Br/R Br Y Br/L 8-123...
  • Page 529 ELECTRICAL COMPONENTS 1. Start/engine stop switch 2. Hazard switch 3. Front brake light switch 4. Rear brake light switch 5. Sidestand switch 6. Main switch 7. Clutch switch 8. Horn switch 9. Turn signal switch 10. Pass switch 11. Dimmer switch 8-124...
  • Page 530 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. ECA18520 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 531: Checking The Bulbs And Bulb Sockets

    ELECTRICAL COMPONENTS EAS30550 EWA13320 CHECKING THE BULBS AND BULB WARNING SOCKETS Since the headlight bulb gets extremely hot, Check each bulb and bulb socket for damage or keep flammable products and your hands wear, proper connections, and also for continuity away from the bulb until it has cooled down.

  • Page 532: Checking The Fuses

    ELECTRICAL COMPONENTS Checking the condition of the bulb sockets Pocket tester The following procedure applies to all of the bulb 90890-03112 sockets. Analog pocket tester 1. Check: YU-03112-C • Bulb socket (for continuity) (with the pocket tester) b. If the pocket tester indicates “∞”, replace the No continuity →...

  • Page 533: Replacing The Ecu (Engine Control Unit)

    ELECTRICAL COMPONENTS 4. Install: • Drink large quantities of water or milk fol- • Center cover lowed with milk of magnesia, beaten egg or Refer to “GENERAL CHASSIS (2)” on page vegetable oil. Get immediate medical atten- 4-3. tion. • Rider seat ECA13661 •...
  • Page 534 ELECTRICAL COMPONENTS 3. Remove: • Battery Refer to “GENERAL CHASSIS (1)” on page 4-1. 4. Check: • Battery charge ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect a pocket tester to the battery termi- nals.
  • Page 535 ELECTRICAL COMPONENTS • As shown in the following illustration, the d. Adjust the voltage so that the current is at the open-circuit voltage of a VRLA (Valve Reg- standard charging level. ulated Lead Acid) battery stabilizes about e. Set the time according to the charging time 30 minutes after charging has been com- suitable for the open-circuit voltage.

  • Page 536: Checking The Relays

    ELECTRICAL COMPONENTS 6. Install: Starter relay • Battery Refer to “GENERAL CHASSIS (1)” on page 4-1. 7. Connect: • Battery leads (to the battery terminals) L/W R/W ECA13630 NOTICE First, connect the positive battery lead “1”, and then the negative battery lead “2”. 1.

  • Page 537: Checking The Turn Signal/Hazard Relay

    ELECTRICAL COMPONENTS EAS30794 2. Negative battery terminal CHECKING THE TURN SIGNAL/HAZARD 3. Positive tester probe RELAY 4. Negative tester probe 1. Check: • Turn signal/hazard relay input voltage Result Out of specification → The wiring circuit from Continuity the main switch to the turn signal/hazard re- (between “3”...

  • Page 538: Checking The Relay Unit (Diode)

    ELECTRICAL COMPONENTS Pocket tester Continuity 90890-03112 Positive tester probe Analog pocket tester Sky blue “1” YU-03112-C Negative tester probe Black/yellow “2” No continuity • Positive tester probe Positive tester probe Brown/white “1” Black/yellow “2” • Negative tester probe Ground Negative tester probe Sky blue “1”...

  • Page 539: Checking The Ignition Coils

    ELECTRICAL COMPONENTS c. Check the relay unit (diode) for continuity. Pocket tester d. Check the relay unit (diode) for no continuity. 90890-03112 ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ Analog pocket tester YU-03112-C EAS30558...

  • Page 540: Checking The Crankshaft Position Sensor

    ELECTRICAL COMPONENTS Gy B b. Measure the crankshaft position sensor re- 2. Ignition coil sistance. c. Turn the main switch to “ON”. ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ d.

  • Page 541: Checking The Starter Motor Operation

    ELECTRICAL COMPONENTS EAS30566 CHECKING THE STATOR COIL 1. Disconnect: • Stator coil coupler (from the wire harness) 2. Check: • Stator coil resistance Out of specification → Replace the stator coil. Stator coil resistance 0.128–0.192 Ω (W-W) c. Set the main switch to “ON”. ▼...

  • Page 542: Checking The Fuel Sender

    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 543: Checking The Radiator Fan Motor

    ELECTRICAL COMPONENTS Coolant temperature sensor re- sistance 2510–2780 Ω@20 °C (2510–2780 Ω@68 °F) ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect the pocket tester (Ω × 1 k) to the coolant temperature sensor as shown.

  • Page 544: Checking The Throttle Position Sensor

    ELECTRICAL COMPONENTS EAS30581 CHECKING THE THROTTLE POSITION When installing the throttle position sensor, ad- SENSOR just its angle properly. Refer to “ADJUSTING 1. Remove: THE THROTTLE POSITION SENSOR” on page • Throttle position sensor 7-15. (from the throttle body) EWA16690 WARNING EAS30593 CHECKING THE INTAKE AIR PRESSURE...

  • Page 545: Checking The Intake Air Temperature Sensor

    ELECTRICAL COMPONENTS c. Set the main switch to “ON”. e. Measure the intake air temperature sensor d. Measure the intake air pressure sensor out- resistance. put voltage. ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲...

  • Page 546: Checking The Fuel Injectors

    ELECTRICAL COMPONENTS 2. Check: • Gear position switch Out of specification → Replace the gear posi- tion switch. O Y/W W Sb Pocket tester 90890-03112 Analog pocket tester YU-03112-C Result EAS30681 CHECKING THE FUEL INJECTORS Neutral position The following procedure applies to all of the fuel Continuity Positive tester probe injectors.

  • Page 547: Troubleshooting

    TROUBLESHOOTING TROUBLESHOOTING..................9-1 GENERAL INFORMATION ............... 9-1 STARTING FAILURE ................9-1 INCORRECT ENGINE IDLING SPEED ............ 9-1 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ......9-2 FAULTY GEAR SHIFTING................ 9-2 SHIFT PEDAL DOES NOT MOVE ............9-2 JUMPS OUT OF GEAR................9-2 FAULTY CLUTCH ..................9-2 OVERHEATING ..................9-2 OVERCOOLING..................9-3 POOR BRAKING PERFORMANCE............

  • Page 548: Troubleshooting

    TROUBLESHOOTING Electrical system EAS20090 TROUBLESHOOTING 1. Battery • Discharged battery EAS30599 • 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 549: Poor Medium-And-High-Speed Performance

    TROUBLESHOOTING Electrical system EAS30605 JUMPS OUT OF GEAR 1. Battery • Discharged battery Shift shaft • Faulty battery • Incorrect shift pedal position 2. Spark plug(s) • Improperly returned stopper lever • Incorrect spark plug gap • Incorrect spark plug heat range Shift forks •...

  • Page 550: Overcooling

    TROUBLESHOOTING 2. Engine oil • Faulty brake caliper seal • Incorrect oil level • Loose union bolt • 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 •...

  • Page 551: Faulty Lighting Or Signaling System

    TROUBLESHOOTING Rear shock absorber assembly • Faulty battery • Faulty rear shock absorber spring • Blown, damaged or incorrect fuse • Leaking oil or gas Turn signal blinks slowly Tire(s) • Faulty turn signal/hazard relay • Uneven tire pressures (front and rear) •...

  • Page 552: Self-Diagnostic Function And Diagnostic Code Table

    SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE EAS20116 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE EAS31118 SELF-DIAGNOSTIC FUNCTION TABLE For details of the fault code, refer to “TROUBLESHOOTING METHOD” on page 8-35. Fault code Item Crankshaft position sensor: no normal signals are received from the crankshaft position sen- sor.

  • Page 553: Communication Error With The Meter

    COMMUNICATION ERROR WITH THE METER For details of the fault code, refer to “TROUBLESHOOTING METHOD” on page 8-35. Fault code No. Item 89 (Yamaha diagnostic tool) Multi-function meter: signals cannot be transmitted between the ECU and Err (meter display) the multi-function meter.
  • Page 554 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Diagnostic Item Meter display Procedure code No. Sidestand switch Extend and retract the side- stand (with the transmission in gear). • Stand retracted • Stand extended Neutral switch and clutch Operate the transmission, switch clutch lever, and sidestand.

  • Page 555: Diagnostic Code: Actuator Operation Table

    Check that a spark is gener- coil five times at one-second ated five times. intervals. • Connect an ignition check- The “CHECK” indicator and “ ” on the Yamaha diag- nostic tool screen come on each time the ignition coil is actuated.
  • Page 556 • Connect an ignition check- The “CHECK” indicator and “ ” on the Yamaha diag- nostic tool screen come on each time the ignition coil is actuated. Fuel injector #1 Actuates fuel injector #1 five...
  • Page 557 The “CHECK” indicator and sound. “ ” on the Yamaha diag- nostic tool screen come on each time the relay is actuat- ISC valve Fully closes the ISC valve, The ISC unit vibrates when and then opens the valve.

  • Page 558: Event Code Table

    EVENT CODE TABLE EAS20164 EVENT CODE TABLE Item Symptom Possible cause Remarks Intake air pressure sen- Brief abnormality de- Same as for fault code Perform the checks and tected in intake air pres- number 13 maintenance jobs for sure sensor fault code number 13.
  • Page 559 EVENT CODE TABLE Item Symptom Possible cause Remarks ISC (idle speed control) Correction value re- Low engine idling • Execute the diagnos- (Correction value re- mains at upper limit speed tic mode (diagnostic mains at upper limit) while the engine is •...

  • Page 560: Wiring Diagram

    42. Front wheel sensor White/Red 43. Rear wheel sensor White/Yellow 44. ABS ECU (electronic control Yellow/Black unit) Yellow/Green 45. Yamaha diagnostic tool coupler Yellow/Blue 46. Fuel sender Yellow/White 47. Fuel pump 48. Oil pressure switch 49. Meter assembly 50. Immobilizer system indicator light 51.

  • Page 563: Wiring Diagrams

    MT07A 2014 MT07A 2014 MT07A 2014 MT07A 2014 MT07A 2014 WIRING DIAGRAM SCHÉMA DE CÂBLAGE SCHALTPLAN SCHEMA ELETTRICO DIAGRAMA ELÉCTRICO R/G W/G Br/L P/L P/L Br/L L W B/L L/W L/WL/WL/W R/W R/W R/W R/W R/W R/W R/W R/W O R/B G/W B/L W Y/W W/R Y/L G/B R/W...
  • Page 564 MT07A 2014 MT07A 2014 MT07A 2014 MT07A 2014 MT07A 2014 WIRING DIAGRAM SCHÉMA DE CÂBLAGE SCHALTPLAN SCHEMA ELETTRICO DIAGRAMA ELÉCTRICO (Gy) (Gy) ( B ) ( B ) (Gy) (Gy) (Gy) (Gy) (Gy) (Gy)

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