Yamaha FZ09E 2014 Service Manual
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Yamaha FZ09E 2014 Service Manual

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Table of Contents

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2014
SERVICE MANUAL
FZ09E
FZ09EC
LIT-11616-27-39
1RC-28197-10

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Summary of Contents for Yamaha FZ09E 2014

  • Page 1 2014 SERVICE MANUAL FZ09E FZ09EC LIT-11616-27-39 1RC-28197-10...
  • Page 3 EAS20050 FZ09E FZ09EC SERVICE MANUAL ©2013 by Yamaha Motor Corporation, U.S.A. First edition, August 2013 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in U.S.A. P/N LIT-11616-27-39...
  • Page 4 If there is any question about a service procedure, it is imperative that you contact a Yamaha dealer for any service information changes that apply to this model. This policy is intended to provide the customer with the most satisfaction from his vehicle and to conform to federal environmental quality objectives.

  • Page 5: How To Use This Manual

    EAS20091 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. •...

  • Page 6: Symbols

    EAS20101 SYMBOLS The following symbols are used in this manual for easier understanding. The following symbols are not relevant to every vehicle. SYMBOL DEFINITION SYMBOL DEFINITION Serviceable with engine mounted Gear oil Filling fluid Molybdenum disulfide oil Lubricant Brake fluid Special tool Wheel bearing grease Tightening torque...

  • Page 7: Table Of Contents

    TABLE OF CONTENTS EAS20110 GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE COOLING SYSTEM FUEL SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING...
  • Page 9 MODEL LABEL...................1-1 FEATURES .......................1-2 OUTLINE OF THE FI SYSTEM ..............1-2 FI SYSTEM ....................1-3 INSTRUMENT FUNCTIONS ..............1-4 YCC-T (Yamaha Chip Controlled Throttle) ..........1-9 IMPORTANT INFORMATION.................1-11 PREPARATION FOR REMOVAL AND DISASSEMBLY ......1-11 REPLACEMENT PARTS ................1-11 GASKETS, OIL SEALS AND O-RINGS ...........1-11 LOCK WASHERS/PLATES AND COTTER PINS ........1-11 BEARINGS AND OIL SEALS ..............1-11...

  • Page 10: Identification

    IDENTIFICATION EAS20130 IDENTIFICATION EAS20140 VEHICLE IDENTIFICATION NUMBER The vehicle identification number “1” is stamped into the right side of the steering head pipe. EAS20150 MODEL LABEL The model label “1” is affixed to the frame. This information will be needed to order spare parts.

  • Page 11: Features

    FEATURES EAS20170 FEATURES EAS1RC1101 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 EAS1RC1102 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 remain open.

  • Page 13: Instrument Functions

    FEATURES • a self-diagnosis device EAS1RC1103 INSTRUMENT FUNCTIONS • a brightness control mode Multi-function meter unit • Be sure to turn the key to “ON” before using the “SELECT” and “RESET” buttons. • To switch the speedometer and multi-function displays between kilometers and miles, press the “SELECT”...
  • Page 14 FEATURES To set the clock This indicator comes on when the vehicle is be- 1. Turn the key to “ON”. ing operated in an environmentally friendly, fu- 2. Push the “SELECT” button and “RESET” but- el-efficient manner. The indicator goes off when ton together for at least two seconds.
  • Page 15 FEATURES km/L, AVE_ _._ L/100 km or AVE_ _._ MPG  Multi-function display F  Air_ _ F  ODO  TRIP 1  TRIP 2  F-TRIP To reset a tripmeter, select it by pushing the “SE- LECT” button, and then push the “RESET” but- ton for at least one second.
  • Page 16 FEATURES Average fuel consumption mode • When the coolant temperature is below 104 F, “LO” will be displayed. • The coolant temperature varies with changes in the weather and engine load. Air intake temperature display 1. Average fuel consumption display The average fuel consumption display can be set to either “AVE_ _._ km/L”, “AVE_ _._ L/100 km”...
  • Page 17 FEATURES the drive mode switch. ECA11591 NOTICE Mode “STD” If the display indicates an error code, the ve- Mode “STD” is suitable for various riding condi- hicle should be checked as soon as possible tions. in order to avoid engine damage. This mode allows the rider to enjoy smooth and Brightness control mode sporty drivability from the low-speed range to the...

  • Page 18: Ycc-T (Yamaha Chip Controlled Throttle)

    Yamaha developed the YCC-T system employing the most advanced electronic control technologies. Electronic control throttle systems have been used on automobiles, but Yamaha has developed a fast- er, more compact system specifically for the needs of a sports motorcycle. The Yamaha-developed system has a high-speed calculating capacity that produces computations of running conditions every 1/1000th of a second.
  • Page 19 FEATURES YCC-T system outline 1. Throttle position sensor 2. Throttle servo motor 3. Accelerator position sensor 4. ECU (engine control unit) 5. Sensor input 6. Gear position sensor 7. Crankshaft position sensor 8. Speed sensor 9. Coolant temperature sensor 1-10...

  • Page 20: Important Information

    5. Keep all parts away from any source of fire. EAS20200 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace- ments. Use oil and grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality.

  • Page 21: Circlips

    IMPORTANT INFORMATION manufacturer marks or numbers are visible. low any items other than the specified one to When installing oil seals, lubricate the oil seal contact the parts. lips with a light coat of lithium-soap-based grease. Oil bearings liberally when installing, if appropriate.

  • Page 22: Basic Service Information

    BASIC SERVICE INFORMATION EAS30380 BASIC SERVICE INFORMATION EAS30390 QUICK FASTENERS Rivet type 1. Remove: • Quick fastener To remove the quick fastener, push its pin with a screwdriver, then pull the fastener out. 2. Install: • Quick fastener To install the quick fastener, insert the fastener into the part to be secured and tighten the screw “a”.
  • Page 23 BASIC SERVICE INFORMATION the battery, be sure to disconnect the nega- while only the negative battery lead is con- tive battery lead first, then the positive bat- nected, a spark could be generated, which is tery lead. If a tool or similar item contacts the extremely dangerous.
  • Page 24 BASIC SERVICE INFORMATION ECA16640 NOTICE When resetting the ECU by turning the main For waterproof couplers, never insert the switch to “OFF”, be sure to wait approximately tester probes directly into the coupler. When 5 seconds before turning the main switch back performing any checks using a waterproof to “ON”.
  • Page 25 BASIC SERVICE INFORMATION • Make sure all connections are tight. ECA16790 NOTICE When disconnecting a connector, do not pull the leads. Hold both sections of the connec- tor securely, and then disconnect the con- nector. 4. Check: • Continuity (with the pocket tester) Pocket tester 90890-03112 Analog pocket tester...
  • Page 26 BASIC SERVICE INFORMATION 5. Check: • Resistance Pocket tester 90890-03112 Analog pocket tester YU-03112-C The resistance values shown were obtained at the standard measuring temperature of 20 C (68 F). If the measuring temperature is not 20 C (68 F), the specified measuring conditions will be shown.

  • Page 27: Special Tools

    SPECIAL TOOLS EAS20260 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country. When placing an order, refer to the list provided below to avoid any mistakes.
  • Page 28 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Flywheel puller 5-32 90890-01362 Heavy duty puller YU-33270-B Steering nut wrench 3-18, 4-61 90890-01403 Exhaust flange nut wrench YU-A9472 Damper rod holder 4-52, 4-53 90890-01423 Damping rod holder YM-01423 Oil filter wrench 3-23 90890-01426 YU-38411...
  • Page 29 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Rod puller 4-55, 4-56, 90890-01437 4-57 Universal damping rod bleeding tool set YM-A8703 YM-A8703 Fork spring compressor 4-51, 4-56, 90890-01441 4-57 YM-01441 Fork seal driver 4-54, 4-55 90890-01442 Adjustable fork seal driver (36–46 mm) YM-01442 Pivot shaft wrench adapter 5-7, 5-8...
  • Page 30 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Sheave holder 5-32, 5-33 90890-01701 Primary clutch holder YS-01880-A Compression gauge 90890-03081 Engine compression tester YU-33223 Vacuum gauge 90890-03094 Vacuummate YU-44456 YU-44456 Pocket tester 1-16, 1-17, 90890-03112 8-91, 8-92, Analog pocket tester 8-93, 8-97, YU-03112-C 8-98, 8-99,...
  • Page 31 90890-03207 YU-03207 Test harness- lean angle sensor (6P) 8-101 90890-03209 YU-03209 Fuel injector pressure adapter 7-11 90890-03210 YU-03210 Yamaha diagnostic tool 8-37 90890-03215 Valve spring compressor 5-23, 5-28 90890-04019 YM-04019 Middle driven shaft bearing driver 6-11 90890-04058 Middle drive bearing installer 40 & 50 mm...
  • Page 32 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Mechanical seal installer 6-11 90890-04078 Water pump seal installer YM-33221-A Universal clutch holder 5-42, 5-45 90890-04086 YM-91042 Valve lapper 90890-04101 Valve lapping tool YM-A8998 Valve spring compressor attachment 5-23, 5-28 90890-04108 Valve spring compressor adapter 22 mm YM-04108 Valve guide remover (ø4.5) 5-25...
  • Page 33 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Extension 90890-04136 Piston installing tool 5-68 90890-04161 YM-04161 Camshaft wrench 5-12, 5-14 90890-04162 YM-04162 Ignition checker 8-100 90890-06754 Oppama pet-4000 spark checker YM-34487 Yamaha bond No.1215 5-34, 5-57 (Three bond No.1215®) 90890-85505 1-24...
  • Page 34 SPECIAL TOOLS 1-25...

  • Page 35: Specifications

    SPECIFICATIONS GENERAL SPECIFICATIONS................2-1 ENGINE SPECIFICATIONS ................2-2 CHASSIS SPECIFICATIONS ................2-7 ELECTRICAL SPECIFICATIONS ..............2-10 TIGHTENING TORQUES ................2-13 GENERAL TIGHTENING TORQUE SPECIFICATIONS ......2-13 ENGINE TIGHTENING TORQUES ............2-14 CHASSIS TIGHTENING TORQUES ............2-18 LUBRICATION POINTS AND LUBRICANT TYPES........2-22 ENGINE ....................2-22 CHASSIS ....................2-23 LUBRICATION SYSTEM CHART AND DIAGRAMS........2-25 ENGINE OIL LUBRICATION CHART............2-25 LUBRICATION DIAGRAMS ..............2-27 COOLING SYSTEM DIAGRAMS ..............2-37...

  • Page 36: General Specifications

    GENERAL SPECIFICATIONS EAS20280 GENERAL SPECIFICATIONS Model Model FZ09E 1RC4 FZ09EC 1RC5 Dimensions Overall length 2075 mm (81.7 in) Overall width 815 mm (32.1 in) Overall height 1135 mm (44.7 in) Seat height 815 mm (32.1 in) Wheelbase 1440 mm (56.7 in) Ground clearance 135 mm (5.31 in) Minimum turning radius...

  • Page 37: Engine Specifications

    ENGINE SPECIFICATIONS EAS20290 ENGINE SPECIFICATIONS Engine Engine type Liquid cooled 4-stroke, DOHC Displacement 847 cm Cylinder arrangement Inline 3-cylinder Bore  stroke 78.0  59.1 mm (3.07  2.33 in) Compression ratio 11.50 : 1 Standard compression pressure (at sea level) 1530 kPa/680 r/min (15.3 kgf/cm /680 r/min, 217.6 psi/680 r/min)
  • Page 38 ENGINE SPECIFICATIONS Radiator cap opening pressure 93.3–122.7 kPa (0.93–1.23 kgf/cm , 13.5–17.8 psi) Radiator core Width 340.0 mm (13.39 in) Height 222.6 mm (8.76 in) Depth 22.0 mm (0.87 in) Water pump Water pump type Single suction centrifugal pump 47/47  29/22 (1.318) Reduction ratio Impeller shaft tilt limit 0.15 mm (0.006 in)
  • Page 39 ENGINE SPECIFICATIONS Valve guide inside diameter (exhaust) 4.500–4.512 mm (0.1772–0.1776 in) Limit 4.542 mm (0.1788 in) Valve-stem-to-valve-guide clearance (intake) 0.010–0.037 mm (0.0004–0.0015 in) Limit 0.080 mm (0.0032 in) Valve-stem-to-valve-guide clearance (ex- 0.025–0.052 mm (0.0010–0.0020 in) haust) Limit 0.100 mm (0.0039 in) Valve stem runout 0.010 mm (0.0004 in) Valve spring...
  • Page 40 ENGINE SPECIFICATIONS End gap (installed) 0.30–0.45 mm (0.0118–0.0177 in) Limit 0.80 mm (0.0315 in) Ring side clearance 0.020–0.055 mm (0.0008–0.0022 in) Limit 0.115 mm (0.0045 in) Oil ring End gap (installed) 0.10–0.40 mm (0.0039–0.0157 in) Connecting rod Oil clearance 0.027–0.051 mm (0.0011–0.0020 in) Bearing color code 1.
  • Page 41 ENGINE SPECIFICATIONS Shifting mechanism Shift mechanism type Shift drum and guide bar Shift fork guide bar bending limit 0.050 mm (0.0020 in) Shift fork thickness 5.76–5.89 mm (0.2268–0.2319 in) Air filter Air filter element Oil-coated paper element Fuel pump Pump type Electrical Maximum consumption amperage 3.3 A...

  • Page 42: Chassis Specifications

    CHASSIS SPECIFICATIONS EAS20300 CHASSIS SPECIFICATIONS Chassis Frame type Diamond 25.00  Caster angle Trail 103 mm (4.1 in) Front wheel Wheel type Cast wheel Rim size 17M/C x MT3.50 Rim material Aluminum Wheel travel 137.0 mm (5.39 in) Radial wheel runout limit 1.0 mm (0.04 in) Lateral wheel runout limit 0.5 mm (0.02 in)
  • Page 43 CHASSIS SPECIFICATIONS Brake disc runout limit (as measured on 0.10 mm (0.0039 in) wheel) 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...
  • Page 44 CHASSIS SPECIFICATIONS Rebound damping adjusting positions Minimum 3 turn(s) out* Standard 1 3/4 turn(s) out* Maximum Adjusting screw fully turned in *With the adjusting screw fully turned in Rear suspension Type Swingarm (link suspension) Spring/shock absorber type Coil spring/gas-oil damper Rear shock absorber assembly travel 60.0 mm (2.36 in) Spring free length...
  • Page 45 ELECTRICAL SPECIFICATIONS EAS20310 ELECTRICAL SPECIFICATIONS Voltage System voltage 12 V Ignition system Ignition system 5.0 1200 r/min Ignition timing (B.T.D.C.) Engine control unit Model/manufacturer TBDFK4/DENSO Ignition coil Minimum ignition spark gap 6.0 mm (0.24 in) 1.19–1.61  Primary coil resistance Secondary coil resistance 9.35–12.65 k...

  • Page 46: Electrical Specifications

    ELECTRICAL SPECIFICATIONS Electric starting system System type Constant mesh Starter motor Power output 0.70 kW 0.0050–0.0150  Armature coil resistance Brush overall length 12.0 mm (0.47 in) Limit 6.50 mm (0.26 in) Brush spring force 6.03–6.52 N (615–665 gf, 21.71–23.47 oz) Mica undercut (depth) 0.70 mm (0.03 in) Starter relay...
  • Page 47 ELECTRICAL SPECIFICATIONS Spare fuse 2.0 A 2-12...

  • Page 48: Tightening Torques

    TIGHTENING TORQUES EAS20320 TIGHTENING TORQUES EAS20331 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 49: Engine Tightening Torques

    TIGHTENING TORQUES EAS20340 ENGINE TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Spark plug 13 Nm (1.3 m·kgf, 9.4 ft·lbf) Cylinder head bolt See TIP. Cylinder head bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Intake camshaft cap bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Exhaust camshaft cap bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Camshaft cap bolt...
  • Page 50 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Throttle body joint clamp screw 3.0 Nm (0.30 m·kgf, 2.2 ft·lbf) Air filter case cover screw 1.6 Nm (0.16 m·kgf, 1.2 ft·lbf) Air filter case joint clamp screw 2.8 Nm (0.28 m·kgf, 2.0 ft·lbf) Fuel injector adapter bolt 12 Nm (1.2 m·kgf, 8.7 ft·lbf) Air filter case bolt...
  • Page 51 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Intake air pressure sensor screw 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Stator coil bolt 14 Nm (1.4 m·kgf, 10 ft·lbf) Oil level switch bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Starter motor bolt 12 Nm (1.2 m·kgf, 8.7 ft·lbf) Starter motor lead nut 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
  • Page 52 TIGHTENING TORQUES Cylinder head bolt 1. Tighten the bolts to 25 Nm (2.5 m·kgf, 18 ft·lbf) with a torque wrench following the tightening order. 2. Perform the following procedure to all the bolts one by one in the tightening sequence as shown in the illustration.

  • Page 53: Chassis Tightening Torques

    TIGHTENING TORQUES EAS20350 CHASSIS TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Engine mounting bolt (front upper 45 Nm (4.5 m·kgf, 33 ft·lbf) and front lower) Engine mounting nut (rear upper) 45 Nm (4.5 m·kgf, 33 ft·lbf) Engine mounting nut (rear lower) 45 Nm (4.5 m·kgf, 33 ft·lbf) Engine mounting adjust bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
  • Page 54 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Front brake master cylinder res- 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf) ervoir cap screw Clutch lever holder pinch bolt 11 Nm (1.1 m·kgf, 8.0 ft·lbf) Horn bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Front fender bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Meter bracket bolt...
  • Page 55 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Passenger footrest and rear 28 Nm (2.8 m·kgf, 20 ft·lbf) frame bolt Rear brake fluid reservoir nut 3.8 Nm (0.38 m·kgf, 2.8 ft·lbf) Sidestand bracket bolt 48 Nm (4.8 m·kgf, 35 ft·lbf) Sidestand switch bolt 4.3 Nm (0.43 m·kgf, 3.1 ft·lbf) Adapter bracket and frame bolt...
  • Page 56 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Thermostat assembly bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Fuel rail bolt 5 Nm (0.5 m·kgf, 3.6 ft·lbf) Air scoop bolt 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf) Canister bolt (for California only) 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Canister bracket bolt (for Califor- 7 Nm (0.7 m·kgf, 5.1 ft·lbf)

  • Page 57: Lubrication Points And Lubricant Types

    LUBRICATION POINTS AND LUBRICANT TYPES EAS20360 LUBRICATION POINTS AND LUBRICANT TYPES EAS20370 ENGINE Lubrication point Lubricant Oil seal lips O-rings Water or Coolant hose insertion part Bearings Cylinder head cover bolt gasket and timing chain bolt gasket Camshaft lobes and journals (intake and exhaust) Valve stem seals (intake and exhaust) Valve lifter outer surface (intake and exhaust) Valve stems and stem ends (intake and exhaust)

  • Page 58: Chassis

    Shit drum moving surface Shift fork pin Shift forks guide bar outer surface Shift shaft washer Shift shaft moving surface Yamaha bond No. 1215 Crankcase mating surface (Three bond No. 1215®) Yamaha bond No. 1215 Stator coil assembly lead grommet (Three bond No.
  • Page 59 LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant Shift pedal pivoting parts Rear footrest ball and metal-to-metal moving parts Shift shaft joint rod moving parts Front wheel oil seal (left and right) Rear wheel oil seal Rear wheel drive hub oil seal Rear wheel drive hub mating surface Brake caliper piston seal Master cylinder inside...

  • Page 60: Lubrication System Chart And Diagrams

    LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART 2-25...
  • Page 61 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil strainer 2. Oil pump 3. Relief valve 4. Oil cooler 5. Oil filter cartridge 6. Main gallery 7. Drive axle 8. Main axle 9. Shift fork (upper) 10. Mission shower 11. Crankshaft 12. AC magneto 13.

  • Page 62: Lubrication Diagrams

    LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20410 LUBRICATION DIAGRAMS 2-27...
  • Page 63 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil level switch 2. Oil filter cartridge union bolt 3. Oil filter cartridge 4. Crankshaft 2-28...
  • Page 64 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-29...
  • Page 65 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Timing chain tensioner 2. Intake camshaft 3. Exhaust camshaft 4. Balancer shaft 5. Crankshaft 6. Oil cooler 7. Oil strainer 8. Oil drain bolt 9. Oil pump driven sprocket 2-30...
  • Page 66 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-31...
  • Page 67 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil cooler 2. Oil filter cartridge 3. Oil level switch 4. Oil strainer 5. Oil pump 6. Main gallery bolt 2-32...
  • Page 68 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-33...
  • Page 69 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Balancer shaft 2. Crankshaft 3. Main axle 4. Shift fork guide bar (shift fork-C side) 5. Drive axle 6. Sub gallery bolt 7. Shift fork 2-34...
  • Page 70 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-35...
  • Page 71 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Cylinder head 2. Exhaust camshaft 3. Intake camshaft 4. Oil passage to the timing chain tensioner 5. Oil passage to the cylinder head 6. Oil passage to the clutch chamber 7. Oil return passage from the cylinder head 8.

  • Page 72: Cooling System Diagrams

    COOLING SYSTEM DIAGRAMS EAS20420 COOLING SYSTEM DIAGRAMS 2-37...
  • Page 73 COOLING SYSTEM DIAGRAMS 1. Water pump 2. Thermostat 3. Radiator 2-38...
  • Page 74 COOLING SYSTEM DIAGRAMS 2-39...
  • Page 75 COOLING SYSTEM DIAGRAMS 1. Water jacket 2. Thermostat 3. Radiator 4. Water pump 5. Oil cooler 6. Coolant reservoir 2-40...

  • Page 76: Cable Routing

    CABLE ROUTING EAS20430 CABLE ROUTING Handlebar (top view) 2-41...
  • Page 77 CABLE ROUTING 1. Front brake master cylinder 2. Throttle cable 3. Rubber cover 4. Handlebar 5. Front brake hose A. When installing the rubber cover, silicone water or soapy water may be applied to the inside of the rubber cover. B.
  • Page 78 CABLE ROUTING Handlebar (front view) 2-43...
  • Page 79 CABLE ROUTING 1. Throttle cable 2. Meter lead 3. Meter assembly 4. Left handlebar switch lead 5. Horn lead 6. Wire harness 7. Right handlebar switch lead 8. Main switch lead 9. Horn lead 10. Handlebar switch coupler 11. Headlight 12.
  • Page 80 CABLE ROUTING Radiator (front side view and right side view) 2-45...
  • Page 81 CABLE ROUTING 1. Radiator cap 2. Radiator 3. Radiator fan 4. Radiator outlet hose 5. Thermostat assembly 6. Water jacket joint 7. Coolant reservoir 8. Radiator inlet hose A. Install the radiator outlet hose with its white paint mark facing inward. B.
  • Page 82 CABLE ROUTING Fuel tank (left and bottom view) 2-47...
  • Page 83 CABLE ROUTING 1. Frame 2. Fuel tank 3. Fuel pump 4. Fuel tank drain hose 5. Fuel tank breather hose 6. Clip 7. Fuel hose assembly A. Insert the fuel tank drain hose up to the section where the fuel tank pipe increases in diameter. Install it so that the white paint mark faces the rearward.
  • Page 84 CABLE ROUTING Canister (for California only) 2-49...
  • Page 85 CABLE ROUTING 1. Canister 2. Bracket 3. Canister purge hose (hose joint to canister) 4. Clip 5. Frame 6. Fuel tank drain hose 7. Fuel tank breather hose (rollover valve to canister) 8. Clamp 9. Rollover valve 10. Fuel tank breather hose (fuel tank to rollover valve) 11.
  • Page 86 CABLE ROUTING Air filter case and throttle body (top view and left side view) 2-51...
  • Page 87 CABLE ROUTING 1. Air filter case joint clamp 2. ECU (engine control unit) 3. Air filter case 4. Throttle body 5. Clip 6. Cylinder head breather hose 7. Throttle cable (decelerator cable) (white plating) 8. Throttle cable (accelerator cable) (black plating) 9.
  • Page 88 CABLE ROUTING Air cut-off valve (left side view) 2-53...
  • Page 89 CABLE ROUTING 1. Radiator fan cover 2. Air filter case 3. Clip 4. Air induction system hose (air filter case to air cut-off valve) 5. Air induction system hose (air cut-off valve to reed valve cover #1) 6. Air induction system hose (air cut-off valve to reed valve cover #2/#3) 7.
  • Page 90 CABLE ROUTING Frame and engine (right side view) 2-55...
  • Page 91 CABLE ROUTING 1. Clamp 2. Rear brake light switch lead 3. Positioning tape 4. O sensor coupler 5. Radiator fan motor coupler 6. Auxiliary DC jack 7. Headlight relay 8. Radiator fan motor lead 9. O sensor lead 10. Frame 11.
  • Page 92 CABLE ROUTING Frame and engine (left side view) 2-57...
  • Page 93 CABLE ROUTING Q. Align the wire harness protector with the edge of 1. Air induction system hose (air filter case to air the Velcro tape and wrap it. However, the tape sur- cut-off valve) face may protrude somewhat. 2. Air filter case R.
  • Page 94 CABLE ROUTING Frame (top view) 2-59...
  • Page 95 CABLE ROUTING 1. Injector coupler #1 2. Injector coupler #2 3. Clamp 4. Ignition coil #1 coupler 5. Ignition coil #2 coupler 6. Air cut-off valve coupler 7. Ignition coil #3 coupler 8. Fuel injector coupler #3 9. Throttle position sensor coupler 10.
  • Page 96 CABLE ROUTING Frame (top view) 2-61...
  • Page 97 CABLE ROUTING 1. Stator coil assembly lead 2. Oil level switch coupler 3. Rear brake light switch coupler 4. Sidestand switch coupler 5. Gear position sensor coupler 1 6. Gear position sensor coupler 2 7. Negative battery lead coupler 8. Lean angle sensor 9.
  • Page 98 CABLE ROUTING Frame (top view) 2-63...
  • Page 99 G. Fasten the wire harness side of the tail/brake light lead to the battery box. H. Insert the rubber bracket of the Yamaha diagnostic tool coupler to the battery box. I. Instructional drawing for routes in the front of the battery J.
  • Page 100 CABLE ROUTING Front brake (right side view and left side view) 2-65...
  • Page 101 CABLE ROUTING 1. Headlight assembly 2. Right brake caliper 3. Front brake hose 4. Clamp 5. Left brake caliper 6. Left reflector 7. Right reflector A. To left brake caliper B. To front brake master cylinder C. Install the front brake hose with its blue paint mark facing outward.
  • Page 102 CABLE ROUTING Rear brake 2-67...
  • Page 103 CABLE ROUTING 1. Rear frame 2. Clamp 3. Rear brake caliper 4. Rear brake hose 5. Swingarm assembly A. Install the clamp facing the direction in the illustra- tion. B. Make sure to install the clamp all the way in the rear frame.
  • Page 104 CABLE ROUTING 2-69...

  • Page 105: 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 ......3-2 CHECKING THE FUEL LINE ..............3-4 CHECKING THE SPARK PLUGS ..............3-4 ADJUSTING THE VALVE CLEARANCE............3-5 CHECKING THE ENGINE IDLING SPEED..........3-7 SYNCHRONIZING THE THROTTLE BODIES ...........3-8 CHECKING THE THROTTLE BODY JOINTS..........3-9 CHECKING THE CANISTER (for California only) ........3-9...
  • Page 106 CHECKING THE COOLANT LEVEL ............3-25 CHECKING THE COOLING SYSTEM .............3-25 CHANGING THE COOLANT ..............3-26 CHECKING THE FRONT BRAKE LIGHT SWITCH .........3-27 ADJUSTING THE REAR BRAKE LIGHT SWITCH ........3-27 CHECKING AND LUBRICATING THE CABLES........3-28 CHECKING THE THROTTLE GRIP ............3-28 CHECKING AND CHARGING THE BATTERY ........3-29 CHECKING THE FUSES................3-29 REPLACING THE HEADLIGHT BULB .............3-29 ADJUSTING THE HEADLIGHT BEAM ............3-30...

  • Page 107: Periodic Maintenance

    • From 24000 mi (37000 km) or 36 months, repeat the maintenance intervals starting from 8000 mi (13000 km) or 12 months. • Items marked with an asterisk require special tools, data and technical skills, have a Yamaha dealer perform the service.

  • Page 108: General Maintenance And Lubrication Chart

    PERIODIC MAINTENANCE EAS1RC1302 GENERAL MAINTENANCE AND LUBRICATION CHART INITIAL ODOMETER READINGS 600 mi 4000 mi 8000 mi 12000 mi 16000 mi 20000 mi ITEM ROUTINE (1000 km) (7000 km) (13000 km) (19000 km) (25000 km) (31000 km) 1 month 6 months 12 months 18 months 24 months...
  • Page 109 Front and rear • Check operation. 26 *       brake switches • Apply Yamaha cable lubricant       27 * Control cables or other suitable cable lubri- cant thoroughly. • Check operation.

  • Page 110: Checking The Fuel Line

    PERIODIC MAINTENANCE 2. Remove: EAS21030 CHECKING THE FUEL LINE • Ignition coils The following procedure applies to all of the fuel, • Spark plugs vacuum and breather hoses. ECA13320 1. Remove: NOTICE • Rider seat Before removing the spark plugs, blow away Refer to “GENERAL CHASSIS”...

  • Page 111: Adjusting The Valve Clearance

    PERIODIC MAINTENANCE page 7-15. Valve clearance (cold) • Air filter case Intake Refer to “GENERAL CHASSIS” on page 4-1. 0.11–0.20 mm (0.0043–0.0079 in) • Fuel tank Exhaust Refer to “FUEL TANK” on page 7-1. 0.26–0.30 mm (0.0102–0.0118 in) • Rider seat Refer to “GENERAL CHASSIS”...
  • Page 112 PERIODIC MAINTENANCE A. Front Valve lapper 90890-04101 d. To measure the valve clearances of the other Valve lapping tool cylinders, starting with cylinder #1 at TDC, YM-A8998 turn the crankshaft counterclockwise as specified in the following table. • Cover the timing chain opening with a rag to prevent the valve pad from falling into the crankcase.

  • Page 113: Checking The Engine Idling Speed

    PERIODIC MAINTENANCE • The valve lifter must turn smoothly when rotat- ed by hand. d. Calculate the sum of the values obtained in steps (b) and (c) to determine the required valve pad thickness and the valve pad num- ber. Example: g.

  • Page 114: Synchronizing The Throttle Bodies

    “02”  Clean the throttle bodies. Refer to “CHECKING AND CLEANING THE THROTTLE BODIES” on page 7-8. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 4. Install: a. Connect the Yamaha diagnostic tool. • Vacuum gauge “1” Use the diagnostic code number “67”. Refer to “SELF-DIAGNOSTIC FUNCTION Vacuum gauge AND DIAGNOSTIC CODE TABLE”...

  • Page 115: Checking The Throttle Body Joints

    PERIODIC MAINTENANCE Adjusting the throttle body synchronization 2. Stop the engine and remove the measuring 1. Adjust: equipment. • Throttle body synchronization 3. Install: • Caps ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 4. Install: a. Start the engine, warm it up for several min- • Air filter case utes, and then let it run at the specified en- Refer to “GENERAL CHASSIS”...

  • Page 116: Checking The Air Induction System

    PERIODIC MAINTENANCE Cracks/damage  Replace. 3. Install: • Fuel tank Refer to “FUEL TANK” on page 7-1. • Rider seat Refer to “GENERAL CHASSIS” on page 4-1. EAS1RC1306 CHECKING THE AIR INDUCTION SYSTEM Refer to “CHECKING THE AIR INDUCTION SYSTEM” on page 7-18. 3.

  • Page 117: Adjusting The Clutch Lever Free Play

    PERIODIC MAINTENANCE tained. EAS20870 ADJUSTING THE CLUTCH LEVER FREE PLAY Direction “a” Clutch lever free play is increased. 1. Check: Direction “b” • Clutch lever free play “a” Clutch lever free play is decreased. Out of specification  Adjust. Clutch lever free play c.

  • Page 118: Adjusting The Front Disc Brake

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

  • Page 119: Adjusting The Rear Disc Brake

    PERIODIC MAINTENANCE EAS21190 ADJUSTING THE REAR DISC BRAKE ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 1. Adjust: 2. Adjust: • Brake pedal position • Rear brake light switch Refer to “ADJUSTING THE REAR BRAKE ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Loosen the locknut “1”. LIGHT SWITCH” on page 3-27. b. Turn the adjusting bolt “2” in direction “a” or EAS21260 “b”...

  • Page 120: Checking The Front Brake Hoses

    PERIODIC MAINTENANCE before applying the brake. Ignoring this pre- i. Repeat steps (e) to (h) until all of the air bub- caution could allow air to enter the hydraulic bles have disappeared from the brake fluid in brake system, considerably lengthening the the plastic hose.

  • Page 121: Checking The Wheels

    PERIODIC MAINTENANCE EAS21670 CHECKING THE WHEELS Tire air pressure (measured on cold tires) The following procedure applies to both of the Loading condition wheels. 0–90 kg (0–198 lb) 1. Check: Front • Wheel 250 kPa (2.50 kgf/cm , 36 psi) Damage/out-of-round ...

  • Page 122: Checking The Wheel Bearings

    1. Check: approved by Yamaha is used on this vehicle. • Wheel bearings Refer to “CHECKING THE FRONT WHEEL” Front tire on page 4-10 and “CHECKING THE REAR Size WHEEL”...

  • Page 123: Lubricating The Drive Chain

    PERIODIC MAINTENANCE b. Turn both adjusting bolts “2” in direction “a” or EWA13120 WARNING “b” until the specified drive chain slack is ob- Securely support the vehicle so that there is tained. no danger of it falling over. Direction “a” Drive chain is tightened.

  • Page 124: Checking And Adjusting The Steering Head

    PERIODIC MAINTENANCE Recommended lubricant Chain lubricant suitable for O-ring chains EAS21510 CHECKING AND ADJUSTING THE STEERING HEAD 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is Steering nut wrench no danger of it falling over. 90890-01403 Exhaust flange nut wrench YU-A9472...

  • Page 125: Lubricating The Steering Head

    PERIODIC MAINTENANCE EAS21380 ADJUSTING THE SHIFT PEDAL The shift pedal position is determined by the in- stalled shift rod length. 1. Measure: • Installed shift rod length “a” Incorrect  Adjust. Installed shift rod length 256.9–258.9 mm (10.11–10.19 in) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 5.

  • Page 126: Lubricating The Sidestand

    PERIODIC MAINTENANCE Rough movement  Repair or replace. no danger of it falling over. Spring preload EAS21721 LUBRICATING THE SIDESTAND EWA1RC1303 Lubricate the pivoting point, metal-to-metal mov- WARNING Always adjust both front fork legs evenly. ing parts and spring contact point of the sides- Uneven adjustment can result in poor han- tand.

  • Page 127: Checking The Rear Shock Absorber Assembly

    PERIODIC MAINTENANCE Spring preload adjusting positions Minimum 19.0 mm (0.75 in) Standard 16.0 mm (0.63 in) Maximum 4.0 mm (0.16 in) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Rebound damping (right side only) ECA13590 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ NOTICE Never go beyond the maximum or minimum EAS1RC1311 CHECKING THE REAR SHOCK ABSORBER adjustment positions.

  • Page 128: Checking The Connecting Arm And Relay Arm

    PERIODIC MAINTENANCE the owner’s tool kit. Rebound damping adjusting posi- b. Turn the adjusting ring “3” in direction “a” or tions “b”. Minimum (soft) c. Align the desired position on the adjusting 3 turn(s) in direction “b”* ring with the stopper “4”. Standard 1 1/2 turn(s) in direction “b”* Direction “a”...

  • Page 129: Changing The Engine Oil

    PERIODIC MAINTENANCE 2. Place a container under the engine oil drain bolt. 3. Remove: • Engine oil filler cap “1” • Engine oil drain bolt “2” • Gasket “3” Recommended brand YAMALUBE Type SAE 10W-30, 10W-40, 10W-50, 15W-40, 20W-40 or 20W-50 Recommended engine oil grade API service SG type or higher, JASO standard MA...

  • Page 130: Measuring The Engine Oil Pressure

    PERIODIC MAINTENANCE LEVEL” on page 3-22. ECA13390 NOTICE Make sure the O-ring “3” is positioned cor- EAS20820 MEASURING THE ENGINE OIL PRESSURE rectly in the groove of the oil filter cartridge. 1. Check: • Engine oil level Below the minimum level mark “a”  Add the recommended engine oil to the proper level.

  • Page 131: Checking The Coolant Level

    PERIODIC MAINTENANCE mark “b”. Below the minimum level mark  Add the recommended coolant to the proper level. 5. Measure: • Engine oil pressure (at the following conditions) ECA1RC1304 Oil pressure NOTICE 230.0 kPa/5000 r/min@100 C • Adding water instead of coolant lowers the (2.3 kgf/cm /5000 r/min, 33.4 antifreeze concentration of the coolant.

  • Page 132: Changing The Coolant

    PERIODIC MAINTENANCE • Coolant reservoir cover “2” • Coolant reservoir “3” • Collars “4” 3. Remove: • Coolant reservoir cap “1” EAS21131 CHANGING THE COOLANT 1. Remove: • Radiator cap bolt “1” • Radiator cap “2” • Radiator cap stopper “3” 4.

  • Page 133: Checking The Front Brake Light Switch

    PERIODIC MAINTENANCE • Coolant reservoir 10.Install: • Coolant reservoir cover • Radiator cap stopper • Coolant reservoir bolts • Radiator cap • Radiator cap bolt Coolant reservoir bolt (M5) 0.5 Nm (0.05 m·kgf, 0.37 ft·lbf) Radiator cap bolt Coolant reservoir bolt (M6) 5 Nm (0.5 m·kgf, 3.6 ft·lbf) 9 Nm (0.9 m·kgf, 6.5 ft·lbf) 11.Fill:...

  • Page 134: Checking And Lubricating The Cables

    PERIODIC MAINTENANCE Damage/deterioration  Replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • Throttle cable installation a. Hold the main body “1” of the rear brake light Incorrect  Reinstall the throttle cables. switch so that it does not rotate and turn the Refer to “HANDLEBAR” on page 4-44. adjusting nut “2”...

  • Page 135: Checking And Charging The Battery

    PERIODIC MAINTENANCE d. Tighten the locknut. 2. Disconnect: • Headlight coupler “1” e. Slide the rubber cover to its original position. Make sure that the adjusting nut is covered com- pletely by the rubber cover. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS21760 CHECKING AND CHARGING THE BATTERY Refer to “CHECKING AND CHARGING THE BATTERY”...

  • Page 136: Adjusting The Headlight Beam

    PERIODIC MAINTENANCE 6. Install: ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • Headlight bulb a. Turn the adjusting screw “1” in direction “a” or Secure the new headlight bulb with the head- “b”. light bulb holder. Direction “a” ECA13690 Headlight beam is raised. NOTICE Direction “b” Avoid touching the glass part of the head- Headlight beam is lowered.
  • Page 137 PERIODIC MAINTENANCE ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3-31...
  • Page 138 PERIODIC MAINTENANCE 3-32...

  • Page 139: Chassis

    CHASSIS GENERAL CHASSIS..................4-1 REMOVING THE AIR SCOOPS..............4-5 INSTALLING THE AIR SCOOPS ...............4-5 INSTALLING THE FUEL TANK MOLES ............4-5 FRONT WHEEL ....................4-8 REMOVING THE FRONT WHEEL ............4-10 DISASSEMBLING THE FRONT WHEEL ..........4-10 CHECKING THE FRONT WHEEL ............4-10 ASSEMBLING THE FRONT WHEEL ............4-11 ADJUSTING THE FRONT WHEEL STATIC BALANCE......4-11 INSTALLING THE FRONT WHEEL (FRONT BRAKE DISCS)....4-12 REAR WHEEL ....................4-14...
  • Page 140 ASSEMBLING THE REAR BRAKE MASTER CYLINDER .......4-43 INSTALLING THE REAR BRAKE MASTER CYLINDER ......4-43 HANDLEBAR....................4-44 REMOVING THE HANDLEBAR ...............4-45 CHECKING THE HANDLEBAR..............4-45 INSTALLING THE HANDLEBAR..............4-45 FRONT FORK....................4-48 REMOVING THE FRONT FORK LEGS ...........4-51 DISASSEMBLING THE FRONT FORK LEGS .........4-51 CHECKING THE FRONT FORK LEGS............4-52 ASSEMBLING THE FRONT FORK LEGS ..........4-53 INSTALLING THE FRONT FORK LEGS..........4-58 STEERING HEAD...................4-59...
  • Page 141 GENERAL CHASSIS EAS21830 GENERAL CHASSIS Removing the seat and battery 2.2 Nm (0.22 m kgf, 1.6 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Rider seat Battery band Negative battery lead Disconnect. Positive battery lead Disconnect. Battery Spacer...
  • Page 142 GENERAL CHASSIS Removing the rear cover 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 6 6 7 Order Job/Parts to remove Q’ty Remarks...
  • Page 143 GENERAL CHASSIS Removing the headlight and meter assembly 1.3 Nm (0.13 m kgf, 0.94 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 0.8 Nm (0.08 m kgf, 0.59 ft Ibf) •...
  • Page 144 GENERAL CHASSIS Removing the air scoop and fuel tank cover 1.5 Nm (0.15 m kgf, 1.1 ft Ibf) • • 1.5 Nm (0.15 m kgf, 1.1 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Air scoop (left) Air scoop (right) Fuel tank cover Fuel tank mole (left) Fuel tank mole (right)

  • Page 145: General Chassis

    GENERAL CHASSIS EAS1RC1401 REMOVING THE AIR SCOOPS 1. Remove: • Air scoop (left) “1” ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the air scoop bolt “2” and quick fas- teners “3”. b. Pull the air scoop off at the areas “a” shown. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Install: •...
  • Page 146 GENERAL CHASSIS ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Install: • Fuel tank mole (right) “1” ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Install the hole “a” in the fuel tank mole onto the projection “b” on the air scoop stay. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...
  • Page 147 GENERAL CHASSIS Removing the air filter case 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • (10) 1.6 Nm (0.16 m kgf, 1.2 ft Ibf) • • 2.8 Nm (0.28 m kgf, 2.0 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS”...
  • Page 148 FRONT WHEEL EAS21870 FRONT WHEEL Removing the front wheel and brake discs 35 Nm (3.5 m kgf, 25 ft Ibf) • • 23 Nm (2.3 m kgf, 17 ft Ibf) • • 65 Nm (6.5 m kgf, 47 ft Ibf) •...
  • Page 149 FRONT WHEEL Disassembling the front wheel Order Job/Parts to remove Q’ty Remarks Oil seal Wheel bearing Spacer...

  • Page 150: Front Wheel

    FRONT WHEEL EAS21900 REMOVING THE FRONT WHEEL 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. 2. Remove: • Left brake caliper • Right brake caliper ECA1RC1439 NOTICE ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...

  • Page 151: Assembling The Front Wheel

    FRONT WHEEL c. Install the new wheel bearing (left side). Place a suitable washer “1” between the socket “2” and the bearing so that both the inner race “3” and outer race “4” are pressed at the same time, and then press the bearing until the inner race makes contact with the spacer “5”.

  • Page 152: Installing The Front Wheel (Front Brake Discs)

    FRONT WHEEL d. Release the front wheel. is balanced. e. When the wheel stops, put an “X ” mark at the bottom of the wheel. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 4. Check: • Front wheel static balance ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the front wheel and make sure it stays at each position shown.
  • Page 153 FRONT WHEEL 3. Lubricate: • Oil seal lips Recommended lubricant Lithium-soap-based grease 4. Install: • Collars • Front wheel • Wheel axle 5. Tighten: • Wheel axle • Wheel axle pinch bolt Wheel axle 65 Nm (6.5 m·kgf, 47 ft·lbf) Wheel axle pinch bolt 23 Nm (2.3 m·kgf, 17 ft·lbf) ECA1RC1401...
  • Page 154 REAR WHEEL EAS22020 REAR WHEEL Removing the rear wheel 150 Nm (15 m kgf, 108 ft Ibf) • • 16 Nm (1.6 m kgf, 12 ft Ibf) 16 Nm (1.6 m kgf, 12 ft Ibf) • • • • Order Job/Parts to remove Q’ty Remarks...
  • Page 155 REAR WHEEL Removing the brake disc and rear wheel sprocket 30 Nm (3.0 m kgf, 22 ft Ibf) • • 80 Nm (8.0 m kgf, 58 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Rear brake disc Bracket Rear wheel sprocket Collar Collar...
  • Page 156 REAR WHEEL Disassembling the rear wheel Order Job/Parts to remove Q’ty Remarks Oil seal Wheel bearing Spacer Wheel bearing 4-16...

  • Page 157: Rear Wheel

    REAR WHEEL EAS22040 REMOVING THE REAR WHEEL 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 158: Checking And Replacing The Rear Wheel Sprocket

    REAR WHEEL EAS1RC1411 CHECKING AND REPLACING THE REAR ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ WHEEL SPROCKET 1. Check: EAS22140 ASSEMBLING THE REAR WHEEL • Rear wheel sprocket 1. Install: More than 1/4 tooth “a” wear  Replace the • Wheel bearings drive sprocket, the rear wheel sprocket and •...
  • Page 159 REAR WHEEL 2. Check: A. Left side • Rear brake disc B. Right side Refer to “CHECKING THE REAR BRAKE DISC” on page 4-38. 5. Install: 3. Lubricate: • Rear brake caliper • Oil seal lips • Rear brake caliper bolts 6.
  • Page 160 FRONT BRAKE EAS22210 FRONT BRAKE Removing the front brake pads 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • 35 Nm (3.5 m kgf, 25 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers.

  • Page 161: Front Brake

    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 162 FRONT BRAKE Disassembling the front brake master cylinder Order Job/Parts to remove Q’ty Remarks Brake master cylinder kit Brake master cylinder body 4-22...
  • Page 163 FRONT BRAKE Removing the front brake calipers 35 Nm (3.5 m kgf, 25 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 164 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 165: Introduction

    FRONT BRAKE d. Hold the dial gauge at a right angle against EAS22220 INTRODUCTION the brake disc surface. EWA14101 e. Measure the runout 1.5 mm (0.06 in) below WARNING the edge of the brake disc. Disc brake components rarely require disas- sembly.

  • Page 166: Replacing The Front Brake Pads

    FRONT BRAKE d. Measure the brake disc runout. 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 runout is within specification. pads as a set.

  • Page 167: Removing The Front Brake Calipers

    FRONT BRAKE 8. Check: • Brake lever operation Soft or spongy feeling  Bleed the brake sys- tem. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-13. EAS22300 REMOVING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers.

  • Page 168: Checking The Front Brake Calipers

    FRONT BRAKE Recommended brake component replacement schedule Brake pads If necessary Piston seals Every two years Piston dust seals Every two years Brake hoses Every four years Every two years and Brake fluid whenever the brake ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ is disassembled a. Secure the right side brake caliper pistons with a piece of wood “a”.

  • Page 169: Installing The Front Brake Calipers

    FRONT BRAKE replace the brake caliper piston dust seals 2. Remove: and brake caliper piston seals. • Front brake caliper 3. Install: • Brake pads Specified brake fluid DOT 4 • Brake pad spring • Brake pad pin • Brake pad clips EAS22440 INSTALLING THE FRONT BRAKE CALIPERS •...

  • Page 170: Removing The Front Brake Master Cylinder

    FRONT BRAKE Obstruction  Blow out with compressed air. 2. Check: • Brake master cylinder kit Damage/scratches/wear  Replace. 3. Check: • Brake master cylinder reservoir “1” • Brake master cylinder reservoir diaphragm holder “2” Cracks/damage  Replace. • Brake master cylinder reservoir diaphragm “3”...
  • Page 171 FRONT BRAKE holder with the punch mark “b” on the handle- (with the specified amount of the specified bar. brake fluid) • First, tighten the upper bolt, then the lower bolt. Specified brake fluid • There should be more than 11 mm (0.43 in) for DOT 4 clearance between the right handlebar switch and the front brake master cylinder holder.

  • Page 172: Rear Brake

    REAR BRAKE EAS22550 REAR BRAKE Removing the rear brake pads Order Job/Parts to remove Q’ty Remarks Screw plug Brake pad retaining bolt Rear brake caliper Brake pad Brake pad shim Brake pad insulator Brake pad spring Bleed screw 4-32...
  • Page 173 REAR BRAKE Removing the rear brake master cylinder 3.8 Nm (0.38 m kgf, 2.8 ft Ibf) • • 110 Nm (11 m kgf, 80 ft Ibf) • • 30 Nm (3.0 m kgf, 22 ft Ibf) • • 30 Nm (3.0 m kgf, 22 ft Ibf) •...
  • Page 174 REAR BRAKE Removing the rear brake master cylinder 3.8 Nm (0.38 m kgf, 2.8 ft Ibf) • • 110 Nm (11 m kgf, 80 ft Ibf) • • 30 Nm (3.0 m kgf, 22 ft Ibf) • • 30 Nm (3.0 m kgf, 22 ft Ibf) •...
  • Page 175 REAR BRAKE Disassembling the rear brake master cylinder Order Job/Parts to remove Q’ty Remarks Brake master cylinder yoke Brake master cylinder kit Hose joint Bushing Brake master cylinder body 4-35...
  • Page 176 REAR BRAKE Removing the rear brake caliper Order Job/Parts to remove Q’ty Remarks Brake hose union bolt Brake hose gasket Brake hose Rear brake caliper 4-36...
  • Page 177 REAR BRAKE Disassembling the rear brake caliper Order Job/Parts to remove Q’ty Remarks Screw plug Brake pad retaining bolt Brake pad Brake pad shim Brake pad insulator Brake pad spring Brake caliper piston Brake caliper piston dust seal Brake caliper piston seal Bleed screw 4-37...

  • Page 178: Introduction

    REAR BRAKE EAS22561 INTRODUCTION Brake disc thickness limit 4.5 mm (0.18 in) EWA14101 WARNING 5. Adjust: Disc brake components rarely require disas- • Brake disc runout sembly. Therefore, always follow these pre- Refer to “CHECKING THE FRONT BRAKE ventive measures: DISCS”...

  • Page 179: Removing The Rear Brake Caliper

    REAR BRAKE lators, brake pad shims, and brake pad spring as 3. Lubricate: • Rear brake caliper bolts a set. Recommended lubricant ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Silicone grease a. Connect a clear plastic hose “1” tightly to the bleed screw “2”. Put the other end of the hose ECA1RC1416 into an open container.

  • Page 180: Disassembling The Rear Brake Caliper

    REAR BRAKE 1. Remove: • Brake hose union bolt “1” • Brake hose gaskets “2” • Brake hose “3” Put the end of the brake hose into a container and pump out the brake fluid carefully. b. Remove the brake caliper piston dust seal and brake caliper piston seal.

  • Page 181: Assembling The Rear Brake Caliper

    REAR BRAKE 2. Check: EWA13530 WARNING • Rear brake caliper bracket “1” Proper brake hose routing is essential to in- Cracks/damage  Replace. sure safe vehicle operation. Refer to “CABLE Refer to “REAR WHEEL” on page 4-14. ROUTING” on page 2-41. ECA1RC1402 NOTICE When installing the brake hose onto the...

  • Page 182: Removing The Rear Brake Master Cylinder

    REAR BRAKE 4. Fill: EAS22700 REMOVING THE REAR BRAKE MASTER • Brake fluid reservoir CYLINDER (with the specified amount of the specified 1. Remove: brake fluid) • Brake hose union bolt “1” • Brake hose gaskets “2” Specified brake fluid DOT 4 •...

  • Page 183: Assembling The Rear Brake Master Cylinder

    REAR BRAKE EAS22730 ASSEMBLING THE REAR BRAKE MASTER Specified brake fluid DOT 4 CYLINDER EWA13520 WARNING EWA13090 WARNING • Before installation, all internal brake com- • Use only the designated brake fluid. Other ponents should be cleaned and lubricated brake fluids may cause the rubber seals to with clean or new brake fluid.

  • Page 184: Handlebar

    HANDLEBAR EAS22840 HANDLEBAR Removing the handlebar 17 Nm (1.7 m kgf, 12 ft Ibf) 3.8 Nm (0.38 m kgf, 2.8 ft Ibf) • • • • 26 Nm (2.6 m kgf, 19 ft Ibf) • • 11 Nm (1.1 m kgf, 8.0 ft Ibf) •...

  • Page 185: Removing The Handlebar

    HANDLEBAR EAS22860 REMOVING THE HANDLEBAR 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. 2. Remove: • Handlebar grip “1” Blow compressed air between the left handlebar EAS22931 and the handlebar grip, and gradually push the INSTALLING THE HANDLEBAR...
  • Page 186 HANDLEBAR • Clutch cable Lower handlebar holder nut 40 Nm (4.0 m·kgf, 29 ft·lbf) Clutch lever holder pinch bolt 11 Nm (1.1 m·kgf, 8.0 ft·lbf) 4. Install: • Throttle grip “1” • Throttle cables Align the center of slit on the clutch lever holder •...
  • Page 187 HANDLEBAR 9. Install: • Left handlebar switch Left handlebar switch screw 2.0 Nm (0.20 m·kgf, 1.4 ft·lbf) Align the projection “a” on the left handlebar switch with the hole “b” in the handlebar. 10.Adjust: • Throttle grip free play Refer to “CHECKING THE THROTTLE GRIP”...

  • Page 188: Front Fork

    FRONT FORK EAS22950 FRONT FORK Removing the front fork legs 23 Nm (2.3 m kgf, 17 ft Ibf) 26 Nm (2.6 m kgf, 19 ft Ibf) 23 Nm (2.3 m kgf, 17 ft Ibf) • • • • • • 10 Nm (1.0 m kgf, 7.2 ft Ibf)
  • Page 189 FRONT FORK Disassembling the left front fork leg Order Job/Parts to remove Q’ty Remarks Cap bolt O-ring Washer Spacer Fork spring Locknut Dust seal Oil seal clip Outer tube Oil seal Washer Outer tube bushing Inner tube bushing Damper rod assembly bolt Copper washer Damper rod assembly Inner tube...
  • Page 190 FRONT FORK Disassembling the right front fork leg Order Job/Parts to remove Q’ty Remarks Cap bolt O-ring Washer Spacer Fork spring Locknut Damper adjusting rod Dust seal Oil seal clip Outer tube Oil seal Washer Outer tube bushing Inner tube bushing Damper rod assembly bolt Copper washer Damper rod assembly...

  • Page 191: Removing The Front Fork Legs

    FRONT FORK • Spacer “3” EAS1RC1412 REMOVING THE FRONT FORK LEGS • Locknut “4” The following procedure applies to both of the ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ front fork legs. a. Press down on the spacer with the fork spring compressor “5”. Each front fork leg is equipped with a spring pre- b.

  • Page 192: Checking The Front Fork Legs

    FRONT FORK ECA1RC1404 Damper rod holder NOTICE 90890-01423 Do not scratch the outer tube. Damping rod holder YM-01423 4. Remove: • Outer tube ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ EAS23011 CHECKING THE FRONT FORK LEGS a. Hold the front fork leg horizontally. The following procedure applies to both of the b.

  • Page 193: Assembling The Front Fork Legs

    FRONT FORK –Copper washer –O-ring • Before assembling the front fork leg, make sure all of the components are clean. 1. Install: • Damper rod assembly “1” ECA1RC1406 NOTICE Allow the damper rod assembly to slide 3. Check: slowly down the inner tube “2” until it pro- •...
  • Page 194 FRONT FORK 3. Lubricate: 5. Install: • Inner tube’s outer surface • Outer tube (to the inner tube) Recommended oil 6. Install: Suspension oil 01 • Outer tube bushing “1” • Washer “2” 4. Install: (with the fork seal driver “3”) •...
  • Page 195 FRONT FORK 8. Install: • Oil seal clip “1” Adjust the oil seal clip so that it fits into the outer tube’s groove. 11.Fill: • Front fork leg (with the specified amount of the recom- mended fork oil) Recommended oil 9.
  • Page 196 FRONT FORK air. 14.Measure: • Front fork leg oil level “a” (from the top of the outer tube, with the outer tube fully compressed and without the fork spring) Out of specification  Correct. Level (left) 147 mm (5.8 in) Level (right) c.
  • Page 197 FRONT FORK j. Install the washer and cap bolt, and then fin- ger tighten the cap bolt. EWA13670 WARNING Always use a new cap bolt O-ring. k. Hold the cap bolt “5” and tighten the locknut “3” to specification. Locknut 15 Nm (1.5 m·kgf, 11 ft·lbf) c.

  • Page 198: Installing The Front Fork Legs

    FRONT FORK j. Position the locknut “3” as specified “b”. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Distance “b” 17.Install: 12 mm (0.47 in) • Cap bolt (to the outer tube) • Temporarily tighten the cap bolt. • When to tighten the cap bolt to the specified torque is after installing the front fork leg to the vehicle and tightening the lower bracket pinch bolts.

  • Page 199: Steering Head

    STEERING HEAD EAS23090 STEERING HEAD Removing the lower bracket 110 Nm (11 m kgf, 80 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 52 Nm (5.2 m kgf, 38 ft Ibf) • • 18 Nm (1.8 m kgf, 13 ft Ibf) •...
  • Page 200 STEERING HEAD Removing the lower bracket 110 Nm (11 m kgf, 80 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 52 Nm (5.2 m kgf, 38 ft Ibf) • • 18 Nm (1.8 m kgf, 13 ft Ibf) •...

  • Page 201: Removing The Lower Bracket

    STEERING HEAD Damage/pitting  Replace the bearings and EAS23110 REMOVING THE LOWER BRACKET bearing races as a set. 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. 2.

  • Page 202: Installing The Steering Head

    STEERING HEAD ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 4. Check: • Upper bracket • Lower bracket (along with the steering stem) Bends/cracks/damage  Replace. EAS23140 INSTALLING THE STEERING HEAD 1. Lubricate: • Upper bearing • Lower bearing Recommended lubricant Lithium-soap-based grease 2. Install: • Lower ring nut “1” •...

  • Page 203: Rear Shock Absorber Assembly

    REAR SHOCK ABSORBER ASSEMBLY EAS23160 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly 44 Nm (4.4 m kgf, 32 ft Ibf) • • 61 Nm (6.1 m kgf, 44 ft Ibf) • • 44 Nm (4.4 m kgf, 32 ft Ibf) •...

  • Page 204: Handling The Rear Shock Absorber

    REAR SHOCK ABSORBER ASSEMBLY EAS23180 HANDLING THE REAR SHOCK ABSORBER Place the vehicle on a suitable stand so that the EWA13740 rear wheel is elevated. WARNING This rear shock absorber contains highly 2. Remove: compressed nitrogen gas. Before handling • Connecting arm lower nut “1” the rear shock absorber, read and make sure •...

  • Page 205: Installing The Relay Arm

    REAR SHOCK ABSORBER ASSEMBLY 2. Check: • Bearings • Oil seals Damage/pitting  Replace. 3. Check: • Collars Damage/scratches  Replace. EAS23272 INSTALLING THE RELAY ARM 1. Lubricate: • Collars 3. Relay arm 4. Connecting arm • Oil seals 5. Rear shock absorber assembly Recommended lubricant A.
  • Page 206 REAR SHOCK ABSORBER ASSEMBLY Rear shock absorber assembly upper nut 44 Nm (4.4 m·kgf, 32 ft·lbf) Relay arm nut 61 Nm (6.1 m·kgf, 44 ft·lbf) Connecting arm lower nut 55 Nm (5.5 m·kgf, 40 ft·lbf) 4-66...

  • Page 207: Swingarm

    SWINGARM EAS23330 SWINGARM Removing the swingarm 110 Nm (11 m kgf, 80 ft Ibf) • • 55 Nm (5.5 m kgf, 40 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...

  • Page 208: Removing The Swingarm

    SWINGARM EAS23350 REMOVING THE SWINGARM 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. Place the vehicle on a suitable stand so that the rear wheel is elevated. 2.

  • Page 209: Installing The Swingarm

    SWINGARM • Collars “3” Damage/scratches  Replace. • Bearings “4” Damage/pitting  Replace. A. Left side B. Right side 3. Install: • Swingarm EAS23380 • Pivot shaft INSTALLING THE SWINGARM 1. Lubricate: Pivot shaft nut • Dust covers 110 Nm (11 m·kgf, 80 ft·lbf) •...

  • Page 210: Chain Drive

    CHAIN DRIVE EAS23400 CHAIN DRIVE Removing the drive chain 95 Nm (9.5 m kgf, 69 ft Ibf) • • 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 14 Nm (1.4 m kgf, 10 ft Ibf) •...

  • Page 211: Removing The Drive Chain

    CHAIN DRIVE (length “b” between pin inner sides + length EAS23410 REMOVING THE DRIVE CHAIN “c” between pin outer sides)/2 1. Stand the vehicle on a level surface. EWA13120 • When measuring a 15-link section of the drive WARNING chain, make sure that the drive chain is taut. Securely support the vehicle so that there is •...

  • Page 212: Checking The Drive Sprocket

    CHAIN DRIVE ECA1RC1403 NOTICE • This vehicle has a drive chain with small rubber O-rings “1” between the drive chain side plates. Never use high-pressure water or air, steam, gasoline, certain solvents (e.g., benzine), or a coarse brush to clean the drive chain.

  • Page 213: Installing The Drive Chain

    CHAIN DRIVE 2. Lubricate: EAS1RC1403 INSTALLING THE DRIVE CHAIN • Drive chain 1. Install: • Drive chain Recommended lubricant Chain lubricant suitable for ECA17410 NOTICE O-ring chains Be sure to put on safety goggles when work- 3. Install: ing. • Drive sprocket •...
  • Page 214 CHAIN DRIVE Refer to “ADJUSTING THE DRIVE CHAIN SLACK” on page 3-16. Drive chain slack 5.0–15.0 mm (0.20–0.59 in) ECA13550 NOTICE A drive chain that is too tight will overload the engine and other vital parts, and one that is too loose can skip and damage the swing- arm or cause an accident.

  • Page 215: Engine

    ENGINE ENGINE INSPECTION..................5-1 MEASURING THE COMPRESSION PRESSURE ........5-1 ENGINE REMOVAL..................5-3 REMOVING THE ENGINE .................5-7 INSTALLING THE ENGINE ................5-7 CAMSHAFTS....................5-9 REMOVING THE CAMSHAFTS ...............5-11 CHECKING THE CAMSHAFTS ...............5-12 CHECKING THE TIMING CHAIN AND CAMSHAFT SPROCKET...5-13 CHECKING THE TIMING CHAIN GUIDES ..........5-13 CHECKING THE TIMING CHAIN TENSIONER ........5-13 INSTALLING THE CAMSHAFTS .............5-14 CYLINDER HEAD...................5-19...
  • Page 216 CHECKING THE CLUTCH HOUSING .............5-44 CHECKING THE CLUTCH BOSS ............5-44 CHECKING THE PRESSURE PLATE .............5-44 CHECKING THE PRIMARY DRIVE GEAR ..........5-44 CHECKING THE PRIMARY DRIVEN GEAR..........5-45 CHECKING THE PULL LEVER SHAFT AND PULL ROD......5-45 INSTALLING THE CLUTCH ..............5-45 SHIFT SHAFT ....................5-48 CHECKING THE SHIFT SHAFT ..............5-49 CHECKING THE STOPPER LEVER............5-49 INSTALLING THE SHIFT SHAFT ............5-49...
  • Page 217 CHECKING THE SHIFT DRUM ASSEMBLY ...........5-81 CHECKING THE TRANSMISSION ............5-81 ASSEMBLING THE MAIN AXLE AND DRIVE AXLE .......5-81 INSTALLING THE TRANSMISSION ............5-82...

  • Page 218: Engine Inspection

    ENGINE INSPECTION EAS1RC1506 ENGINE INSPECTION EAS20710 MEASURING THE COMPRESSION PRESSURE The following procedure applies to all of the cyl- inders. Insufficient compression pressure will result in a loss of performance. 5. Measure: 1. Measure: • Compression pressure • Valve clearance Out of specification ...
  • Page 219 ENGINE INSPECTION Compression pressure (with oil applied into the cylinder) Reading Diagnosis Higher than without Piston ring(s) wear or damage  Repair. Piston, valves, cylin- der head gasket pos- Same as without oil sibly defective  Repair. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 6. Install: •...

  • Page 220: Engine Removal

    ENGINE REMOVAL EAS23711 ENGINE REMOVAL Removing the muffler and exhaust pipe 20 Nm (2.0 m kgf, 14 ft Ibf) • • 20 Nm (2.0 m kgf, 14 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • •...
  • Page 221 ENGINE REMOVAL Disconnecting the leads and hoses 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Rider seat 4-1.
  • Page 222 ENGINE REMOVAL Disconnecting the leads and hoses 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Gear position sensor coupler Disconnect. Crankshaft position sensor coupler Disconnect.
  • Page 223 ENGINE REMOVAL Removing the engine 7 Nm (0.7 m kgf, 5.1 ft Ibf) 45 Nm (4.5 m kgf, 33 ft Ibf) • • • • 45 Nm (4.5 m kgf, 33 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) •...

  • Page 224: Removing The Engine

    ENGINE REMOVAL EAS1RC1501 REMOVING THE ENGINE 1. Loosen: • Engine mounting adjust bolt (front) Loosen the engine mounting adjust bolt with the pivot shaft wrench “1”. Pivot shaft wrench 90890-01485 Frame mount insert wrench YM-01485 EAS23720 INSTALLING THE ENGINE 1. Install: •...
  • Page 225 ENGINE REMOVAL • Tighten the engine mounting adjust bolts to specification with the pivot shaft wrench and pivot shaft wrench adapter. • Make sure that the flange on the engine mounting adjust bolt contacts the engine. Engine mounting adjust bolt (rear) 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Pivot shaft wrench...

  • Page 226: Camshafts

    CAMSHAFTS EAS23760 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) • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Rider seat 4-1.
  • Page 227 CAMSHAFTS Removing the camshafts 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 24 Nm (2.4 m kgf, 17 ft Ibf) •...

  • Page 228: Removing The Camshafts

    CAMSHAFTS 4. Remove: EAS23810 REMOVING THE CAMSHAFTS • Camshaft cap “1” 1. Remove: • Intake camshaft cap “2” • Timing mark accessing bolt “1” • Exhaust camshaft cap “3” • Crankshaft end cover “2” ECA13720 NOTICE To prevent damage to the cylinder head, camshafts or camshaft caps, loosen the camshaft cap bolts in stages and in a criss- cross pattern, working from the outside in.

  • Page 229: Checking The Camshafts

    CAMSHAFTS Camshaft wrench 90890-04162 YM-04162 3. Measure: • Camshaft runout Out of specification  Replace. Camshaft runout limit EAS23850 CHECKING THE CAMSHAFTS 0.030 mm (0.0012 in) 1. Check: • Camshaft lobes Blue discoloration/pitting/scratches  Re- place the camshaft. 2. Measure: •...

  • Page 230: Checking The Timing Chain And Camshaft Sprocket

    CAMSHAFTS 2. Check: • Camshaft sprocket • Tighten the camshaft cap bolts in stages and in More than 1/4 tooth wear “a”  Replace the a crisscross pattern, working from the inner caps out. camshaft sprockets and the timing chain as a •...

  • Page 231: Installing The Camshafts

    CAMSHAFTS b. Keep pressing the timing chain tensioner rod by hand, remove the hexagon wrench and ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ slowly release the timing chain tensioner rod. 3. Install: c. Make sure that the timing chain tensioner rod • Intake camshaft sprocket “1” •...
  • Page 232 CAMSHAFTS 4. Install: 6. Tighten: • Exhaust camshaft “1” • Camshaft cap bolts • Intake camshaft “2” Camshaft cap bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) • Make sure the punch mark “a” on each cam- shaft faces up. • When installing the camshaft, no need to align Tighten the camshaft cap bolts in the tightening the mark “b”...
  • Page 233 CAMSHAFTS c. Keep pressing the timing chain tensioner rod 8. Check: by hand, remove the hexagon wrench, and • Camshaft punch mark “a” then insert the hexagon wrench “2” (Parts Make sure the punch mark “a” on the cam- No.: 1RC-12228-00) into the timing chain ten- shaft is aligned with the camshaft cap align- sioner rod.
  • Page 234 CAMSHAFTS turning the hexagon wrench clockwise. g. Remove the hexagon wrench, and check the timing chain tension. 12.Measure: • Valve clearance Out of specification  Adjust. Refer to “ADJUSTING THE VALVE CLEAR- h. Install the timing chain tensioner cap bolt and gasket, and then tighten the timing chain ten- ANCE”...
  • Page 235 CAMSHAFTS After installing the cylinder head gasket “1” to the cylinder head cover, cut off the “a” section. 15.Install: • Spark plugs • Ignition coils “1” Spark plug 13 Nm (1.3 m·kgf, 9.4 ft·lbf) Install the ignition coils “1” in the direction shown in the illustration.

  • Page 236: Cylinder Head

    CYLINDER HEAD EAS24100 CYLINDER HEAD Removing the cylinder head 25 Nm (2.5 m kgf, 18 ft Ibf) • • 16 Nm (1.6 m kgf, 12 ft Ibf), • • Specified angle 10 Nm (1.0 m kgf, 7.2 ft Ibf) • •...

  • Page 237: Removing The Cylinder Head

    CYLINDER HEAD • Cylinder head water jacket EAS24120 REMOVING THE CYLINDER HEAD Mineral deposits/rust  Eliminate. 1. Remove: 3. Measure: • Intake camshaft • Cylinder head warpage • Exhaust camshaft Out of specification  Resurface the cylinder Refer to “REMOVING THE CAMSHAFTS” head.

  • Page 238: Installing The Cylinder Head

    CYLINDER HEAD 4. Install: EAS24240 INSTALLING THE CYLINDER HEAD • Exhaust camshaft 1. Install: • Intake camshaft • Timing chain guide (exhaust side) “1” Refer to “INSTALLING THE CAMSHAFTS” • Cylinder head gasket “2” on page 5-14. • Dowel pins “3” 2.
  • Page 239 VALVES AND VALVE SPRINGS EAS24270 VALVES AND VALVE SPRINGS Removing the valves and valve springs Order Job/Parts to remove Q’ty Remarks Cylinder head Refer to “CYLINDER HEAD” on page 5-19. Intake valve lifter Intake valve pad Intake valve cotter Intake valve spring retainer Intake valve spring Intake valve Intake valve stem seal...

  • Page 240: Valves And Valve Springs

    VALVES AND VALVE SPRINGS EAS24280 REMOVING THE VALVES Remove the valve cotters by compressing the The following procedure applies to all of the valve spring with the valve spring compressor valves and related components. “1” and the valve spring compressor attachment “2”.
  • Page 241 VALVES AND VALVE SPRINGS guide. • Valve-stem-to-valve-guide clearance = Valve guide inside diameter “a” - Valve stem diameter “b” Valve-stem-to-valve-guide clear- ance (intake) 0.010–0.037 mm (0.0004–0.0015 Limit b. Install the new valve guide with the valve 0.080 mm (0.0032 in) guide installer “2”...

  • Page 242: 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 243: Checking The Valve Springs

    VALVES AND VALVE SPRINGS • Valve seat After replacing the cylinder head or replacing the valve and valve guide, the valve seat and valve face should be lapped. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Apply a coarse lapping compound “a” to the valve face. ECA13790 NOTICE h.

  • Page 244: Checking The Valve Lifters

    VALVES AND VALVE SPRINGS 2. Measure: EAS24320 CHECKING THE VALVE LIFTERS • Compressed valve spring force “a” The following procedure applies to all of the Out of specification  Replace the valve valve lifters. spring. 1. Check: • Valve lifter Damage/scratches ...
  • Page 245 VALVES AND VALVE SPRINGS Valve spring compressor 90890-04019 YM-04019 Valve spring compressor attach- ment 90890-04108 Valve spring compressor adapter 22 mm YM-04108 3. Install: • Valve spring seat “1” • Valve stem seal “2” • Valve “3” • Valve spring “4” •...
  • Page 246 VALVES AND VALVE SPRINGS • The valve lifter must move smoothly when ro- tated with a finger. • Each valve lifter and valve pad must be rein- stalled in its original position. 5-29...

  • Page 247: Generator And Starter Clutch

    GENERATOR AND STARTER CLUTCH EAS24480 GENERATOR AND STARTER CLUTCH Removing the stator coil, generator rotor and starter clutch 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 32 Nm (3.2 m kgf, 23 ft Ibf) • • 14 Nm (1.4 m kgf, 10 ft Ibf) •...
  • Page 248 GENERATOR AND STARTER CLUTCH Removing the stator coil, generator rotor and starter clutch 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 32 Nm (3.2 m kgf, 23 ft Ibf) • • 14 Nm (1.4 m kgf, 10 ft Ibf) •...

  • Page 249: Removing The Generator

    GENERATOR AND STARTER CLUTCH EAS24490 REMOVING THE GENERATOR 1. Remove: • Generator rotor bolt “1” • Washer While holding the generator rotor “2” with the sheave holder “3”, loosen the generator rotor bolt. Sheave holder EAS24560 90890-01701 REMOVING THE STARTER CLUTCH Primary clutch holder 1.

  • Page 250: Installing The Starter Clutch

    GENERATOR AND STARTER CLUTCH erator rotor “2” and hold the generator rotor. b. When turning the starter clutch gear clock- wise “A”, the starter clutch and the starter clutch gear should engage, otherwise the starter clutch is faulty and must be replaced. c.
  • Page 251 GENERATOR AND STARTER CLUTCH 3. Apply: • Sealant (onto the stator coil assembly lead grommet) Yamaha bond No.1215 (Three bond No.1215®) 90890-85505 4. Install: • Generator cover gasket • Generator cover Generator cover bolt “1” 12 Nm (1.2 m·kgf, 8.7 ft·lbf) LOCTITE®...

  • Page 252: Electric Starter

    ELECTRIC STARTER EAS24780 ELECTRIC STARTER Removing the starter motor 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Rider seat 4-1.
  • Page 253 ELECTRIC STARTER Disassembling the starter motor Order Job/Parts to remove Q’ty Remarks O-ring Front cover Starter motor yoke Armature assembly Gasket Brush holder set Rear cover 5-36...

  • Page 254: Checking The Starter Motor

    ELECTRIC STARTER EAS24791 CHECKING THE STARTER MOTOR 1. Check: • Commutator Dirt  Clean with 600 grit sandpaper. 2. Measure: • Mica undercut “a” Out of specification  Scrape the mica to the proper measurement with a hacksaw blade that has been grounded to fit the commutator. 1.

  • Page 255: Assembling The Starter Motor

    ELECTRIC STARTER 7. Check: 2. Connect: • Bearing • Starter motor lead • Oil seal Damage/wear  Replace the starter motor. EAS24800 ASSEMBLING THE STARTER MOTOR 1. Install: • Brush holder set • Insulator “1” Install the insulator as shown in the illustration. 45˚...

  • Page 256: Clutch

    CLUTCH EAS25061 CLUTCH Removing the clutch cover 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 1.5 Nm (0.15 m kgf, 1.1 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) •...
  • Page 257 CLUTCH Removing the pull lever shaft Order Job/Parts to remove Q’ty Remarks Circlip Pull lever Pull lever spring Circlip Pull lever shaft Oil seal Bearing Bearing 5-40...
  • Page 258 CLUTCH Removing the clutch 125 Nm (12.5 m kgf, 90 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Oil pump driven sprocket Refer to “OIL PUMP” on page 5-50. Compression spring Pressure plate Pull rod...

  • Page 259: Removing The Clutch

    CLUTCH EAS30712 REMOVING THE CLUTCH 1. Remove: • Cover “1” • Clutch cover “2” • Gasket Loosen each bolt 1/4 of a turn at a time, in stag- es and in a crisscross pattern. After all of the bolts are fully loosened, remove them.

  • Page 260: Checking The Friction Plates

    CLUTCH A. Friction plate 1 8. Remove: B. Friction plate 2 • Clutch boss nut • Conical spring washer EAS25111 CHECKING THE CLUTCH PLATES • Washer The following procedure applies to all of the • Clutch boss clutch plates. • Thrust plate 1.

  • Page 261: Checking The Clutch Housing

    CLUTCH 2. Measure: 3. Check: • Clutch spring free length “a” • Bearing Out of specification  Replace the clutch Damage/wear  Replace the bearing and springs as a set. clutch housing. Clutch spring free length EAS25160 CHECKING THE CLUTCH BOSS 52.50 mm (2.07 in) 1.

  • Page 262: Checking The Primary Driven Gear

    CLUTCH EAS25210 CHECKING THE PRIMARY DRIVEN GEAR 1. Check: • Primary driven gear “1” Damage/wear  Replace the clutch housing and crankshaft as a set. Excessive noise during operation  Replace the clutch housing and crankshaft as a set. 2. Install: •...
  • Page 263 CLUTCH 3. Install: • Friction plate 1 • Clutch plate • Friction plate 2 • First, install a friction plate and then alternate between a clutch plate and a friction plate. • Install the last friction plate “1” offset from the other friction plates “2”, making sure to align a projection on the friction plate with the punch mark “a”...
  • Page 264 CLUTCH 7. Adjust: • Clutch lever free play Refer to “ADJUSTING THE CLUTCH LEVER FREE PLAY” on page 3-11. Clutch lever free play 10.0–15.0 mm (0.39–0.59 in) 5-47...

  • Page 265: Shift Shaft

    SHIFT SHAFT EAS25410 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 assembly Refer to “CLUTCH” on page 5-39. Shift arm Refer to “CHAIN DRIVE” on page 4-70. Circlip Washer Shift shaft...

  • Page 266: Checking The Shift Shaft

    SHIFT SHAFT EAS25420 CHECKING THE SHIFT SHAFT 1. Check: • Shift shaft “1” Bends/damage/wear  Replace. • Shift shaft spring “2” • Collar Damage/wear  Replace. 2. Install: • Bearing • Oil seal • Washer “1” • Circlip “2” • Lubricate seal lips with...

  • Page 267: Oil Pump

    OIL PUMP EAS24921 OIL PUMP Removing the oil pump 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) 15 Nm (1.5 m kgf, 11 ft Ibf) • • • • Order Job/Parts to remove Q’ty Remarks...
  • Page 268 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 shaft Oil pump inner rotor Oil pump outer rotor Hold down the washer when removing the Circlip circlip.

  • Page 269: Checking The Sprocket And Chain

    OIL PUMP EAS25620 CHECKING THE SPROCKET AND CHAIN Inner-rotor-to-outer-rotor-tip clearance 1. Check: Less than 0.120 mm (0.0047 in) • Oil pump drive sprocket Limit Refer to “CHECKING THE CLUTCH HOUS- 0.20 mm (0.0079 in) ING” on page 5-44. Outer-rotor-to-oil-pump-housing 2. Check: clearance •...

  • Page 270: Checking The Relief Valve

    OIL PUMP 3. Check: EAS24971 CHECKING THE RELIEF VALVE • Oil pump operation 1. Check: Refer to “CHECKING THE OIL PUMP” on • Relief valve “1” page 5-52. • Spring “2” Damage/wear  Replace the oil pump as- EAS25030 INSTALLING THE OIL PUMP sembly.

  • Page 271: Oil Pan

    OIL PAN EAS1RC1502 OIL PAN Removing the oil pan (13) 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 43 Nm (4.3 m kgf, 31 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • Order Job/Parts to remove Q’ty...

  • Page 272: Removing The Oil Pan

    OIL PAN EAS24930 REMOVING THE OIL PAN Engine oil drain bolt 43 Nm (4.3 m·kgf, 31 ft·lbf) 1. Remove: • Oil level switch “1” EWA12820 • Oil pan “2” WARNING • Oil pan gasket Always use new copper washers. Loosen each bolt 1/4 of a turn at a time, in stag- es and in a crisscross pattern.

  • Page 273: Crankcase

    CRANKCASE EAS25540 CRANKCASE Separating the crankcase 24 Nm (2.4 m kgf, 17 ft Ibf) 25 Nm (2.5 m kgf, 18 ft Ibf) • • • • 18 Nm (1.8 m kgf, 13 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...

  • Page 274: Disassembling The Crankcase

    Recommended lubricant Engine oil 2. Apply: • Sealant (onto the crankcase mating surfaces) Yamaha bond No.1215 (Three bond No.1215®) 90890-85505 Do not allow any sealant to come into contact with the oil gallery or crankshaft journal bear- ings, or balancer shaft journal bearings.
  • Page 275 CRANKCASE 4. Set the shift drum assembly and transmission gears in the neutral position. 5. Install: 19 20 • Lower crankcase “1” 23 24 (onto the upper crankcase “2”) ECA13980 NOTICE Before tightening the crankcase bolts, make sure the transmission gears shift correctly when the shift drum assembly is turned by hand.
  • Page 276 CRANKCASE 8. Tighten: • Crankcase bolts “9”–“30” Crankcase bolts “9”–“14” 24 Nm (2.4 m·kgf, 17 ft·lbf) Crankcase bolts “15”–“30” 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Tighten the bolts in the tightening sequence cast on the crankcase. 19 20 23 24 5-59...
  • Page 277 CONNECTING RODS AND PISTONS EAS1RC1503 CONNECTING RODS AND PISTONS Removing the connecting rods and pistons 20 Nm (2.0 m kgf, 14 ft Ibf) • • Specified angle 175–185˚ Order Job/Parts to remove Q’ty Remarks Lower crankcase Refer to “CRANKCASE” on page 5-56. Connecting rod cap Big end lower bearing Piston pin clip...

  • Page 278: Connecting Rods And Pistons

    CONNECTING RODS AND PISTONS EAS26030 REMOVING THE CONNECTING RODS AND PISTONS The following procedure applies to all of the con- necting rods and pistons. 1. Remove: • Connecting rod cap “1” • Connecting rod • Big end bearings • Identify the position of each big end bearing so that it can be reinstalled in its original place.

  • Page 279: Checking The Piston Rings

    CONNECTING RODS AND PISTONS and front-to-back measurements of the cylinder. with the following formula. Then, find the average of the measurements. Piston-to-cylinder clearance = Cylinder bore “C” - Piston skirt diameter “P” Bore 78.000–78.010 mm Piston-to-cylinder clearance (3.0709–3.0713 in) 0.010–0.035 mm (0.0004–0.0014 Taper limit 0.050 mm (0.0020 in) Limit...

  • Page 280: Checking The Piston Pin

    CONNECTING RODS AND PISTONS Piston pin outside diameter Use the piston crown to level the piston ring near 16.990–16.995 mm bottom of cylinder “a”, where cylinder wear is (0.6689–0.6691 in) lowest. Limit 16.970 mm (0.6681 in) 3. Measure: • Piston ring end gap Out of specification ...
  • Page 281 CONNECTING RODS AND PISTONS Out of specification  Replace the big end plastic-region tightening angle method. Al- ways install new bolts. bearings. Oil clearance • Clean the connecting rod bolts and lubricate 0.027–0.051 mm (0.0011–0.0020 the bolt threads and seats with molybdenum disulfide oil.
  • Page 282 CONNECTING RODS AND PISTONS big end bearing kept in the current condition. • Do not move the connecting rod or crankshaft until the clearance measurement has been completed. • Make sure that the projection “a” on the con- necting rod cap faces the same direction as the “Y”...

  • Page 283: Installing The Connecting Rod And Piston

    CONNECTING RODS AND PISTONS EAS26190 INSTALLING THE CONNECTING ROD AND ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ PISTON 2. Select: The following procedure applies to all of the con- • Big end bearings (P –P necting rods and pistons. 1. Install: • The numbers “A” stamped into the crankshaft •...
  • Page 284 CONNECTING RODS AND PISTONS the bolt threads and seats with molybdenum disulfide oil. c. After installing the big end bearing, assemble the connecting rod and connecting rod cap without installing them onto the crankshaft. d. Tighten the connecting rod bolt while check- ing that the sections shown “a”...

  • Page 285: Piston Installing Tool

    CONNECTING RODS AND PISTONS 6. Offset: • Piston ring end gaps 90˚ 90˚ 9. Install: 45˚ • Connecting rod caps • Connecting rod bolts a. Top ring b. 2nd ring • Make sure the “Y” marks “a” on the connecting c.
  • Page 286 CONNECTING RODS AND PISTONS Connecting rod bolt (1st) 20 Nm (2.0 m·kgf, 14 ft·lbf) b. Put a mark “1” on the corner of the connecting rod bolt “2” and the connecting rod cap “3”. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ c. Tighten the connecting rod bolts further to reach the specified angle 175–185.
  • Page 287 CRANKSHAFT AND BALANCER SHAFT EAS25950 CRANKSHAFT AND BALANCER SHAFT Removing the crankshaft and balancer shaft Order Job/Parts to remove Q’ty Remarks Lower crankcase Refer to “CRANKCASE” on page 5-56. Refer to “REMOVING THE CONNECTING Connecting rod RODS AND PISTONS” on page 5-61. Balancer shaft Balancer shaft journal lower bearing Balancer shaft journal upper bearing...

  • Page 288: Crankshaft And Balancer Shaft

    CRANKSHAFT AND BALANCER SHAFT EAS25980 REMOVING THE CRANKSHAFT AND BALANCER SHAFT 1. Remove: • Balancer shaft “1” • Balancer shaft journal bearings • Crankshaft assembly “2” • Crankshaft journal bearings Identify the position of each balancer shaft jour- nal bearings and crankshaft journal bearings so that it can be reinstalled in its original place.
  • Page 289 CRANKSHAFT AND BALANCER SHAFT nal-bearing clearance is out of specification, select replacement crankshaft journal bear- ings. d. Put a piece of Plastigauge® “1” on each crankshaft journal. Do not put the Plastigauge® over the oil hole in the crankshaft journal. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...

  • Page 290: Checking The Balancer Shaft

    CRANKSHAFT AND BALANCER SHAFT Balancer shaft journal to balancer shaft bearing clearance 0.024–0.048 mm (0.0009–0.0019 ECA1RC1511 NOTICE Do not interchange the balancer shaft jour- nal bearings. To obtain the correct balancer shaft-journal-to-balancer shaft-journal bear- ing clearance and prevent engine damage, the balancer shaft journal bearings must be installed in their original positions.

  • Page 291: Installing The Crankshaft

    CRANKSHAFT AND BALANCER SHAFT e. Install the balancer shaft journal lower bear- • If “J ”–“J ” are the same, use the same size for ings “1” into the lower crankcase and assem- all of the bearings. ble the crankcase halves. For example, if the crankcase “J ”...

  • Page 292: Installing The Balancer Assembly

    CRANKSHAFT AND BALANCER SHAFT nal bearings “1” with the notches “b” in the crankcase. • Be sure to install each crankshaft journal bear- ings in its original place. EAS26220 INSTALLING THE BALANCER ASSEMBLY 1. Install: • Balancer journal upper bearings (into the upper crankcase) •...

  • Page 293: Transmission

    TRANSMISSION EAS26241 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...
  • Page 294 TRANSMISSION Disassembling the main axle assembly Order Job/Parts to remove Q’ty Remarks 2nd pinion gear Toothed lock washer Toothed lock washer retainer 6th pinion gear Collar Washer Circlip 3rd pinion gear Circlip Washer 5th pinion gear Collar Bearing housing Bearing Main axle 5-77...
  • Page 295 TRANSMISSION Disassembling the drive axle assembly Order Job/Parts to remove Q’ty Remarks Bearing Washer 1st wheel gear Collar 5th wheel gear Circlip Washer 3rd wheel gear Collar Toothed lock washer Toothed lock washer retainer 4th wheel gear Collar Washer Circlip 6th wheel gear Circlip Washer...
  • Page 296 TRANSMISSION Disassembling the drive axle assembly Order Job/Parts to remove Q’ty Remarks Collar Bearing Circlip Drive axle 5-79...

  • Page 297: Removing The Transmission

    TRANSMISSION EAS26250 REMOVING THE TRANSMISSION 1. Remove: • Drive axle assembly “1” • Shift drum retainers “2” • Shift fork guide bars • Shift fork-L • Shift fork-R • Shift drum assembly • Shift fork-C EAS26260 CHECKING THE SHIFT FORKS The following procedure applies to all of the shift forks.
  • Page 298 TRANSMISSION Out of specification  Replace the drive axle. Drive axle runout limit 0.08 mm (0.0032 in) EAS26270 CHECKING THE SHIFT DRUM ASSEMBLY 1. Check: • Shift drum groove Damage/scratches/wear  Replace the shift drum assembly. • Shift drum segment “1” 3.
  • Page 299 TRANSMISSION • Align the opening between the ends “b” of the circlip with a groove “c” in the axle. • Install the circlip so that a spline “d” is in the center of the gap between the circlip ends “e” as shown.
  • Page 300 TRANSMISSION • Touch the protrusion “d” on the shift fork guide bar to the side of the shift drum retainer. • Make sure that the drive axle bearing circlip “4” is inserted into the grooves “e” in the upper crankcase. 3.
  • Page 301 COOLING SYSTEM RADIATOR .......................6-1 CHECKING THE RADIATOR ..............6-2 INSTALLING THE RADIATOR ..............6-2 OIL COOLER ....................6-4 CHECKING THE OIL COOLER..............6-5 INSTALLING THE OIL COOLER..............6-5 THERMOSTAT ....................6-6 CHECKING THE THERMOSTAT ...............6-7 INSTALLING THE THERMOSTAT ASSEMBLY ........6-7 WATER PUMP....................6-8 DISASSEMBLING THE WATER PUMP ...........6-10 CHECKING THE WATER PUMP .............6-10 ASSEMBLING THE WATER PUMP ............6-10...

  • Page 302: Radiator

    RADIATOR EAS26380 RADIATOR Removing the radiator 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • 0.5 Nm (0.05 m kgf, 0.37 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) 9 Nm (0.9 m...

  • Page 303: Cooling System

    RADIATOR EAS26390 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 304 RADIATOR pressure. c. Measure the indicated pressure with the gauge. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Measure: • Radiator cap opening pressure Below the specified pressure  Replace the radiator cap. Refer to “CHECKING THE RADIATOR” on page 6-2.

  • Page 305: Oil Cooler

    OIL COOLER EAS26410 OIL COOLER Removing the oil cooler 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 35 Nm (3.5 m kgf, 25 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Coolant reservoir Refer to “RADIATOR” on page 6-1. Muffler assembly Refer to “ENGINE REMOVAL”...

  • Page 306: Checking The Oil Cooler

    OIL COOLER 3. Fill: EAS26420 CHECKING THE OIL COOLER • Cooling system 1. Check: (with the specified amount of the recom- • Oil cooler mended coolant) Cracks/damage  Replace. Refer to “CHANGING THE COOLANT” on 2. Check: page 3-26. • Oil cooler inlet hose •...

  • Page 307: Thermostat

    THERMOSTAT EAS26440 THERMOSTAT Removing the thermostat assembly 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Muffler assembly Refer to “ENGINE REMOVAL” on page 5-3. Drain. Coolant Refer to “CHANGING THE COOLANT” on page 3-26.

  • Page 308: Checking The Thermostat

    THERMOSTAT EAS26450 CHECKING THE THERMOSTAT 1. Check: • Thermostat assembly “1” Cracks/damage  Replace. EAS26480 INSTALLING THE THERMOSTAT ASSEMBLY 1. Fill: • Cooling system (with the specified amount of the recom- mended coolant) Refer to “CHANGING THE COOLANT” on page 3-26. 2.

  • Page 309: Water Pump

    WATER PUMP EAS26500 WATER PUMP Removing the water pump 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Drain. Coolant Refer to “CHANGING THE COOLANT” on page 3-26. Water pump inlet hose Disconnect. Water pump assembly...
  • Page 310 WATER PUMP Disassembling the water pump 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Water pump housing cover O-ring Circlip Water pump driven gear Washer Impeller shaft Mechanical seal Bearing Oil seal...

  • Page 311: Disassembling The Water Pump

    WATER PUMP EAS26520 EAS26541 DISASSEMBLING THE WATER PUMP CHECKING THE WATER PUMP 1. Remove: 1. Check: • Mechanical seal (housing side) “1” • Water pump housing cover “1” • Impeller “2” Cracks/damage/wear  Replace. Remove the mechanical seal (housing side) •...
  • Page 312 WATER PUMP with oil or grease. (4). ECA1RC1602 NOTICE Use the special tools and a press to press the Make sure the mechanical seal (impeller mechanical seal (housing side) straight in until it side) is flush with the impeller. touches the water pump housing. Impeller shaft tilt limit Mechanical seal installer 0.15 mm (0.006 in)

  • Page 313: Fuel System

    FUEL SYSTEM FUEL TANK ......................7-1 REMOVING THE FUEL TANK ..............7-3 REMOVING THE FUEL PUMP ..............7-3 CHECKING THE FUEL PUMP BODY ............7-3 CHECKING THE FUEL PUMP OPERATION ..........7-3 CHECKING THE ROLLOVER VALVE (for California only) ......7-3 INSTALLING THE FUEL PUMP ..............7-3 INSTALLING THE FUEL TANK ..............7-4 THROTTLE BODIES ..................7-5 CHECKING THE INJECTORS (BEFORE REMOVING)......7-8...

  • Page 314: Fuel Tank

    FUEL TANK EAS26620 FUEL TANK Removing the fuel tank 7 Nm (0.7 m kgf, 5.1 ft Ibf) 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 4.0 Nm (0.40 m kgf, 2.9 ft Ibf) •...
  • Page 315 FUEL TANK Removing the rollover valve and canister (for California only) 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Rider seat 4-1.

  • Page 316: Removing The Fuel Tank

    FUEL TANK EAS1RC1701 EAS26640 REMOVING THE FUEL TANK REMOVING THE FUEL PUMP 1. Extract the fuel in the fuel tank through the 1. Remove: • Fuel pump fuel tank cap with a pump. 2. Remove: ECA14720 NOTICE • Rider seat •...

  • Page 317: Installing The Fuel Tank

    FUEL TANK Fuel pump bolt 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf) • Do not damage the installation surfaces of the fuel tank when installing the fuel pump. • Always use a new fuel pump gasket. • Install the fuel pump gasket so that the lip side turns to the inside of the fuel tank.
  • Page 318 THROTTLE BODIES EAS26970 THROTTLE BODIES Removing the throttle bodies 4.5 Nm (0.45 m kgf, 3.3 ft Ibf) • • 3.0 Nm (0.30 m kgf, 2.2 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Rider seat 4-1.
  • Page 319 THROTTLE BODIES Removing the sensors 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 Negative pressure hose Hose joint Canister purge hose For California only. Hose joint For California only.
  • Page 320 THROTTLE BODIES Removing the injectors 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Throttle bodies/Throttle body joint Refer to “THROTTLE BODIES” on page 7-5. Fuel rail Injector Injector coupler...

  • Page 321: Throttle Bodies

    THROTTLE BODIES hose may cause the fuel to spray out. Place EAS1RC1706 CHECKING THE INJECTORS (BEFORE a container or rag under the hose to catch REMOVING) any fuel that spills. Always clean up any 1. Check: spilt fuel immediately. • Injectors •...
  • Page 322 • Do not turn the bypass air screws “a”; oth- erwise, the throttle body synchronization will be affected. Recommended cleaning solvent Yamaha Oil & Brake Cleaner d. Apply the recommended cleaning solvent to the throttle valves and the inside of the throt- tle bodies to remove any carbon deposits.

  • Page 323: Replacing The Throttle Bodies

    THROTTLE BODIES • Do not allow carbon deposits or other for- TLE BODIES” on page 3-8. eign materials to enter any of the passages 5. Place the vehicle on a suitable stand so that in each throttle body or in the space be- the rear wheel is elevated.

  • Page 324: Checking The Fuel Pressure

    THROTTLE BODIES ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the injector pressure adapter “1” to a. Remove the rider seat, air scoop and fuel the fuel rail joint “2”, and then connect an air tank cover. compressor “3” to the adapter. Refer to “GENERAL CHASSIS” on page 4-1. b.

  • Page 325: Installing The Fuel Hose (Fuel Rail Side)

    THROTTLE BODIES Faulty  Replace the fuel pump. 2. Adjust: • Throttle position sensor angle Fuel line pressure at idling 300–390 kPa (3.0–3.9 kgf/cm Before adjusting the throttle position sensor, the 43.5–56.6 psi) throttle bodies must be removed. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ a.

  • Page 326: Adjusting The Accelerator Position Sensor

    THROTTLE BODIES Throttle position sensor screw 3.5 Nm (0.35 m·kgf, 2.5 ft·lbf) “dIAG” appears on the display. g. Simultaneously press the “SELECT” button “1” and “RESET” button “2” for 2 seconds or ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ more to set the diagnostic mode. EAS1RC1717 ADJUSTING THE ACCELERATOR POSITION SENSOR EWA1RC1706...
  • Page 327 THROTTLE BODIES m. Check the meter display value. If the meter display value is not 97–107, adjust the accel- erator position sensor angle. n. Select the diagnostic code number “15”. o. Turn the throttle grip to the fully closed posi- tion.

  • Page 328: Air Induction System

    AIR INDUCTION SYSTEM EAS27040 AIR INDUCTION SYSTEM 7-15...
  • Page 329 AIR INDUCTION SYSTEM 1. Air filter case 2. Air induction system hose (air filter case to air cut-off valve) 3. Air cut-off valve 4. Air induction system hose (air cut-off valve to reed valve cover) 7-16...
  • Page 330 AIR INDUCTION SYSTEM Removing the air cut-off valve assembly and reed valves 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Rider seat 4-1.

  • Page 331: Checking The Air Induction System

    AIR INDUCTION SYSTEM Cracks/damage  Replace the reed valve EAS27060 CHECKING THE AIR INDUCTION SYSTEM assembly. Air injection 3. Measure: The air induction system burns unburned ex- • Reed valve bending limit “a” haust gases by injecting fresh air (secondary air) Out of specification ...
  • Page 332 AIR INDUCTION SYSTEM 2. Install: • Reed valve assembly 1 • Reed valve assembly 2 • Install the reed valve assembly 1 so that the open side turns to the exhaust side of the en- gine. • Install the reed valve assembly 2 so that the open side turns to the intake side of the engine.

  • Page 333: Electrical System

    CIRCUIT DIAGRAM .................8-27 TROUBLESHOOTING................8-29 FUEL INJECTION SYSTEM ................8-31 CIRCUIT DIAGRAM .................8-31 ECU SELF-DIAGNOSTIC FUNCTION .............8-33 TROUBLESHOOTING METHOD .............8-35 DIAGNOSTIC MODE................8-36 YAMAHA DIAGNOSTIC TOOL ..............8-37 TROUBLESHOOTING DETAILS..............8-38 FUEL PUMP SYSTEM..................8-81 CIRCUIT DIAGRAM .................8-81 TROUBLESHOOTING................8-83 ELECTRICAL COMPONENTS...............8-85 CHECKING THE SWITCHES..............8-89 CHECKING THE BULBS AND BULB SOCKETS........8-92 CHECKING THE FUSES................8-93...
  • Page 334 CHECKING THE RELAY UNIT (DIODE)..........8-99 CHECKING THE IGNITION COILS ............8-100 CHECKING THE IGNITION SPARK GAP ..........8-100 CHECKING THE CRANKSHAFT POSITION SENSOR ......8-101 CHECKING THE LEAN ANGLE SENSOR ..........8-101 CHECKING THE STARTER MOTOR OPERATION ......8-102 CHECKING THE STATOR COIL............8-102 CHECKING THE RECTIFIER/REGULATOR .........8-102 CHECKING THE HORN .................8-103 CHECKING THE ENGINE OIL LEVEL SWITCH........8-104 CHECKING THE FUEL SENDER ............8-104...
  • Page 336 IGNITION SYSTEM EAS27090 IGNITION SYSTEM EAS27110 CIRCUIT DIAGRAM...
  • Page 337 IGNITION SYSTEM 3. Main switch 4. Main fuse 9. Ignition fuse 13.Battery 14.Engine ground 15.Fuel injection system fuse 18.Joint connector 19.Joint coupler 20.Relay unit 23.ECU (engine control unit) 24.Ignition coil #1 25.Ignition coil #2 26.Ignition coil #3 27.Spark plug 33.Crankshaft position sensor 38.Lean angle sensor 58.Gear position sensor 61.Sidestand switch...
  • Page 338 IGNITION SYSTEM EAS1RC1804 ENGINE STOPPING DUE TO SIDESTAND OPERATION When the engine is running and the transmission is in gear, the engine will stop if the sidestand is moved down. This is because the electric current from the ignition coils does not flow to the ECU when both the gear position sensor (neutral circuit) and sidestand switch are set to “OFF”, thereby preventing the spark plugs from producing a spark.
  • Page 339 IGNITION SYSTEM EAS27150 TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Air scoop 3. Fuel tank cover 4. Fuel tank 5. Air filter case 1. Check the fuses. (Main, ignition and fuel injection system) Replace the fuse(s).
  • Page 340 IGNITION SYSTEM 9. Check the gear position sensor. Refer to “CHECKING THE GEAR Replace the gear position sensor. POSITION SENSOR” on page NG 8-110. OK 10.Check the sidestand switch. Refer to “CHECKING THE NG Replace the sidestand switch. SWITCHES” on page 8-89. OK...
  • Page 341 IGNITION SYSTEM...

  • Page 342: Electric Starting System

    ELECTRIC STARTING SYSTEM EAS27160 ELECTRIC STARTING SYSTEM EAS27170 CIRCUIT DIAGRAM...
  • Page 343 ELECTRIC STARTING SYSTEM 3. Main switch 4. Main fuse 9. Ignition fuse 13.Battery 14.Engine ground 15.Fuel injection system fuse 16.Starter relay 17.Starter motor 18.Joint connector 19.Joint coupler 20.Relay unit 21.Starting circuit cut-off relay 58.Gear position sensor 61.Sidestand switch 62.Right handlebar switch 64.Start/engine stop switch 70.Clutch switch...
  • Page 344 ELECTRIC STARTING SYSTEM EAS27180 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 345 ELECTRIC STARTING SYSTEM a. WHEN THE TRANSMISSION IS IN NEU- TRAL b. WHEN THE SIDESTAND IS UP AND THE CLUTCH LEVER IS PULLED TO THE HAN- DLEBAR 1. Battery 2. Main fuse 3. Main switch 4. Ignition fuse 5. Start/engine stop switch 6.
  • Page 346 ELECTRIC STARTING SYSTEM EAS27190 TROUBLESHOOTING The starter motor fails to turn. • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Air scoop 3. Fuel tank cover 4. Fuel tank 5. Air filter case 6. Throttle bodies 1. Check the fuses. (Main, ignition and fuel injection system) Replace the fuse(s).
  • Page 347 ELECTRIC STARTING SYSTEM 9. Check the gear position sensor. Refer to “CHECKING THE GEAR Replace the gear position sensor. POSITION SENSOR” on page NG 8-110. OK 10.Check the sidestand switch. Refer to “CHECKING THE Replace the sidestand switch. NG SWITCHES” on page 8-89. OK...
  • Page 348 CHARGING SYSTEM EAS27200 CHARGING SYSTEM EAS27210 CIRCUIT DIAGRAM 8-13...
  • Page 349 CHARGING SYSTEM 1. AC magneto 2. Rectifier/regulator 4. Main fuse 13.Battery 14.Engine ground 8-14...
  • Page 350 CHARGING SYSTEM EAS27230 TROUBLESHOOTING The battery is not being charged. • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Rear side cover 1. Check the fuse. (Main) Replace the fuse. Refer to “CHECKING THE FUSES” NG on page 8-93. OK...
  • Page 351 CHARGING SYSTEM 8-16...
  • Page 352 LIGHTING SYSTEM EAS27240 LIGHTING SYSTEM EAS27250 CIRCUIT DIAGRAM 8-17...
  • Page 353 LIGHTING SYSTEM 3. Main switch 4. Main fuse 9. Ignition fuse 10.Signal fuse 11.Headlight fuse 13.Battery 14.Engine ground 18.Joint connector 19.Joint coupler 23.ECU (engine control unit) 45.Meter assembly 47.Meter light 54.High beam indicator light 69.Left handlebar switch 74.Pass switch 75.Dimmer switch 78.Front right turn signal/position light 79.Front left turn signal/position light 80.Headlight...
  • Page 354 LIGHTING SYSTEM EAS27260 TROUBLESHOOTING Any of the following fail to light: headlight, high beam indicator light, taillight, license light or meter light. • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Air scoop 3. Fuel tank cover 4. Fuel tank 5.
  • Page 355 LIGHTING SYSTEM 8. Check the entire lighting system’s wiring. Properly connect or repair the lighting sys- Refer to “CIRCUIT DIAGRAM” on tem’s wiring. NG page 8-17. OK Replace the ECU or meter assembly. Refer to “REPLACING THE ECU (en- gine control unit)” on page 8-93. 8-20...
  • Page 356 SIGNALING SYSTEM EAS27270 SIGNALING SYSTEM EAS27280 CIRCUIT DIAGRAM 8-21...
  • Page 357 SIGNALING SYSTEM 3. Main switch 4. Main fuse 8. Parking lighting fuse 9. Ignition fuse 10.Signal fuse 13.Battery 14.Engine ground 18.Joint connector 19.Joint coupler 20.Relay unit 23.ECU (engine control unit) 35.Coolant temperature sensor 39.Speed sensor 45.Meter assembly 46.Neutral indicator light 48.Tachometer 49.Multi-function meter 50.Oil level warning light...
  • Page 358 SIGNALING SYSTEM EAS27290 TROUBLESHOOTING • Any of the following fail to light: turn signal light, brake light or an indicator light. • The horn fails to sound. • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Air scoop 3.
  • Page 359 SIGNALING SYSTEM 3. Check the entire signaling system’s wiring. Properly connect or repair the signaling Refer to “CIRCUIT DIAGRAM” on system’s wiring. NG page 8-21. OK This circuit is OK. The tail/brake light fails to come on. 1. Check the front brake light switch. Refer to “CHECKING THE Replace the front brake light switch.
  • Page 360 SIGNALING SYSTEM 5. Check the entire signaling system’s wiring. Properly connect or repair the signaling Refer to “CIRCUIT DIAGRAM” on system’s wiring. NG page 8-21. OK Replace the meter assembly. The neutral indicator light fails to come on. 1. Check the gear position sensor. Refer to “CHECKING THE GEAR Replace the gear position sensor.
  • Page 361 SIGNALING SYSTEM 2. Check the entire signaling system’s wiring. Properly connect or repair the signaling Refer to “CIRCUIT DIAGRAM” on system’s wiring. NG page 8-21. OK Replace the ECU or meter assembly. Refer to “REPLACING THE ECU (en- gine control unit)” on page 8-93. The speedometer fails to operate.
  • Page 362 COOLING SYSTEM EAS27300 COOLING SYSTEM EAS27310 CIRCUIT DIAGRAM 8-27...
  • Page 363 COOLING SYSTEM 3. Main switch 4. Main fuse 7. Radiator fan fuse 9. Ignition fuse 13.Battery 14.Engine ground 18.Joint connector 23.ECU (engine control unit) 35.Coolant temperature sensor 85.Radiator fan motor relay 86.Radiator fan motor 8-28...
  • Page 364 COOLING SYSTEM EAS27320 TROUBLESHOOTING • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Air scoop 3. Fuel tank cover 4. Fuel tank 5. Air filter case 6. Throttle bodies 1. Check the fuses. (Main, ignition and radiator fan) Replace the fuse(s).
  • Page 365 COOLING SYSTEM 8-30...
  • Page 366 FUEL INJECTION SYSTEM EAS27331 FUEL INJECTION SYSTEM EAS27340 CIRCUIT DIAGRAM 8-31...
  • Page 367 37.Intake air pressure sensor 2 38.Lean angle sensor 39.Speed sensor 40.Throttle servo motor 41.Accelerator position sensor 42.Throttle position sensor 43.Yamaha diagnostic tool connector 44.Yamaha diagnostic tool coupler 45.Meter assembly 49.Multi-function meter 52.Engine trouble warning light 58.Gear position sensor 60.Fuel pump 61.Sidestand switch...
  • Page 368 FUEL INJECTION SYSTEM EAS27351 ECU SELF-DIAGNOSTIC FUNCTION The ECU is equipped with a self-diagnostic function in order to ensure that the fuel injection system is operating normally. If this function detects a malfunction in the system, it immediately operates the en- gine under substitute characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the system.
  • Page 369 FUEL INJECTION SYSTEM ECU detects an abnormal signal from a sensor If the ECU detects an abnormal signal from a sensor while the vehicle is being driven, the ECU illumi- nates the engine trouble warning light and provides the engine with alternate operating instructions that are appropriate for the type of malfunction.
  • Page 370 FUEL INJECTION SYSTEM EAS30580 TROUBLESHOOTING METHOD Setting the main switch to “OFF” will not erase The engine operation is not normal and the the malfunction history. engine trouble warning light comes on. The engine operation is not normal, but the 1.
  • Page 371 FUEL INJECTION SYSTEM EAS27411 DIAGNOSTIC MODE Setting the diagnostic mode 1. Turn the main switch to “OFF”. 2. Disconnect the wire harness coupler from the fuel pump. 3. Simultaneously press and hold the “SELECT” button “1” and “RESET” button “2” , turn the main switch to “ON”, and continue to press the buttons for 8 seconds or more.
  • Page 372 9. Connect the wire harness coupler to the fuel pump. EAS1RC1812 YAMAHA DIAGNOSTIC TOOL This model uses the Yamaha diagnostic tool to identify malfunctions. For information about using the Yamaha diagnostic tool, refer to the operation manual that is included with the tool. Yamaha diagnostic tool 90890-03215...
  • Page 373 FUEL INJECTION SYSTEM Lg/L Lg/W L Br When the Yamaha diagnostic tool is connected to the vehicle, the operation of the multi-function meter and indicators will be different from the normal operation. EAS27462 TROUBLESHOOTING DETAILS This section describes the measures per fault code number displayed on the meter. Check and service the items or components that are the probable cause of the malfunction following the order given.
  • Page 374 FUEL INJECTION SYSTEM Fault code No. Crankshaft position sensor: no normal signals are received Item from the crankshaft position sensor. Improperly connected  Connection of wire harness Crank the engine. ECU coupler. Connect the coupler securely Fault code number is not dis- played ...
  • Page 375 FUEL INJECTION SYSTEM Fault code No. Item Intake air pressure sensor 1: open or short circuit detected. Procedure Shift the transmission into gear, extend the sidestand, and then operate the throttle while pushing the “ ” side of the start/engine stop switch.
  • Page 376 FUEL INJECTION SYSTEM Fault code No. Item Intake air pressure sensor 1: open or short circuit detected. Defective intake air pressure Execute the diagnostic Turn the main switch to “ON”. sensor 1. mode. (Code No. 03) Fault code number is not dis- played ...
  • Page 377 FUEL INJECTION SYSTEM Fault code No. Intake air pressure sensor 1: hose system malfunction Item (clogged or detached hose). Item Probable cause of Maintenance job Confirmation of service malfunction and check completion Clogged or detached hose  Condition of intake air pres- Start the engine and let it idle sure sensor 1 hose.
  • Page 378 FUEL INJECTION SYSTEM Fault code No. Item Throttle position sensor: open or short circuit detected. Meter display Throttle position sensor signal 1 • 11–21 (fully closed position) • 96–106 (fully open position) Procedure • Check with throttle valves fully closed. •...
  • Page 379 FUEL INJECTION SYSTEM Fault code No. Item Throttle position sensor: open or short circuit detected. Throttle position sensor Measure the throttle position Turn the main switch to “ON”. resistance. sensor resistance. Fault code number is not dis- played  Service is finished. black/blue–blue Refer to “CHECKING THE Fault code number is dis-...
  • Page 380 FUEL INJECTION SYSTEM Fault code No. Sidestand switch: a break or disconnection of the black/red Item lead of the ECU is detected. Item Probable cause of Maintenance job Confirmation of service malfunction and check completion Improperly connected  Connection of sidestand Turn the main switch to “ON”, switch coupler.
  • Page 381 FUEL INJECTION SYSTEM Fault code No. Sidestand switch: a break or disconnection of the black/red Item lead of the ECU is detected. Defective sidestand switch. Execute the diagnostic Turn the main switch to “ON”, mode. (Code No. 20) and then extend and retract Shift the transmission into the sidestand.
  • Page 382 FUEL INJECTION SYSTEM Fault code No. Intake air pressure sensor 1 or intake air pressure sensor 2: when the main switch is turned to “ON”, the intake air pres- Item sure sensor 1 voltage and intake air pressure sensor 2 volt- age differ greatly.
  • Page 383 FUEL INJECTION SYSTEM Fault code No. Item Coolant temperature sensor: open or short circuit detected. Fail-safe system Able to start engine Able to drive vehicle Diagnostic code No. Meter display Displays the coolant temperature. Procedure Compare the actually measured coolant temperature with the meter display value.
  • Page 384 FUEL INJECTION SYSTEM Fault code No. Item Coolant temperature sensor: open or short circuit detected. Defective coolant tempera- Execute the diagnostic Turn the main switch to “ON”. ture sensor. mode. (Code No. 06) Fault code number is not dis- played  Service is finished. When engine is cold: Displayed temperature is Fault code number is dis-...
  • Page 385 FUEL INJECTION SYSTEM Fault code No. Item Intake air temperature sensor: open or short circuit detected. Open or short circuit  Wire harness continuity. Turn the main switch to “ON”. Replace the wire harness. Fault code number is not dis- played ...
  • Page 386 FUEL INJECTION SYSTEM Fault code No. sensor: no normal signals are received from the O sen- Item sor. Item Probable cause of Maintenance job Confirmation of service malfunction and check completion Installed condition of O sen- Improperly installed sensor Start the engine, warm it up, ...
  • Page 387 FUEL INJECTION SYSTEM Fault code No. sensor: no normal signals are received from the O sen- Item sor. Check fuel pressure. Refer to “CHECKING THE Start the engine, warm it up, FUEL PRESSURE” on page and then race it, or execute 7-11.
  • Page 388 FUEL INJECTION SYSTEM Fault code No. Item Intake air pressure sensor 2: open or short circuit detected. Improperly connected  Connection of wire harness Turn the main switch to “ON”. ECU coupler. Connect the coupler securely Fault code number is not dis- played ...
  • Page 389 FUEL INJECTION SYSTEM Fault code No. Item Intake air pressure sensor 2: open or short circuit detected. Defective intake air pressure Execute the diagnostic Turn the main switch to “ON”. sensor 2. mode. (Code No. 04) Fault code number is not dis- played ...
  • Page 390 FUEL INJECTION SYSTEM Fault code No. Intake air pressure sensor 2: hose system malfunction Item (clogged or detached hose). Procedure Shift the transmission into gear, extend the sidestand, and then operate the throttle while pushing the “ ” side of the start/engine stop switch.
  • Page 391 FUEL INJECTION SYSTEM Fault code No. Item Latch up detected. Fail-safe system Unable to start engine Unable to drive vehicle Diagnostic code No. Meter display Lean angle sensor output voltage • 0.4–1.4 (upright) • 3.7–4.4 (overturned) Procedure Remove the lean angle sensor and incline it more than 65 degrees.

  • Page 392: Ignition Checker

    FUEL INJECTION SYSTEM Fault code No. Cylinder-#1 ignition coil: open or short circuit detected in the Item primary lead of the cylinder-#1 ignition coil. Actuation Actuates the cylinder-#1 ignition coil five times at one-second intervals. Illuminates the engine trouble warning light. Procedure Check that a spark is generated five times.
  • Page 393 FUEL INJECTION SYSTEM Fault code No. Cylinder-#1 ignition coil: open or short circuit detected in the Item primary lead of the cylinder-#1 ignition coil. Malfunction in ECU. Execute the diagnostic mode. (Code No. 30) No spark  Replace the ECU. Refer to “REPLACING THE ECU (engine control unit)”...
  • Page 394 FUEL INJECTION SYSTEM Fault code No. Cylinder-#2 ignition coil: open or short circuit detected in the Item primary lead of the cylinder-#2 ignition coil. Installed condition of cylin- Improperly installed ignition Start the engine and let it idle coil  Reinstall or replace der-#2 ignition coil.
  • Page 395 FUEL INJECTION SYSTEM Fault code No. Cylinder-#3 ignition coil: open or short circuit detected in the Item primary lead of the cylinder-#3 ignition coil. Improperly connected  Connection of wire harness Start the engine and let it idle ECU coupler. Connect the coupler securely for approximately 5 seconds.
  • Page 396 FUEL INJECTION SYSTEM Fault code No. Item Injector: open or short circuit detected. Actuation Actuates injector #2 five times at one-second intervals. Illuminates the engine trouble warning light. Procedure Check that injector #2 is actuated five times by listening for the operating sound.
  • Page 397 FUEL INJECTION SYSTEM Fault code No. Item Injector: open or short circuit detected. Open or short circuit  Wire harness continuity. Execute the diagnostic Replace the wire harness. mode. (Code Nos. 36, 37, Between injector coupler and No operating sound  Go to ECU coupler.
  • Page 398 FUEL INJECTION SYSTEM Fault code No. Item Lean angle sensor: open or short circuit detected. Improperly connected  Connection of wire harness Turn the main switch to “ON”, ECU coupler. Connect the coupler securely then to “OFF”, and then back Check the locking condition or replace the wire harness.
  • Page 399 FUEL INJECTION SYSTEM Fault code No. Speed sensor: no normal signals are received from the speed sensor. Item B Neutral switch: open or short circuit is detected. C Clutch switch: open or short circuit is detected. Procedure Check that the number increases when the rear wheel is rotated. The number is cumulative and does not reset each time the wheel is stopped.
  • Page 400 FUEL INJECTION SYSTEM Fault code No. Speed sensor: no normal signals are received from the speed sensor. Item B Neutral switch: open or short circuit is detected. C Clutch switch: open or short circuit is detected. Open or short circuit  Wire harness continuity.
  • Page 401 FUEL INJECTION SYSTEM Fault code No. Speed sensor: no normal signals are received from the speed sensor. Item B Neutral switch: open or short circuit is detected. C Clutch switch: open or short circuit is detected. Meter display Neutral • “ON” (when the transmission is in neutral) •...
  • Page 402 FUEL INJECTION SYSTEM Fault code No. Speed sensor: no normal signals are received from the speed sensor. Item B Neutral switch: open or short circuit is detected. C Clutch switch: open or short circuit is detected. Improperly connected  Connection of wire harness Execute the diagnostic ECU coupler.
  • Page 403 FUEL INJECTION SYSTEM Fault code No. Speed sensor: no normal signals are received from the speed sensor. Item B Neutral switch: open or short circuit is detected. C Clutch switch: open or short circuit is detected. Malfunction  Replace the Faulty shift drum (neutral Execute the diagnostic detection area).
  • Page 404 FUEL INJECTION SYSTEM Fault code No. Speed sensor: no normal signals are received from the speed sensor. Item B Neutral switch: open or short circuit is detected. C Clutch switch: open or short circuit is detected. Procedure Operate the transmission, clutch lever, and sidestand. Item Probable cause of Maintenance job...
  • Page 405 FUEL INJECTION SYSTEM Fault code No. Speed sensor: no normal signals are received from the speed sensor. Item B Neutral switch: open or short circuit is detected. C Clutch switch: open or short circuit is detected. Improperly connected  Connection of wire harness Execute the diagnostic ECU coupler.
  • Page 406 FUEL INJECTION SYSTEM Fault code No. Speed sensor: no normal signals are received from the speed sensor. Item B Neutral switch: open or short circuit is detected. C 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 407 FUEL INJECTION SYSTEM Fault code No. Fuel system voltage: incorrect voltage supplied to the fuel Item injector and fuel pump. Improperly connected  Connection of wire harness Start the engine and let it idle ECU coupler. Connect the coupler securely for approximately 5 seconds.
  • Page 408 FUEL INJECTION SYSTEM Fault code No. EEPROM fault code number: an error is detected while read- Item ing or writing on EEPROM. Meter display EEPROM fault code display • 00 (no history) • 01–03: Cylinder fault code number (history exists) If more than one cylinder is defective, the display switches every two seconds to show the cylinder fault code numbers of all defective cylinders in a repeating cycle.
  • Page 409 FUEL INJECTION SYSTEM Fault code No. Faulty ECU memory. (When this malfunction is detected in Item the ECU, the fault code number might not appear on the meter display.) Fail-safe system Able/Unable to start engine Able/Unable to drive vehicle Diagnostic code No. —...
  • Page 410 FUEL INJECTION SYSTEM Fault code No. Item Accelerator position sensor: open or short circuit detected. Improperly connected  Connection of accelerator Turn the main switch to “ON”. position sensor coupler. Connect the coupler securely Fault code number is not dis- played ...
  • Page 411 FUEL INJECTION SYSTEM Fault code No. Item Accelerator position sensor: open or short circuit detected. Defective accelerator posi- Check accelerator position Turn the main switch to “ON”. tion sensor. sensor signal 1. Fault code number is not dis- played  Service is finished. Execute the diagnostic mode.
  • Page 412 FUEL INJECTION SYSTEM Fault code No. Item YCC-T drive system: malfunction detected. Improperly connected  Connection of throttle servo Turn the main switch to “ON”. motor coupler. Connect the coupler securely Fault code number is not dis- played  Service is finished. Check the locking condition or replace the wire harness.
  • Page 413 FUEL INJECTION SYSTEM 89 (Yamaha diagnostic tool) Fault code No. Err (multi-function meter display) Multi-function meter: signals cannot be transmitted between Item the ECU and the multi-function meter. Fail-safe system Able to start engine Able to drive vehicle Diagnostic code No.
  • Page 414 FUEL INJECTION SYSTEM 89 (Yamaha diagnostic tool) Fault code No. Err (multi-function meter display) Multi-function meter: signals cannot be transmitted between Item the ECU and the multi-function meter. Malfunction in ECU. Replace the ECU. Refer to “REPLACING THE ECU (engine control unit)” on page 8-93.
  • Page 415 FUEL INJECTION SYSTEM 8-80...
  • Page 416 FUEL PUMP SYSTEM EAS27550 FUEL PUMP SYSTEM EAS27560 CIRCUIT DIAGRAM 8-81...
  • Page 417 FUEL PUMP SYSTEM 3. Main switch 4. Main fuse 9. Ignition fuse 13.Battery 14.Engine ground 15.Fuel injection system fuse 18.Joint connector 20.Relay unit 22.Fuel pump relay 23.ECU (engine control unit) 60.Fuel pump 62.Right handlebar switch 64.Start/engine stop switch 8-82...
  • Page 418 FUEL PUMP SYSTEM EAS27570 TROUBLESHOOTING If the fuel pump fails to operate. • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Air scoop 3. Fuel tank cover 4. Fuel tank 1. Check the fuses. (Main, ignition and fuel injection system) Replace the fuse(s).
  • Page 419 FUEL PUMP SYSTEM 8-84...
  • Page 420 ELECTRICAL COMPONENTS EAS27973 ELECTRICAL COMPONENTS 8-85...
  • Page 421 ELECTRICAL COMPONENTS 1. Main switch 2. Clutch switch 3. Front brake light switch 4. Battery 5. Fuse box 2 6. Main fuse 7. Fuel injection system fuse 8. Starter relay 9. Rectifier/regulator 10.Rear brake light switch 11.Gear position sensor 12.Sidestand switch 13.O sensor 14.Oil level switch...
  • Page 422 ELECTRICAL COMPONENTS 8-87...
  • Page 423 ELECTRICAL COMPONENTS 1. Intake air temperature sensor 2. Headlight relay 3. ECU (engine control unit) 4. Fuel pump 5. Lean angle sensor 6. Radiator fan motor relay 7. Turn signal/hazard relay 8. Relay unit 9. Speed sensor 10.Stator coil 11.Crankshaft position sensor 12.Coolant temperature sensor 13.Throttle servo motor 14.Accelerator position sensor...
  • Page 424 ELECTRICAL COMPONENTS EAS27981 CHECKING THE SWITCHES 8-89...
  • Page 425 ELECTRICAL COMPONENTS 1. Dimmer switch 2. Pass switch 3. Turn signal switch 4. Horn switch 5. Clutch switch 6. Oil level switch 7. Sidestand switch 8. Hazard switch 9. Start/engine stop switch 10.Drive mode switch 11.Front brake light switch 12.Main switch 13.Rear brake light switch 8-90...
  • Page 426 ELECTRICAL COMPONENTS Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. ECA14370 NOTICE Never insert the tester probes into the coupler terminal slots “a”. Always insert the probes from the opposite end of the coupler, taking care not to loosen or damage the leads.
  • Page 427 ELECTRICAL COMPONENTS keep flammable products and your hands EAS27990 CHECKING THE BULBS AND BULB away from the bulb until it has cooled down. SOCKETS ECA14380 Check each bulb and bulb socket for damage or NOTICE wear, proper connections, and also for continuity •...
  • Page 428 ELECTRICAL COMPONENTS 1. Check: 3. Replace: • Bulb socket (for continuity) • Blown fuse (with the pocket tester) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ No continuity  Replace. a. Set the main switch to “OFF”. b. Install a new fuse of the correct amperage Pocket tester rating.
  • Page 429 ELECTRICAL COMPONENTS (idle speed control) learning value. (Valve Regulated Lead Acid) battery should be charged according to the appropriate Refer to “CHECKING AND CLEANING THE THROTTLE BODIES” on page 7-8. charging method. If the battery is over- charged, the electrolyte level will drop con- 4.
  • Page 430 ELECTRICAL COMPONENTS • No charging is necessary when the open-cir- tery overheating and battery plate damage. • If it is impossible to regulate the charging cuit voltage equals or exceeds 12.8 V. current on the battery charger, be careful b. Check the charge of the battery, as shown in not to overcharge the battery.
  • Page 431 ELECTRICAL COMPONENTS charging. c. Make sure that the current is higher than the standard charging current written on the bat- tery. Voltage should be measured 30 minutes after the engine is stopped. If the current is lower than the standard charging b.
  • Page 432 ELECTRICAL COMPONENTS 10.Install: Relay unit (starting circuit cut-off relay) • Rider seat Refer to “GENERAL CHASSIS” on page 4-1. EAS28040 CHECKING THE RELAYS Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, re- place the relay. Pocket tester 90890-03112 Analog pocket tester...
  • Page 433 ELECTRICAL COMPONENTS Headlight relay ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester (DC 20 V) to the turn signal/hazard relay terminal as shown. Pocket tester 90890-03112 Analog pocket tester YU-03112-C • Positive tester probe blue/red “1” • Negative tester probe 1. Positive battery terminal Ground 2.
  • Page 434 ELECTRICAL COMPONENTS Continuity Positive tester probe sky blue “1” Negative tester probe black/yellow “2” No continuity Positive tester probe black/yellow “2” Negative tester probe sky blue “1” Continuity b. Turn the main switch to “ON”. Positive tester probe c. Measure the turn signal/hazard relay output sky blue “1”...
  • Page 435 ELECTRICAL COMPONENTS unit terminal as shown. Secondary coil resistance c. Check the relay unit (diode) for continuity. 9.35–12.65 k d. Check the relay unit (diode) for no continuity. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ a. Connect the pocket tester (  1 k) to the ig- nition coil as shown.
  • Page 436 ELECTRICAL COMPONENTS b. Measure the crankshaft position sensor re- 2. Ignition coil sistance. c. Turn the main switch to “ON”. d. Measure the ignition spark gap “a”. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ e. Crank the engine by pushing the “ ” side of the start/engine stop switch and gradually in- EAS28131 CHECKING THE LEAN ANGLE SENSOR crease the spark gap until a misfire occurs.
  • Page 437 ELECTRICAL COMPONENTS EAS28150 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 0.152–0.228  (W-W) c. Set the main switch to “ON”. d.
  • Page 438 ELECTRICAL COMPONENTS Rectifier/regulator input voltage Pocket tester above 14 V at 5000 r/min 90890-03112 Analog pocket tester YU-03112-C ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Set the engine tachometer to the ignition coil of cylinder #1. • Positive tester probe  b. Connect the pocket tester (AC 20 V) to the positive battery terminal “1”...
  • Page 439 ELECTRICAL COMPONENTS Maximum level position “B” • Positive tester probe Connector (gray) “1” • Negative tester probe Body earth “2” c. Measure the horn resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Check: • Horn sound Faulty sound  Replace. b. Measure the oil level switch resistance. EAS28190 CHECKING THE ENGINE OIL LEVEL ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...
  • Page 440 ELECTRICAL COMPONENTS EAS29050 CHECKING THE OIL LEVEL WARNING LIGHT This model is equipped with a self-diagnosis de- vice for the oil level detection circuit. 1. Check: • Oil level warning light “1” (Turn the main switch to “ON”.) Warning light comes on for a few seconds, then goes off ...
  • Page 441 ELECTRICAL COMPONENTS EWA14130 WARNING • Handle the coolant temperature sensor with special care. • Never subject the coolant temperature sen- sor to strong shocks. If the coolant temper- ature sensor is dropped, replace it. 2. Check: • Coolant temperature sensor resistance Out of specification ...
  • Page 442 ELECTRICAL COMPONENTS e. Measure the coolant temperature sensor re- b. Measure the throttle position sensor maxi- sistance. mum resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Install: 3. Install: • Coolant temperature sensor • Throttle position sensor Coolant temperature sensor When installing the throttle position sensor, ad- 16 Nm (1.6 m·kgf, 12 ft·lbf) just its angle properly.
  • Page 443 ELECTRICAL COMPONENTS L B/L W b. Measure the accelerator position sensor maximum resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Install: • Accelerator position sensor When installing the accelerator position sensor, adjust its angle properly. Refer to “ADJUSTING THE ACCELERATOR POSITION SENSOR” on A. Check that the throttle valves “2” open. page 7-13.
  • Page 444 ELECTRICAL COMPONENTS c. Measure the air induction system solenoid re- sistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS28411 CHECKING THE INTAKE AIR PRESSURE SENSOR 1. Check: • Intake air pressure sensor output voltage Out of specification  Replace. A. Intake air pressure sensor 1 B. Intake air pressure sensor 2 Intake air pressure sensor output voltage c.
  • Page 445 ELECTRICAL COMPONENTS Pocket tester Result 90890-03112 Neutral position Analog pocket tester Continuity YU-03112-C Positive tester probe sky blue “1” Negative tester probe b. Immerse the intake air temperature sensor Sensor terminal “a” “1” in a container filled with water “2”. 1st position Continuity Make sure that the intake air temperature sensor...
  • Page 446 ELECTRICAL COMPONENTS EAS1RC1817 CHECKING THE FUEL INJECTORS The following procedure applies to all of the fuel injectors. 1. Remove: • Fuel injector Refer to “THROTTLE BODIES” on page 7-5. 2. Check: • Fuel injector resistance Out of specification  Replace the fuel injec- tor.

  • Page 447: Troubleshooting

    TROUBLESHOOTING TROUBLESHOOTING..................9-1 GENERAL INFORMATION ................9-1 STARTING FAILURES ................9-1 INCORRECT ENGINE IDLING SPEED .............9-1 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ......9-2 FAULTY GEAR SHIFTING .................9-2 SHIFT PEDAL DOES NOT MOVE .............9-2 JUMPS OUT OF GEAR ................9-2 FAULTY CLUTCH ..................9-2 OVERHEATING..................9-2 OVERCOOLING ..................9-3 POOR BRAKING PERFORMANCE ............9-3 FAULTY FRONT FORK LEGS ..............9-3 UNSTABLE HANDLING ................9-3 FAULTY LIGHTING OR SIGNALING SYSTEM .........9-3...
  • Page 448 TROUBLESHOOTING 2. Fuse(s) EAS28451 TROUBLESHOOTING • Blown, damaged or incorrect fuse • Improperly installed fuse EAS28460 3. Spark plug(s) GENERAL INFORMATION • Incorrect spark plug gap • Incorrect spark plug heat range The following guide for troubleshooting does not • Fouled spark plug cover all the possible causes of trouble.
  • Page 449 TROUBLESHOOTING • Worn or damaged electrode EAS28560 FAULTY CLUTCH • Worn or damaged insulator Clutch slips 3. Ignition coil(s) 1. Clutch • Broken or shorted primary or secondary coils • Improperly assembled clutch • Cracked or broken ignition coil • Improperly adjusted clutch cable 4.
  • Page 450 TROUBLESHOOTING • Damaged pipe • Incorrect oil viscosity • Improperly connected pipe • Incorrect oil level Fuel system EAS28670 1. Throttle body (-ies) UNSTABLE HANDLING • Damaged or loose throttle body joint 1. Handlebar 2. Air filter • Bent or improperly installed handlebar •...
  • Page 451 TROUBLESHOOTING • Faulty rectifier/regulator • Improperly grounded circuit • Faulty main switch • Faulty dimmer switch • Headlight bulb life expired Tail/brake light does not come on • Too many electrical accessories • Incorrect connection Turn signal does not come on •...
  • Page 452 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE EAS1RC1902 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Self-diagnostic function table Fault Reference Item code No. pages Crankshaft position sensor: no normal signals are received from the 8-38 crankshaft position sensor. Intake air pressure sensor 1: open or short circuit detected. 8-39 Intake air pressure sensor 1: hose system malfunction (clogged or 8-41...
  • Page 453 Engine idling stop — Communication error with the meter Reference Fault code No. Item pages 89 (Yamaha diagnostic tool) Multi-function meter: signals cannot be transmit- Err (multi-function meter dis- ted between the ECU and the multi-function 8-78 play) meter. Diagnostic code: sensor operation table...
  • Page 454 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Diagnostic Item Meter display Procedure code No. Coolant temperature When engine is cold: Dis- Compare the actually plays temperature closer measured coolant temper- to air temperature. ature with the meter dis- When engine is hot: Dis- play value.
  • Page 455 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Diagnostic Item Meter display Procedure code No. Sidestand switch Extend and retract the sid- estand (with the transmis- • Stand retracted sion in gear). • Stand extended Gear position sensor and Operate the transmission, clutch switch clutch lever, and sides- tand.
  • Page 456 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Diagnostic Item Meter display Procedure code No. Malfunction history code — display • No history • History exists Fault codes 12–89 • (If more than one code number is detected, the display alternates every two seconds to show all the detected code num- bers.
  • Page 457 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Diagnostic Item Meter display Procedure code No. ISC (idle speed control) To erase the ISC (idle learning condition display ISC (idle speed control) speed control) learning ISC (idle speed control) learning data has been data, set the start/engine learning data erasure erased.
  • Page 458 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Diagnostic Item Actuation Procedure code No. Air induction system sole- Actuates the air induction Check that the air induc- noid system solenoid five times tion system solenoid is at one-second intervals. actuated five times by lis- Illuminates the engine tening for the operating trouble warning light.
  • Page 459 EVENT CODE TABLE EAS1RC1903 EVENT CODE TABLE The event code numbers listed below cannot be displayed on the meter. To display the event code numbers, use the Yamaha diagnostic tool. Item Symptom Possible causes Note Intake air pres- Brief abnormality...
  • Page 460 EVENT CODE TABLE Item Symptom Possible causes Note sensor During O feed- – Open or short cir- – If a fault code is cuit in the wire har- occurring, respond to (Stuck at the back, the adjust- upper limit for ment is maintained ness between the that first.
  • Page 461 EVENT CODE TABLE Item Symptom Possible causes Note During idling, the Idling engine speed is – If a fault code is (Stuck at the adjustment is main- fast occurring, respond to lower limit for tained at the lower – Poorly adjusted that first.
  • Page 462 EVENT CODE TABLE 9-15...

  • Page 463: Wiring Diagram

    39. Speed sensor Red/White 40. Throttle servo motor Red/Yellow 41. Accelerator position sensor Sb/W Sky blue/White 42. Throttle position sensor White/Black 43. Yamaha diagnostic tool con- White/Green nector White/Blue 44. Yamaha diagnostic tool cou- White/Red pler White/Yellow 45. Meter assembly Yellow/Black 46.
  • Page 467 FZ09E/FZ09EC 2014 WIRING DIAGRAM...
  • Page 468 FZ09E/FZ09EC 2014 WIRING DIAGRAM...

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