Yamaha Tracer MT09TRAH 2017 Service Manual
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Yamaha Tracer MT09TRAH 2017 Service Manual

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Table of Contents

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2017
SERVICE MANUAL
MT09TRA
MT09TRAH
2SC-28197-E0

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Summary of Contents for Yamaha Tracer MT09TRAH 2017

  • Page 1 2017 SERVICE MANUAL MT09TRA MT09TRAH 2SC-28197-E0...
  • Page 3 EAS20002 MT09TRA/MT09TRAH SERVICE MANUAL ©2016 by Yamaha Motor Co., Ltd. First edition, November 2016 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.
  • Page 4 EAS20003 IMPORTANT This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one man- ual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles.

  • Page 5: How To Use This Manual

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

  • Page 6: Symbols

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

  • Page 7: Table Of Contents

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

  • Page 9: General Information

    GENERAL INFORMATION IDENTIFICATION....................1-1 VEHICLE IDENTIFICATION NUMBER ............1-1 MODEL LABEL...................1-1 FEATURES .......................1-2 YCC-T (Yamaha Chip Controlled Throttle)..........1-2 OUTLINE OF THE TCS (Traction Control System)........1-4 INSTRUMENT FUNCTIONS ..............1-8 D-mode (drive mode)................1-16 IMPORTANT INFORMATION .................1-17 PREPARATION FOR REMOVAL AND DISASSEMBLY......1-17 REPLACEMENT PARTS................1-17 GASKETS, OIL SEALS AND O-RINGS ...........1-17 LOCK WASHERS/PLATES AND COTTER PINS ........1-17...

  • Page 10: Identification

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

  • Page 11: Features

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

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

    FEATURES EAS30855 OUTLINE OF THE TCS (Traction Control System) The traction control system controls excessive spinning (slipping) of the rear wheel when accelerating on slippery surfaces, such as unpaved or wet roads. The ECU monitors the front and rear wheel speeds using the signals from the front and rear wheel sen- sors, and detects rear wheel slipping according to the difference between the wheel speeds.
  • Page 14 FEATURES TCS (Traction control system) block diagram The signals from the front and rear wheel sensors are sent to the ECU through the ABS ECU, and the ECU calculates the amount of slip according to the difference between the detected front and rear wheel speeds.
  • Page 15 FEATURES Traction control system The traction control system (TCS) helps maintain traction when accelerating on slippery surfaces, such as unpaved or wet roads. If sensors detect that the rear wheel is starting to slip (uncontrolled spinning), the traction control system assists by regulating engine power as needed until traction is restored. EWA15433 WARNING The traction control system is not a substitute for riding appropriately for the conditions.
  • Page 16 FEATURES TCS settings can be changed only when the vehicle is stopped and the throttle closed. • Push the “TCS” button to change between TCS settings “1” and “2”. • Push the button for two seconds to turn the traction control system off. •...

  • Page 17: Instrument Functions

    FEATURES use the handlebar switches and buttons. EAS30682 INSTRUMENT FUNCTIONS Multi-function meter unit GEAR A.TEMP °C C.TEMP °C TIME TRIP 0:00 1. Menu switch “MENU” 2. Select switch “ ” 1. “RESET” button 2. “TCS” button Speedometer 3. Clock 4. Tachometer 5.
  • Page 18 FEATURES Eco indicator ECA20410 NOTICE Do not operate the engine in the tachometer high-rpm zone. Clock 1. Eco indicator “ECO” The eco indicator comes on when the vehicle is being operated in an environmentally friendly, fuel-efficient manner. The indicator goes off 1.
  • Page 19 FEATURES Drive mode display lect switch “ ” to change the selected infor- mation display. The following items are shown in the information displays: • an odometer display • tripmeter displays • a fuel reserve tripmeter display • an elapsed time display •...
  • Page 20 FEATURES To reset a tripmeter, use the select switch to dis- play the tripmeter you want to reset. Then push There are also “TIME–2” and “TIME–3” elapsed the “RESET” button briefly so that the tripmeter time displays, but they cannot be set to the infor- flashes, and then push the “RESET”...
  • Page 21 FEATURES This function calculates the instantaneous fuel consumption (fuel economy) under current rid- The selected information display cannot be switched while the message “Hi” is flashing. ing conditions. The instantaneous fuel con- sumption display can be set to “km/L” or ECA10022 “L/100km”;...
  • Page 22 FEATURES Display Description Maintenance This function allows you to check and reset the “OIL” oil change interval (distance trav- “Maintenance” eled), and the “FREE-1” and FREE-1 “FREE-2” maintenance inter- vals. This function allows you to FREE-2 check and reset the “TIME–2” and “TIME–3”...
  • Page 23 FEATURES 4. Use the select switch to move from “km or MENU Maintenance mile” to “km/L or L/100km”. Time Trip 5. Push the menu switch, then use the select Unit switch to toggle between “km/L” and Display “L/100km”, and then push the menu switch to Brightness confirm the selection.
  • Page 24 FEATURES Adjusting the meter panel brightness 1. Use the select switch to highlight “Bright- Display-1 ness”. A.TEMP MENU Maintenance C.TEMP Time Trip Unit TIME TRIP Display Brightness 4. Use the select switch to select the item you Clock All Reset want to display, and then push the menu switch.

  • Page 25: D-Mode (Drive Mode)

    FEATURES Clock 5 55 4. Push the menu switch, and the minute digits 1. Drive mode switch “MODE” start flashing. 5. Use the select switch to set the minutes. Before using D-mode, make sure you under- 6. Push the menu switch to return to the setting stand its operation along with the operation of mode menu.

  • Page 26: Important Information

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

  • Page 27: Circlips

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

  • Page 28: Basic Service Information

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

  • Page 29: Electrical System

    BASIC SERVICE INFORMATION If a battery lead is difficult to disconnect due to rust on the battery terminal, remove the rust us- ing hot water. EAS30014 ELECTRICAL SYSTEM Electrical parts handling ECA16600 NOTICE ECA16760 NOTICE Never disconnect a battery lead while the en- Be sure to connect the battery leads to the gine is running;...
  • Page 30 BASIC SERVICE INFORMATION ECA16610 NOTICE When resetting the ECU by turning the main Turn the main switch to “OFF” before dis- switch to “OFF”, be sure to wait approximately connecting or connecting an electrical com- 5 seconds before turning the main switch back ponent.
  • Page 31 BASIC SERVICE INFORMATION ECA16640 NOTICE ECA16790 For waterproof couplers, never insert the NOTICE tester probes directly into the coupler. When When disconnecting a connector, do not pull performing any checks using a waterproof the leads. Hold both sections of the connec- coupler, use the specified test harness or a tor securely, and then disconnect the con- suitable commercially available test har-...
  • Page 32 BASIC SERVICE INFORMATION • Make sure all connections are tight. 5. Check: • Resistance Digital circuit tester (CD732) 90890-03243 Model 88 Multimeter with tachom- eter YU-A1927 The resistance values shown were obtained at the standard measuring temperature of 20 C (68 F).

  • Page 33: Special Tools

    Model 88 Multimeter with tachometer 8-157, 8-161, YU-A1927 8-162, 8-163, 8-164, 8-165, 8-166, 8-167, 8-168, 8-170, 8-171, 8-172, 8-173, 8-174 Yamaha diagnostic tool USB 3-4, 3-11, 4-65, 90890-03250 4-67, 8-34, 8-127, 8-147 Yamaha diagnostic tool (A/I) 3-4, 3-11, 4-65, 90890-03252 4-67, 8-34,...
  • Page 34 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Vacuum gauge 90890-03094 Vacuummate YU-44456 YU-44456 Carburetor angle driver 2 3-10 90890-03173 Steering nut wrench 3-20, 4-89 90890-01403 Exhaust flange nut wrench YU-A9472 Oil filter wrench 3-25 90890-01426 Oil filter wrench YU-38411 Pressure gauge 3-26, 7-11 90890-03153...
  • Page 35 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Rod holder 4-79, 4-84, 4-85 90890-01434 Damper rod holder double ended YM-01434 Damper rod holder (ø27) 4-80, 4-82 90890-01582 Damper rod holder YM-01582 Fork seal driver 4-82, 4-83 90890-01442 Adjustable fork seal driver (36–46 mm) YM-01442 Rod puller 4-83, 4-84, 4-85...
  • Page 36 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Drive chain cut & rivet tool 4-99, 4-101 90890-01550 Drive chain cut & rivet tool YM-01550 Compression gauge 90890-03081 90890-03081 Engine compression tester YU-33223 YU-33223 Extension 90890-04136 Pivot shaft wrench 90890-01485 Frame mount insert wrench YM-01485 Pivot shaft wrench 5-7, 5-8...
  • Page 37 Valve guide reamer (ø4.5) 5-25 90890-04118 Valve guide reamer (4.5 mm) YM-04118 Sheave holder 5-31, 5-32 90890-01701 Primary clutch holder YS-01880-A Flywheel puller 5-31 90890-01362 Heavy duty puller YU-33270-B Yamaha bond No. 1215 5-33, 5-58 90890-85505 (Three bond No.1215®) 1-28...
  • Page 38 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Universal clutch holder 5-42, 5-46 90890-04086 Universal clutch holder YM-91042 Piston pin puller set 5-62 90890-01304 Piston pin puller YU-01304 YU-01304 Piston installing tool 5-69 90890-04161 Piston installing tool YM-04161 Radiator cap tester 90890-01325 Mityvac cooling system tester kit YU-24460-A...
  • Page 39 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Radiator cap tester adapter 90890-01352 Pressure tester adapter YU-33984 YU-33984 Mechanical seal installer 6-11 90890-04078 Water pump seal installer YM-33221-A Middle driven shaft bearing driver 6-11 90890-04058 Middle drive bearing installer 40 & 50 mm YM-04058 Fuel injector pressure adapter 7-11...
  • Page 40 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Test harness– lean angle sensor (6P) 8-165 90890-03209 Test harness– lean angle sensor (6P) YU-03209 Test harness S– pressure sensor (3P) 8-172 90890-03207 Test harness S– pressure sensor (3P) YU-03207 1-31...

  • Page 41: Specifications

    SPECIFICATIONS GENERAL SPECIFICATIONS................2-1 ENGINE SPECIFICATIONS ................2-2 CHASSIS SPECIFICATIONS ................2-7 ELECTRICAL SPECIFICATIONS ..............2-10 TIGHTENING TORQUES ................2-12 GENERAL TIGHTENING TORQUE SPECIFICATIONS......2-12 ENGINE TIGHTENING TORQUES............2-13 CHASSIS TIGHTENING TORQUES............2-13 LUBRICATION POINTS AND LUBRICANT TYPES........2-15 ENGINE....................2-15 CHASSIS....................2-16 LUBRICATION SYSTEM CHART AND DIAGRAMS ........2-19 ENGINE OIL LUBRICATION CHART ............2-19 LUBRICATION DIAGRAMS ..............2-21 COOLING SYSTEM DIAGRAMS ..............2-31 CABLE ROUTING ..................2-35...

  • Page 42: General Specifications

    GENERAL SPECIFICATIONS EAS20013 GENERAL SPECIFICATIONS Model Model 2SCL (MT09TRA_EUR/HRV/TUR/ZAF) 2SCM (MT09TRAH) 2SCT (MT09TRA_RUS) Dimensions Overall length 2160 mm (85.0 in) Overall width 950 mm (37.4 in) Overall height 1345/1375 mm (53.0/54.1 in) Seat height 845/860 mm (33.3/33.9 in) Wheelbase 1440 mm (56.7 in) Ground clearance 135 mm (5.31 in) Minimum turning radius...

  • Page 43: Engine Specifications

    ENGINE SPECIFICATIONS EAS20014 ENGINE SPECIFICATIONS Engine Combustion cycle 4-stroke Cooling system Liquid cooled Valve train DOHC Displacement 847 cm³ Cylinder arrangement Inline Number of cylinders 3-cylinder Bore  stroke 78.0  59.1 mm (3.07  2.33 in) Compression ratio 11.5 : 1 Compression pressure 1331–1713 kPa/680 r/min (13.3–17.1 kgf/cm²/680 r/min, 189.3–243.7 psi/680 r/min)
  • Page 44 ENGINE SPECIFICATIONS Water pump Water pump type Single suction centrifugal pump Impeller shaft tilt limit 0.15 mm (0.006 in) Spark plug(s) Manufacturer/model NGK/CPR9EA9 Spark plug gap 0.8–0.9 mm (0.031–0.035 in) Cylinder head Warpage limit 0.10 mm (0.0039 in) Camshaft Camshaft cap inside diameter 24.500–24.521 mm (0.9646–0.9654 in) Camshaft journal diameter 24.459–24.472 mm (0.9630–0.9635 in)
  • Page 45 ENGINE SPECIFICATIONS Wear limit 78.060 mm (3.0732 in) Piston Diameter 77.975–77.990 mm (3.0699–3.0705 in) Measuring point (from piston skirt bottom) 12.0 mm (0.47 in) Piston-to-cylinder clearance 0.010–0.035 mm (0.0004–0.0014 in) Piston pin bore inside diameter 17.002–17.013 mm (0.6694–0.6698 in) Limit 17.043 mm (0.6710 in) Piston pin outside diameter 16.990–16.995 mm (0.6689–0.6691 in)
  • Page 46 ENGINE SPECIFICATIONS Clutch Clutch type Wet, multiple-disc Clutch lever free play 10.0–15.0 mm (0.39–0.59 in) Friction plate 1 thickness 2.92–3.08 mm (0.115–0.121 in) Wear limit 2.82 mm (0.111 in) Plate quantity 3 pcs Friction plate 2 thickness 2.92–3.08 mm (0.115–0.121 in) Wear limit 2.82 mm (0.111 in) Plate quantity...
  • Page 47 ENGINE SPECIFICATIONS Idling condition Engine idling speed 1100–1300 r/min AI system Inactive feedback control Inactive Exhaust gas sampling point Sampling port on the exhaust pipe To be measured Coolant temperature 90–110 C (194–230 F) Temperature 1.5–3.5 % Difference in vacuum pressure between the 1.3 kPa (10 mmHg, 0.4 inHg) cylinders Fuel line pressure (at idle)

  • Page 48: Chassis Specifications

    CHASSIS SPECIFICATIONS EAS20015 CHASSIS SPECIFICATIONS Chassis Frame type Diamond 24.0  Caster angle Trail 100 mm (3.9 in) Front wheel Wheel type Cast wheel Rim size 17M/C x MT3.50 Rim material Aluminum Radial wheel runout limit 1.0 mm (0.04 in) Lateral wheel runout limit 0.5 mm (0.02 in) Rear wheel...
  • Page 49 305.3 mm (12.02 in) Limit 299.1 mm (11.78 in) Inner tube bending limit 0.2 mm (0.01 in) Recommended oil Yamaha Suspension Oil 01 Quantity (left) 444.0 cm³ (15.01 US oz, 15.66 Imp.oz) Quantity (right) 431.0 cm³ (14.57 US oz, 15.20 Imp.oz) Level (left) 174 mm (6.9 in)
  • Page 50 CHASSIS SPECIFICATIONS Adjustment value from the start position (Hard) Drive chain Size DID525V10 Chain type Sealed type Number of links Drive chain slack 5.0–15.0 mm (0.20–0.59 in) 15-link length limit 239.3 mm (9.42 in)

  • Page 51: Electrical Specifications

    ELECTRICAL SPECIFICATIONS EAS20016 ELECTRICAL SPECIFICATIONS Voltage System voltage 12 V Ignition system Ignition system Advancer type Digital 5.0 1200 r/min Ignition timing (B.T.D.C.) Engine control unit Model TBDF0C (MT09TRAH) TBDFZ7 (MT09TRA) Ignition coil 1.19–1.61  Primary coil resistance Secondary coil resistance 9.35–12.65 k...
  • Page 52 ELECTRICAL SPECIFICATIONS Starter motor Power output 0.70 kW 0.0050–0.0150  Armature coil resistance Brush overall length 12.0 mm (0.47 in) Limit 6.50 mm (0.26 in) Brush spring force 6.03–6.52 N (615–665 gf, 21.71–23.47 oz) Mica undercut (depth) 0.70 mm (0.03 in) Oil level switch 484.0–536.0 ...

  • Page 53: Tightening Torques

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

  • Page 54: Engine Tightening Torques

    TIGHTENING TORQUES EAS30016 ENGINE TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Exhaust pipe nut 20 N·m (2.0 kgf·m, 14 lb·ft) Muffler protector bolt 10 N·m (1.0 kgf·m, 7.2 lb·ft) Spark plug 13 N·m (1.3 kgf·m, 9.4 lb·ft) Cylinder head cover bolt 10 N·m (1.0 kgf·m, 7.2 lb·ft) Generator rotor bolt 75 N·m (7.5 kgf·m, 54 lb·ft)
  • Page 55 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Stake. Drive sprocket nut 95 N·m (9.5 kgf·m, 69 lb·ft) Lower ring nut 1. Tighten the ring nut to approximately 52 N·m (5.2 kgf·m, 38 lb·ft) with a torque wrench, then loosen the lower ring nut completely.

  • Page 56: Lubrication Points And Lubricant Types

    LUBRICATION POINTS AND LUBRICANT TYPES EAS20018 LUBRICATION POINTS AND LUBRICANT TYPES EAS30018 ENGINE Lubrication point Lubricant Oil seal lips O-rings Water or Coolant hose insertion part Bearing Cylinder head cover bolt gasket and timing chain bolt gasket Camshaft lobes and journals (intake and exhaust) Valve stem seals (intake and exhaust) Valve lifter outer surface (intake and exhaust) Valve stems and stem ends (intake and exhaust)

  • Page 57: Chassis

    Shift drum moving surface Shift fork pin Shift forks guide bar outer surface Shift shaft washer Shift shaft moving surface Yamaha bond No. 1215 Crankcase mating surface (Three bond No. 1215®) Yamaha bond No. 1215 Stator coil assembly lead grommet (Three bond No.
  • Page 58 LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant 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 Brake caliper piston dust seal Brake caliper bolts 2-17...
  • Page 59 LUBRICATION POINTS AND LUBRICANT TYPES 2-18...

  • Page 60: Lubrication System Chart And Diagrams

    LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20019 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS30020 ENGINE OIL LUBRICATION CHART 2-19...
  • 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.Oil nozzle 14.Balancer shaft 15.Timing chain tensioner 16.Intake camshaft...

  • Page 62: Lubrication Diagrams

    LUBRICATION SYSTEM CHART AND DIAGRAMS EAS30021 LUBRICATION DIAGRAMS 2-21...
  • Page 63 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil level switch 2. Oil filter cartridge union bolt 3. Oil filter cartridge 4. Crankshaft 2-22...
  • Page 64 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-23...
  • 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 2-24...
  • Page 66 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-25...
  • 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 2-26...
  • Page 68 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-27...
  • 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 2-28...
  • Page 70 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-29...
  • 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 EAS20020 COOLING SYSTEM DIAGRAMS 2-31...
  • Page 73 COOLING SYSTEM DIAGRAMS 1. Water pump 2. Thermostat 3. Radiator 2-32...
  • Page 74 COOLING SYSTEM DIAGRAMS 2-33...
  • Page 75 COOLING SYSTEM DIAGRAMS 1. Water jacket 2. Thermostat 3. Radiator 4. Water pump 5. Oil cooler 6. Coolant reservoir 2-34...

  • Page 76: Cable Routing

    CABLE ROUTING EAS20021 CABLE ROUTING Handlebar (top view) 2-35...
  • Page 77 CABLE ROUTING 1. Front brake master cylinder 2. Throttle cable 3. Rubber cover 4. Handlebar 5. Front brake light switch connector 6. Front brake light switch 7. Front brake hose A. When installing the rubber cover, silicone water or soapy water may be applied to the inside of the rubber cover.
  • Page 78 CABLE ROUTING Handlebar (front view) 2-37...
  • Page 79 CABLE ROUTING 1. Throttle cable 2. Clutch cable 3. Handlebar switch lead (left) 4. Main switch lead/Immobilizer lead 5. Steering stopper 6. Horn lead 7. Handlebar switch lead (right) 8. Front brake hose A. Fasten the handlebar switch lead (right) onto the handlebar with the clamp.
  • Page 80 CABLE ROUTING Radiator (front side view and right side view) 2-39...
  • 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) 2-41...
  • Page 83 CABLE ROUTING 1. Frame 2. Fuel tank 3. Fuel pump 4. Fuel tank drain hose 5. Clip 6. Fuel hose assembly A. Insert the fuel tank drain hose up to the sec- tion where the fuel tank pipe increases in diameter.
  • Page 84 CABLE ROUTING Canister (top view and left side view) 2-43...
  • Page 85 CABLE ROUTING 1. Frame 2. Clamp 3. Canister 4. Canister holder 5. Canister breather hose 6. Fuel tank drain hose 7. Fuel tank breather hose 8. Canister purge hose 9. Fuel tank 10.Rear shock absorber assembly 11.Canister bracket A. Front side of the vehicle B.
  • Page 86 CABLE ROUTING Air filter case and throttle body (top view and left side view) 2-45...
  • 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 plat- ing) 8. Throttle cable (accelerator cable) (black plat- ing) 9.
  • Page 88 CABLE ROUTING Air cut-off valve (left side view) 2-47...
  • 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) 2-49...
  • Page 91 CABLE ROUTING 1. Clamp 2. Rear brake light switch lead 3. O sensor coupler 4. Radiator fan motor coupler 5. Handlebar switch coupler (right) 6. Inner panel 7. Front right turn signal light coupler 8. Fuse box 1 9. Front turn signal light lead (right) 10.Bracket 11.Fuse box 2 12.Coupler cover...
  • Page 92 CABLE ROUTING Frame and engine (right side view) 2-51...
  • Page 93 CABLE ROUTING I. Fasten the auxiliary light lead and auxiliary 1. Guide DC jack lead with the clamp and then insert 2. Wire harness the clamp into the hole in the headlight stay. 3. Pipe (headlight stay) J. Fasten the main switch lead to the coupler 4.
  • Page 94 CABLE ROUTING Frame and engine (left side view) 2-53...
  • Page 95 CABLE ROUTING N. Align each rounded end of the sidestand 1. Air induction system hose (air filter case to air switch lead, oil level switch lead and drain cut-off valve) hose, and clamp them. The opening of the 2. Air filter case clamp should face toward the rear side of the 3.
  • Page 96 CABLE ROUTING Frame (top view) 2-55...
  • Page 97 CABLE ROUTING 1. Injector #1 coupler 2. Injector #2 coupler 3. Clamp 4. Ignition coil #1 coupler 5. Ignition coil #2 coupler 6. Air cut-off valve coupler 7. Ignition coil #3 coupler 8. Injector #3 coupler 9. Throttle position sensor coupler 10.Throttle servo motor coupler 11.Cross tube 12.Accelerator position sensor coupler...
  • Page 98 CABLE ROUTING Frame (top view) 2-57...
  • Page 99 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 switch coupler 1 6. Gear position switch coupler 2 7. Negative battery lead coupler 8. Lean angle sensor 9.
  • Page 100 CABLE ROUTING Frame (top view) 2-59...
  • Page 101 CABLE ROUTING M. Insert the Yamaha diagnostic tool coupler to 1. Rear wheel sensor coupler the battery box. 2. Negative battery lead coupler N. Install the rubber bracket of the starter relay 3. Positive battery terminal in the battery box.
  • Page 102 CABLE ROUTING Front brake (right side view and left side view) 2-61...
  • Page 103 CABLE ROUTING 1. Front brake hose assembly 1 2. Front wheel sensor lead 3. Clamp 4. Bracket 5. Brake caliper (right) 6. Front fender 7. Reflector (left and right) 8. Brake caliper (left) 9. Clamp 10.Clamp A. Make sure that the bracket has contact with the axle bracket, and install it.
  • Page 104 CABLE ROUTING Rear brake 2-63...
  • Page 105 CABLE ROUTING 1. Brake fluid reservoir 2. Rear frame 3. Rear frame (welded portion) 4. Rear brake master cylinder 5. Rear wheel sensor 6. Rear wheel sensor lead 7. Rear brake caliper 8. Rear brake hose 9. Clamp 10.Brake fluid reservoir hose 11.Swingarm assembly A.
  • Page 106 CABLE ROUTING Hydraulic unit (top view and left side view) 2-65...
  • Page 107 CABLE ROUTING 1. Wire harness 2. Battery box 3. Brake hose (front brake master cylinder to hydraulic unit) 4. Brake hose (hydraulic unit to front brake cali- pers) 5. Brake hose (rear brake master cylinder to hydraulic unit) 6. Brake hose (hydraulic unit to rear brake cali- per) 7.
  • Page 108 CABLE ROUTING 2-67...

  • Page 109: Periodic Checks And Adjustments

    INTRODUCTION ..................3-1 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM ....................3-1 GENERAL MAINTENANCE AND LUBRICATION CHART ......3-1 CHECKING THE VEHICLE USING THE YAMAHA DIAGNOSTIC TOOL ......................3-4 CHECKING THE FUEL LINE ..............3-4 CHECKING THE SPARK PLUGS ..............3-5 ADJUSTING THE VALVE CLEARANCE ...........3-5 CHECKING THE ENGINE IDLING SPEED ..........3-8...
  • Page 110 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY....3-23 CHECKING THE CONNECTING ARM AND RELAY ARM......3-24 CHECKING THE ENGINE OIL LEVEL.............3-24 CHANGING THE ENGINE OIL ..............3-24 MEASURING THE ENGINE OIL PRESSURE .........3-25 CHECKING THE COOLANT LEVEL............3-26 CHECKING THE COOLING SYSTEM .............3-26 CHANGING THE COOLANT..............3-27 CHECKING THE FRONT BRAKE LIGHT SWITCH .........3-28 ADJUSTING THE REAR BRAKE LIGHT SWITCH ........3-29 CHECKING AND LUBRICATING THE CABLES ........3-29...

  • Page 111: Periodic Maintenance

    UK, a mileage-based maintenance, is performed instead. • From 50000 km (30000 mi), repeat the maintenance intervals starting from 10000 km (6000 mi). • Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
  • Page 112 PERIODIC MAINTENANCE ODOMETER READING CHECK OR MAINTENANCE ANNUAL ITEM CHECK 1000 km 10000 km 20000 km 30000 km 40000 km (600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi) • Check operation, fluid level, and for fluid leakage.  ...
  • Page 113 PERIODIC MAINTENANCE ODOMETER READING CHECK OR MAINTENANCE ANNUAL ITEM CHECK 1000 km 10000 km 20000 km 30000 km 40000 km (600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi) Rear suspension • Check operation. relay arm and   ...

  • Page 114: Checking The Vehicle Using The Yamaha Diagnostic Tool

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

  • Page 115: Checking The Spark Plugs

    PERIODIC MAINTENANCE 4-6. Spark plug gap 0.8–0.9 mm (0.031–0.035 in) EAS30620 CHECKING THE SPARK PLUGS The following procedure applies to all of the spark plugs. 1. Remove: • Fuel tank front cover/Front side panel/Front side cowling Refer to “GENERAL CHASSIS (2)” on page 4-6.
  • Page 116 PERIODIC MAINTENANCE Refer to “GENERAL CHASSIS (2)” on page 4-6. • Passenger seat/Rider seat Refer to “GENERAL CHASSIS (1)” on page 4-1. • Fuel tank cover Refer to “GENERAL CHASSIS (3)” on page 4-13. • Fuel tank Refer to “FUEL TANK” on page 7-1. •...
  • Page 117 PERIODIC MAINTENANCE d. To measure the valve clearances of the other prevent the valve pad from falling into the cylinders, starting with cylinder #1 at TDC, crankcase. • Make a note of the position of each valve lifter turn the crankshaft counterclockwise as specified in the following table.

  • Page 118: Checking The Engine Idling Speed

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

  • Page 119: Synchronizing The Throttle Bodies

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

  • Page 120: Checking The Throttle Body Joints

    PERIODIC MAINTENANCE dard. Otherwise, the engine may run roughly 4-6. at idle and the throttle bodies may not oper- 5. Adjust: ate properly. • Throttle grip free play Refer to “CHECKING THE THROTTLE GRIP” on page 3-29. • Turn the bypass air screw using the carburetor angle driver.

  • Page 121: Adjusting The Exhaust Gas Volume

    4-6. tion manual of the Yamaha diagnostic tool. • Passenger seat/Rider seat Refer to “GENERAL CHASSIS (1)” on page 1. Connect the Yamaha diagnostic tool to the 4-1. coupler. For information about connecting the • Fuel tank cover Yamaha diagnostic tool, refer to “YAMAHA Refer to “GENERAL CHASSIS (3)”...

  • Page 122: Adjusting The Clutch Lever Free Play

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

  • Page 123: Checking The Brake Operation

    PERIODIC MAINTENANCE Clutch cable locknut 7 N·m (0.7 kgf·m, 5.1 lb·ft) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS30801 CHECKING THE BRAKE OPERATION 1. Check: • Brake operation Brake not working properly  Check the brake system. A. Front brake Refer to “FRONT BRAKE” on page 4-35 and B.

  • Page 124: Checking The Front Brake Pads

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

  • Page 125: Checking The Rear Brake Pads

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

  • Page 126: Checking The Wheels

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

  • Page 128: Checking The Wheel Bearings

    PERIODIC MAINTENANCE 3. Check: EAS30641 CHECKING THE WHEEL BEARINGS • Drive chain slack “a” The following procedure applies to all of the Out of specification  Adjust. wheel bearings. 1. Check: • Wheel bearings Refer to “CHECKING THE FRONT WHEEL” on page 4-21 and “CHECKING THE REAR WHEEL”...

  • Page 129: Lubricating The Drive Chain

    PERIODIC MAINTENANCE EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. Place the vehicle on a maintenance stand so that the front wheel is elevated. 2. Check: • Steering head Grasp the bottom of the front fork legs and gently rock the front fork.

  • Page 130: Lubricating The Steering Head

    PERIODIC MAINTENANCE EAS30646 Steering nut wrench LUBRICATING THE STEERING HEAD 90890-01403 1. Lubricate: Exhaust flange nut wrench • Upper bearing YU-A9472 • Lower bearing • Bearing race Lower ring nut (initial tightening Recommended lubricant torque) Lithium-soap-based grease 52 N·m (5.2 kgf·m, 38 lb·ft) EAS31186 c.

  • Page 131: Checking The Sidestand

    PERIODIC MAINTENANCE EAS30856 CHECKING THE CENTERSTAND 1. Check: • Centerstand operation Check that the centerstand moves smoothly. Rough movement  Repair or replace. EAS30857 LUBRICATING THE CENTERSTAND Lubricate the pivoting point and metal-to-metal moving parts of the centerstand. 2. Adjust: Recommended lubricant •...
  • Page 132 PERIODIC MAINTENANCE front fork legs. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. Spring preload EWA17040 WARNING Always adjust both front fork legs evenly. Uneven adjustment can result in poor han- dling and loss of stability. Spring preload Minimum ECA13590...

  • Page 133: Checking The Rear Shock Absorber Assembly

    PERIODIC MAINTENANCE range. To obtain a precise adjustment, it would Spring preload be advisable to check the number of clicks of Adjustment value (Soft) each damping force adjusting mechanism and to modify the specifications as necessary. Adjustment value (STD) Adjustment value (Hard) 3 2 1 7 6 5 4 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...

  • Page 134: Checking The Connecting Arm And Relay Arm

    PERIODIC MAINTENANCE ifications listed due to small differences in ECA13361 NOTICE production. • Engine oil also lubricates the clutch and the wrong oil types or additives could cause clutch slippage. Therefore, do not add any chemical additives or use engine oils with a grade of “CD”...

  • Page 135: Engine

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

  • Page 136: Checking The Coolant Level

    PERIODIC MAINTENANCE 6. Install: EWA12980 WARNING • Main gallery bolt The engine, muffler and engine oil are ex- Main gallery bolt tremely hot. 8 N·m (0.8 kgf·m, 5.8 lb·ft) EAS30811 CHECKING THE COOLANT LEVEL 1. Stand the vehicle on a level surface. •...

  • Page 137: Changing The Coolant

    PERIODIC MAINTENANCE • Oil cooler “4” • Oil cooler inlet hose “5” • Oil cooler outlet hose “6” • Water jacket joint “7” • Water pump inlet hose “8” Cracks/damage  Replace. Refer to “RADIATOR” on page 6-1, “OIL COOLER” on page 6-4, “THERMOSTAT” on page 6-6 and “WATER PUMP”...

  • Page 138: Cooling System

    PERIODIC MAINTENANCE and if necessary, correct the antifreeze 6. Drain: • Coolant concentration of the coolant. • Use only distilled water. However, if dis- (from the engine and radiator) 7. Install: tilled water is not available, soft water may • Water pump drain bolt be used.

  • Page 139: Adjusting The Rear Brake Light Switch

    PERIODIC MAINTENANCE EAS30659 ADJUSTING THE REAR BRAKE LIGHT Recommended lubricant Engine oil or a suitable cable lu- SWITCH bricant The rear brake light switch is operated by move- ment of the brake pedal. The rear brake light Hold the cable end upright and pour a few drops switch is properly adjusted when the brake light of lubricant into the cable sheath or use a suit- comes on just before the braking effect starts.

  • Page 140: Checking And Charging The Battery

    PERIODIC MAINTENANCE tle body synchronization should be adjusted properly. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Slide back the rubber cover “1”. b. Loosen the locknut “2”. c. Turn the adjusting nut “3” in direction “a” or “b” until the specified throttle grip free play is ob- tained.
  • Page 141 CHASSIS GENERAL CHASSIS (1) ..................4-1 INSTALLING THE SEATS................4-4 GENERAL CHASSIS (2) ..................4-6 REMOVING THE FUEL TANK FRONT COVER........4-10 INSTALLING THE FUEL TANK FRONT COVER ........4-10 REMOVING THE FRONT SIDE COWLINGS ..........4-10 INSTALLING THE FRONT SIDE COWLINGS .........4-11 ADJUSTING THE WINDSHIELD HEIGHT..........4-12 GENERAL CHASSIS (3) ................4-13 REMOVING THE FUEL TANK COVERS..........4-17 INSTALLING THE FUEL TANK COVERS ..........4-17...
  • Page 142 ASSEMBLING THE FRONT BRAKE MASTER CYLINDER ....4-45 INSTALLING THE FRONT BRAKE MASTER CYLINDER.......4-45 REAR BRAKE ....................4-48 INTRODUCTION ..................4-54 CHECKING THE REAR BRAKE DISC.............4-54 REPLACING THE REAR BRAKE PADS..........4-54 REMOVING THE REAR BRAKE CALIPER ..........4-55 DISASSEMBLING THE REAR BRAKE CALIPER ........4-56 CHECKING THE REAR BRAKE CALIPER..........4-56 ASSEMBLING THE REAR BRAKE CALIPER .........4-57 INSTALLING THE REAR BRAKE CALIPER..........4-57...
  • Page 143 INSTALLING THE RELAY ARM...............4-93 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY ....4-93 SWINGARM....................4-95 REMOVING THE SWINGARM..............4-96 CHECKING THE SWINGARM ..............4-96 INSTALLING THE SWINGARM ...............4-97 CHAIN DRIVE....................4-98 REMOVING THE DRIVE CHAIN..............4-99 CHECKING THE DRIVE CHAIN ..............4-99 CHECKING THE DRIVE SPROCKET............4-100 CHECKING THE REAR WHEEL SPROCKET........4-100 CHECKING THE REAR WHEEL DRIVE HUB ........4-100 INSTALLING THE DRIVE CHAIN ............4-101...
  • Page 144 GENERAL CHASSIS (1) EAS20026 GENERAL CHASSIS (1) Removing the seats and battery 2.2 N ・ m (0.22 kgf ・ m, 1.6 lb ・ ft) 25 N ・ m (2.5 kgf ・ m, 18 lb ・ ft) 32 N ・ m (3.2 kgf ・ m, 23 lb ・ ft) Order Job/Parts to remove Q’ty...
  • Page 145 GENERAL CHASSIS (1) Removing the rear side covers 26 N ・ m (2.6 kgf ・ m, 19 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) 13 N ・ m (1.3 kgf ・ m, 9.4 lb ・ ft) 26 N ・...
  • Page 146 GENERAL CHASSIS (1) Removing the tail/brake light and mudguard assembly 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS (1)”...

  • Page 147: General Chassis (1)

    GENERAL CHASSIS (1) EAS30125 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ INSTALLING THE SEATS To install the rider seat in the low position 1. Install: a. Insert the projection “a” on the rider seat • Rider seat height position adjuster “1” height position adjuster into the grommet “b”. •...

  • Page 148: General Chassis (2)

    GENERAL CHASSIS (1)
  • Page 149 GENERAL CHASSIS (2) EAS20155 GENERAL CHASSIS (2) Removing the fuel tank front cover, front side panels and front side cowlings 1.5 N ・ m (0.15 kgf ・ m, 1.1 lb ・ ft) 4.0 N ・ m (0.40 kgf ・ m, 2.9 lb ・ ft) 4.0 N ・...
  • Page 150 GENERAL CHASSIS (2) Removing the headlight assembly and meter assembly 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) 2.8 N ・...
  • Page 151 GENERAL CHASSIS (2) Disassembling the headlight assembly Order Job/Parts to remove Q’ty Remarks Headlight top cover (left) Headlight top cover (right) Headlight side cover (left) Headlight side cover (right) Center cover Headlight control unit coupler Disconnect. Headlight control unit...
  • Page 152 GENERAL CHASSIS (2) Removing the headlight stay 33 N ・ m (3.3 kgf ・ m, 24 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Fuel tank front cover/Front side panel/Front side Refer to “GENERAL CHASSIS (2)” on page cowling 4-6.

  • Page 153: Removing The Fuel Tank Front Cover

    GENERAL CHASSIS (2) EAS31379 REMOVING THE FUEL TANK FRONT COVER Fuel tank front cover bolt 4.0 N·m (0.40 kgf·m, 2.9 lb·ft) 1. Remove: • Fuel tank front cover “1” ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the quick fastener screws “2” and fuel tank front cover bolts “3”. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...

  • Page 154: Installing The Front Side Cowlings

    GENERAL CHASSIS (2) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS31382 INSTALLING THE FRONT SIDE COWLINGS 1. Install: • Front side cowling (left) “1” ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Insert the slot “a” into the projection “b”, and then install the front side cowling as shown in the illustration. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...

  • Page 155: Adjusting The Windshield Height

    GENERAL CHASSIS (2) 2. Install: EAS31383 ADJUSTING THE WINDSHIELD HEIGHT • Front side cowling (right) “1” 1. Adjust: ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • Windshield height position a. Insert the slot “a” into the projection “b”, and ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ then install the front side cowling as shown in a.

  • Page 156: General Chassis (3)

    GENERAL CHASSIS (3) EAS20156 GENERAL CHASSIS (3) Removing the fuel tank covers and fuel tank protector 4.0 N ・ m (0.40 kgf ・ m, 2.9 lb ・ ft) 4.0 N ・ m (0.40 kgf ・ m, 2.9 lb ・ ft) Order Job/Parts to remove Q’ty...
  • Page 157 GENERAL CHASSIS (3) Removing the electrical components tray (left) 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Fuel tank front cover/Front side panel/Front side Refer to “GENERAL CHASSIS (2)” on page cowling 4-6.
  • Page 158 GENERAL CHASSIS (3) Removing the electrical components tray (right) 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Fuel tank front cover/Front side panel/Front side Refer to “GENERAL CHASSIS (2)”...
  • Page 159 GENERAL CHASSIS (3) Removing the air filter case 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) (10) 1.6 N ・ m (0.16 kgf ・ m, 1.2 lb ・ ft) 2.8 N ・ m (0.28 kgf ・ m, 2.0 lb ・ ft) Order Job/Parts to remove Q’ty...

  • Page 160: Removing The Fuel Tank Covers

    GENERAL CHASSIS (3) then install the fuel tank cover as shown in EAS31384 REMOVING THE FUEL TANK COVERS the illustration. 1. Remove: • Fuel tank front cover • Front side panel • Front side cowling 2. Remove: • Passenger seat •...
  • Page 161 GENERAL CHASSIS (3) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Install: • Rider seat • Passenger seat 4. Install: • Front side cowling • Front side panel • Fuel tank front cover 4-18...
  • Page 162 FRONT WHEEL EAS20028 FRONT WHEEL Removing the front wheel and brake discs 35 N ・ m (3.5 kgf ・ m, 25 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) 65 N ・ m (6.5 kgf ・ m, 47 lb ・ ft) 23 N ・...
  • Page 163 FRONT WHEEL Disassembling the front wheel 8 N ・ m (0.8 kgf ・ m, 5.8 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Front wheel sensor rotor Oil seal Wheel bearing Spacer 4-20...

  • Page 164: Front Wheel

    FRONT WHEEL tor, wipe it off immediately. EAS30145 REMOVING THE FRONT WHEEL 1. Remove: ECA21380 • Oil seals NOTICE • Wheel bearings Keep magnets (including magnetic pick-up tools, magnetic screwdrivers, etc.) away ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ from the front wheel sensor “1”, otherwise a.

  • Page 165: Assembling The Front Wheel

    FRONT WHEEL EAS30151 ASSEMBLING THE FRONT WHEEL ECA21340 NOTICE • Do not drop the wheel sensor rotor or sub- ject it to shocks. • If any solvent gets on the wheel sensor ro- tor, wipe it off immediately. 1. Install: •...

  • Page 166: Maintenance Of The Front Wheel Sensor And Sensor Rotor

    FRONT WHEEL • Do not drop or shock the wheel sensor or ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ the wheel sensor rotor. 2. Install: • Front wheel sensor rotor 1. Check: • Front wheel sensor “1” Wheel sensor rotor bolt Cracks/bends/distortion  Replace. 8 N·m (0.8 kgf·m, 5.8 lb·ft) Iron powder/dust ...

  • Page 167: Adjusting The Front Wheel Static Balance

    FRONT WHEEL b. When the front wheel stops, put an “X ” mark at the bottom of the wheel. c. Turn the front wheel 90 so that the “X ” mark is positioned as shown. d. Release the front wheel. e.

  • Page 168: Installing The Front Wheel (Disc Brake)

    FRONT WHEEL c. If the heavy spot does not stay in that posi- 2. Check: tion, install a heavier weight. • Front brake discs d. Repeat steps (b) and (c) until the front wheel Refer to “CHECKING THE FRONT BRAKE is balanced.
  • Page 169 FRONT WHEEL sor rotor and the front wheel sensor. Thickness gauge 90890-03180 Feeler gauge set YU-26900-9 6. Install: • Front wheel sensor • Front wheel sensor bracket Front wheel sensor bolt 7 N·m (0.7 kgf·m, 5.1 lb·ft) ECA21020 NOTICE Make sure there are no foreign materials in the front wheel sensor rotor and front wheel sensor.
  • Page 170 REAR WHEEL EAS20029 REAR WHEEL Removing the rear wheel 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) 150 N ・ m (15 kgf ・ m, 108 lb ・ ft) 16 N ・ m (1.6 kgf ・ m, 12 lb ・ ft) 16 N ・...
  • Page 171 REAR WHEEL Removing the brake disc and rear wheel sprocket 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) 80 N ・ m (8.0 kgf ・ m, 58 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Rear brake disc Bracket Rear wheel sprocket...
  • Page 172 REAR WHEEL Disassembling the rear wheel 8 N ・ m (0.8 kgf ・ m, 5.8 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Rear wheel sensor rotor Oil seal Wheel bearing Spacer Wheel bearing 4-29...

  • Page 173: Rear Wheel

    REAR WHEEL EAS30156 REMOVING THE REAR WHEEL ECA21390 NOTICE Keep magnets (including magnetic pick-up tools, magnetic screwdrivers, etc.) away from the rear wheel sensor “1”, otherwise the wheel sensor may be damaged, resulting in improper performance of the ABS. 4. Remove: •...

  • Page 174: Checking The Rear Wheel

    REAR WHEEL EAS30159 CHECKING THE REAR WHEEL 1. Check: • Wheel axle • Wheel bearings • Oil seals Refer to “CHECKING THE FRONT WHEEL” on page 4-21. 2. Check: • Tire • Rear wheel Damage/wear  Replace. b. Correct Refer to “CHECKING THE TIRES” on page 1.

  • Page 175: Maintenance Of The Rear Wheel Sensor And Sensor Rotor

    REAR WHEEL 1. Install: EAS30165 INSTALLING THE REAR WHEEL (DISC • Wheel bearings BRAKE) • Oil seal 1. Install: Refer to “ASSEMBLING THE FRONT • Rear brake disc WHEEL” on page 4-22. Rear brake disc bolt EAS30167 30 N·m (3.0 kgf·m, 22 lb·ft) MAINTENANCE OF THE REAR WHEEL LOCTITE®...
  • Page 176 REAR WHEEL 8. Install: • Rear wheel sensor Rear wheel sensor bolt 7 N·m (0.7 kgf·m, 5.1 lb·ft) ECA21080 NOTICE Make sure there are no foreign materials in the rear wheel sensor rotor and rear wheel sensor. Foreign materials cause damage to the rear wheel sensor rotor and rear wheel A.
  • Page 177 REAR WHEEL Thickness gauge 90890-03180 Feeler gauge set YU-26900-9 4-34...

  • Page 178: Front Brake

    FRONT BRAKE EAS20030 FRONT BRAKE Removing the front brake pads 5 N ・ m (0.5 kgf ・ m, 3.6 lb ・ ft) 35 N ・ m (3.5 kgf ・ m, 25 lb ・ ft) Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers.
  • Page 179 FRONT BRAKE Removing the front brake master cylinder 1.0 N ・ m (0.10 kgf ・ m, 0.72 lb ・ ft) 1.5 N ・ m (0.15 kgf ・ m, 1.1 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) 17 N ・...
  • Page 180 FRONT BRAKE Disassembling the front brake master cylinder Order Job/Parts to remove Q’ty Remarks Brake master cylinder kit Brake master cylinder body 4-37...
  • Page 181 FRONT BRAKE Removing the front brake calipers 35 N ・ m (3.5 kgf ・ m, 25 lb ・ ft) 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers.
  • Page 182 FRONT BRAKE Disassembling the front brake calipers 5 N ・ m (0.5 kgf ・ m, 3.6 lb ・ ft) 5 N ・ m (0.5 kgf ・ m, 3.6 lb ・ ft) Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers.

  • Page 183: Introduction

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

  • Page 184: Replacing The Front Brake Pads

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

  • Page 185: Removing The Front Brake Calipers

    FRONT BRAKE c. Tighten the bleed screw. 8. Check: • Brake lever operation Brake caliper bleed screw Soft or spongy feeling  Bleed the brake sys- 5 N·m (0.5 kgf·m, 3.6 lb·ft) tem. d. Install the brake pads and brake pad spring. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM (ABS)”...

  • Page 186: Disassembling The Front Brake Calipers

    FRONT BRAKE EAS30172 DISASSEMBLING THE FRONT BRAKE Recommended brake component replacement schedule CALIPERS The following procedure applies to both of the Brake pads If necessary brake calipers. Piston seals Every two years 1. Remove: • Brake caliper pistons “1” Piston dust seals Every two years •...

  • Page 187: Installing The Front Brake Calipers

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

  • Page 188: Removing The Front Brake Master Cylinder

    FRONT BRAKE (brake master cylinder body) Obstruction  Blow out with compressed air. 2. Check: • Brake master cylinder kit Damage/scratches/wear  Replace. 3. Check: • Brake master cylinder reservoir “1” • Brake master cylinder reservoir diaphragm holder “2” Cracks/damage  Replace. •...
  • Page 189 FRONT BRAKE • Align the end of the front brake master cylinder 3. Fill: holder with the punch mark “b” on the handle- • Brake master cylinder reservoir bar. (with the specified amount of the specified • First, tighten the upper bolt, then the lower bolt. brake fluid) •...
  • Page 190 FRONT BRAKE BRAKE SYSTEM (ABS)” on page 3-15. 4-47...

  • Page 191: Rear Brake

    REAR BRAKE EAS20031 REAR BRAKE Removing the rear brake pads 5 N ・ m (0.5 kgf ・ m, 3.6 lb ・ ft) 27 N ・ m (2.7 kgf ・ m, 20 lb ・ ft) 22 N ・ m (2.2 kgf ・ m, 16 lb ・ ft) 17 N ・...
  • Page 192 REAR BRAKE Removing the rear brake master cylinder 3.8 N ・ m (0.38 kgf ・ m, 2.8 lb ・ ft) 110 N ・ m (11 kgf ・ m, 80 lb ・ ft) 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) 30 N ・...
  • Page 193 REAR BRAKE Removing the rear brake master cylinder 3.8 N ・ m (0.38 kgf ・ m, 2.8 lb ・ ft) 110 N ・ m (11 kgf ・ m, 80 lb ・ ft) 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) 30 N ・...
  • Page 194 REAR BRAKE Disassembling the rear brake master cylinder 18 N ・ m (1.8 kgf ・ m, 13 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Brake master cylinder yoke Brake master cylinder kit Hose joint Bushing Brake master cylinder body 4-51...
  • Page 195 REAR BRAKE Removing the rear brake caliper 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) 22 N ・ m (2.2 kgf ・ m, 16 lb ・ ft) 27 N ・ m (2.7 kgf ・ m, 20 lb ・ ft) Order Job/Parts to remove Q’ty...
  • Page 196 REAR BRAKE Disassembling the rear brake caliper 5 N ・ m (0.5 kgf ・ m, 3.6 lb ・ ft) 17 N ・ m (1.7 kgf ・ m, 12 lb ・ ft) 2.5 N ・ m (0.25 kgf ・ m, 1.8 lb ・ ft) Order Job/Parts to remove Q’ty...

  • Page 197: Introduction

    REAR BRAKE EAS30183 INTRODUCTION Brake disc thickness limit 4.5 mm (0.18 in) EWA14101 WARNING 5. Adjust: Disc brake components rarely require disas- • Brake disc runout sembly. Therefore, always follow these pre- Refer to “CHECKING THE FRONT BRAKE ventive measures: DISCS”...

  • Page 198: Removing The Rear Brake Caliper

    REAR BRAKE ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Recommended lubricant a. Connect a clear plastic hose “1” tightly to the Silicone grease bleed screw “2”. Put the other end of the hose into an open container. ECA14150 b. Loosen the bleed screw and push the brake NOTICE caliper piston into the brake caliper with your •...

  • Page 199: Disassembling The Rear Brake Caliper

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

  • Page 200: Assembling The Rear Brake Caliper

    REAR BRAKE 2. Check: EWA13531 WARNING • Rear brake caliper bracket “1” Proper brake hose routing is essential to in- Cracks/damage  Replace. sure safe vehicle operation. Refer to “REAR WHEEL” on page 4-27. ECA19080 NOTICE When installing the brake hose onto the brake caliper “1”, make sure the brake pipe “a”...

  • Page 201: Removing The Rear Brake Master Cylinder

    REAR BRAKE • Brake fluid reservoir EAS30193 REMOVING THE REAR BRAKE MASTER (with the specified amount of the specified CYLINDER brake fluid) 1. Remove: Specified brake fluid • Brake hose union bolt “1” DOT 4 • Brake hose gaskets “2” •...

  • Page 202: Assembling The Rear Brake Master Cylinder

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

  • Page 203: Abs (Anti-Lock Brake System)

    ABS (ANTI-LOCK BRAKE SYSTEM) EAS20032 ABS (ANTI-LOCK BRAKE SYSTEM) Removing the hydraulic unit assembly 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) 7 N ・...
  • Page 204 ABS (ANTI-LOCK BRAKE SYSTEM) Removing the hydraulic unit assembly 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) 7 N ・...

  • Page 205: Abs Components Chart

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

  • Page 206: Removing The Hydraulic Unit Assembly

    ABS (ANTI-LOCK BRAKE SYSTEM) EAS30197 REMOVING THE HYDRAULIC UNIT Do not operate the brake lever and brake pedal ASSEMBLY while removing the brake hoses. ECA21091 NOTICE ECA18251 NOTICE Unless necessary, avoid removing and in- When removing the brake hoses, cover the stalling the brake hoses of the hydraulic unit area around the hydraulic unit assembly to assembly.
  • Page 207 ABS (ANTI-LOCK BRAKE SYSTEM) Do not allow any foreign materials to enter the hydraulic unit assembly or the brake hoses when installing the hydraulic unit assembly. 2. Remove: • Rubber plugs or bolts (M10  1.0) 3. Install: • Front brake hose (front brake master cylinder to hydraulic unit) “1”...

  • Page 208: Hydraulic Unit Operation Tests

    • For the brake line routing confirmation, use the diagnosis of function of the Yamaha diagnostic 6. Start the Yamaha diagnostic tool and display tool. the diagnosis of function screen. • Before performing the brake line routing confir- 7.
  • Page 209 Securely support the vehicle so that there is no danger of it falling over. • For the ABS reaction-force confirmation, use the diagnosis of function of the Yamaha diag- nostic tool. For more information, refer to the operation manual of the Yamaha diagnostic tool.
  • Page 210 • “ON” and “OFF” on the tool screen indicate 6. Start the Yamaha diagnostic tool and display when the brakes are being applied and re- the diagnosis of function screen.

  • Page 211: Checking The Abs Warning Light

    12.Turn the main switch to “OFF”. 13.Remove the Yamaha diagnostic tool from the Yamaha diagnostic tool coupler, and then in- stall the protective cap. 14.Turn the main switch to “ON”.

  • Page 212: Handlebar

    HANDLEBAR EAS20033 HANDLEBAR Removing the handlebar 1/2 17 N ・ m (1.7 kgf ・ m, 12 lb ・ ft) 17 N ・ m (1.7 kgf ・ m, 12 lb ・ ft) 4.3 N ・ m (0.43 kgf ・ m, 3.1 lb ・ ft) 17 N ・...
  • Page 213 HANDLEBAR Removing the handlebar 2/2 3.8 N ・ m (0.38 kgf ・ m, 2.8 lb ・ ft) 26 N ・ m (2.6 kgf ・ m, 19 lb ・ ft) 22 N ・ m (2.2 kgf ・ m, 16 lb ・ ft) 11 N ・...

  • Page 214: Adjusting The Handlebar Position

    HANDLEBAR d. Install the handlebar “2” and upper handlebar EAS31396 ADJUSTING THE HANDLEBAR POSITION holders “1”. 1. Check: • Handlebar position Upper handlebar holder bolt 22 N·m (2.2 kgf·m, 16 lb·ft) The handlebar position can be adjusted in two ECA19130 positions to suit the rider’s preference.

  • Page 215: Removing The Handlebar

    HANDLEBAR EAS30203 REMOVING THE HANDLEBAR 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. 2. Remove: • Handlebar grip “1” Blow compressed air between the handlebar (left) and the handlebar grip, and gradually push EAS30205 INSTALLING THE HANDLEBAR...
  • Page 216 HANDLEBAR • Clutch cable Lower handlebar holder nut 40 N·m (4.0 kgf·m, 29 lb·ft) Clutch lever holder pinch bolt 11 N·m (1.1 kgf·m, 8.0 lb·ft) 4. Install: • Throttle grip “1” • Throttle cables Align the center of slit on the clutch lever holder •...

  • Page 217: Installing The Rearview Mirrors And Handguards

    HANDLEBAR EWA13700 WARNING Do not touch the handlebar grip until the rub- ber adhesive has fully dried. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 10.Adjust: • Throttle grip free play Refer to “CHECKING THE THROTTLE GRIP” on page 3-29. b. Tighten the handguard bracket bolts “3” to Throttle grip free play specification.
  • Page 218 HANDLEBAR b. Tighten the handguard bracket bolts “3” to specification. Handguard bracket bolt 7 N·m (0.7 kgf·m, 5.1 lb·ft) c. Tighten the rearview mirror locknut “4” to specification. Rearview mirror locknut 17 N·m (1.7 kgf·m, 12 lb·ft) d. Tighten the handguard bolt “5” to specifica- tion.

  • Page 219: Front Fork

    FRONT FORK EAS20034 FRONT FORK Removing the front fork legs 23 N ・ m (2.3 kgf ・ m, 17 lb ・ ft) 26 N ・ m (2.6 kgf ・ m, 19 lb ・ ft) 23 N ・ m (2.3 kgf ・ m, 17 lb ・ ft) 10 N ・...
  • Page 220 FRONT FORK Disassembling the left front fork leg 23 N ・ m (2.3 kgf ・ m, 17 lb ・ ft) 15 N ・ m (1.5 kgf ・ m, 11 lb ・ ft) 23 N ・ m (2.3 kgf ・ m, 17 lb ・ ft) Order Job/Parts to remove Q’ty...
  • Page 221 FRONT FORK Disassembling the right front fork leg 23 N ・ m (2.3 kgf ・ m, 17 lb ・ ft) 15 N ・ m (1.5 kgf ・ m, 11 lb ・ ft) 23 N ・ m (2.3 kgf ・ m, 17 lb ・ ft) Order Job/Parts to remove Q’ty...

  • Page 222: Removing The Front Fork Legs

    FRONT FORK • Locknut “4” EAS30206 REMOVING THE FRONT FORK LEGS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ The following procedure applies to both of the a. Press down on the spacer with the fork spring front fork legs. compressor “5”. b. Install the rod holder “6” between the locknut Each front fork leg is equipped with a spring pre- “4”...

  • Page 223: Checking The Front Fork Legs

    FRONT FORK • Oil seal clip “2” Damper rod holder (ø27) (with a flat-head screwdriver) 90890-01582 ECA19100 Damper rod holder NOTICE YM-01582 Do not scratch the outer tube. 4. Remove: EAS30208 • Outer tube CHECKING THE FRONT FORK LEGS The following procedure applies to both of the ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...

  • Page 224: Assembling The Front Fork Legs

    FRONT FORK –Oil seal –Oil seal clip –Dust seal –Copper washer –O-ring • Before assembling the front fork leg, make sure all of the components are clean. 1. Install: • Damper rod assembly “1” ECA19120 NOTICE 3. Check: Allow the damper rod assembly to slide •...
  • Page 225 3. Lubricate: 90890-01442 • Inner tube’s outer surface Adjustable fork seal driver (36–46 Recommended oil YM-01442 Yamaha Suspension Oil 01 4. Install: • Dust seal “1” • Oil seal clip “2” • Oil seal “3” • Washer “4” • Outer tube bushing “5”...
  • Page 226 • Front fork leg (with the specified amount of the recom- mended fork oil) Recommended oil 9. Install: Yamaha Suspension Oil 01 • Dust seal “1” Quantity (left) (with the fork seal driver “2”) 444.0 cm³ (15.01 US oz, 15.66 Imp.oz)
  • Page 227 FRONT FORK Be sure to bleed the front fork leg of any residual 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 ...
  • Page 228 FRONT FORK ment. 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. Front fork cap bolt locknut 15 N·m (1.5 kgf·m, 11 lb·ft) c.

  • Page 229: Installing The Front Fork Legs

    FRONT FORK ment. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ j. Position the locknut “3” as specified “b”. 17.Install: • Cap bolt Distance “b” (to the outer tube) 12 mm (0.47 in) • 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 230: Steering Head

    STEERING HEAD EAS20035 STEERING HEAD Removing the lower bracket 110 N ・ m (11 kgf ・ m, 80 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) 52 N ・ m (5.2 kgf ・ m, 38 lb ・ ft) 18 N ・...
  • Page 231 STEERING HEAD Removing the lower bracket 110 N ・ m (11 kgf ・ m, 80 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) 52 N ・ m (5.2 kgf ・ m, 38 lb ・ ft) 18 N ・...

  • Page 232: Removing The Lower Bracket

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

  • Page 233: Installing The Steering Head

    STEERING HEAD ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 4. Check: • Upper bracket • Lower bracket (along with the steering stem) Bends/cracks/damage  Replace. EAS30216 INSTALLING THE STEERING HEAD 1. Lubricate: • Upper bearing • Lower bearing Recommended lubricant Lithium-soap-based grease 2. Install: • Lower ring nut “1” •...
  • Page 234 REAR SHOCK ABSORBER ASSEMBLY EAS20036 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly 44 N ・ m (4.4 kgf ・ m, 32 lb ・ ft) 61 N ・ m (6.1 kgf ・ m, 44 lb ・ ft) 44 N ・ m (4.4 kgf ・ m, 32 lb ・ ft) 55 N ・...

  • Page 235: Rear Shock Absorber Assembly

    REAR SHOCK ABSORBER ASSEMBLY EAS30826 HANDLING THE REAR SHOCK ABSORBER Place the vehicle on the centerstand 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 236: Installing The Relay Arm

    REAR SHOCK ABSORBER ASSEMBLY 2. Check: • Bearings • Oil seals Damage/pitting  Replace. 3. Check: • Collars Damage/scratches  Replace. EAS30222 INSTALLING THE RELAY ARM 1. Lubricate: • Collars 3. Relay arm • Oil seals 4. Connecting arm 5. Rear shock absorber assembly Recommended lubricant A.
  • Page 237 REAR SHOCK ABSORBER ASSEMBLY Rear shock absorber assembly nut (upper) 44 N·m (4.4 kgf·m, 32 lb·ft) Relay arm nut 61 N·m (6.1 kgf·m, 44 lb·ft) Connecting arm lower nut 55 N·m (5.5 kgf·m, 40 lb·ft) 4-94...

  • Page 238: Swingarm

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

  • Page 239: Removing The Swingarm

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

  • Page 240: Installing The Swingarm

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

  • Page 241: Chain Drive

    CHAIN DRIVE EAS20038 CHAIN DRIVE Removing the drive chain 95 N ・ m (9.5 kgf ・ m, 69 lb ・ ft) 8 N ・ m (0.8 kgf ・ m, 5.8 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) 14 N ・...

  • Page 242: Removing The Drive Chain

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

  • Page 243: Checking The Drive Sprocket

    CHAIN DRIVE ECA19090 NOTICE • This vehicle has a drive chain with small rubber O-rings “1” between the drive chain side plates. Never use high-pressure water or air, steam, gasoline, certain solvents (e.g., benzine), or a coarse brush to clean the drive chain.

  • Page 244: Installing The Drive Chain

    CHAIN DRIVE EAS30234 INSTALLING THE DRIVE CHAIN 1. Install: • Drive chain ECA17410 NOTICE Be sure to put on safety goggles when work- ing. Install the drive chain joint with the drive chain cut & rivet tool. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Lubricate: Drive chain cut &...
  • Page 245 CHAIN DRIVE 5. Adjust: • Drive chain slack Refer to “DRIVE CHAIN SLACK” on page 3-18. 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 246 CHAIN DRIVE 4-103...
  • Page 247 ENGINE ENGINE INSPECTION ..................5-1 MEASURE THE COMPRESSION PRESSURE.........5-1 ENGINE REMOVAL..................5-3 REMOVING THE ENGINE .................5-7 INSTALLING THE ENGINE................5-7 CAMSHAFTS....................5-9 REMOVING THE CAMSHAFTS...............5-11 CHECKING THE CAMSHAFTS ...............5-12 CHECKING THE TIMING CHAIN AND CAMSHAFT SPROCKET ..5-13 CHECKING THE TIMING CHAIN GUIDES..........5-13 CHECKING THE TIMING CHAIN TENSIONER........5-13 INSTALLING THE CAMSHAFTS .............5-14 CYLINDER HEAD...................5-19 REMOVING THE CYLINDER HEAD............5-20...
  • Page 248 CHECKING THE CLUTCH HOUSING .............5-44 CHECKING THE CLUTCH BOSS............5-45 CHECKING THE PRESSURE PLATE .............5-45 CHECKING THE PRIMARY DRIVE GEAR..........5-45 CHECKING THE PRIMARY DRIVEN GEAR ...........5-45 CHECKING THE PULL LEVER SHAFT AND PULL ROD .......5-45 INSTALLING THE CLUTCH..............5-46 SHIFT SHAFT....................5-49 CHECKING THE SHIFT SHAFT ..............5-50 CHECKING THE STOPPER LEVER ............5-50 INSTALLING THE SHIFT SHAFT ............5-50 OIL PUMP.......................5-51...
  • Page 249 CHECKING THE SHIFT DRUM ASSEMBLY...........5-82 CHECKING THE TRANSMISSION ............5-82 ASSEMBLING THE MAIN AXLE AND DRIVE AXLE .......5-82 INSTALLING THE TRANSMISSION ............5-83...

  • Page 250: Engine Inspection

    ENGINE INSPECTION EAS20041 ENGINE INSPECTION Compression gauge 90890-03081 Engine compression tester EAS30249 MEASURE THE COMPRESSION PRESSURE YU-33223 The following procedure applies to all of the cyl- Extension inders. 90890-04136 Insufficient compression pressure will result in a loss of performance. 1. Measure: •...
  • Page 251 ENGINE INSPECTION Compression pressure (with oil applied into the cylinder) Reading Diagnosis Piston ring(s) wear or Higher than without oil damage  Repair. Piston, valves, cylinder Same as without oil head gasket possibly defective  Repair. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 6. Install: • Spark plugs Spark plug 13 N·m (1.3 kgf·m, 9.4 lb·ft) 7.

  • Page 252: Engine Removal

    ENGINE REMOVAL EAS20042 ENGINE REMOVAL Removing the muffler and exhaust pipe 20 N ・ m (2.0 kgf ・ m, 14 lb ・ ft) 20 N ・ m (2.0 kgf ・ m, 14 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) 12 N ・...
  • Page 253 ENGINE REMOVAL Disconnecting the leads and hoses 12 N ・ m (1.2 kgf ・ m, 8.7 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Fuel tank front cover/Front side panel/Front side Refer to “GENERAL CHASSIS (2)”...
  • Page 254 ENGINE REMOVAL Disconnecting the leads and hoses 12 N ・ m (1.2 kgf ・ m, 8.7 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Gear position switch coupler Disconnect.
  • Page 255 ENGINE REMOVAL Removing the engine 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) 45 N ・ m (4.5 kgf ・ m, 33 lb ・ ft) 45 N ・ m (4.5 kgf ・ m, 33 lb ・ ft) 12 N ・...

  • Page 256: Removing The Engine

    ENGINE REMOVAL EAS30250 REMOVING THE ENGINE 1. Loosen: • Engine mounting adjust bolt (front) Loosen the engine mounting adjust bolt with the pivot shaft wrench “1”. Pivot shaft wrench 90890-01485 Frame mount insert wrench YM-01485 EAS30251 INSTALLING THE ENGINE 1. Install: •...
  • Page 257 ENGINE REMOVAL 7. Tighten: • Engine mounting adjust bolt (rear) “2” • Tighten the engine mounting adjust bolts to specification with the pivot shaft wrench and pivot shaft wrench adapter. • Make sure that the flange on the engine mounting adjust bolt contacts the engine. Engine mounting adjust bolt (rear) 7 N·m (0.7 kgf·m, 5.1 lb·ft)

  • Page 258: Camshafts

    CAMSHAFTS EAS20043 CAMSHAFTS Removing the cylinder head cover 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) 13 N ・ m (1.3 kgf ・ m, 9.4 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Fuel tank front cover/Front side panel/Front side Refer to “GENERAL CHASSIS (2)”...
  • Page 259 CAMSHAFTS Removing the camshafts 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) 24 N ・...

  • Page 260: Removing The Camshafts

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

  • Page 261: Checking The Camshafts

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

  • Page 262: Checking The Timing Chain And Camshaft Sprocket

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

  • Page 263: Installing The Camshafts

    CAMSHAFTS b. Make sure that the timing chain tensioner rod ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ moves in and out of the timing chain tension- 3. Install: er housing smoothly. If there is rough move- • Intake camshaft sprocket “1” ment, replace the timing chain tensioner. •...
  • Page 264 CAMSHAFTS shaft faces up. • When installing the camshaft, no need to align Tighten the camshaft cap bolts in the tightening the mark “b” on the camshaft sprocket. sequence as shown. ECA17430 NOTICE • Lubricate the camshaft cap bolts with the engine oil.
  • Page 265 CAMSHAFTS 8. Check: c. Tighten the timing chain tensioner bolts to the • Camshaft punch mark “a” specified torque. Make sure the camshaft punch mark “a” on Timing chain tensioner bolt the camshaft is aligned with the camshaft cap 10 N·m (1.0 kgf·m, 7.2 lb·ft) alignment mark “b”.
  • Page 266 CAMSHAFTS 10.Turn: • Crankshaft (several turns counterclockwise) 11.Check: • Mark “a” Make sure the mark “a” on the generator rotor is aligned with the generator rotor cover mark “b”. • Camshaft punch mark “c” Make sure the camshaft punch mark “c” on the camshaft is aligned with the camshaft cap 14.Install: alignment mark “d”.
  • Page 267 CAMSHAFTS Install the ignition coils “1” in the direction shown in the illustration. 5-18...

  • Page 268: Cylinder Head

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

  • Page 269: Removing The Cylinder Head

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

  • Page 270: Installing The Cylinder Head

    CYLINDER HEAD 4. Install: EAS30282 INSTALLING THE CYLINDER HEAD • Exhaust camshaft 1. Install: • Intake camshaft • Timing chain guide (exhaust side) “1” Refer to “INSTALLING THE CAMSHAFTS” • Cylinder head gasket “2” on page 5-14. • Dowel pins “3” 2.
  • Page 271 VALVES AND VALVE SPRINGS EAS20045 VALVES AND VALVE SPRINGS Removing the valves and valve springs Order Job/Parts to remove Q’ty Remarks Cylinder head Refer to “CYLINDER HEAD” on page 5-19. Intake valve lifter Intake valve pad Intake valve cotter Intake valve spring retainer Intake valve spring Intake valve Intake valve stem seal...

  • Page 272: Valves And Valve Springs

    VALVES AND VALVE SPRINGS EAS30283 REMOVING THE VALVES Remove the valve cotters by compressing the The following procedure applies to all of the valve spring with the valve spring compressor valves and related components. “1” and the valve spring compressor attachment “2”.
  • Page 273 VALVES AND VALVE SPRINGS 1. Measure: • Valve-stem-to-valve-guide clearance Out of specification  Replace the valve guide. • Valve-stem-to-valve-guide clearance = Valve guide inside diameter “a” - Valve stem diameter “b” Valve-stem-to-valve-guide clear- ance (intake) 0.010–0.037 mm (0.0004–0.0015 b. Install the new valve guide with the valve guide installer “2”...

  • Page 274: Checking The Valve Seats

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

  • Page 275: Checking The Valve Springs

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

  • Page 276: Checking The Valve Lifters

    VALVES AND VALVE SPRINGS 1. Deburr: • Valve stem end (with an oil stone) 2. Measure: • Valve spring tilt “a” Out of specification  Replace the valve spring. 2. Lubricate: • Valve stem “1” Spring tilt (intake) • Valve stem seal “2” 1.7 mm (0.07 in) (with the recommended lubricant) Spring tilt (exhaust)
  • Page 277 VALVES AND VALVE SPRINGS 6. Lubricate: b. Smaller pitch • Valve pad 4. Install: (with the recommended lubricant) • Valve cotters “1” Recommended lubricant Molybdenum disulfide oil Install the valve cotters by compressing the valve spring with the valve spring compressor •...
  • Page 278 GENERATOR AND STARTER CLUTCH EAS20140 GENERATOR AND STARTER CLUTCH Removing the stator coil, generator rotor and starter clutch 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) 32 N ・ m (3.2 kgf ・ m, 23 lb ・ ft) 14 N ・...
  • Page 279 GENERATOR AND STARTER CLUTCH Removing the stator coil, generator rotor and starter clutch 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) 32 N ・ m (3.2 kgf ・ m, 23 lb ・ ft) 14 N ・ m (1.4 kgf ・ m, 10 lb ・ ft) 75 N ・...

  • Page 280: Generator And Starter Clutch

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

  • Page 281: 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 282 GENERATOR AND STARTER CLUTCH 3. Apply: • Sealant (onto the stator coil assembly lead grommet) Yamaha bond No. 1215 90890-85505 (Three bond No.1215®) 4. Install: • Generator cover gasket • Generator cover Generator cover bolt “1” 12 N·m (1.2 kgf·m, 8.7 lb·ft) LOCTITE®...

  • Page 283: Electric Starter

    ELECTRIC STARTER EAS20052 ELECTRIC STARTER Removing the starter motor 12 N ・ m (1.2 kgf ・ m, 8.7 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Fuel tank front cover/Front side panel/Front side Refer to “GENERAL CHASSIS (2)”...
  • Page 284 ELECTRIC STARTER Disassembling the starter motor 11 N ・ m (1.1 kgf ・ m, 8.0 lb ・ ft) 5 N ・ m (0.5 kgf ・ m, 3.6 lb ・ ft) Order Job/Parts to remove Q’ty Remarks O-ring Starter motor front cover Starter motor yoke Armature assembly Gasket...

  • Page 285: Checking The Starter Motor

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

  • Page 286: Assembling The Starter Motor

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

  • Page 287: Clutch

    CLUTCH EAS20055 CLUTCH Removing the clutch cover 12 N ・ m (1.2 kgf ・ m, 8.7 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) 12 N ・ m (1.2 kgf ・ m, 8.7 lb ・ ft) 1.5 N ・...
  • Page 288 CLUTCH Removing the pull lever shaft 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Install the clutch cover damper plate with its Clutch cover damper plate folded-up side facing upward.
  • Page 289 CLUTCH Removing the clutch 125 N ・ m (12.5 kgf ・ m, 90 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Oil pump driven sprocket Refer to “OIL PUMP” on page 5-51. Pressure plate 1 Clutch spring Absorber...
  • Page 290 CLUTCH Removing the clutch 125 N ・ m (12.5 kgf ・ m, 90 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Thrust plate Clutch housing Oil pump drive chain Bearing Spacer Thrust plate...

  • Page 291: Removing The Clutch

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

  • Page 292: Checking The Friction Plates

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

  • Page 293: Checking The Clutch Springs

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

  • Page 294: Checking The Clutch Boss

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

  • Page 295: Installing The Clutch

    CLUTCH Universal clutch holder 90890-04086 Universal clutch holder YM-91042 2. Check: • Pull rod bearing Damage/wear  Replace. EAS30363 INSTALLING THE CLUTCH 1. Install: • Oil pump drive chain “1” • Clutch housing “2” Install the oil pump drive chain onto the oil pump drive sprocket “a”.
  • Page 296 CLUTCH • Clutch springs a crisscross pattern. • Pressure plate 1 6. Install: • Clutch spring bolts “1” • Pull lever Clutch spring bolt • Install the pull lever with the “O” mark facing to- 10 N·m (1.0 kgf·m, 7.2 lb·ft) ward lower side.
  • Page 297 CLUTCH 8. Adjust: • Clutch lever free play Refer to “ADJUSTING THE CLUTCH LEVER FREE PLAY” on page 3-12. Clutch lever free play 10.0–15.0 mm (0.39–0.59 in) 5-48...

  • Page 298: Shift Shaft

    SHIFT SHAFT EAS20057 SHIFT SHAFT Removing the shift shaft and stopper lever 22 N ・ m (2.2 kgf ・ m, 16 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Clutch assembly Refer to “CLUTCH” on page 5-38. Shift arm Refer to “CHAIN DRIVE”...

  • Page 299: Checking The Shift Shaft

    SHIFT SHAFT EAS30377 CHECKING THE SHIFT SHAFT 1. Check: • Shift shaft “1” Bends/damage/wear  Replace. • Shift shaft spring “2” • Collar Damage/wear  Replace. 2. Install: • Bearing • Oil seal • Washer “1” • Circlip “2” • Lubricate the oil seal lips with lithium-soap- based grease.

  • Page 300: Oil Pump

    OIL PUMP EAS20054 OIL PUMP Removing the oil pump 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) 15 N ・ m (1.5 kgf ・ m, 11 lb ・ ft) Order Job/Parts to remove Q’ty...
  • Page 301 OIL PUMP Disassembling the oil pump 3.8 N ・ m (0.38 kgf ・ m, 2.8 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Oil pump cover Oil pump shaft Oil pump inner rotor Oil pump outer rotor Hold down the washer when removing the Circlip circlip.

  • Page 302: Checking The Sprocket And Chain

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

  • Page 303: Assembling The Oil Pump

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

  • Page 304: Oil Pan

    OIL PAN EAS20177 OIL PAN Removing the oil pan 43 N ・ m (4.3 kgf ・ m, 31 lb ・ ft) (13) 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) Order Job/Parts to remove Q’ty...

  • Page 305: Removing The Oil Pan

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

  • Page 306: Crankcase

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

  • Page 307: Disassembling The Crankcase

    Recommended lubricant Engine oil 2. Apply: • Sealant (onto the crankcase mating surfaces) Yamaha bond No. 1215 90890-85505 (Three bond No.1215®) Do not allow any sealant to come into contact with the oil gallery or crankshaft journal bear- ings, or balancer shaft journal bearings.
  • Page 308 CRANKCASE 4. Set the shift drum assembly and transmission gears in the neutral position. 5. Install: 19 20 • Lower crankcase “1” 21 22 23 24 (onto the upper crankcase “2”) ECA13980 NOTICE Before tightening the crankcase bolts, make sure the transmission gears shift correctly when the shift drum assembly is turned by hand.
  • Page 309 CRANKCASE 8. Tighten: • Crankcase bolts “9”–“30” Crankcase bolts “9”–“14” 24 N·m (2.4 kgf·m, 17 lb·ft) Crankcase bolts “15”–“30” 10 N·m (1.0 kgf·m, 7.2 lb·ft) Tighten the bolts in the tightening sequence cast on the crankcase. 19 20 23 24 5-60...
  • Page 310 CONNECTING RODS AND PISTONS EAS20132 CONNECTING RODS AND PISTONS Removing the connecting rods and pistons 20 N ・ m (2.0 kgf ・ m, 14 lb ・ ft) Specified angle 175–185˚ Order Job/Parts to remove Q’ty Remarks Lower crankcase Refer to “CRANKCASE” on page 5-57. Connecting rod cap Big end lower bearing Piston pin clip...

  • Page 311: Connecting Rods And Pistons

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

  • Page 312: Checking The Piston Rings

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

  • Page 313: Checking The Piston Pin

    CONNECTING RODS AND PISTONS 3. Measure: • Piston ring end gap Out of specification  Replace the piston ring. The oil ring expander spacer’s end gap cannot be measured. If the oil ring rail’s gap is exces- sive, replace all three piston rings. Top ring End gap (installed) 3.
  • Page 314 CONNECTING RODS AND PISTONS • Make sure that the projection “a” on the con- ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ necting rod cap faces the same direction as the The following procedure applies to all of the “Y” mark “b” on the connecting rod. connecting rods. •...
  • Page 315 CONNECTING RODS AND PISTONS tighten it. Instead, replace the bolt with a new necting rod cap faces the same direction as the “Y” mark “b” on the connecting rod. one and perform the procedure again. • Make sure the “Y” marks “b” on the connecting ECA20890 rods face towards the left side of the crank- NOTICE...

  • Page 316: Installing The Connecting Rod And Piston

    CONNECTING RODS AND PISTONS ings with the notches “b” in the connecting rods Bearing color code and connecting rod caps. Code 1 • Make sure that the projection “c” on the con- Blue necting rod cap faces the same direction as the Code 2 “Y”...
  • Page 317 CONNECTING RODS AND PISTONS • Install the piston pin clips, so that the clip ends are 3 mm (0.12 in) “c” or more from the cutout To install the big end bearing, care should be taken not to install it at an angle and the position in the piston.
  • Page 318 CONNECTING RODS AND PISTONS 7. Lubricate: • Crankshaft pins • Connecting rod big end bearing inner surface (with the recommended lubricant) Recommended lubricant Engine oil 8. Install: • Piston assemblies “1” (into the cylinder “2” and onto the crankshaft 10.Tighten: pin) •...
  • Page 319 CONNECTING RODS AND PISTONS 180˚ EWA16610 WARNING If the bolt is tightened more than the speci- fied angle, do not loosen the bolt and then re- tighten it. Instead, replace the bolt with a new one and perform the procedure again. ECA20890 NOTICE Do not use a torque wrench to tighten the...
  • Page 320 CRANKSHAFT AND BALANCER SHAFT EAS20178 CRANKSHAFT AND BALANCER SHAFT Removing the crankshaft and balancer shaft Order Job/Parts to remove Q’ty Remarks Lower crankcase Refer to “CRANKCASE” on page 5-57. Refer to “REMOVING THE CONNECTING Connecting rod RODS AND PISTONS” on page 5-62. Balancer shaft Balancer shaft journal lower bearing Balancer shaft journal upper bearing...

  • Page 321: Crankshaft And Balancer Shaft

    CRANKSHAFT AND BALANCER SHAFT EAS31171 REMOVING THE CRANKSHAFT AND BALANCER SHAFT 1. Remove: • Balancer shaft “1” • Balancer shaft journal bearing • Crankshaft assembly “2” • Crankshaft journal bearings Identify the position of each balancer shaft jour- nal bearings and crankshaft journal bearings so that it can be reinstalled in its original place.
  • Page 322 CRANKSHAFT AND BALANCER SHAFT nal-bearing clearance is out of specification, select replacement crankshaft journal bear- ings. d. Put a piece of Plastigauge® “1” on each crankshaft journal. Do not put the Plastigauge® over the oil hole in ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ the crankshaft journal. 4.

  • Page 323: Checking The Balancer Shaft

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

  • Page 324: Installing The Crankshaft

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

  • Page 325: Installing The Balancer Assembly

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

  • Page 326: Transmission

    TRANSMISSION EAS20062 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks 12 N ・ m (1.2 kgf ・ m, 8.7 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) Order Job/Parts to remove Q’ty...
  • Page 327 TRANSMISSION Disassembling the main axle assembly Order Job/Parts to remove Q’ty Remarks 2nd pinion gear Toothed lock washer Toothed lock washer retainer 6th pinion gear Collar Washer Circlip 3rd pinion gear Circlip Washer 5th pinion gear Collar Bearing housing Bearing Main axle 5-78...
  • Page 328 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 329 TRANSMISSION Disassembling the drive axle assembly Order Job/Parts to remove Q’ty Remarks Collar Bearing Circlip Drive axle 5-80...

  • Page 330: Removing The Transmission

    TRANSMISSION EAS30430 REMOVING THE TRANSMISSION 1. Remove: • Drive axle assembly “1” • Shift drum retainers “2” • Shift fork guide bars • Shift fork-L • Shift fork-R • Shift drum assembly • Shift fork-C EAS30431 CHECKING THE SHIFT FORKS The following procedure applies to all of the shift forks.
  • Page 331 TRANSMISSION Out of specification  Replace the drive axle. Drive axle runout limit 0.08 mm (0.0032 in) EAS30432 CHECKING THE SHIFT DRUM ASSEMBLY 1. Check: • Shift drum groove Damage/scratches/wear  Replace the shift drum assembly. • Shift drum segment “1” 3.
  • Page 332 TRANSMISSION positioned opposite side to the toothed washer and gear. • Align the opening between the ends “b” of the circlip with a groove “c” in the axle. • Install the circlip so that a spline “d” is in the center of the gap between the circlip ends “e”...
  • Page 333 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 334 TRANSMISSION 5-85...
  • Page 335 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 336: Radiator

    RADIATOR EAS20063 RADIATOR Removing the radiator 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) 5 N ・ m (0.5 kgf ・ m, 3.6 lb ・ ft) 0.5 N ・ m (0.05 kgf ・ m, 0.36 lb ・ ft) 10 N ・...

  • Page 337: Checking The Radiator

    RADIATOR EAS30439 CHECKING THE RADIATOR 1. Check: • Radiator fins Obstruction  Clean. Apply compressed air to the rear of the radia- tor. Damage  Repair or replace. Straighten any flattened fins with a thin, flat-head screwdriver. b. Apply the specified pressure for ten seconds and make sure there is no drop in pressure.
  • Page 338 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 339: Oil Cooler

    OIL COOLER EAS20064 OIL COOLER Removing the oil cooler 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Coolant reservoir Refer to “RADIATOR”...

  • Page 340: Checking The Oil Cooler

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

  • Page 341: Thermostat

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

  • Page 342: Checking The Thermostat

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

  • Page 343: Water Pump

    WATER PUMP EAS20066 WATER PUMP Removing the water pump 12 N ・ m (1.2 kgf ・ m, 8.7 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Drain. Coolant Refer to “CHANGING THE COOLANT” on page 3-27. Water pump inlet hose Disconnect.
  • Page 344 WATER PUMP Disassembling the water pump 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Water pump housing cover O-ring Circlip Water pump driven gear Washer Impeller shaft Mechanical seal Bearing Oil seal...

  • Page 345: Disassembling The Water Pump

    WATER PUMP EAS30446 EAS30447 DISASSEMBLING THE WATER PUMP CHECKING THE WATER PUMP 1. Remove: 1. Check: • Mechanical seal (housing side) “1” • Water pump housing cover “1” • Impeller shaft “2” Cracks/damage/wear  Replace. Remove the mechanical seal (housing side) •...
  • Page 346 WATER PUMP ing side) surface with oil or grease. (4). ECA20340 NOTICE Use the special tools and a press to press the Make sure the mechanical seal (impeller mechanical seal (housing side) straight in until it side) is flush with the impeller. touches the water pump housing.

  • Page 347: Fuel System

    FUEL SYSTEM FUEL TANK ......................7-1 REMOVING THE FUEL TANK ..............7-3 REMOVING THE FUEL PUMP ..............7-3 CHECKING THE FUEL PUMP BODY............7-3 CHECKING THE FUEL PUMP OPERATION..........7-3 INSTALLING THE FUEL PUMP..............7-4 INSTALLING THE FUEL TANK..............7-4 THROTTLE BODIES ..................7-5 CHECKING THE INJECTORS (BEFORE REMOVING) ......7-8 REMOVING THE FUEL HOSE (FUEL RAIL SIDE) ........7-8 REMOVING THE INJECTORS ..............7-8 CHECKING THE INJECTORS ..............7-8...
  • Page 348 FUEL TANK EAS20067 FUEL TANK Removing the fuel tank 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) 4.0 N ・...
  • Page 349 FUEL TANK Removing the canister 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Fuel tank front cover/Front side panel/Front side Refer to “GENERAL CHASSIS (2)” on page cowling 4-6. Refer to “GENERAL CHASSIS (1)” on page Passenger seat/Rider seat 4-1.

  • Page 350: Fuel Tank

    FUEL TANK EAS30450 REMOVING THE FUEL TANK 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. 2. Remove: • Fuel tank front cover/Front side panel/Front side cowling Refer to “GENERAL CHASSIS (2)” on page 4-6.
  • Page 351 FUEL TANK EAS30456 INSTALLING THE FUEL PUMP 1. Install: • Fuel pump gasket • Fuel pump • Fuel pump bracket • Fuel pump bolts Fuel pump bolt 4.0 N·m (0.40 kgf·m, 2.9 lb·ft) 2. Connect: • Do not damage the installation surfaces of the •...
  • Page 352 THROTTLE BODIES EAS20070 THROTTLE BODIES Removing the throttle bodies 4.5 N ・ m (0.45 kgf ・ m, 3.3 lb ・ ft) 3.0 N ・ m (0.30 kgf ・ m, 2.2 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Fuel tank front cover/Front side panel/Front side Refer to “GENERAL CHASSIS (2)”...
  • Page 353 THROTTLE BODIES Removing the sensors 3.5 N ・ m (0.35 kgf ・ m, 2.5 lb ・ ft) 3.5 N ・ m (0.35 kgf ・ m, 2.5 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Negative pressure hose Hose joint Canister purge hose Hose joint Intake air pressure sensor 2...
  • Page 354 THROTTLE BODIES Removing the injectors 5 N ・ m (0.5 kgf ・ m, 3.6 lb ・ ft) 12 N ・ m (1.2 kgf ・ m, 8.7 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Throttle bodies/Throttle body joint Refer to “THROTTLE BODIES” on page 7-5. Fuel rail Injector Injector coupler...
  • Page 355 THROTTLE BODIES hose may cause the fuel to spray out. Place EAS30475 CHECKING THE INJECTORS (BEFORE a container or rag under the hose to catch REMOVING) any fuel that spills. Always clean up any 1. Check: spilt fuel immediately. • Injectors •...
  • Page 356 • 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 357 THROTTLE BODIES • Do not allow carbon deposits or other for- 5. Place the vehicle on the centerstand so that eign materials to enter any of the passages the rear wheel is elevated. in each throttle body or in the space be- 6.
  • Page 358 THROTTLE BODIES to the fuel rail joint “2”, and then connect an side cowling air compressor “3” to the adapter. Refer to “GENERAL CHASSIS (2)” on page b. Connect the pressure gauge “4” to the fuel in- 4-6. jector pressure adapter “1”. •...
  • Page 359 • Fuel hose (fuel rail side) d. Remove the protective cap “1”, and then con- ECA17500 nect the Yamaha diagnostic tool to coupler. NOTICE When installing the fuel hose, make sure that For information about using the Yamaha diag-...
  • Page 360 Connect the throttle cables to the throttle bod- ies. e. Remove the protective cap “1”, and then con- nect the Yamaha diagnostic tool to coupler. e. Diagnostic code number “01” is selected. For information about using the Yamaha diag- f.
  • Page 361 If the Yamaha diagnostic tool screen value is not 95–109, adjust the accelerator position sensor angle. q. Repeat steps (f) to (p) until the Yamaha diag- nostic tool screen values are within the spec- ified ranges. r. If the Yamaha diagnostic tool screen values...

  • Page 362: Air Induction System

    AIR INDUCTION SYSTEM EAS20071 AIR INDUCTION SYSTEM 7-15...
  • Page 363 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 364 AIR INDUCTION SYSTEM Removing the air cut-off valve assembly and reed valves 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Fuel tank front cover/Front side panel/Front side...
  • Page 365 AIR INDUCTION SYSTEM 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Reed valve assembly 2 Reed valve plate 7-18...
  • Page 366 AIR INDUCTION SYSTEM • Reed valve seat EAS30488 CHECKING THE AIR INDUCTION SYSTEM Cracks/damage  Replace the reed valve Air injection assembly. The air induction system burns unburned ex- 3. Measure: haust gases by injecting fresh air (secondary air) • Reed valve bending limit “a” into the exhaust port, reducing the emission of Out of specification ...
  • Page 367 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 368 AIR INDUCTION SYSTEM 7-21...

  • Page 369: Electrical System

    COOLING SYSTEM..................8-27 CIRCUIT DIAGRAM .................8-27 TROUBLESHOOTING ................8-29 FUEL INJECTION SYSTEM................8-31 CIRCUIT DIAGRAM .................8-31 ECU SELF-DIAGNOSTIC FUNCTION.............8-33 TROUBLESHOOTING METHOD.............8-33 YAMAHA DIAGNOSTIC TOOL ..............8-34 TROUBLESHOOTING DETAILS (FAULT CODE) ........8-35 FUEL PUMP SYSTEM..................8-103 CIRCUIT DIAGRAM ................8-103 TROUBLESHOOTING ................8-105 IMMOBILIZER SYSTEM................8-107 CIRCUIT DIAGRAM ................8-107 GENERAL INFORMATION ..............8-109...
  • Page 370 ABS (ANTI-LOCK BRAKE SYSTEM)............8-117 CIRCUIT DIAGRAM ................8-117 ABS COMPONENTS CHART ..............8-119 ABS COUPLER LOCATION CHART .............8-121 MAINTENANCE OF THE ABS ECU ............8-123 ABS TROUBLESHOOTING OUTLINE...........8-123 BASIC INSTRUCTIONS FOR TROUBLESHOOTING ......8-124 BASIC PROCESS FOR TROUBLESHOOTING ........8-125 [A] CHECKING THE ABS WARNING LIGHT.........8-126 [A-1] ONLY THE ABS WARNING LIGHT FAILS TO COME ON....8-126 [A-2] THE ABS WARNING LIGHT AND OTHER INDICATOR LIGHTS FAIL TO COME ON ..............8-126...
  • Page 372 IGNITION SYSTEM EAS20072 IGNITION SYSTEM EAS30490 CIRCUIT DIAGRAM...
  • Page 373 IGNITION SYSTEM 3. Main switch 4. Main fuse 11.Ignition fuse 15.Battery 16.Engine ground 17.Fuel injection system fuse 20.Joint connector 21.Joint coupler 22.Relay unit 25.Sidestand switch 28.ECU (Engine Control Unit) 29.Ignition coil #1 30.Ignition coil #2 31.Ignition coil #3 32.Spark plug 40.Crankshaft position sensor 45.Lean angle sensor 67.Gear position switch...
  • Page 374 IGNITION SYSTEM EAS30491 ENGINE STOPPING DUE TO SIDESTAND OPERATION When the engine is running and the transmission is in gear, the engine will stop if the sidestand is moved down. This is because the electric current from the ignition coils does not flow to the ECU when both the gear position switch (neutral circuit) and sidestand switch are set to “OFF”, thereby preventing the spark plugs from producing a spark.
  • Page 375 IGNITION SYSTEM EAS30492 TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). • Before troubleshooting, remove the following part(s): 1. Fuel tank front cover/Front side panel/Front side cowling 2. Passenger seat/Rider seat 3. Fuel tank cover 4. Fuel tank 5.
  • Page 376 IGNITION SYSTEM 9. Check the gear position switch. Refer to “CHECKING THE GEAR Replace the gear position switch. POSITION SWITCH” on page NG 8-173. OK 10.Check the sidestand switch. Refer to “CHECKING THE Replace the sidestand switch. NG SWITCHES” on page 8-153. OK...
  • Page 377 IGNITION SYSTEM...

  • Page 378: Electric Starting System

    ELECTRIC STARTING SYSTEM EAS20073 ELECTRIC STARTING SYSTEM EAS30493 CIRCUIT DIAGRAM...
  • Page 379 ELECTRIC STARTING SYSTEM 3. Main switch 4. Main fuse 11.Ignition fuse 15.Battery 16.Engine ground 17.Fuel injection system fuse 18.Starter relay 19.Starter motor 20.Joint connector 21.Joint coupler 22.Relay unit 23.Starting circuit cut-off relay 25.Sidestand switch 67.Gear position switch 70.Handlebar switch (right) 72.Start/engine stop switch 77.Handlebar switch (left) 78.Clutch switch...
  • Page 380 ELECTRIC STARTING SYSTEM EAS30494 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the main switch is turned to “ON” and the “ ” side of the start/engine stop switch is pushed, the starter motor can only operate if at least one of the following conditions is met: •...
  • Page 381 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 382 ELECTRIC STARTING SYSTEM EAS30495 TROUBLESHOOTING The starter motor fails to turn. • Before troubleshooting, remove the following part(s): 1. Fuel tank front cover/Front side panel/Front side cowling 2. Passenger seat/Rider seat 3. Fuel tank cover 4. Fuel tank 5. Air filter case 6.
  • Page 383 ELECTRIC STARTING SYSTEM 9. Check the gear position switch. Refer to “CHECKING THE GEAR Replace the gear position switch. POSITION SWITCH” on page NG 8-173. OK 10.Check the sidestand switch. Refer to “CHECKING THE Replace the sidestand switch. NG SWITCHES” on page 8-153. OK...
  • Page 384 CHARGING SYSTEM EAS20074 CHARGING SYSTEM EAS30496 CIRCUIT DIAGRAM 8-13...
  • Page 385 CHARGING SYSTEM 1. AC magneto 2. Rectifier/regulator 4. Main fuse 15.Battery 16.Engine ground A. Wire harness D. Negative battery sub-wire harness 8-14...
  • Page 386 CHARGING SYSTEM EAS30497 TROUBLESHOOTING The battery is not being charged. • Before troubleshooting, remove the following part(s): 1. Passenger seat/Rider seat 2. Rear side cover (left)/Lower tail cover 1. Check the fuse. (Main) Replace the fuse. Refer to “CHECKING THE FUSES” NG...
  • Page 387 CHARGING SYSTEM 8-16...
  • Page 388 LIGHTING SYSTEM EAS20075 LIGHTING SYSTEM EAS30498 CIRCUIT DIAGRAM 8-17...
  • Page 389 LIGHTING SYSTEM 3. Main switch 4. Main fuse 11.Ignition fuse 13.Signaling system fuse 15.Battery 16.Engine ground 20.Joint connector 21.Joint coupler 28.ECU (Engine Control Unit) 53.Meter assembly 56.Meter light 62.High beam indicator light 77.Handlebar switch (left) 84.Dimmer/pass switch 89.Headlight control unit 90.Headlight (high beam) 91.Headlight (low beam) 92.Auxiliary light (right)
  • Page 390 LIGHTING SYSTEM EAS30499 TROUBLESHOOTING Any of the following fail to light: headlight, high beam indicator light, taillight, license light or meter light. • Before troubleshooting, remove the following part(s): 1. Fuel tank front cover/Front side panel/Front side cowling 2. Passenger seat/Rider seat 3.
  • Page 391 LIGHTING SYSTEM 8-20...
  • Page 392 SIGNALING SYSTEM EAS20076 SIGNALING SYSTEM EAS30500 CIRCUIT DIAGRAM 8-21...
  • Page 393 SIGNALING SYSTEM 3. Main switch 4. Main fuse 11.Ignition fuse 13.Signaling system fuse 15.Battery 16.Engine ground 20.Joint connector 21.Joint coupler 22.Relay unit 28.ECU (Engine Control Unit) 42.Coolant temperature sensor 47.Rear wheel sensor 48.ABS ECU (electronic control unit) 53.Meter assembly 55.Neutral indicator light 57.Tachometer 58.Multi-function meter 59.Oil level warning light...
  • Page 394 SIGNALING SYSTEM EAS30501 TROUBLESHOOTING • Any of the following fail to light: turn signal light, brake light or an indicator light. • The horn fails to sound. • The fuel meter fails to comeon. • The speedometer fails to operate. •...
  • Page 395 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 396 SIGNALING SYSTEM 5. Check the entire signaling system’s wiring. Properly connect or repair the signaling Refer to “CIRCUIT DIAGRAM” on system’s wiring. NG page 8-21. OK Replace the meter assembly. The neutral indicator light fails to come on. 1. Check the gear position switch. Refer to “CHECKING THE GEAR Replace the gear position switch.
  • Page 397 SIGNALING SYSTEM 2. Check the entire signaling system’s wiring. Properly connect or repair the signaling Refer to “CIRCUIT DIAGRAM” on system’s wiring. NG page 8-21. OK Replace the ECU or meter assembly. Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-157. The speedometer fails to operate.
  • Page 398 COOLING SYSTEM EAS20077 COOLING SYSTEM EAS30502 CIRCUIT DIAGRAM 8-27...
  • Page 399 COOLING SYSTEM 3. Main switch 4. Main fuse 9. Radiator fan motor fuse 11.Ignition fuse 15.Battery 16.Engine ground 20.Joint connector 21.Joint coupler 28.ECU (Engine Control Unit) 42.Coolant temperature sensor 96.Radiator fan motor relay 97.Radiator fan motor A. Wire harness C. Sub-wire harness (Coolant temperature sen- sor) D.
  • Page 400 COOLING SYSTEM EAS30503 TROUBLESHOOTING • Before troubleshooting, remove the following part(s): 1. Fuel tank front cover/Front side panel/Front side cowling 2. Passenger seat/Rider seat 3. Fuel tank cover 4. Fuel tank 5. Air filter case 6. Canister 7. Throttle bodies 1.
  • Page 401 COOLING SYSTEM 8-30...
  • Page 402 FUEL INJECTION SYSTEM EAS20078 FUEL INJECTION SYSTEM EAS30504 CIRCUIT DIAGRAM 8-31...
  • Page 403 45.Lean angle sensor 47.Rear wheel sensor 48.ABS ECU (electronic control unit) 49.Throttle servo motor 50.Accelerator position sensor 51.Throttle position sensor 52.Yamaha diagnostic tool coupler 53.Meter assembly 58.Multi-function meter 60.Engine trouble warning light 67.Gear position switch 69.Fuel pump 70.Handlebar switch (right) 71.Drive mode switch...
  • Page 404 • Fault code number ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Check the fault code numbers that have a condition of “Detected” using the Yamaha diagnostic tool. b. Identify the faulty system with the fault code number. c. Identify the probable cause of the malfunction.
  • Page 405 EAS30951 YAMAHA DIAGNOSTIC TOOL This model uses the Yamaha diagnostic tool to identify malfunctions. For information about using the Yamaha diagnostic tool, refer to the operation manual that is included with the tool. Yamaha diagnostic tool USB 90890-03250 Yamaha diagnostic tool (A/I) 90890-03252 A generic scan tool can also be used to identify malfunctions.
  • Page 406 Write the VIN/frame number in the ECU. View logs: Displays the logging data. However, the Yamaha diagnostic tool cannot be used to freely change the basic vehicle functions, such as adjusting the ignition timing. Connecting the Yamaha diagnostic tool Remove the protective cap “1”, and then connect the Yamaha diagnostic tool to the coupler.
  • Page 407 FUEL INJECTION SYSTEM Parts connected to the ECU The following parts are connected to the ECU. When checking for a power short circuit, the couplers must be disconnected from all of the following parts beforehand. • Crankshaft position sensor • Intake air temperature sensor •...
  • Page 408 Check the locking condition of function mode of the Yamaha the coupler. diagnostic tool. Disconnect the coupler and Condition is “Recovered”  Go check the pins (bent or broken to item 6 and finish the service.
  • Page 409 Turn the main switch to “ON”, and then check the condition of the fault code using the mal- function mode of the Yamaha diagnostic tool. Condition is “Recovered”  Go to item 6 and finish the service. Condition is “Detected”  Start the engine, and then check the condition of the fault code.
  • Page 410 Disconnect the coupler and function mode of the Yamaha check the pins (bent or broken diagnostic tool. Condition is “Recovered”  Go terminals and locking condition of the pins).
  • Page 411 FUEL INJECTION SYSTEM Fault code No. P0107, P0108 [P0107] Intake air pressure sensor 1: ground short circuit detected. Item [P0108] Intake air pressure sensor 1: open or power short circuit detected. [For P0108] Open circuit Between intake air pressure sensor 1 coupler and ECU coupler: blue–blue If there is no continuity, replace the wire harness.
  • Page 412 Improperly installed sensor  the fault code using the mal- Reinstall or replace the sensor. function mode of the Yamaha diagnostic tool. Condition is “Recovered”  Go to item 7 and finish the service.
  • Page 413 Check the locking condition of replace the wire harness. the fault code using the mal- the coupler. function mode of the Yamaha Disconnect the coupler and diagnostic tool. Condition is “Recovered”  Go check the pins (bent or broken terminals and locking condition to item 7 and finish the service.
  • Page 414 FUEL INJECTION SYSTEM Fault code No. P0112, P0113 [P0112] Intake air temperature sensor: ground short circuit detected. Item [P0113] Intake air temperature sensor: open or power short circuit detected. Br/W Br/W 1. Intake air temperature sensor 2. ECU 3. Sensor output lead 4.
  • Page 415 Improperly installed sensor  the fault code using the mal- Reinstall or replace the sensor. function mode of the Yamaha diagnostic tool. Condition is “Recovered”  Go to item 7 and finish the service.
  • Page 416 Check the locking condition of replace the wire harness. the fault code using the mal- the coupler. function mode of the Yamaha Disconnect the coupler and diagnostic tool. Condition is “Recovered”  Go check the pins (bent or broken terminals and locking condition to item 7 and finish the service.
  • Page 417 Yamaha diagnostic tool. Condition is “Recovered”  Go to item 7 and finish the service. Condition is “Detected”  Go to item 4.
  • Page 418 FUEL INJECTION SYSTEM Fault code No. P0117, P0118 [P0117] Coolant temperature sensor: ground short circuit detected. Item [P0118] Coolant temperature sensor: open or power short circuit detected. [For P0118] Open circuit Between wire harness coupler (ECU side) and ECU coupler: green/white–green/white Between sub-wire harness coupler (coolant temperature sensor side) and coolant temperature sen- sor coupler: green/white–green/white If there is no continuity, replace the wire harness and/or sub-wire harness.
  • Page 419 Improperly installed sensor  the fault code using the mal- Reinstall or replace the sensor. function mode of the Yamaha diagnostic tool. Condition is “Recovered”  Go to item 7 and finish the service.
  • Page 420 Check the locking condition of replace the wire harness. the fault code using the mal- the coupler. function mode of the Yamaha Disconnect the coupler and diagnostic tool. Condition is “Recovered”  Go check the pins (bent or broken terminals and locking condition to item 8 and finish the service.
  • Page 421 FUEL INJECTION SYSTEM Fault code No. P0122, P0123, P0222, P0223, P2135 [P0122] Throttle position sensor: ground short circuit detected. [P0123] Throttle position sensor: open or power short circuit detected. Item [P0222] Throttle position sensor: ground short circuit detected. [P0223] Throttle position sensor: open or power short circuit detected.
  • Page 422 FUEL INJECTION SYSTEM Fault code No. P0122, P0123, P0222, P0223, P2135 [P0122] Throttle position sensor: ground short circuit detected. [P0123] Throttle position sensor: open or power short circuit detected. Item [P0222] Throttle position sensor: ground short circuit detected. [P0223] Throttle position sensor: open or power short circuit detected.
  • Page 423 FUEL INJECTION SYSTEM Fault code No. P0122, P0123, P0222, P0223, P2135 [P0122] Throttle position sensor: ground short circuit detected. [P0123] Throttle position sensor: open or power short circuit detected. Item [P0222] Throttle position sensor: ground short circuit detected. [P0223] Throttle position sensor: open or power short circuit detected.
  • Page 424 Improperly installed sensor  the fault code using the mal- Reinstall or adjust the sensor. function mode of the Yamaha Refer to “ADJUSTING THE diagnostic tool. Condition is “Recovered”  Go THROTTLE POSITION SEN- SOR”...
  • Page 425 1. and then check the condition of Execute the diagnostic mode. the fault code using the mal- function mode of the Yamaha (Code No. 01) When the throttle valves are diagnostic tool. Condition is “Recovered”  Go fully closed: A value of 11–21 is indicated.
  • Page 426 Improperly installed sensor  the fault code using the mal- Reinstall or replace the sensor. function mode of the Yamaha diagnostic tool. Condition is “Recovered”  Go to item 7 and finish the service.

  • Page 427: Specifications

    Actuates fuel injector #1 five times at one-second intervals. Actuation The “check” indicator on the Yamaha diagnostic tool screen comes on each time the fuel injector is actuated. Disconnect the fuel pump coupler. Check that fuel injector #1 is actuated Procedure five times by listening for the operating sound.
  • Page 428 Actuates fuel injector #2 five times at one-second intervals. Actuation The “check” indicator on the Yamaha diagnostic tool screen comes on each time the fuel injector is actuated. Disconnect the fuel pump coupler. Check that fuel injector #2 is actuated Procedure five times by listening for the operating sound.
  • Page 429 Actuates fuel injector #3 five times at one-second intervals. Actuation The “check” indicator on the Yamaha diagnostic tool screen comes on each time the fuel injector is actuated. Disconnect the fuel pump coupler. Check that fuel injector #3 is actuated Procedure five times by listening for the operating sound.
  • Page 430 5 seconds. light goes off. Confirm that the fault code has a condition of “Recovered” using the malfunction mode of the Yamaha diagnostic tool, and then delete the fault code. Fault code No. P0335 Fault code No. P0335 Crankshaft position sensor: no normal signals are received from Item the crankshaft position sensor.
  • Page 431 Crank the engine, and then the wire harness. check the condition of the fault Between crankshaft position code using the malfunction sensor coupler and ECU cou- mode of the Yamaha diagnostic pler. tool. Condition is “Recovered”  Go gray–gray Between crankshaft position to item 7 and finish the service.
  • Page 432 Diagnostic code No. Actuates the cylinder-#1 ignition coil five times at one-second intervals. Actuation The “check” indicator on the Yamaha diagnostic tool screen comes on each time the ignition coil is actuated. Check that a spark is generated five times.
  • Page 433 Diagnostic code No. Actuates the cylinder-#2 ignition coil five times at one-second intervals. Actuation The “check” indicator on the Yamaha diagnostic tool screen comes on each time the ignition coil is actuated. Check that a spark is generated five times.
  • Page 434 Check the condition of the fault Disconnect the coupler and code using the malfunction check the pins (bent or broken mode of the Yamaha diagnostic terminals and locking condition tool. Condition is “Recovered”  Go of the pins).
  • Page 435 Diagnostic code No. Actuates the cylinder-#3 ignition coil five times at one-second intervals. Actuation The “check” indicator on the Yamaha diagnostic tool screen comes on each time the ignition coil is actuated. Check that a spark is generated five times.
  • Page 436 Check the condition of the fault Replace if out of specification. code using the malfunction Refer to “CHECKING THE mode of the Yamaha diagnostic IGNITION COILS” on page tool. Condition is “Recovered”  Go 8-163. to item 7 and finish the service.
  • Page 437 FUEL INJECTION SYSTEM Fault code No. P0500, P1500 Rear wheel sensor: no normal signals are received from the rear wheel sensor. Item Neutral switch: open or short circuit is detected. Clutch switch: open or short circuit is detected. Value does not increase  Go Locate the malfunction.
  • Page 438 (12 to 19 mph). Confirm that the fault code has a condition of “Recovered” using the malfunction mode of the Yamaha diagnostic tool, and then delete the fault code. Delete this fault code even if it has a condition of “Detected”.
  • Page 439 FUEL INJECTION SYSTEM Fault code No. P0500, P1500 Rear wheel sensor: no normal signals are received from the rear wheel sensor. Item Neutral switch: open or short circuit is detected. Clutch switch: open or short circuit is detected. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No.
  • Page 440 FUEL INJECTION SYSTEM Fault code No. P0500, P1500 Rear wheel sensor: no normal signals are received from the rear wheel sensor. Item Neutral switch: open or short circuit is detected. Clutch switch: open or short circuit is detected. Improperly connected  Con- Connection of ECU coupler.
  • Page 441 (12 to 19 mph). Confirm that the fault code has a condition of “Recovered” using the malfunction mode of the Yamaha diagnostic tool, and then delete the fault code. Delete this fault code even if it has a condition of “Detected”.
  • Page 442 FUEL INJECTION SYSTEM Fault code No. P0500, P1500 Rear wheel sensor: no normal signals are received from the rear wheel sensor. Item Neutral switch: open or short circuit is detected. Clutch switch: open or short circuit is detected. Value does not increase  Go Locate the malfunction.
  • Page 443 FUEL INJECTION SYSTEM Fault code No. P0500, P1500 Rear wheel sensor: no normal signals are received from the rear wheel sensor. Item Neutral switch: open or short circuit is detected. Clutch switch: open or short circuit is detected. Improperly connected  Con- Connection of ECU coupler.
  • Page 444 (12 to 19 mph). Confirm that the fault code has a condition of “Recovered” using the malfunction mode of the Yamaha diagnostic tool, and then delete the fault code. Delete this fault code even if it has a condition of “Detected”.
  • Page 445 FUEL INJECTION SYSTEM Fault code No. P0601, P0606 Fault code No. P0601, P0606 Internal malfunction in ECU. (When this malfunction is detected in Item the ECU, the fault code number might not appear on the tool dis- play.) Able/Unable to start engine Fail-safe system Able/Unable to drive vehicle Diagnostic code No.
  • Page 446 CO EEPROM. the fault code using the mal- concentration of cylinder #1. Refer to “ADJUSTING THE function mode of the Yamaha EXHAUST GAS VOLUME” on diagnostic tool. Condition is “Recovered”  Go page 3-11. After this adjustment is made, to item 7 and finish the service.
  • Page 447 Check the locking condition of replace the wire harness. the fault code using the mal- the coupler. function mode of the Yamaha Disconnect the coupler and diagnostic tool. Condition is “Recovered”  Go check the pins (bent or broken terminals and locking condition to item 8 and finish the service.
  • Page 448 Actuates the relay unit five times at one-second intervals. Actuation The “check” indicator on the Yamaha diagnostic tool screen come on each time the relay is actuated. Check that the relay unit is actuated five times by listening for the operat- Procedure ing sound.
  • Page 449 Check the condition of the fault Disconnect the coupler and code using the malfunction check the pins (bent or broken mode of the Yamaha diagnostic terminals and locking condition tool. Condition is “Recovered”  Go of the pins).
  • Page 450 (Code No. 03) and then check the condition of When engine is stopped: the fault code using the mal- Atmospheric pressure at the function mode of the Yamaha current altitude and weather diagnostic tool. Condition is “Recovered”  Go conditions is indicated.
  • Page 451 Actuates the air induction system solenoid five times at one-second inter- vals. Actuation The “check” indicator on the Yamaha diagnostic tool screen come on each time the air induction system solenoid is actuated. Check that the air induction system solenoid is actuated five times by lis- Procedure tening for the operating sound.
  • Page 452 Disconnect the coupler and function mode of the Yamaha check the pins (bent or broken diagnostic tool. Condition is “Recovered”  Go terminals and locking condition of the pins).
  • Page 453 Check the condition of the fault Disconnect the coupler and code using the malfunction check the pins (bent or broken mode of the Yamaha diagnostic terminals and locking condition tool. Condition is “Recovered”  Go of the pins).
  • Page 454 ECU coupler. Check the condition of the fault black/red–black/red code using the malfunction Between relay unit coupler and mode of the Yamaha diagnostic sidestand switch coupler. tool. Condition is “Recovered”  Go blue/black–blue/black to item 7 and finish the service.
  • Page 455 Disconnect the coupler and function mode of the Yamaha check the pins (bent or broken diagnostic tool. Condition is “Recovered”  Go terminals and locking condition of the pins).
  • Page 456 Check the condition of the fault Disconnect the coupler and code using the malfunction check the pins (bent or broken mode of the Yamaha diagnostic terminals and locking condition tool. Condition is “Recovered”  Go of the pins).
  • Page 457 FUEL INJECTION SYSTEM Fault code No. P1604, P1605 [P1604] Lean angle sensor: ground short circuit detected. Item [P1605] Lean angle sensor: open or power short circuit. 1. Lean angle sensor 2. ECU 3. Sensor input lead 4. Sensor output lead 5.
  • Page 458 FUEL INJECTION SYSTEM Fault code No. P1604, P1605 [P1604] Lean angle sensor: ground short circuit detected. Item [P1605] Lean angle sensor: open or power short circuit. [For P1605] Open circuit Between lean angle sensor coupler and ECU coupler: yellow/green–yellow/green If there is no continuity, replace the wire harness. [For P1605] Open circuit Between lean angle sensor coupler and ECU coupler: black/blue–black/blue If there is no continuity, replace the wire harness.
  • Page 459 “OFF”, and then back to page 8-165. “ON”. Check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool. Condition is “Recovered”  Go to item 6 and finish the service. Condition is “Detected”  Go to item 5.
  • Page 460 Turn the main switch to “ON”, the wire harness. and then check the condition of the fault code using the mal- function mode of the Yamaha diagnostic tool. Condition is “Recovered”  Go to item 7 and finish the service.
  • Page 461 FUEL INJECTION SYSTEM Fault code No. P1606, P1607 [P1606] Intake air pressure sensor 2: ground short circuit detected. Item [P1607] Intake air pressure sensor 2: open or power short circuit detected. [For P1607] Open circuit Between Intake air pressure sensor 2 coupler and ECU coupler: blue–blue If there is no continuity, replace the wire harness.
  • Page 462 Improperly installed sensor  the fault code using the mal- Reinstall or replace the sensor. function mode of the Yamaha diagnostic tool. Condition is “Recovered”  Go to item 7 and finish the service.
  • Page 463 Check the locking condition of replace the wire harness. the fault code using the mal- the coupler. function mode of the Yamaha Disconnect the coupler and diagnostic tool. Condition is “Recovered”  Go check the pins (bent or broken terminals and locking condition to item 8 and finish the service.
  • Page 464 Disconnect the coupler and function mode of the Yamaha check the pins (bent or broken diagnostic tool. Condition is “Recovered”  Go terminals and locking condition of the pins).
  • Page 465 FUEL INJECTION SYSTEM Fault code No. P2122, P2123, P2127, P2128, P2138 [P2122] Accelerator position sensor: open or ground short circuit detected. [P2123] Accelerator position sensor: power short circuit detected. Item [P2127] Accelerator position sensor: ground short circuit detected. [P2128] Accelerator position sensor: open or power short circuit detected.
  • Page 466 FUEL INJECTION SYSTEM Fault code No. P2122, P2123, P2127, P2128, P2138 [P2122] Accelerator position sensor: open or ground short circuit detected. [P2123] Accelerator position sensor: power short circuit detected. Item [P2127] Accelerator position sensor: ground short circuit detected. [P2128] Accelerator position sensor: open or power short circuit detected.
  • Page 467 Improperly installed sensor  the fault code using the mal- Reinstall or adjust the sensor. function mode of the Yamaha Refer to “ADJUSTING THE diagnostic tool. Condition is “Recovered”  Go ACCELERATOR POSITION SENSOR”...
  • Page 468 1. and then check the condition of Execute the diagnostic mode. the fault code using the mal- (Code No. 14) function mode of the Yamaha When the throttle grip is fully diagnostic tool. Condition is “Recovered”  Go closed: A value of 12–22 is indicated.
  • Page 469 FUEL INJECTION SYSTEM Fault code No. P2158 Front wheel sensor: no normal signals are received from the front Item wheel sensor. Locate the malfunction. If the ABS warning light is on, refer to “BASIC INSTRUC- TIONS FOR TROUBLESHOOT- ING” on page 8-124. If the ABS warning light is off, perform the following procedure.
  • Page 470 (12 to 19 mph). Confirm that the fault code has a condition of “Recovered” using the malfunction mode of the Yamaha diagnostic tool, and then delete the fault code. Delete this fault code even if it has a condition of “Detected”.
  • Page 471 Improperly installed sensor  Check the condition of the fault Reinstall or replace the sensor. code using the malfunction mode of the Yamaha diagnostic tool. Condition is “Recovered”  Go to item 8 and finish the service. Condition is “Detected”  Go to item 2.
  • Page 472 FUEL PRESSURE” on page approximately 10 seconds. 7-11. Check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool. Condition is “Recovered”  Go to item 8 and finish the service. Condition is “Detected”  Go to item 6.
  • Page 473 Disconnect the coupler and function mode of the Yamaha check the pins (bent or broken diagnostic tool. Condition is “Recovered”  Go terminals and locking condition of the pins).
  • Page 474 FUEL PUMP SYSTEM EAS20081 FUEL PUMP SYSTEM EAS30513 CIRCUIT DIAGRAM 8-103...
  • Page 475 FUEL PUMP SYSTEM 3. Main switch 4. Main fuse 11.Ignition fuse 15.Battery 16.Engine ground 17.Fuel injection system fuse 20.Joint connector 21.Joint coupler 22.Relay unit 24.Fuel pump relay 28.ECU (Engine Control Unit) 69.Fuel pump 70.Handlebar switch (right) 72.Start/engine stop switch A. Wire harness D.
  • Page 476 FUEL PUMP SYSTEM EAS30514 TROUBLESHOOTING If the fuel pump fails to operate. • Before troubleshooting, remove the following part(s): 1. Fuel tank front cover/Front side panel/Front side cowling 2. Passenger seat/Rider seat 3. Fuel tank cover 4. Fuel tank 1. Check the fuses. (Main, ignition and fuel injection system) Replace the fuse(s).
  • Page 477 FUEL PUMP SYSTEM 8-106...
  • Page 478 IMMOBILIZER SYSTEM EAS20084 IMMOBILIZER SYSTEM EAS30519 CIRCUIT DIAGRAM 8-107...
  • Page 479 IMMOBILIZER SYSTEM 3. Main switch 4. Main fuse 8. Backup fuse 11.Ignition fuse 15.Battery 16.Engine ground 20.Joint connector 21.Joint coupler 26.Immobilizer unit 28.ECU (Engine Control Unit) 53.Meter assembly 54.Immobilizer system indicator light 58.Multi-function meter A. Wire harness D. Negative battery sub-wire harness 8-108...
  • Page 480 IMMOBILIZER SYSTEM EAS30520 GENERAL INFORMATION This vehicle is equipped with an immobilizer system to help prevent theft by re-registering codes in the standard keys. This system consists of the following: • A code re-registering key (with a red bow) • Two standard keys (with a black bow) that can be re-registered with new codes •...
  • Page 481 IMMOBILIZER SYSTEM Parts to be replaced Main switch/ Key registration immobilizer unit Acces- requirement Standard sory lock* and key Main Immobi- switch lizer unit  Standard key is lost New standard key All keys have been lost Code re-registering  ...
  • Page 482 IMMOBILIZER SYSTEM Standard key registration: Standard key registration is required when a standard key is lost and needs to be replaced, or when the code re-registering key is re-registered after the immobilizer unit or ECU are replaced. Do not start the engine with a standard key that has not been registered. If the main switch is turned “ON”...
  • Page 483 IMMOBILIZER SYSTEM Standard key code voiding method a. Main switch “ON” b. Main switch “OFF” c. LED on d. LED off e. Less than 5.0 s f. Code re-registering key g. Remaining standard key h. Registration mode A. If the immobilizer system indicator light stops flashing 5 seconds after the first standard key is registered, the second standard key cannot be registered.
  • Page 484 IMMOBILIZER SYSTEM EAS30522 TROUBLESHOOTING When the main switch is turned to “ON”, the immobilizer system indicator light does not come on nor flashes. 1. Check the fuses. (Main, ignition, and backup) Replace the fuse(s). Refer to “CHECKING THE FUSES” NG on page 8-157.
  • Page 485 IMMOBILIZER SYSTEM EAS30523 SELF-DIAGNOSIS FAULT CODE INDICATION When a system failure occurs, the immobilizer system indicator light blinks. The pattern of blinking shows the fault code. Fault Part Symptom Cause Action code IMMOBILIZER Code cannot be trans- 1. Radio wave interfer- 1.
  • Page 486 IMMOBILIZER SYSTEM Fault Part Symptom Cause Action code Unidentified code is Noise interference or dis- 1. Check the wire received. connected lead/cable. harness and con- nector. 2. Replace the main switch/immobi- lizer unit. 3. Replace the ECU. Refer to “REPLACING THE ECU (Engine Control Unit)”...
  • Page 487 IMMOBILIZER SYSTEM 8-116...
  • Page 488 ABS (ANTI-LOCK BRAKE SYSTEM) EAS20085 ABS (ANTI-LOCK BRAKE SYSTEM) EAS30843 CIRCUIT DIAGRAM 8-117...
  • Page 489 22.Relay unit 23.Starting circuit cut-off relay 28.ECU (Engine Control Unit) 46.Front wheel sensor 47.Rear wheel sensor 48.ABS ECU (electronic control unit) 52.Yamaha diagnostic tool coupler 53.Meter assembly 58.Multi-function meter 65.ABS warning light 70.Handlebar switch (right) 72.Start/engine stop switch 74.Front brake light switch 75.Rear brake light switch...
  • Page 490 ABS (ANTI-LOCK BRAKE SYSTEM) EAS30525 ABS COMPONENTS CHART 8-119...
  • Page 491 ABS (ANTI-LOCK BRAKE SYSTEM) 1. Hydraulic unit assembly 2. Fuse box 3 3. Yamaha diagnostic tool coupler 4. Rear wheel sensor 5. Rear wheel sensor rotor 6. Front wheel sensor 7. Front wheel sensor rotor 8. ABS warning light 9. Fuse box 2...
  • Page 492 ABS (ANTI-LOCK BRAKE SYSTEM) EAS30844 ABS COUPLER LOCATION CHART 8-121...
  • Page 493 ABS (ANTI-LOCK BRAKE SYSTEM) 1. Meter assembly coupler 2. Rear wheel sensor coupler 3. ABS ECU coupler 4. Yamaha diagnostic tool coupler 5. Front wheel sensor coupler 8-122...
  • Page 494 The following troubleshooting describes the problem identification and service method using the Yamaha diagnostic tool. For information about using the Yamaha diagnostic tool, refer to “[B-2] DIAG- NOSIS USING THE FAULT CODES” on page 8-127. For troubleshooting items other than the following items, follow the normal service method.
  • Page 495 Previous malfunctions can be checked since the ABS ECU also stores the mal- function history. The fault codes recorded in the ABS ECU can be checked using the Yamaha diagnostic tool. When the service is finished, check the normal operation of the vehicle, and then delete the fault code(s). For in- formation about deleting the fault codes, refer to “[B-3] DELETING THE FAULT CODES”...
  • Page 496 • Can the tool communicate with is defective. the ABS ECU? Can communicate [A-5] ABS ECU and FI ECU The connection with the Yamaha • Return to [A]. fail to communicate. diagnostic tool is defective. • The wire harness is defective.
  • Page 497 EAS31162 [A-3] THE ABS WARNING LIGHT COMES ON Connect the Yamaha diagnostic tool to the Yamaha diagnostic tool coupler and execute functional di- agnosis. (For information about how to execute functional diagnosis, refer to the operation manual that is included with the tool.) Check that communication with the ABS ECU is possible.
  • Page 498 Check for continuity between black/yellow terminal of the ABS ECU coupler and the ground. If there is no continuity, the wire harness is defective. Replace the wire harness. • Open circuit in the wire harness between the ABS ECU coupler and the Yamaha diagnostic tool cou- pler.
  • Page 499 Removing the rider seat. Refer to “GENERAL CHASSIS (1)” on page 4-1. Removing the protective cap “1”, and then connect the Yamaha diagnostic tool to the coupler. Details about the displayed fault codes are shown in the following chart. Refer to this chart and check the vehicle.
  • Page 500 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code Item Symptom Check point Rear wheel sensor (abnor- Rear wheel sensor signal is • Foreign material adhered mal pulse period) not received properly. (The around the rear wheel sen- pulse period is abnormal • Incorrect installation of the while the vehicle is traveling.) rear wheel •...
  • Page 501 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code Item Symptom Check point Brake light switch or Brake light signal is not • Defective signaling system tail/brake light received properly while the (tail/brake light or brake vehicle is traveling. (Brake light switch) • Defective coupler between light circuit, or front or rear brake light switch circuit.) the signaling system...
  • Page 502 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code Item Symptom Check point Rear wheel ABS (intermit- • Pulses from the rear wheel • Incorrect installation of the tent wheel speed pulses or sensor are received inter- rear wheel sensor (for fault incorrect depressurization) mittently while the vehicle code No.

  • Page 503: Troubleshooting Details

    ABS (ANTI-LOCK BRAKE SYSTEM) Fault code Item Symptom Check point Hydraulic unit assembly Abnormal data is detected in • Defective hydraulic unit (defective ABS ECU) the hydraulic unit assembly. assembly Hydraulic unit assembly Abnormality is detected in • Defective hydraulic unit (abnormal internal power the power supply circuit in assembly...
  • Page 504 ABS (ANTI-LOCK BRAKE SYSTEM) With the front wheel stopped, the rear wheel was rotated for longer than about 20 seconds (fault code No. 11) or for longer than about 2 seconds (fault code No. 25). Fault code No. 12 Fault code No. Item Rear wheel sensor (intermittent pulses or no pulses) Rear wheel sensor signal is not received properly.
  • Page 505 ABS (ANTI-LOCK BRAKE SYSTEM) • If the front brake ABS operates continuously for 20 seconds or more, fault code No. 26 will be record- ed. If the front brake ABS operates continuously for 36 seconds or more, fault code No. 13 will be re- corded.
  • Page 506 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Item Front wheel sensor (open or short circuit) Symptom Open or short circuit is detected in the front wheel sensor. Order Item/components and probable cause Check or maintenance job • Check for continuity between the white terminal “1” Open or short circuit in the wire harness between the front wheel sensor and the and the white terminal “4”...
  • Page 507 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Item Rear wheel sensor (open or short circuit) Symptom Open or short circuit is detected in the rear wheel sensor. Order Item/components and probable cause Check or maintenance job • Check for continuity between the white terminal “1” Open or short circuit in the wire harness between the rear wheel sensor and the and the white terminal “4”...
  • Page 508 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Item Front wheel sensor (missing pulses) Front wheel sensor signal is not received properly. (Missing pulses Symptom are detected in the signal while the vehicle is traveling.) Order Item/components and probable cause Check or maintenance job Defective sensor rotor or incorrect instal- Check the surface of the sensor rotor for damage.
  • Page 509 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. 21 Fault code No. Item Hydraulic unit assembly (defective solenoid drive circuit) Solenoid drive circuit in the hydraulic unit assembly is open or Symptom short-circuited. Order Item/components and probable cause Check or maintenance job Defective hydraulic unit assembly Replace the hydraulic unit assembly.
  • Page 510 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Item Hydraulic unit assembly (abnormal ABS solenoid power supply) Power is not supplied to the solenoid circuit in the hydraulic unit Symptom assembly. Order Item/components and probable cause Check or maintenance job Defective coupler between the battery •...
  • Page 511 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Item Hydraulic unit assembly (abnormal ABS motor power supply) Power is not supplied to the motor circuit in the hydraulic unit Symptom assembly. Order Item/components and probable cause Check or maintenance job Open or short circuit in the wire harness •...
  • Page 512 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Front wheel ABS (intermittent wheel speed pulses or incorrect Item depressurization) • Pulses from the front wheel sensor are received intermittently while the vehicle is traveling. Symptom • Front wheel will not recover from the locking tendency even though the signal is transmitted from the ABS ECU to reduce the hydraulic pressure.
  • Page 513 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. 43 Fault code No. Item Front wheel sensor (missing pulses) Front wheel sensor signal is not received properly. (Missing pulses Symptom are detected in the signal while the vehicle is traveling.) Order Item/components and probable cause Check or maintenance job Foreign material adhered around the front Check the surface of the sensor rotor and wheel sensor...
  • Page 514 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. 51, 52 Fault code No. • Vehicle system power supply (voltage of ABS ECU power supply is high) (for fault code No. 51) Item • Vehicle system power supply (voltage of wheel sensor power sup- ply is high) (for fault code No.
  • Page 515 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. 54 Fault code No. Hydraulic unit assembly (defective ABS solenoid and ABS motor Item power supply circuits) Abnormality is detected in the solenoid or motor power supply cir- Symptom cuit in the hydraulic unit assembly. Order Item/components and probable cause Check or maintenance job Defective battery...
  • Page 516 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. 56 Fault code No. Item Hydraulic unit assembly (abnormal internal power supply) Abnormality is detected in the power supply circuit in the hydraulic Symptom unit assembly. Order Item/components and probable cause Check or maintenance job Defective hydraulic unit assembly Replace the hydraulic unit assembly.
  • Page 517 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Item Front wheel sensor power supply (voltage of power supply is low) Power voltage supplied from the ABS ECU to the front wheel sensor Symptom is too low. Order Item/components and probable cause Check or maintenance job Defective hydraulic unit assembly Replace the hydraulic unit assembly.
  • Page 518 EAS31167 [B-3] DELETING THE FAULT CODES To delete the fault codes, use the Yamaha diagnostic tool. For information about deleting the fault codes, refer to the operation manual of the Yamaha diagnostic tool. Check that all the displayed fault codes are deleted.
  • Page 519 ABS (ANTI-LOCK BRAKE SYSTEM) Check for continuity between green/red terminal of the ABS ECU coupler and green/red terminal of the meter assembly coupler. • Malfunction in the meter assembly circuit. • Malfunction in the ABS warning light circuit in the hydraulic unit assembly. 8-148...
  • Page 520 ELECTRICAL COMPONENTS EAS20089 ELECTRICAL COMPONENTS 8-149...
  • Page 521 ELECTRICAL COMPONENTS 1. Main switch/Immobilizer unit 2. Clutch switch 3. Front brake light switch 4. Hydraulic unit assembly 5. Battery 6. Fuse box 3 7. Main fuse 8. Fuel injection system fuse 9. Starter relay 10.Rectifier/regulator 11.Rear wheel sensor 12.Rear brake light switch 13.Gear position switch 14.Sidestand switch 15.O...
  • Page 522 ELECTRICAL COMPONENTS 8-151...
  • Page 523 ELECTRICAL COMPONENTS 1. Intake air temperature sensor 2. ECU (Engine Control Unit) 3. Fuel pump 4. Lean angle sensor 5. Radiator fan motor relay 6. Turn signal/hazard relay 7. Relay unit 8. Stator coil 9. Crankshaft position sensor 10.Coolant temperature sensor 11.Throttle servo motor 12.Accelerator position sensor 13.Throttle position sensor...
  • Page 524 ELECTRICAL COMPONENTS EAS30549 CHECKING THE SWITCHES Br/W B/Y W/R B W/G Br B/R B/L B/L Br/W 8-153...
  • Page 525 ELECTRICAL COMPONENTS 1. Dimmer/pass switch 2. Turn signal switch 3. Horn switch 4. Select switch 5. Menu switch 6. Clutch switch 7. Oil level switch 8. Sidestand switch 9. Hazard switch 10.Start/engine stop switch 11.Drive mode switch 12.Front brake light switch 13.Main switch 14.Rear brake light switch 8-154...
  • Page 526 ELECTRICAL COMPONENTS Check each switch for continuity with the digital curcuit tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. ECA14371 NOTICE Never insert the tester probes into the coupler terminal slots. Always insert the probes from the opposite end “a”...
  • Page 527 ELECTRICAL COMPONENTS EAS30550 CHECKING THE BULBS AND BULB Digital circuit tester (CD732) 90890-03243 SOCKETS Model 88 Multimeter with tachom- Check each bulb and bulb socket for damage or eter wear, proper connections, and also for continuity YU-A1927 between the terminals. Damage/wear ...
  • Page 528 ELECTRICAL COMPONENTS ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Amperage Fuses Q’ty rating EAS30551 CHECKING THE FUSES Main 50 A The following procedure applies to all of the fus- Headlight 7.5 A Signaling system 7.5 A ECA13680 NOTICE Ignition 15 A To avoid a short circuit, always set the main switch to “OFF”...
  • Page 529 ELECTRICAL COMPONENTS be charged according to the appropriate Refer to “CHECKING AND CLEANING THE THROTTLE BODIES” on page 7-8. charging method. If the battery is over- charged, the electrolyte level will drop con- 4. Check: • Engine idling speed siderably. Therefore, take special care when charging the battery.
  • Page 530 ELECTRICAL COMPONENTS tery overheating and battery plate damage. nected). • No charging is necessary when the open-cir- • If it is impossible to regulate the charging current on the battery charger, be careful cuit voltage equals or exceeds 12.8 V. not to overcharge the battery.
  • Page 531 ELECTRICAL COMPONENTS charging. tery. Voltage should be measured 30 minutes after If the current is lower than the standard charging the engine is stopped. current written on the battery, this type of battery charger cannot charge the VRLA (Valve Regu- b.
  • Page 532 ELECTRICAL COMPONENTS Relay unit (starting circuit cut-off relay) 10.Install: • Rider seat/Passenger seat Refer to “GENERAL CHASSIS (1)” on page 4-1. EAS30553 CHECKING THE RELAYS Check each switch for continuity with the digital circuit tester. If the continuity reading is incor- rect, replace the relay.
  • Page 533 ELECTRICAL COMPONENTS Radiator fan motor relay b. Turn the main switch to “ON”. 1. Positive battery terminal c. Measure the turn signal/hazard relay input 2. Negative battery terminal voltage. 3. Positive tester probe ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 4. Negative tester probe 2. Check: •...
  • Page 534 ELECTRICAL COMPONENTS EAS30795 CHECKING THE RELAY UNIT (DIODE) 1. Check: • Relay unit (diode) Out of specification  Replace. Digital circuit tester (CD732) 90890-03243 Model 88 Multimeter with tachom- eter YU-A1927 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the relay unit coupler from the The digital circuit tester readings are shown in wire harness.
  • Page 535 ELECTRICAL COMPONENTS Minimum ignition spark gap 6.0 mm (0.24 in) If the ignition spark gap is within specification, the ignition system circuit is operating normally. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the ignition coil from the spark plug. b. Connect the ignition checker “1” as shown. c.
  • Page 536 ELECTRICAL COMPONENTS Digital circuit tester (CD732) Digital circuit tester (CD732) 90890-03243 90890-03243 Model 88 Multimeter with tachom- Model 88 Multimeter with tachom- eter eter YU-A1927 YU-A1927 Test harness– lean angle sensor (6P) • Positive tester probe 90890-03209 gray “1” Test harness– lean angle sensor •...
  • Page 537 ELECTRICAL COMPONENTS fluid is in the vicinity. b. Measure the stator coil resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ b. Check the starter motor operation. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS30680 CHECKING THE RECTIFIER/REGULATOR EAS30566 1. Check: CHECKING THE STATOR COIL • Rectifier/regulator input voltage 1. Disconnect: Out of specification  Correct the stator coil •...
  • Page 538 ELECTRICAL COMPONENTS EAS30569 CHECKING THE HORN 1. Check: • Horn resistance Out of specification  Replace. Horn Coil resistance 1.07–1.11  ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the horn leads from the horn ter- c. Start the engine and let it run at approximate- minals.
  • Page 539 ELECTRICAL COMPONENTS 4. Check: Oil level switch • Fuel sender resistance Oil level switch resistance (maxi- Out of specification  Replace the fuel pump mum level position) assembly. 484.0–536.0  Oil level switch resistance (mini- Sender unit resistance (full) mum level position) 9.0–11.0 ...
  • Page 540 ELECTRICAL COMPONENTS 1. Check: ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • Fuel meter/fuel level warning light “1” a. Disconnect the radiator fan motor coupler (Turn the main switch to “ON”.) from the wire harness. Warning light comes on for a few seconds, b. Connect the battery (DC 12 V) as shown. then goes off ...
  • Page 541 ELECTRICAL COMPONENTS Digital circuit tester (CD732) Resistance 90890-03243 1.20–2.80 k Model 88 Multimeter with tachom- eter ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ YU-A1927 a. Connect the digital circuit tester () to the throttle position sensor terminals as shown. b. Immerse the coolant temperature sensor “1” Digital circuit tester (CD732) in a container filled with coolant “2”.
  • Page 542 ELECTRICAL COMPONENTS tance servo motor terminals “1” as shown. Out of specification  Replace the accelera- ECA17660 NOTICE tor position sensor. Do not use a 12 V battery to operate the throt- Resistance tle servo motor. 1.08–2.52 k Do not use old batteries to operate the throttle ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...
  • Page 543 ELECTRICAL COMPONENTS Digital circuit tester (CD732) Digital circuit tester (CD732) 90890-03243 90890-03243 Model 88 Multimeter with tachom- Model 88 Multimeter with tachom- eter eter YU-A1927 YU-A1927 Test harness S– pressure sensor (3P) • Positive tester probe  90890-03207 Air induction system solenoid terminal “1” Test harness S–...
  • Page 544 ELECTRICAL COMPONENTS with special care. EAS31088 CHECKING THE GEAR POSITION SWITCH • Never subject the intake air temperature 1. Remove: sensor to strong shocks. If the intake air • Fuel tank temperature sensor is dropped, replace it. Refer to “FUEL TANK” on page 7-1. 2.
  • Page 545 ELECTRICAL COMPONENTS EAS30681 Result CHECKING THE FUEL INJECTORS Neutral position The following procedure applies to all of the fuel Continuity injectors. Positive tester probe 1. Remove: sky blue “1” • Fuel injector Negative tester probe Refer to “THROTTLE BODIES” on page 7-5. Sensor terminal “a”...
  • Page 546 ELECTRICAL COMPONENTS 8-175...

  • Page 547: Troubleshooting

    TROUBLESHOOTING TROUBLESHOOTING..................9-1 GENERAL INFORMATION ................9-1 STARTING FAILURES................9-1 INCORRECT ENGINE IDLING SPEED .............9-1 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ......9-2 FAULTY GEAR SHIFTING.................9-2 SHIFT PEDAL DOES NOT MOVE .............9-2 JUMPS OUT OF GEAR................9-2 FAULTY CLUTCH ..................9-2 OVERHEATING ..................9-2 OVERCOOLING..................9-3 POOR BRAKING PERFORMANCE............9-3 FAULTY FRONT FORK LEGS..............9-3 UNSTABLE HANDLING ................9-3 FAULTY LIGHTING OR SIGNALING SYSTEM .........9-3 TROUBLESHOOTING AT THE ABS WARNING LIGHT ......9-4...

  • Page 548: Troubleshooting

    TROUBLESHOOTING 2. Fuse(s) EAS20090 TROUBLESHOOTING • Blown, damaged or incorrect fuse • Improperly installed fuse EAS30599 3. Spark plug(s) GENERAL INFORMATION • Incorrect spark plug gap • Incorrect spark plug heat range The following guide for troubleshooting does not • Fouled spark plug cover all the possible causes of trouble.
  • Page 549 TROUBLESHOOTING • Worn or damaged electrode EAS30849 FAULTY CLUTCH • Worn or damaged insulator Clutch slips 3. Ignition coil(s) 1. Clutch • Broken or shorted primary or secondary coils • Improperly assembled clutch • Cracked or broken ignition coil • Improperly adjusted clutch cable 4.
  • Page 550 TROUBLESHOOTING • Damaged pipe • Incorrect oil viscosity • Improperly connected pipe • Incorrect oil level Fuel system EAS30611 1. Throttle body (-ies) UNSTABLE HANDLING • Damaged or loose throttle body joint Handlebar 2. Air filter • Bent or improperly installed handlebar •...
  • Page 551 TROUBLESHOOTING • Incorrect connection • Faulty tail/brake light assembly Turn signal does not come on • Faulty turn signal switch • Faulty turn signal/hazard relay • Burnt-out turn signal bulb • Incorrect connection • Damaged or faulty wire harness • Improperly grounded circuit •...
  • Page 552 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE EAS20116 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE EAS31794 SELF-DIAGNOSTIC FUNCTION TABLE (FOR FUEL INJECTION SYSTEM) For details of the fault code, refer to “TROUBLESHOOTING METHOD” on page 8-33. Fault Probable cause of Fail-safe system Item Vehicle symptom code No.
  • Page 553 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Fault Probable cause of Fail-safe system Item Vehicle symptom code No. malfunction operation P0117 [P0117] Coolant tem- [P0117] Low voltage Engine is difficult to The radiator fan motor P0118 perature sensor of the coolant temper- start.
  • Page 554 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Fault Probable cause of Fail-safe system Item Vehicle symptom code No. malfunction operation P0132 sensor (short cir- [P0132] High voltage Increased exhaust feedback is not of the O sensor cir- emissions. cuit detected (power carried out.
  • Page 555 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Fault Probable cause of Fail-safe system Item Vehicle symptom code No. malfunction operation P0351 [P0351] Cylinder-#1 • Defective coupler Engine stops. Injection to the appli- P0352 ignition coil (open or between ignition coil Loss of engine power. cable cylinder group is P0353 short circuit detected...
  • Page 556 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Fault Probable cause of Fail-safe system Item Vehicle symptom code No. malfunction operation P0601 Internal malfunction in • Malfunction in ECU. Engine cannot be Engine cannot be ECU (ROM data started. started. error) (When this mal- function is detected in the ECU, the fault code number might...
  • Page 557 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Fault Probable cause of Fail-safe system Item Vehicle symptom code No. malfunction operation P1004 Intake air pressure • Malfunction in ECU. Engine is difficult to Intake air pressure is • Hose of intake air sensor 1 or intake air start.
  • Page 558 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Fault Probable cause of Fail-safe system Item Vehicle symptom code No. malfunction operation P1602 Malfunction in ECU • Open or short cir- Engine idling speed is feedback learning internal circuit (mal- cuit in wire harness unstable.
  • Page 559 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Fault Probable cause of Fail-safe system Item Vehicle symptom code No. malfunction operation P2122 [P2122] Accelerator [P2122, P2127] Low Engine response is No change in acceler- P2123 position sensor (open voltage of the acceler- poor.
  • Page 560 Vehicle symptom code No. malfunction operation U0155 CAN communication Communication Defective meter dis- Grip warmer output: (Yamaha error (with the meter) between the ECU and play. OFF is fixed. diagnostic the meter is not possi- Traction control does MAP changeover: tool) not work.
  • Page 561 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Diagnostic Item Tool display Procedure code No. Air temperature Displays the air temperature. Compare the actually mea- sured air temperature with the tool display value. Coolant temperature When engine is cold: Dis- Compare the actually mea- plays temperature closer to sured coolant temperature air temperature.
  • Page 562 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Diagnostic Item Tool display Procedure code No. Sidestand switch Extend and retract the sides- tand (with the transmission in • Stand retracted gear). • Stand extended gear position switch and Operate the transmission, clutch switch clutch lever, and sidestand.
  • Page 563 • Connect an ignition The “check” indicator on the checker. Yamaha diagnostic tool screen come on each time the ignition coil is actuated. Cylinder-#2 ignition coil Actuates the cylinder-#2 igni- Check that a spark is gener- tion coil five times at one- ated five times.
  • Page 564 Check that injector #3 is The “check” indicator on the actuated five times by listen- Yamaha diagnostic tool ing for the operating sound. screen come on each time the injector is actuated. Air induction system solenoid Actuates the air induction...
  • Page 565 EVENT CODE TABLE EAS20164 EVENT CODE TABLE Item Symptom Possible causes Note Intake air pres- Brief abnormality Same as for fault code Perform the checks and sure sensor 1 detected in the intake number P0107 and maintenance jobs for fault air pressure sensor 1 P0108 code number P0107 and...
  • Page 566 EVENT CODE TABLE Item Symptom Possible causes Note During idling, the Idling engine speed is • Implement diagnosis (Stuck at the adjustment is main- slow mode (diagnostic code • Clogged throttle body upper limit for tained at the upper number 67), and check •...
  • Page 567 EVENT CODE TABLE EAS32023 TROUBLESHOOTING DETAILS (EVENT CODE) Event code No. 30 Event code No. Item Latch up detected. Unable to start engine Fail-safe system Unable to drive vehicle Diagnostic code No. Lean angle sensor output voltage Tool display • 0.4–1.4 (upright) •...
  • Page 568 EVENT CODE TABLE Event code No. 70 If another error code is displayed at the same time, check the other error code first and repair it. Event code No. Engine forcibly stops when the vehicle is left idling for a long period Item of time.

  • Page 569: Wiring Diagram

    49. Throttle servo motor A. Wire harness 50. Accelerator position sensor B. Sub-wire harness (Injector #2) 51. Throttle position sensor C. Sub-wire harness (Coolant 52. Yamaha diagnostic tool cou- temperature sensor) pler D. Negative battery sub-wire har- 53. Meter assembly ness 54.
  • Page 570 EAS30613 COLOR CODE Black Brown Chocolate Dark green Green Gray Blue Light green Orange Pink Sky blue Violet White Yellow Black/Blue Black/Red Black/White Black/Yellow Br/B Brown/Black Br/L Brown/Blue Br/R Brown/Red Br/W Brown/White Br/Y Brown/Yellow Green/Black Green/Red Green/White Green/Yellow Gy/G Gray/Green Gy/R Gray/Red Blue/Black...
  • Page 573 MT09TRA/MT09TRAH 2017 MT09TRA/MT09TRAH 2017 MT09TRA/MT09TRAH 2017 MT09TRA/MT09TRAH 2017 MT09TRA/MT09TRAH 2017 SCHÉMA DE CÂBLAGE SCHEMA ELETTRICO WIRING DIAGRAM SCHALTPLAN DIAGRAMA ELÉCTRICO...
  • Page 574 MT09TRA/MT09TRAH 2017 MT09TRA/MT09TRAH 2017 MT09TRA/MT09TRAH 2017 MT09TRA/MT09TRAH 2017 MT09TRA/MT09TRAH 2017 SCHÉMA DE CÂBLAGE SCHEMA ELETTRICO WIRING DIAGRAM SCHALTPLAN DIAGRAMA ELÉCTRICO...

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