Page 1 2015 SERVICE MANUAL MT09TRA MT09TRAF 2PP-28197-E0...
Page 3 EAS20002 MT09TRA/MT09TRAF SERVICE MANUAL ©2014 by Yamaha Motor Co., Ltd. First edition, June 2014 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 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
VEHICLE IDENTIFICATION NUMBER ............1-1 MODEL LABEL...................1-1 FEATURES .......................1-2 OUTLINE OF THE FI SYSTEM..............1-2 FI SYSTEM....................1-3 YCC-T (Yamaha Chip Controlled Throttle)..........1-4 OUTLINE OF THE ABS................1-5 ABS COMPONENT FUNCTIONS ............1-10 ABS OPERATION ..................1-15 ABS WARNING LIGHT AND OPERATION..........1-18 OUTLINE OF THE TCS (Traction Control System)........1-19 MULTI-FUNCTION METER UNIT ............1-23...
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
FEATURES EAS20008 FEATURES EAS30005 OUTLINE OF THE FI SYSTEM The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature. In the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the combustion chamber is created by the volume of the intake air and the fuel that is metered by the jet used in the respective carburetor.
Page 12: Fi System
FEATURES EAS30617 FI SYSTEM The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the fuel pressure that is applied to the fuel injector at a certain level. Accordingly, when the energizing signal from the ECU energizes the fuel injector, the fuel passage opens, causing the fuel to be injected into the intake manifold only during the time the passage remain open.
Page 13: Ycc-T (Yamaha Chip Controlled Throttle)
Yamaha developed the YCC-T system employing the most advanced electronic control technologies. Electronic control throttle systems have been used on automobiles, but Yamaha has developed a fast- er, more compact system specifically for the needs of a sports motorcycle. The Yamaha-developed system has a high-speed calculating capacity that produces computations of running conditions every 1/1000th of a second.
Page 14: Outline Of The Abs
EAS30683 OUTLINE OF THE ABS 1. The Yamaha ABS (anti-lock brake system) features an electronic control system, which acts on the front and rear brakes independently. 2. The ABS features a compact and lightweight design to help maintain the basic maneuverability of the vehicle.
Page 15 4. Rear wheel sensor 5. Rear wheel sensor rotor The operation of the Yamaha ABS brakes is the same as conventional brakes on other vehicles, with a brake lever for operating the front brake and a brake pedal for operating the rear brake.
Page 16 FEATURES continues to travel. • Side force: The force on the tires which supports the vehicle when cornering. • Slip ratio: When the brakes are applied, slipping occurs between the tires and the road surface. This causes a difference between the wheel speed and the chassis speed. Slip ratio is the value that shows the rate of wheel slippage and is defined by the following formula.
Page 17 FEATURES Wheel slip and hydraulic control The ABS ECU calculates the wheel speed of each wheel according to the rotation signal received from the front and rear wheel sensors. In addition, the ABS ECU calculates the vehicle chassis speed and the rate of speed reduction based on the wheel speed values.
Page 18 Slip ratio (%) b. Brake force Electronic ABS features The Yamaha ABS (anti-lock brake system) has been developed with the most advanced electronic technology. The ABS control is processed with good response under various vehicle travel conditions. The ABS also includes a highly developed self-diagnosis function. The ABS detects any problem con- dition and allows normal braking even if the ABS is not operating properly.
Page 19: Abs Component Functions
FEATURES ABS block diagram 8. ABS ECU 1. Rear brake master cylinder 9. Buffer chamber 2. Hydraulic unit assembly 10.Rear brake caliper 3. Front brake master cylinder 11.Rear wheel sensor 4. Inlet solenoid valve 12.ABS warning light 5. ABS motor 13.Front brake caliper 6.
Page 20 FEATURES 6. Wheel sensor rotor 3. At low speed 7. Voltage 4. At high speed 5. Wheel sensor 8. Time ABS warning light The ABS warning light “1” comes on to warn the rider if a malfunction in the ABS occurs. When the main switch is turned to “ON”, the ABS warning light comes on to check the electrical circuit and the system function (ABS self-diagnosis), and goes off when the vehicle is operated (the function check is properly completed at a speed of about 6 to 10 km/h [3.8 to 6.3 mi/h]).
Page 21 FEATURES Hydraulic unit assembly The hydraulic unit assembly “1” is composed of hydraulic control valves (each with a outlet solenoid valve and inlet solenoid valve), buffer chambers, hydraulic pumps, an ABS motor, and ABS ECU. The hydraulic unit adjusts the front and rear wheel brake fluid pressure to control the wheel speed according to signals transmitted from the ABS ECU.
Page 22 FEATURES 3. When the ABS ECU sends a signal to stop reducing the hydraulic pressure, the outlet solenoid valve “2” closes and the brake fluid is pressurized again. The inlet solenoid valve “1” controls the hydraulic pressure difference between the brake fluid in the upper brake lines (brake master cylinder side) and the brake fluid in the lower brake lines (brake caliper side).
Page 23 FEATURES 15.ABS ECU 1. Battery 16.ABS motor relay 2. AC magneto 17.Solenoid relay 3. Rectifier/regulator 18.Front brake outlet solenoid 4. Main fuse 19.Front brake inlet solenoid 5. ABS motor fuse 20.Rear brake outlet solenoid 6. ABS solenoid fuse 21.Rear brake inlet solenoid 7.
Page 24: Abs Operation
FEATURES 5. Self-diagnosis (when riding) 1. Software operation flow 6. Receive signals 2. Main switch “ON” 7. Control operation 3. Initialize 8. Depressurize/pressurize 4. Self-diagnosis (when static) EAS30710 ABS OPERATION The ABS hydraulic circuit consists of two systems: the front wheel, and rear wheel. The following de- scribes the system for the front wheel only.
Page 25 FEATURES 8. Brake caliper 1. Brake master cylinder 9. Wheel sensor 2. Brake light switch 10.ABS ECU 3. ABS motor 11.ABS warning light 4. Hydraulic pump 12.Brake fluid pressure 5. Buffer chamber 13.Time 6. Outlet solenoid valve 7. Inlet solenoid valve Emergency braking (ABS activated) 1.
Page 26 FEATURES 8. Brake caliper 1. Brake master cylinder 2. Brake light switch 9. Wheel sensor 10.ABS ECU 3. ABS motor 11.ABS warning light 4. Hydraulic pump 12.Brake fluid pressure 5. Buffer chamber 13.Time 6. Outlet solenoid valve 7. Inlet solenoid valve 2.
Page 27: Abs Warning Light And Operation
FEATURES 8. Brake caliper 1. Brake master cylinder 2. Brake light switch 9. Wheel sensor 10.ABS ECU 3. ABS motor 11.ABS warning light 4. Hydraulic pump 12.Brake fluid pressure 5. Buffer chamber 13.Time 6. Outlet solenoid valve 7. Inlet solenoid valve EAS30712 ABS WARNING LIGHT AND OPERATION ABS warning light...
Page 28: Outline Of The Tcs (Traction Control System)
FEATURES ABS function EWA16521 WARNING • When hydraulic control is performed by the ABS, the brake system alerts the rider that the wheels have a tendency to lock by generating a reaction-force pulsating action in the brake lever or brake pedal. When the ABS is activated, the grip between the road surface and tires is close to the limit.
Page 29 FEATURES TCS (Traction control system) layout 8, 9 6. Rear wheel sensor 1. “TCS” button 7. Front wheel sensor 2. Traction control system indicator/warning light 8. Ignition coil 3. ECU (engine control unit) 9. Spark plug 4. Throttle servo motor 10.Fuel injector 5.
Page 30 FEATURES C. Exceeds preset value 1. Front wheel sensor D. Actuator control 2. Rear wheel sensor E. Fuel cut-off 3. ABS ECU F. Ignition timing (retarded) 4. “TCS” button G. Traction control system indicator/warning 5. ECU (engine control unit) light (flashes) A.
Page 31 FEATURES Turn the traction control system off to help free the rear wheel if the motorcycle gets stuck in mud, sand, or other soft surfaces. ECA19650 NOTICE Use only the specified tires. Using different sized tires will prevent the traction control system from controlling tire rotation accurately.
Page 32: Multi-Function Meter Unit
FEATURES The multi-function meter unit is equipped with EAS30982 MULTI-FUNCTION METER UNIT the following: • a speedometer 5 6 7 • a tachometer • a clock • a fuel meter GEAR • an eco indicator A.TEMP °C C.TEMP °C • a transmission gear display TIME TRIP 0:00 •...
Page 33 FEATURES itor the engine speed and keep it within the ideal level. power range. When the key is turned to “ON”, the tachometer This fuel meter is equipped with a self-diagnosis will sweep across the r/min range and then re- system.
Page 34 FEATURES Odometer display: by the transmission gear display “ ”. Drive mode display Tripmeter displays: 1. Drive mode display This display indicates which drive mode has been selected: “STD”, “A” or “B”. For more de- TRIP-1 tails on the modes and on how to select them, refer to “D-mode (drive mode)”...
Page 35 FEATURES In that case, pushing the select switch switch- • –9 C will be displayed even if the ambient tem- es the display between the various informa- perature falls below –9 C. tion displays in the following order; • The accuracy of the temperature reading may TRIP-F ...
Page 36 FEATURES Setting mode The average fuel consumption display modes “km/L”, “L/100km” or “MPG” (for the UK only) show the average fuel consumption since the display was last reset. • The “km/L” display shows the average dis- tance that can be traveled on 1.0 L of fuel. MENU •...
Page 37 FEATURES This function allows you to “Display” change the items shown in 3 MENU information displays. Maintenance This function allows you to Time Trip adjust the brightness of the Unit “Brightness” multi-function meter unit panel Display to suit the rider’s preference. Brightness This function allows you to set Clock...
Page 38 FEATURES Unit MENU Maintenance Time Trip km or mile Unit Display km/L or L/100km Brightness km/L Clock All Reset 2. Push the menu switch “MENU”, use the se- • For the UK: Continue with the following steps. lect switch to highlight the display to change, •...
Page 39 FEATURES Setting the clock the previous display. 1. Use the select switch to highlight “Clock”. Display-1 MENU Maintenance Time Trip Unit C.TEMP Display Brightness TIME TRIP Clock All Reset 6. Use the select switch to highlight “ ”, and then push the menu switch “MENU” to return 2.
Page 40: D-Mode (Drive Mode)
FEATURES than one immobilizer key on the same key ring! Immobilizer system keys may cause signal inter- All Reset ference, which may prevent the engine from starting. 2. If the engine starts, turn it off, and try starting the engine with the standard keys. 3.
Page 41 FEATURES Mode “B” Mode “B” offers response that is somewhat less sharp compared to mode “STD” for riding situa- tions that require especially sensitive throttle op- eration. 1-32...
Page 42: 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 43: 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 44: 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 45: 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 46 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 47 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 48 BASIC SERVICE INFORMATION • Make sure all connections are tight. 5. Check: • Resistance Pocket tester 90890-03112 Analog pocket tester YU-03112-C The resistance values shown were obtained at the standard measuring temperature of 20 C (68 F). If the measuring temperature is not 20 C (68 F), the specified measuring condi- 4.
Page 49: Special Tools
SPECIAL TOOLS EAS20012 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country. When placing an order, refer to the list provided below to avoid any mistakes.
Page 50 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Flywheel puller 5-32 90890-01362 Heavy duty puller YU-33270-B Steering nut wrench 3-20, 4-89 90890-01403 Exhaust flange nut wrench YU-A9472 Damper rod holder 4-80, 4-82 90890-01582 Damper rod holder YM-01582 Oil filter wrench 3-25 90890-01426 Oil filter wrench...
Page 51 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Rod puller 4-83, 4-84, 4-85 90890-01437 Universal damping rod bleeding tool set YM-A8703 YM-A8703 Fork spring compressor 4-79, 4-84, 4-85 90890-01441 Fork spring compressor YM-01441 Fork seal driver 4-82, 4-83 90890-01442 Adjustable fork seal driver (36–46 mm) YM-01442 Pivot shaft wrench adapter 5-7, 5-8...
Page 52 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Sheave holder 5-32, 5-33 90890-01701 Primary clutch holder YS-01880-A Compression gauge 90890-03081 90890-03081 Engine compression tester YU-33223 YU-33223 Vacuum gauge 90890-03094 Vacuummate YU-44456 YU-44456 Pocket tester 1-39, 8-129, 90890-03112 8-130, 8-131, Analog pocket tester 8-135, 8-136, YU-03112-C 8-137, 8-138,...
Page 53 8-139 90890-03209 Test harness– lean angle sensor (6P) YU-03209 Fuel injector pressure adapter 7-10 90890-03210 Fuel injector pressure adapter YU-03210 Yamaha diagnostic tool 4-65, 4-66, 8-37, 90890-03231 8-101, 8-122 Valve spring compressor 5-23, 5-28 90890-04019 Valve spring compressor YM-04019 1-44...
Page 54 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Middle driven shaft bearing driver 6-11 90890-04058 Middle drive bearing installer 40 & 50 mm YM-04058 Mechanical seal installer 6-11 90890-04078 Water pump seal installer YM-33221-A Universal clutch holder 5-42, 5-45 90890-04086 Universal clutch holder YM-91042 Valve lapper...
Page 55 YM-04118 Extension 90890-04136 Piston installing tool 5-68 90890-04161 Piston installing tool YM-04161 Camshaft wrench 5-12, 5-15 90890-04162 Camshaft wrench YM-04162 Ignition checker 8-138 90890-06754 Oppama pet–4000 spark checker YM-34487 Yamaha bond No. 1215 5-34, 5-57 90890-85505 (Three bond No.1215®) 1-46...
Page 56 SPECIAL TOOLS 1-47...
Page 57: Specifications
SPECIFICATIONS GENERAL SPECIFICATIONS................2-1 ENGINE SPECIFICATIONS ................2-2 CHASSIS SPECIFICATIONS ................2-7 ELECTRICAL SPECIFICATIONS ..............2-10 TIGHTENING TORQUES ................2-13 GENERAL TIGHTENING TORQUE SPECIFICATIONS......2-13 ENGINE TIGHTENING TORQUES............2-14 CHASSIS TIGHTENING TORQUES............2-18 LUBRICATION POINTS AND LUBRICANT TYPES........2-22 ENGINE....................2-22 CHASSIS....................2-23 LUBRICATION SYSTEM CHART AND DIAGRAMS ........2-25 ENGINE OIL LUBRICATION CHART ............2-25 LUBRICATION DIAGRAMS ..............2-27 COOLING SYSTEM DIAGRAMS ..............2-37 CABLE ROUTING ..................2-41...
Page 58: General Specifications
GENERAL SPECIFICATIONS EAS20013 GENERAL SPECIFICATIONS Model Model MT09TRA 2SC1 (AUT)(BEL)(CHE)(CYP)(CZE) (DEU)(DNK)(ESP)(FIN)(GBR)(GRC)(HUN) (IRL)(ITA)(NLD)(NOR)(POL)(PRT)(SVK)(SVN) (SWE)(TUR) MT09TRA 2SC2 (BEL)(FRA) MT09TRA 2SC3 (RUS) MT09TRA 2SC9 (AUT)(BEL)(CHE)(CYP)(CZE) (DEU)(DNK)(ESP)(FIN)(GBR)(GRC)(HUN) (IRL)(ITA)(NLD)(NOR)(POL)(PRT)(SVK)(SVN) (SWE)(TUR)(ZAF) MT09TRA 2SCA (BEL)(FRA) MT09TRA 2SCB (RUS) MT09TRAF 2SC4 Dimensions Overall length 2160 mm (85.0 in) Overall width 950 mm (37.4 in) Overall height...
Page 59: Engine Specifications
ENGINE SPECIFICATIONS EAS20014 ENGINE SPECIFICATIONS Engine Engine type Liquid cooled 4-stroke, DOHC Displacement 847 cm³ Cylinder arrangement Inline 3-cylinder Bore  stroke 78.0  59.1 mm (3.07  2.33 in) Compression ratio 11.5 : 1 Standard compression pressure (at sea level) 1530 kPa/680 r/min (15.3 kgf/cm²/680 r/min, 217.6 psi/680 r/min) Minimum–maximum...
Page 60 ENGINE SPECIFICATIONS Relief valve operating pressure 670.0–810.0 kPa (6.70–8.10 kgf/cm², 97.2–117.5 psi) Cooling system Coolant quantity Radiator (including all routes) 1.93 L (2.04 US qt, 1.70 Imp.qt) Coolant reservoir (up to the maximum level 0.25 L (0.26 US qt, 0.22 Imp.qt) mark) Radiator cap opening pressure 93.3–122.7 kPa (0.93–1.23 kgf/cm², 13.5–17.8...
Page 61 ENGINE SPECIFICATIONS Limit 1.8 mm (0.07 in) Valve stem diameter (intake) 4.475–4.490 mm (0.1762–0.1768 in) Limit 4.445 mm (0.1750 in) Valve stem diameter (exhaust) 4.460–4.475 mm (0.1756–0.1762 in) Limit 4.430 mm (0.1744 in) Valve guide inside diameter (intake) 4.500–4.512 mm (0.1772–0.1776 in) Limit 4.542 mm (0.1788 in) Valve guide inside diameter (exhaust)
Page 62 ENGINE SPECIFICATIONS Limit 0.50 mm (0.0197 in) Ring side clearance 0.030–0.065 mm (0.0012–0.0026 in) Limit 0.115 mm (0.0045 in) 2nd ring Ring type Taper End gap (installed) 0.30–0.45 mm (0.0118–0.0177 in) Limit 0.80 mm (0.0315 in) Ring side clearance 0.020–0.055 mm (0.0008–0.0022 in) Limit 0.115 mm (0.0045 in) Oil ring...
Page 63 ENGINE SPECIFICATIONS 1.381 (29/21) 1.190 (25/21) 1.037 (28/27) Main axle runout limit 0.08 mm (0.0032 in) Drive axle runout limit 0.08 mm (0.0032 in) Shifting mechanism Shift mechanism type Shift drum and guide bar Shift fork guide bar bending limit 0.050 mm (0.0020 in) Shift fork thickness 5.76–5.89 mm (0.2268–0.2319 in)
Page 64: Chassis Specifications
CHASSIS SPECIFICATIONS EAS20015 CHASSIS SPECIFICATIONS Chassis Frame type Diamond 24.00  Caster angle Trail 100 mm (3.9 in) Front wheel Wheel type Cast wheel Rim size 17M/C x MT3.50 Rim material Aluminum Wheel travel 137 mm (5.4 in) Radial wheel runout limit 1.0 mm (0.04 in) Lateral wheel runout limit 0.5 mm (0.02 in)
Page 65 CHASSIS SPECIFICATIONS Brake pad lining thickness (inner) 4.5 mm (0.18 in) Limit 0.5 mm (0.02 in) Brake pad lining thickness (outer) 4.5 mm (0.18 in) Limit 0.5 mm (0.02 in) Master cylinder inside diameter 15.00 mm (0.59 in) Caliper cylinder inside diameter 30.23 mm (1.19 in) Caliper cylinder inside diameter 27.00 mm (1.06 in)
Page 66 CHASSIS SPECIFICATIONS Standard 7 click(s) out* Maximum 1 click(s) out* *With the adjusting screw fully turned in Rear suspension Type Swingarm (link suspension) Spring/shock absorber type Coil spring/gas-oil damper Rear shock absorber assembly travel 60.0 mm (2.36 in) Spring installed length 179.8 mm (7.08 in) Spring rate K1 99.96 N/mm (10.19 kgf/mm, 570.77 lbf/in)
Page 67: Electrical Specifications
ELECTRICAL SPECIFICATIONS EAS20016 ELECTRICAL SPECIFICATIONS Voltage System voltage 12 V Ignition system Ignition system 5.0 1200 r/min Ignition timing (B.T.D.C.) Engine control unit Model/manufacturer MT09TRA TBDFN6/DENSO (AUT)(BEL)(CHE) (CYP)(CZE)(DEU)(DNK)(ESP)(FIN)(GBR) (GRC)(HUN)(IRL)(ITA)(NLD)(NOR)(POL) (PRT)(RUS)(SVK)(SVN)(SWE)(TUR)(ZAF) MT09TRA TBDFN7/DENSO (BEL)(FRA) MT09TRAF TBDFN6/DENSO Ignition coil Minimum ignition spark gap 6.0 mm (0.24 in) 1.19–1.61 ...
Page 68 ELECTRICAL SPECIFICATIONS ABS warning light Immobilizer system indicator light Traction control system indicator/warning light Electric starting system System type Constant mesh Starter motor Power output 0.70 kW 0.0050–0.0150  Armature coil resistance Brush overall length 12.0 mm (0.47 in) Limit 6.50 mm (0.26 in) Brush spring force 6.03–6.52 N (615–665 gf, 21.71–23.47 oz)
Page 69 ELECTRICAL SPECIFICATIONS ABS solenoid fuse 15.0 A Auxiliary fuse 1 2.0 A Auxiliary fuse 2 2.0 A Terminal fuse 1 2.0 A Terminal fuse 2 2.0 A Backup fuse 7.5 A Electronic throttle valve fuse 7.5 A Spare fuse 30.0 A Spare fuse 20.0 A Spare fuse...
Page 70: 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 71: Engine Tightening Torques
TIGHTENING TORQUES EAS30016 ENGINE TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Spark plug 13 Nm (1.3 m·kgf, 9.4 ft·lbf) Cylinder head bolt See TIP. Cylinder head bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Intake camshaft cap bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Exhaust camshaft cap bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Camshaft cap bolt...
Page 72 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Air filter case joint clamp screw 2.8 Nm (0.28 m·kgf, 2.0 ft·lbf) Fuel injector adapter bolt 12 Nm (1.2 m·kgf, 8.7 ft·lbf) Air filter case bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Exhaust pipe nut 20 Nm (2.0 m·kgf, 14 ft·lbf) Muffler bolt...
Page 73 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Starter motor lead nut 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Shift rod locknut (front) 8 Nm (0.8 m·kgf, 5.8 ft·lbf) Shift rod locknut (rear) 8 Nm (0.8 m·kgf, 5.8 ft·lbf) Left thread Shift rod joint bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Centerstand bracket bolt...
Page 74 TIGHTENING TORQUES Connecting rod bolt 1. Tighten the bolts to 20 Nm (2.0 m·kgf, 14 ft·lbf) 2. Tighten the bolts further to reach the specified angle 175–185. Crankcase bolt (main journal) 1. Lubricate the bolt threads and both sides of the washers with engine oil. 2.
Page 75: Chassis Tightening Torques
TIGHTENING TORQUES EAS30017 CHASSIS TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Engine mounting bolt (front upper 45 Nm (4.5 m·kgf, 33 ft·lbf) and front lower side) Engine mounting nut (rear upper 45 Nm (4.5 m·kgf, 33 ft·lbf) side) Engine mounting nut (rear lower 45 Nm (4.5 m·kgf, 33 ft·lbf) side)
Page 76 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Front brake master cylinder reservoir 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf) cap screw Clutch lever holder pinch bolt 11 Nm (1.1 m·kgf, 8.0 ft·lbf) Horn bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Front fender bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Meter assembly screw...
Page 77 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Sidestand switch bolt 4.3 Nm (0.43 m·kgf, 3.1 ft·lbf) Battery box bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Mudguard assembly nut 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Rectifier/regulator bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Hydraulic unit and Hydraulic unit 7 Nm (0.7 m·kgf, 5.1 ft·lbf) bracket...
Page 78 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Handguard bracket nut (right) 6 Nm (0.6 m·kgf, 4.3 ft·lbf) Grab bar bolt (front) 25 Nm (2.5 m·kgf, 18 ft·lbf) Grab bar bolt (rear) 32 Nm (3.2 m·kgf, 23 ft·lbf) Rear side cover bolt 3.5 Nm (0.35 m·kgf, 2.5 ft·lbf) Rear side cover and Stay 26 Nm (2.6 m·kgf, 19 ft·lbf)
Page 79: 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 80: Chassis
Shit drum moving surface Shift fork pin Shift forks guide bar outer surface Shift shaft washer Shift shaft moving surface Yamaha bond No. 1215 Crankcase mating surface (Three bond No. 1215®) Yamaha bond No. 1215 Stator coil assembly lead grommet (Three bond No.
Page 81 LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant Shift pedal pivoting parts Passenger footrest ball and metal-to-metal moving parts Shift shaft joint rod moving parts Front wheel oil seal (left and right) Rear wheel oil seal Rear wheel drive hub oil seal Rear wheel drive hub mating surface Brake caliper piston seal Master cylinder inside...
Page 82: Lubrication System Chart And Diagrams
LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20019 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS30020 ENGINE OIL LUBRICATION CHART 2-25...
Page 83 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 84: Lubrication Diagrams
LUBRICATION SYSTEM CHART AND DIAGRAMS EAS30021 LUBRICATION DIAGRAMS 2-27...
Page 85 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil level switch 2. Oil filter cartridge union bolt 3. Oil filter cartridge 4. Crankshaft 2-28...
Page 86 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-29...
Page 87 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 A. MT09TRA for Europe: RN29F0011886 and after MT09TRAG for Oceania: RN29K 0000556 and after...
Page 88 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-31...
Page 89 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil cooler 2. Oil filter cartridge 3. Oil level switch 4. Oil strainer 5. Oil pump 6. Main gallery bolt 2-32...
Page 90 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-33...
Page 91 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Balancer shaft 2. Crankshaft 3. Main axle 4. Shift fork guide bar (shift fork-C side) 5. Drive axle 6. Sub gallery bolt 7. Shift fork 2-34...
Page 92 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-35...
Page 93 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 94: Cooling System Diagrams
COOLING SYSTEM DIAGRAMS EAS20020 COOLING SYSTEM DIAGRAMS 2-37...
Page 95 COOLING SYSTEM DIAGRAMS 1. Water pump 2. Thermostat 3. Radiator 2-38...
Page 96 COOLING SYSTEM DIAGRAMS 2-39...
Page 97 COOLING SYSTEM DIAGRAMS 1. Water jacket 2. Thermostat 3. Radiator 4. Water pump 5. Oil cooler 6. Coolant reservoir 2-40...
Page 98: Cable Routing
CABLE ROUTING EAS20021 CABLE ROUTING Handlebar (top view) 2-41...
Page 99 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 100 CABLE ROUTING Handlebar (front view) 2-43...
Page 101 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 right handlebar switch lead onto the handlebar with the clamp.
Page 102 CABLE ROUTING Radiator (front side view and right side view) 2-45...
Page 103 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 104 CABLE ROUTING Fuel tank (left and bottom view) 2-47...
Page 105 CABLE ROUTING 1. Frame 2. Fuel tank 3. Fuel pump 4. Fuel tank drain hose 5. Fuel tank breather hose 6. Clip 7. Fuel hose assembly A. Insert the fuel tank drain hose up to the sec- tion where the fuel tank pipe increases in diameter.
Page 106 CABLE ROUTING Air filter case and throttle body (top view and left side view) 2-49...
Page 107 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 108 CABLE ROUTING Air cut-off valve (left side view) 2-51...
Page 109 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 110 CABLE ROUTING Frame and engine (right side view) 2-53...
Page 111 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. Bracket 10.Fuse box 2 11.Coupler cover 12.O...
Page 112 CABLE ROUTING Frame and engine (right side view) 2-55...
Page 113 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 114 CABLE ROUTING Frame and engine (left side view) 2-57...
Page 115 CABLE ROUTING O. It does not matter whether the oil level switch 1. Air induction system hose (air filter case to air lead or the sidestand switch lead is on top. cut-off valve) P. It does not matter whether the fuel tank drain 2.
Page 116 CABLE ROUTING Frame (top view) 2-59...
Page 117 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 118 CABLE ROUTING Frame (top view) 2-61...
Page 119 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 120 CABLE ROUTING Frame (top view) 2-63...
Page 121 The order of the leads does not matter. L. Route the Yamaha diagnostic tool coupler lead at the bottom of the battery box. M. Insert the Yamaha diagnostic tool coupler to the battery box. 2-64...
Page 122 CABLE ROUTING Front brake (right side view and left side view) 2-65...
Page 123 CABLE ROUTING P. Install the clamp so that the front wheel sen- 1. Front brake hose sor lead is on the right side of the vehicle. 2. Front wheel sensor lead 3. Clamp 4. Front wheel sensor protector 5. Brake caliper (right) 6.
Page 124 CABLE ROUTING Rear brake 2-67...
Page 125 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 126 CABLE ROUTING Hydraulic unit (top view and left side view) 2-69...
Page 127 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 128 CABLE ROUTING 2-71...
Page 129: Periodic Checks And Adjustments
PERIODIC CHECKS AND ADJUSTMENTS PERIODIC MAINTENANCE ................3-1 INTRODUCTION ..................3-1 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM ....................3-1 GENERAL MAINTENANCE AND LUBRICATION CHART ......3-1 CHECKING THE FUEL LINE ..............3-4 CHECKING THE SPARK PLUGS ..............3-4 ADJUSTING THE VALVE CLEARANCE ...........3-5 CHECKING THE ENGINE IDLING SPEED ..........3-8 SYNCHRONIZING THE THROTTLE BODIES...........3-8 CHECKING THE THROTTLE BODY JOINTS .........3-10 ADJUSTING THE EXHAUST GAS VOLUME ..........3-10...
Page 130 CHANGING THE ENGINE OIL ..............3-25 MEASURING THE ENGINE OIL PRESSURE .........3-26 CHECKING THE COOLANT LEVEL............3-27 CHECKING THE COOLING SYSTEM .............3-27 CHANGING THE COOLANT..............3-27 CHECKING THE FRONT BRAKE LIGHT SWITCH .........3-29 ADJUSTING THE REAR BRAKE LIGHT SWITCH ........3-29 CHECKING AND LUBRICATING THE CABLES ........3-29 CHECKING THE THROTTLE GRIP............3-30 CHECKING AND CHARGING THE BATTERY........3-30 CHECKING THE FUSES .................3-30...
Page 131: 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 132 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) 6 * Brake fluid • Replace. Every 2 years • Check runout and for dam- 7 * Wheels ...
Page 133 PERIODIC MAINTENANCE ODOMETER READING CHECK OR MAINTENANCE ANNUAL ITEM CHECK 1000 km 10000 km 20000 km 30000 km 40000 km (600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi) Moving parts and • Lubricate.      cables •...
Page 134: Checking The Fuel Line
PERIODIC MAINTENANCE 4-6. EAS30619 CHECKING THE FUEL LINE The following procedure applies to all of the fuel, EAS30620 CHECKING THE SPARK PLUGS drain and breather hoses. The following procedure applies to all of the 1. Remove: spark plugs. • Fuel tank front cover/Front side panel/Front 1.
Page 135: Adjusting The Valve Clearance
PERIODIC MAINTENANCE Refer to “GENERAL CHASSIS (2)” on page Spark plug gap 4-6. 0.8–0.9 mm (0.031–0.035 in) • 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.
Page 136 PERIODIC MAINTENANCE d. To measure the valve clearances of the other cylinders, starting with cylinder #1 at TDC, turn the crankshaft counterclockwise as specified in the following table. TDC on the compression stroke can be found when the camshaft lobes are turned away from each other.
Page 137 PERIODIC MAINTENANCE prevent the valve pad from falling into the the following table, and then select the suit- crankcase. able valve pad. • Make a note of the position of each valve lifter Last digit Rounded value “1” and valve pad “2” so that they can be in- 0, 1, 2 stalled in the correct place.
Page 138: Checking The Engine Idling Speed
“02”  Clean the throttle bodies. Refer to “CHECKING AND CLEANING THE THROTTLE BODIES” on page 7-7. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the Yamaha diagnostic tool. 4. Install: Use the diagnostic code number “67”. • Vacuum gauge “1” Refer to “SELF-DIAGNOSTIC FUNCTION Vacuum gauge AND DIAGNOSTIC CODE TABLE”...
Page 139 PERIODIC MAINTENANCE dard. Otherwise, the engine may run roughly at idle and the throttle bodies may not oper- ate properly. • Turn the bypass air screw using the carburetor angle driver. • After each step, rev the engine two or three times, each time for less than a second, and check the synchronization again.
Page 140: Checking The Throttle Body Joints
PERIODIC MAINTENANCE 4-6. 5. Adjust: • Throttle grip free play Refer to “CHECKING THE THROTTLE SELECT GRIP” on page 3-30. Throttle grip free play 3.0–5.0 mm (0.12–0.20 in) EAS30798 CHECKING THE THROTTLE BODY JOINTS 1. Remove: 4. Press the “TCS” button “1” to select the CO •...
Page 141: Checking The Air Induction System
PERIODIC MAINTENANCE pressing the “TCS” button or “RESET” but- ton. DATA 3. Install: • Air filter case Refer to “GENERAL CHASSIS (3)” on page 4-13. The CO adjustment volume appears on the multi-function meter right display. EAS30628 REPLACING THE AIR FILTER ELEMENT •...
Page 142: 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 143: Checking The Brake Operation
PERIODIC MAINTENANCE Clutch cable locknut 7 Nm (0.7 m·kgf, 5.1 ft·lbf) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 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 144: 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 145: Checking The Rear Brake Pads
PERIODIC MAINTENANCE • a brake hose is loosened, disconnected or replaced. • the brake fluid level is very low. • brake operation is faulty. • Be careful not to spill any brake fluid or allow the brake master cylinder reservoir or brake fluid reservoir to overflow.
Page 146: Checking The Front Brake Hoses
PERIODIC MAINTENANCE e. Slowly apply the brake several times. 4. Check: f. Fully squeeze the brake lever or fully depress • Brake hose Brake fluid leakage  Replace the damaged the brake pedal and hold it in position. g. Loosen the bleed screw. hose.
Page 147 Front en if a tire combination other than one 250 kPa (2.50 kgf/cm², 36 psi) Rear approved by Yamaha is used on this vehicle. 290 kPa (2.90 kgf/cm², 42 psi) Maximum load Front tire 180 kg (397 lb)
Page 148: Checking The Wheel Bearings
PERIODIC MAINTENANCE • Install the tire with the mark pointing in the di- the drive chain slack within the specified lim- rection of wheel rotation. its. • Align the mark “2” with the valve installation 1. Stand the vehicle on a level surface. point.
Page 149: Lubricating The Drive Chain
PERIODIC MAINTENANCE 5. Adjust: and thoroughly lubricate it with engine oil or • Drive chain slack chain lubricant that is suitable for O-ring chains. Do not use any other lubricants on the drive ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ chain since they may contain solvents that could a.
Page 150: Lubricating The Steering Head
PERIODIC MAINTENANCE ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Steering nut wrench 5. Install: 90890-01403 • Upper bracket Exhaust flange nut wrench Refer to “HANDLEBAR” on page 4-69. YU-A9472 EAS30646 LUBRICATING THE STEERING HEAD Lower ring nut (initial tightening 1. Lubricate: torque) • Upper bearing 52 Nm (5.2 m·kgf, 38 ft·lbf) •...
Page 151: Adjusting The Shift Pedal
PERIODIC MAINTENANCE Rough movement  Repair or replace. EAS30851 ADJUSTING THE SHIFT PEDAL EAS30651 LUBRICATING THE SIDESTAND The shift pedal position is determined by the in- Lubricate the pivoting point, metal-to-metal mov- stalled shift rod length. ing parts and spring contact point of the sides- 1.
Page 152: Adjusting The Front Fork Legs
PERIODIC MAINTENANCE A. Left side EAS30806 ADJUSTING THE FRONT FORK LEGS B. Right side The following procedure applies to both of the front fork legs. The spring preload setting is determined by EWA13120 measuring the distance “c” shown in the illustra- WARNING tion.
Page 153: Checking The Rear Shock Absorber Assembly
PERIODIC MAINTENANCE Spring preload Direction “a” ECA13590 Rebound damping is increased (sus- NOTICE pension is harder). Never go beyond the maximum or minimum Direction “b” adjustment positions. Rebound damping is decreased (sus- pension is softer). 1. Adjust: • Spring preload Rebound damping adjusting posi- ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...
Page 154: Checking The Connecting Arm And Relay Arm
PERIODIC MAINTENANCE The engine oil level should be between the Direction “a” minimum level mark “a” and maximum level Rebound damping is increased (sus- mark “b”. pension is harder). Below the minimum level mark  Add the Direction “b” recommended engine oil to the proper level. Rebound damping is decreased (sus- pension is softer).
Page 155: Changing The Engine Oil
PERIODIC MAINTENANCE minutes until the oil has settled. filter wrench “2”. Oil filter wrench EAS30657 90890-01426 CHANGING THE ENGINE OIL Oil filter wrench 1. Start the engine, warm it up for several min- YU-38411 utes, and then turn it off. 2.
Page 156: Engine
PERIODIC MAINTENANCE tremely hot. Engine oil quantity Quantity (disassembled) 3.40 L (3.59 US qt, 2.99 Imp.qt) Without oil filter cartridge re- placement 2.40 L (2.54 US qt, 2.11 Imp.qt) With oil filter cartridge replace- ment 2.70 L (2.85 US qt, 2.38 Imp.qt) 8.
Page 157: Checking The Coolant Level
PERIODIC MAINTENANCE • Oil cooler outlet hose “6” Main gallery bolt • Water jacket joint “7” 8 Nm (0.8 m·kgf, 5.8 ft·lbf) • Water pump inlet hose “8” Cracks/damage  Replace. EAS30811 Refer to “RADIATOR” on page 6-1, “OIL CHECKING THE COOLANT LEVEL COOLER”...
Page 158: Cooling System
PERIODIC MAINTENANCE 6. Drain: • Coolant (from the engine and radiator) 7. Install: • Water pump drain bolt • Copper washer Water pump drain bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) 8. Install: • Collars 2. Remove: • Coolant reservoir •...
Page 159: Checking The Front Brake Light Switch
PERIODIC MAINTENANCE and if necessary, correct the antifreeze EAS30659 ADJUSTING THE REAR BRAKE LIGHT concentration of the coolant. SWITCH • Use only distilled water. However, if dis- tilled water is not available, soft water may The rear brake light switch is operated by move- be used.
Page 160: Checking The Throttle Grip
PERIODIC MAINTENANCE tle body synchronization should be adjusted Recommended lubricant properly. Engine oil or a suitable cable lu- bricant ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Slide back the rubber cover “1”. b. Loosen the locknut “2”. Hold the cable end upright and pour a few drops c.
Page 161 PERIODIC MAINTENANCE ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Adjust: • Headlight beam (horizontally) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the adjusting screws “1” in direction “a” or “b”. Left headlight Direction “a” Headlight beam moves to the right. Direction “b” Headlight beam moves to the left. Right headlight Direction “a”...
Page 162 PERIODIC MAINTENANCE 3-32...
Page 163 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 164 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 165 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 166: General Chassis (1)
GENERAL CHASSIS (1) EAS20026 GENERAL CHASSIS (1) Removing the seats and battery 2.2 Nm (0.22 m kgf, 1.6 ft lbf) 25 Nm (2.5 m kgf, 18 ft lbf) 32 Nm (3.2 m kgf, 23 ft lbf) • • • • •...
Page 167 GENERAL CHASSIS (1) Removing the rear side covers 26 Nm (2.6 m kgf, 19 ft lbf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 13 Nm (1.3 m kgf, 9.4 ft lbf) • • 26 Nm (2.6 m kgf, 19 ft lbf) •...
Page 168 GENERAL CHASSIS (1) Removing the tail/brake light and mudguard assembly 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS (1)” on page Passenger seat/Rider seat 4-1.
Page 169: Installing The Seats
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 170: General Chassis (2)
GENERAL CHASSIS (1)
Page 171 GENERAL CHASSIS (2) EAS20155 GENERAL CHASSIS (2) Removing the fuel tank front cover, front side panels and front side cowlings 1.5 Nm (0.15 m kgf, 1.1 ft lbf) 4.0 Nm (0.40 m kgf, 2.9 ft lbf) • • • • 4.0 Nm (0.40 m kgf, 2.9 ft lbf)
Page 172 GENERAL CHASSIS (2) Removing the headlight assembly and meter assembly 7 Nm (0.7 m kgf, 5.1 ft Ibf) 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 2.8 Nm (0.28 m kgf, 2.0 ft lbf)
Page 173 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 174 GENERAL CHASSIS (2) Removing the headlight stay 33 Nm (3.3 m kgf, 24 ft lbf) • • 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 (2)” on page Headlight assembly 4-6.
Page 175: Removing The Fuel Tank Front Cover
GENERAL CHASSIS (2) EAS31379 REMOVING THE FUEL TANK FRONT COVER Fuel tank front cover bolt 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf) 1. Remove: • Fuel tank front cover “1” ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the quick fastener screws “2” and fuel tank front cover bolts “3”. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...
Page 176: 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 177: 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 178 GENERAL CHASSIS (3) EAS20156 GENERAL CHASSIS (3) Removing the fuel tank covers and fuel tank protector 4.0 Nm (0.40 m kgf, 2.9 ft lbf) • • 4.0 Nm (0.40 m kgf, 2.9 ft lbf) • • Order Job/Parts to remove Q’ty Remarks Fuel tank front cover/Front side panel/Front side...
Page 179 GENERAL CHASSIS (3) Removing the electrical components tray (left) 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 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 180 GENERAL CHASSIS (3) Removing the electrical components tray (right) 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Fuel tank front cover/Front side panel/Front side Refer to “GENERAL CHASSIS (2)”...
Page 181 GENERAL CHASSIS (3) Removing the air filter case 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • (10) 1.6 Nm (0.16 m kgf, 1.2 ft Ibf) • • 2.8 Nm (0.28 m kgf, 2.0 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks...
Page 182: 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 183 GENERAL CHASSIS (3) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Install: • Rider seat • Passenger seat 4. Install: • Front side cowling • Front side panel • Fuel tank front cover 4-18...
Page 184: Front Wheel
FRONT WHEEL EAS20028 FRONT WHEEL Removing the front wheel and brake discs 35 Nm (3.5 m kgf, 25 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...
Page 185 FRONT WHEEL Disassembling the front wheel 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Front wheel sensor rotor Oil seal Wheel bearing Spacer 4-20...
Page 186: Removing The 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 187: 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 188: 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 Nm (0.8 m·kgf, 5.8 ft·lbf) Iron powder/dust ...
Page 189: 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 190: 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 191 FRONT WHEEL Distance “a” (between the front Check that wheel axle end “a” is flush with front wheel sensor rotor and front folk surface “b” and then tighten the wheel axle wheel sensor) pinch bolt. If end “a” is not flush with surface “b”, 0.9–1.5 mm (0.04–0.06 in) align the ends manually or with a plastic ham- mer.
Page 192: Rear Wheel
REAR WHEEL EAS20029 REAR WHEEL Removing the rear wheel 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 150 Nm (15 m kgf, 108 ft Ibf) • • 16 Nm (1.6 m kgf, 12 ft Ibf) 16 Nm (1.6 m kgf, 12 ft Ibf) •...
Page 193 REAR WHEEL Removing the brake disc and rear wheel sprocket 30 Nm (3.0 m kgf, 22 ft Ibf) • • 80 Nm (8.0 m kgf, 58 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Rear brake disc Bracket Rear wheel sprocket Collar Collar...
Page 194 REAR WHEEL Disassembling the rear wheel 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Rear wheel sensor rotor Oil seal Wheel bearing Spacer Wheel bearing 4-29...
Page 195: Removing The 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 196: 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 197: Maintenance Of The Rear Wheel Sensor And Sensor Rotor
REAR WHEEL • Oil seal EAS30165 INSTALLING THE REAR WHEEL (DISC Refer to “ASSEMBLING THE FRONT BRAKE) WHEEL” on page 4-22. 1. Install: • Rear brake disc EAS30167 MAINTENANCE OF THE REAR WHEEL Rear brake disc bolt SENSOR AND SENSOR ROTOR 30 Nm (3.0 m·kgf, 22 ft·lbf) ECA21060 LOCTITE®...
Page 198 REAR WHEEL 8. Install: • Rear wheel sensor Rear wheel sensor bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) 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 199 REAR WHEEL Thickness gauge 90890-03180 Feeler gauge set YU-26900-9 4-34...
Page 200: Front Brake
FRONT BRAKE EAS20030 FRONT BRAKE Removing the front brake pads 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • 35 Nm (3.5 m kgf, 25 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers.
Page 201 FRONT BRAKE Removing the front brake master cylinder 1.0 Nm (0.10 m kgf, 0.72 ft lbf) • • 1.5 Nm (0.15 m kgf, 1.1 ft lbf) • • 10 Nm (1.0 m kgf, 7.2 ft lbf) • • 17 Nm (1.7 m kgf, 12 ft lbf) •...
Page 202 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 203 FRONT BRAKE Removing the front brake calipers 35 Nm (3.5 m kgf, 25 ft Ibf) • • 30 Nm (3.0 m kgf, 22 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers.
Page 204 FRONT BRAKE Disassembling the front brake calipers 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers.
Page 205: 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 206: 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 207: 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 Nm (0.5 m·kgf, 3.6 ft·lbf) tem. d. Install the brake pads and brake pad spring. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM (ABS)”...
Page 208: 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 209: 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 210: 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 211 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 212 FRONT BRAKE BRAKE SYSTEM (ABS)” on page 3-15. 4-47...
Page 213: Rear Brake
REAR BRAKE EAS20031 REAR BRAKE Removing the rear brake pads Order Job/Parts to remove Q’ty Remarks Screw plug Brake pad retaining bolt Rear brake caliper Brake pad Brake pad shim Brake pad insulator Brake pad spring Bleed screw 4-48...
Page 214 REAR BRAKE Removing the rear brake master cylinder 3.8 Nm (0.38 m kgf, 2.8 ft Ibf) • • 110 Nm (11 m kgf, 80 ft Ibf) • • 30 Nm (3.0 m kgf, 22 ft Ibf) • • 30 Nm (3.0 m kgf, 22 ft Ibf) •...
Page 215 REAR BRAKE Removing the rear brake master cylinder 3.8 Nm (0.38 m kgf, 2.8 ft Ibf) • • 110 Nm (11 m kgf, 80 ft Ibf) • • 30 Nm (3.0 m kgf, 22 ft Ibf) • • 30 Nm (3.0 m kgf, 22 ft Ibf) •...
Page 216 REAR BRAKE Disassembling the rear brake master cylinder Order Job/Parts to remove Q’ty Remarks Brake master cylinder yoke Brake master cylinder kit Hose joint Bushing Brake master cylinder body 4-51...
Page 217 REAR BRAKE Removing the rear brake caliper Order Job/Parts to remove Q’ty Remarks Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM (ABS)” on page 3-15. Brake hose union bolt Brake hose gasket Brake hose Rear brake caliper 4-52...
Page 218 REAR BRAKE Disassembling the rear brake caliper Order Job/Parts to remove Q’ty Remarks Screw plug Brake pad retaining bolt Brake pad Brake pad shim Brake pad insulator Brake pad spring Brake caliper piston Brake caliper piston dust seal Brake caliper piston seal Bleed screw 4-53...
Page 219: 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 220: Removing The Rear Brake Caliper
REAR BRAKE ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Always install new brake pads, brake pad insu- 3. Lubricate: lators, brake pad shims, and brake pad spring as • Rear brake caliper bolts a set. Recommended lubricant ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Silicone grease a. Connect a clear plastic hose “1” tightly to the bleed screw “2”.
Page 221: Disassembling The Rear Brake Caliper
REAR BRAKE the brake fluid from the entire brake system. 1. Remove: • Brake hose union bolt “1” • Brake hose gaskets “2” • Brake hose “3” Put the end of the brake hose into a container and pump out the brake fluid carefully. b.
Page 222: 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 223: Removing The Rear Brake Master Cylinder
REAR BRAKE 4. Fill: EAS30193 REMOVING THE REAR BRAKE MASTER • Brake fluid reservoir CYLINDER (with the specified amount of the specified 1. Remove: brake fluid) • Brake hose union bolt “1” Specified brake fluid • Brake hose gaskets “2” DOT 4 •...
Page 224: 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 225: Abs (Anti-Lock Brake System)
ABS (ANTI-LOCK BRAKE SYSTEM) EAS20032 ABS (ANTI-LOCK BRAKE SYSTEM) Removing the hydraulic unit assembly 30 Nm (3.0 m kgf, 22 ft Ibf) 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • • • 30 Nm (3.0 m kgf, 22 ft Ibf) •...
Page 226 ABS (ANTI-LOCK BRAKE SYSTEM) Removing the hydraulic unit assembly 30 Nm (3.0 m kgf, 22 ft Ibf) 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • • • 30 Nm (3.0 m kgf, 22 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...
Page 227: Abs Components Chart
ABS (ANTI-LOCK BRAKE SYSTEM) EAS30728 ABS COMPONENTS CHART 1. Hydraulic unit assembly 2. Fuse box 3 3. ABS test 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 228: 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 229 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 230: Hydraulic Unit Operation Tests
WARNING Securely support the vehicle so that there is no danger of it falling over. 6. Start the Yamaha diagnostic tool and display the diagnosis mode screen. • For the brake line routing confirmation, use the 7. Select code No. 2, “Brake line routing confir- diagnosis mode of the Yamaha diagnostic tool.
Page 231 Securely support the vehicle so that there is no danger of it falling over. • For the ABS reaction-force confirmation, use the diagnosis mode of the Yamaha diagnostic tool. For more information, refer to the opera- tion manual of the Yamaha diagnostic tool.
Page 232 • “ON” and “OFF” on the tool screen indicate when the brakes are being applied and re- leased respectively. 6. Start the Yamaha diagnostic tool and display the diagnosis mode screen. 7. Select code No. 1, “ABS reaction-force con- firmation”.
Page 233: Checking The Abs Warning Light
12.Turn the main switch to “OFF”. 13.Remove the Yamaha diagnostic tool coupler from the ABS test coupler, and then install the protective cap. 14.Turn the main switch to “ON”.
Page 234: Handlebar
HANDLEBAR EAS20033 HANDLEBAR Removing the handlebar 1/2 17 Nm (1.7 m kgf, 12 ft lbf) • • 17 Nm (1.7 m kgf, 12 ft lbf) • • 4.3 Nm (0.43 m kgf, 3.1 ft lbf) • • 17 Nm (1.7 m kgf, 12 ft lbf) •...
Page 235 HANDLEBAR Removing the handlebar 2/2 3.8 Nm (0.38 m kgf, 2.8 ft lbf) • • 26 Nm (2.6 m kgf, 19 ft lbf) • • 22 Nm (2.2 m kgf, 16 ft lbf) • • 11 Nm (1.1 m kgf, 8.0 ft lbf) •...
Page 236: Adjusting The Handlebar Position
HANDLEBAR holders “1”. EAS31396 ADJUSTING THE HANDLEBAR POSITION 1. Check: Upper handlebar holder bolt 22 Nm (2.2 m·kgf, 16 ft·lbf) • Handlebar position ECA19130 The handlebar position can be adjusted in two NOTICE positions to suit the rider’s preference. • First, tighten the bolts on the front side of the upper handlebar holder, and then on the rear side.
Page 237: 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 left handlebar and the handlebar grip, and gradually push the EAS30205 INSTALLING THE HANDLEBAR...
Page 238 HANDLEBAR • Clutch cable Lower handlebar holder nut 40 Nm (4.0 m·kgf, 29 ft·lbf) Clutch lever holder pinch bolt 11 Nm (1.1 m·kgf, 8.0 ft·lbf) 4. Install: • Throttle grip “1” • Throttle cables Align the center of slit on the clutch lever holder •...
Page 239: 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 3-30. b. Tighten the handguard bracket bolts “3” to Throttle grip free play specification.
Page 240 HANDLEBAR b. Tighten the handguard bracket bolts “3” to specification. Handguard bracket bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) c. Tighten the rearview mirror locknut “4” to specification. Rearview mirror locknut 17 Nm (1.7 m·kgf, 12 ft·lbf) d. Tighten the handguard bolt “5” to specifica- tion.
Page 241: Front Fork
FRONT FORK EAS20034 FRONT FORK Removing the front fork legs 26 Nm (2.6 m kgf, 19 ft Ibf) 23 Nm (2.3 m kgf, 17 ft Ibf) 23 Nm (2.3 m kgf, 17 ft Ibf) • • • • • • 10 Nm (1.0 m kgf, 7.2 ft Ibf)
Page 242 FRONT FORK Disassembling the left front fork leg Order Job/Parts to remove Q’ty Remarks Cap bolt O-ring Washer Spacer Fork spring Locknut Dust seal Oil seal clip Outer tube Oil seal Washer Outer tube bushing Inner tube bushing Damper rod assembly bolt Copper washer Damper rod assembly Inner tube...
Page 243 FRONT FORK Disassembling the right front fork leg Order Job/Parts to remove Q’ty Remarks Cap bolt O-ring Washer Spacer Fork spring Locknut Damper adjusting rod Dust seal Oil seal clip Outer tube Oil seal Washer Outer tube bushing Inner tube bushing Damper rod assembly bolt Copper washer Damper rod assembly...
Page 244: 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 245: Checking The Front Fork Legs
FRONT FORK (with a flat-head screwdriver) Damper rod holder ECA19100 90890-01582 NOTICE Damper rod holder Do not scratch the outer tube. YM-01582 4. Remove: • Outer tube EAS30208 CHECKING THE FRONT FORK LEGS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Hold the front fork leg horizontally. The following procedure applies to both of the b.
Page 246: 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 247 FRONT FORK damper rod holder “1”, tighten the damper rod assembly bolt. Damper rod holder 90890-01582 Damper rod holder YM-01582 5. Install: • Outer tube (to the inner tube) 6. Install: • Outer tube bushing “1” • Washer “2” (with the fork seal driver “3”) Fork seal driver 3.
Page 248 FRONT FORK 8. Install: • Oil seal clip “1” Adjust the oil seal clip so that it fits into the outer tube’s groove. 11.Fill: • Front fork leg (with the specified amount of the recom- mended fork oil) Recommended oil 9.
Page 249 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 250 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 Nm (1.5 m·kgf, 11 ft·lbf) c.
Page 251: 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 252: Steering Head
STEERING HEAD EAS20035 STEERING HEAD Removing the lower bracket 110 Nm (11 m kgf, 80 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 52 Nm (5.2 m kgf, 38 ft Ibf) • • 18 Nm (1.8 m kgf, 13 ft Ibf) •...
Page 253 STEERING HEAD Removing the lower bracket 110 Nm (11 m kgf, 80 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 52 Nm (5.2 m kgf, 38 ft Ibf) • • 18 Nm (1.8 m kgf, 13 ft Ibf) •...
Page 254: Removing The Lower Bracket
STEERING HEAD Damage/pitting  Replace the bearings and EAS30213 REMOVING THE LOWER BRACKET bearing races as a set. 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. 2.
Page 255: 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 256: Rear Shock Absorber Assembly
REAR SHOCK ABSORBER ASSEMBLY EAS20036 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly 44 Nm (4.4 m kgf, 32 ft Ibf) • • 61 Nm (6.1 m kgf, 44 ft Ibf) • • 44 Nm (4.4 m kgf, 32 ft Ibf) •...
Page 257: Handling The Rear Shock Absorber
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 258: 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 Lithium-soap-based grease A.
Page 259 REAR SHOCK ABSORBER ASSEMBLY Rear shock absorber assembly nut (upper) 44 Nm (4.4 m·kgf, 32 ft·lbf) Relay arm nut 61 Nm (6.1 m·kgf, 44 ft·lbf) Connecting arm lower nut 55 Nm (5.5 m·kgf, 40 ft·lbf) 4-94...
Page 260: Swingarm
SWINGARM EAS20037 SWINGARM Removing the swingarm 110 Nm (11 m kgf, 80 ft Ibf) • • 55 Nm (5.5 m kgf, 40 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...
Page 261: 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 262: 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 Nm (11 m·kgf, 80 ft·lbf) •...
Page 263: Chain Drive
CHAIN DRIVE EAS20038 CHAIN DRIVE Removing the drive chain 95 Nm (9.5 m kgf, 69 ft Ibf) • • 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 14 Nm (1.4 m kgf, 10 ft Ibf) •...
Page 264: 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 265: 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 266: 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 267 CHAIN DRIVE 5. Adjust: • Drive chain slack Refer to “ADJUSTING THE 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 268 CHAIN DRIVE 4-103...
Page 269 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........5-14 INSTALLING THE CAMSHAFTS .............5-14 CYLINDER HEAD...................5-19 REMOVING THE CYLINDER HEAD............5-20...
Page 270 CHECKING THE CLUTCH HOUSING .............5-44 CHECKING THE CLUTCH BOSS............5-44 CHECKING THE PRESSURE PLATE .............5-44 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..............5-45 SHIFT SHAFT....................5-48 CHECKING THE SHIFT SHAFT ..............5-49 CHECKING THE STOPPER LEVER ............5-49 INSTALLING THE SHIFT SHAFT ............5-49 OIL PUMP.......................5-50...
Page 271 CHECKING THE SHIFT DRUM ASSEMBLY...........5-81 CHECKING THE TRANSMISSION ............5-81 ASSEMBLING THE MAIN AXLE AND DRIVE AXLE .......5-81 INSTALLING THE TRANSMISSION ............5-82...
Page 272: 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 273 ENGINE INSPECTION gine oil into the spark plug bore and measure again. Refer to the following table. 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 ...
Page 274: Engine Removal
ENGINE REMOVAL EAS20042 ENGINE REMOVAL Removing the muffler and exhaust pipe 20 Nm (2.0 m kgf, 14 ft Ibf) • • 20 Nm (2.0 m kgf, 14 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • •...
Page 275 ENGINE REMOVAL Disconnecting the leads and hoses 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Fuel tank front cover/Front side panel/Front side Refer to “GENERAL CHASSIS (2)”...
Page 276 ENGINE REMOVAL Disconnecting the leads and hoses 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Gear position switch coupler Disconnect. Crankshaft position sensor coupler Disconnect.
Page 277 ENGINE REMOVAL Removing the engine 7 Nm (0.7 m kgf, 5.1 ft Ibf) 45 Nm (4.5 m kgf, 33 ft Ibf) • • • • 45 Nm (4.5 m kgf, 33 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) •...
Page 278: 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 279 ENGINE REMOVAL 7. Tighten: Centerstand bracket bolt • Engine mounting adjust bolt (rear) “2” 12 Nm (1.2 m·kgf, 8.7 ft·lbf) • 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.
Page 280: Camshafts
CAMSHAFTS EAS20043 CAMSHAFTS Removing the cylinder head cover 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 13 Nm (1.3 m kgf, 9.4 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Fuel tank front cover/Front side panel/Front side Refer to “GENERAL CHASSIS (2)”...
Page 281 CAMSHAFTS Removing the camshafts 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 24 Nm (2.4 m kgf, 17 ft Ibf) •...
Page 282: 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 283: Checking The Camshafts
CAMSHAFTS Camshaft wrench 90890-04162 Camshaft wrench YM-04162 EAS30257 CHECKING THE CAMSHAFTS 1. Check: • Camshaft lobes Blue discoloration/pitting/scratches  Re- place the camshaft. 3. Measure: 2. Measure: • Camshaft runout • Camshaft lobe dimensions “a” and “b” Out of specification  Replace. Out of specification ...
Page 284: Checking The Timing Chain And Camshaft Sprocket
CAMSHAFTS c. Install the dowel pins and camshaft caps. EAS30258 CHECKING THE TIMING CHAIN AND CAMSHAFT SPROCKET • Tighten the camshaft cap bolts in stages and in 1. Check: a crisscross pattern, working from the inner • Timing chain caps out. Damage/stiffness ...
Page 285: Checking The Timing Chain Tensioner
CAMSHAFTS EAS30269 INSTALLING THE CAMSHAFTS 1. Remove: • Timing mark accessing bolt “1” • Crankshaft end cover “2” EAS30266 CHECKING THE TIMING CHAIN TENSIONER 1. Check: • Timing chain tensioner Cracks/damage/rough movement  Re- 2. Align: place. • Mark “a” on the generator rotor ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...
Page 286 CAMSHAFTS Camshaft wrench 90890-04162 Camshaft wrench YM-04162 5. Install: • Camshaft cap • Intake camshaft cap • Exhaust camshaft cap • Make sure each camshaft cap is installed in its original place. Refer to the identification marks as follows: “IL”: Intake left side camshaft cap mark “EL”: Exhaust left side camshaft cap mark •...
Page 287 CAMSHAFTS 7. Tighten: 9. Install: • Camshaft cap bolts “1” • Timing chain tensioner • Timing chain tensioner gasket Camshaft cap bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Apply a few drops of engine oil to the inside “a”...
Page 288 CAMSHAFTS d. Install the timing chain tensioner gasket “3”, h. Install the timing chain tensioner cap bolt and the timing chain tensioner “4”, and the timing gasket, and then tighten the timing chain ten- sioner cap bolt to the specified torque. chain tensioner bolts “5”...
Page 289 CAMSHAFTS 12.Measure: • Valve clearance Out of specification  Adjust. Refer to “ADJUSTING THE VALVE CLEAR- ANCE” on page 3-5. 13.Install: • Timing mark accessing bolt “1” Timing mark accessing bolt 15 Nm (1.5 m·kgf, 11 ft·lbf) 15.Install: • Crankshaft end cover “2” •...
Page 290: Cylinder Head
CYLINDER HEAD EAS20044 CYLINDER HEAD Removing the cylinder head 25 Nm (2.5 m kgf, 18 ft Ibf) • • 16 Nm (1.6 m kgf, 12 ft Ibf), • • Specified angle 10 Nm (1.0 m kgf, 7.2 ft Ibf) • •...
Page 291: Removing The Cylinder Head
CYLINDER HEAD Damage/scratches  Replace. EAS30276 REMOVING THE CYLINDER HEAD • Cylinder head water jacket 1. Remove: Mineral deposits/rust  Eliminate. • Intake camshaft 3. Measure: • Exhaust camshaft • Cylinder head warpage Refer to “REMOVING THE CAMSHAFTS” Out of specification  Resurface the cylinder on page 5-11.
Page 292: 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 293 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 294: 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 295 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 296: 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 297: 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 298: Checking The Valve Lifters
VALVES AND VALVE SPRINGS 2. Measure: EAS30287 CHECKING THE VALVE LIFTERS • Compressed valve spring force “a” The following procedure applies to all of the Out of specification  Replace the valve valve lifters. spring. 1. Check: • Valve lifter Damage/scratches ...
Page 299 VALVES AND VALVE SPRINGS Valve spring compressor 90890-04019 Valve spring compressor YM-04019 Valve spring compressor attach- ment 90890-04108 Valve spring compressor adapter 22 mm YM-04108 3. Install: • Valve spring seat “1” • Valve stem seal “2” • Valve “3” •...
Page 300 VALVES AND VALVE SPRINGS • Valve lifter • The valve lifter must move smoothly when ro- tated with a finger. • Each valve lifter and valve pad must be rein- stalled in its original position. 5-29...
Page 301: Generator And Starter Clutch
GENERATOR AND STARTER CLUTCH EAS20140 GENERATOR AND STARTER CLUTCH Removing the stator coil, generator rotor and starter clutch 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 32 Nm (3.2 m kgf, 23 ft Ibf) • • 14 Nm (1.4 m kgf, 10 ft Ibf) •...
Page 302 GENERATOR AND STARTER CLUTCH Removing the stator coil, generator rotor and starter clutch 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 32 Nm (3.2 m kgf, 23 ft Ibf) • • 14 Nm (1.4 m kgf, 10 ft Ibf) •...
Page 303: Removing The Generator
GENERATOR AND STARTER CLUTCH EAS30867 REMOVING THE GENERATOR 1. Remove: • Generator rotor bolt “1” • Washer While holding the generator rotor “2” with the sheave holder “3”, loosen the generator rotor bolt. Sheave holder EAS30868 90890-01701 REMOVING THE STARTER CLUTCH Primary clutch holder 1.
Page 304: 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 305 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 Nm (1.2 m·kgf, 8.7 ft·lbf) LOCTITE®...
Page 306: Electric Starter
ELECTRIC STARTER EAS20052 ELECTRIC STARTER Removing the starter motor 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Fuel tank front cover/Front side panel/Front side Refer to “GENERAL CHASSIS (2)”...
Page 307 ELECTRIC STARTER Disassembling the starter motor Order Job/Parts to remove Q’ty Remarks O-ring Starter motor front cover Starter motor yoke Armature assembly Gasket Brush holder set Starter motor rear cover 5-36...
Page 308: 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 309: Assembling The Starter Motor
ELECTRIC STARTER 6. Check: Starter motor bolt • Gear teeth 12 Nm (1.2 m·kgf, 8.7 ft·lbf) 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 310: Clutch
CLUTCH EAS20055 CLUTCH Removing the clutch cover 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 1.5 Nm (0.15 m kgf, 1.1 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) •...
Page 311 CLUTCH Removing the pull lever shaft Order Job/Parts to remove Q’ty Remarks Circlip Pull lever Pull lever spring Circlip Pull lever shaft Oil seal Bearing Bearing 5-40...
Page 312 CLUTCH Removing the clutch 125 Nm (12.5 m kgf, 90 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Oil pump driven sprocket Refer to “OIL PUMP” on page 5-50. Compression spring Pressure plate Pull rod...
Page 313: Removing The Clutch
CLUTCH EAS30346 REMOVING THE CLUTCH 1. Remove: • Cover “1” • Clutch cover “2” • Gasket Loosen each bolt 1/4 of a turn at a time, in stag- es and in a crisscross pattern. After all of the bolts are fully loosened, remove them.
Page 314: Checking The Friction Plates
CLUTCH 8. Remove: A. Friction plate 1 • Clutch boss nut B. Friction plate 2 • Conical spring washer • Washer EAS30349 CHECKING THE CLUTCH PLATES • Clutch boss The following procedure applies to all of the • Thrust plate clutch plates.
Page 315: Checking The Clutch Housing
CLUTCH set. 2. Measure: • Clutch spring free length “a” Out of specification  Replace the clutch springs as a set. Clutch spring free length 52.50 mm (2.07 in) Limit 49.88 mm (1.96 in) 3. Check: • Bearing Damage/wear  Replace the bearing and clutch housing.
Page 316: Checking The Primary Drive Gear
CLUTCH EAS30356 CHECKING THE PRIMARY DRIVE GEAR Install the oil pump drive chain onto the oil pump 1. Check: drive sprocket “a”. • Primary drive gear Damage/wear  Replace the crankshaft and clutch housing as a set. Excessive noise during operation  Replace the crankshaft and clutch housing as a set.
Page 317 CLUTCH Oil pump driven sprocket bolt 15 Nm (1.5 m·kgf, 11 ft·lbf) LOCTITE® • Tighten the clutch spring bolts in stages and in a crisscross pattern. • Apply lithium-soap-based grease onto the pull rod. • Position the pull rod so that the teeth “a” face towards the hole “b”.
Page 318 CLUTCH pull lever aligns with the mark “b” on the clutch cover. Make sure that the pull rod teeth and pull lever shaft pinion gear are engaged. 7. Adjust: • Clutch lever free play Refer to “ADJUSTING THE CLUTCH LEVER FREE PLAY”...
Page 319 SHIFT SHAFT EAS20057 SHIFT SHAFT Removing the shift shaft and stopper lever 22 Nm (2.2 m kgf, 16 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Clutch assembly Refer to “CLUTCH” on page 5-39. Shift arm Refer to “CHAIN DRIVE” on page 4-98. Circlip Washer Shift shaft...
Page 320: 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 321: Oil Pump
OIL PUMP EAS20054 OIL PUMP Removing the oil pump 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) 15 Nm (1.5 m kgf, 11 ft Ibf) • • • • Order Job/Parts to remove Q’ty Remarks...
Page 322 OIL PUMP Disassembling the oil pump 3.8 Nm (0.38 m kgf, 2.8 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Oil pump cover Oil pump shaft Oil pump inner rotor Oil pump outer rotor Hold down the washer when removing the Circlip circlip.
Page 323: 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 324: Checking The Relief Valve
OIL PUMP 3. Check: EAS30338 CHECKING THE RELIEF VALVE • Oil pump operation 1. Check: Refer to “CHECKING THE OIL PUMP” on • Relief valve “1” page 5-52. • Spring “2” Damage/wear  Replace the oil pump as- EAS30343 INSTALLING THE OIL PUMP sembly.
Page 325: Oil Pan
OIL PAN EAS20177 OIL PAN Removing the oil pan 43 Nm (4.3 m kgf, 31 ft lbf) • • (13) 10 Nm (1.0 m kgf, 7.2 ft lbf) • • 43 Nm (4.3 m kgf, 31 ft lbf) • • 10 Nm (1.0 m kgf, 7.2 ft lbf)
Page 326: Removing The Oil Pan
OIL PAN EAS31068 EAS31070 REMOVING THE OIL PAN INSTALLING THE OIL PAN 1. Remove: 1. Install: • Oil level switch “1” • Gasket • Oil pan “2” • Oil pan “1” • Oil pan gasket Oil pan bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Loosen each bolt 1/4 of a turn at a time, in stag- es and in a crisscross pattern.
Page 327: Crankcase
CRANKCASE EAS20059 CRANKCASE Separating the crankcase 25 Nm (2.5 m kgf, 18 ft Ibf) 24 Nm (2.4 m kgf, 17 ft Ibf) • • • • 18 Nm (1.8 m kgf, 13 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...
Page 328: 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 329 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 330 CRANKCASE 8. Tighten: • Crankcase bolts “9”–“30” Crankcase bolts “9”–“14” 24 Nm (2.4 m·kgf, 17 ft·lbf) Crankcase bolts “15”–“30” 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Tighten the bolts in the tightening sequence cast on the crankcase. 19 20 23 24 5-59...
Page 331 CONNECTING RODS AND PISTONS EAS20132 CONNECTING RODS AND PISTONS Removing the connecting rods and pistons 20 Nm (2.0 m kgf, 14 ft Ibf) • • Specified angle 175–185˚ Order Job/Parts to remove Q’ty Remarks Lower crankcase Refer to “CRANKCASE” on page 5-56. Connecting rod cap Big end lower bearing Piston pin clip...
Page 332: 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 333: Checking The Piston Rings
CONNECTING RODS AND PISTONS d. If out of specification, replace the piston and piston rings as a set. Measure cylinder bore “C” by taking side-to-side and front-to-back measurements of the cylinder. e. Calculate the piston-to-cylinder clearance with the following formula. Then, find the average of the measurements.
Page 334: Checking The Piston Pin
CONNECTING RODS AND PISTONS Piston pin outside diameter Use the piston crown to level the piston ring near 16.990–16.995 mm (0.6689– bottom of cylinder “a”, where cylinder wear is 0.6691 in) lowest. Limit 16.970 mm (0.6681 in) 3. Measure: • Piston ring end gap Out of specification ...
Page 335 CONNECTING RODS AND PISTONS Out of specification  Replace the big end plastic-region tightening angle method. Al- bearings. ways install new bolts. Oil clearance • Clean the connecting rod bolts and lubricate 0.027–0.051 mm (0.0011–0.0020 the bolt threads and seats with molybdenum disulfide oil.
Page 336 CONNECTING RODS AND PISTONS big end bearing kept in the current condition. • Do not move the connecting rod or crankshaft until the clearance measurement has been completed. • Make sure that the projection “a” on the con- necting rod cap faces the same direction as the “Y”...
Page 337: Installing The Connecting Rod And Piston
CONNECTING RODS AND PISTONS 2. Select: EAS30751 INSTALLING THE CONNECTING ROD AND • Big end bearings (P –P PISTON The following procedure applies to all of the con- • The numbers “A” stamped into the crankshaft necting rods and pistons. web and the numbers “1”...
Page 338 CONNECTING RODS AND PISTONS the bolt threads and seats with molybdenum disulfide oil. c. After installing the big end bearing, assemble the connecting rod and connecting rod cap without installing them onto the crankshaft. d. Tighten the connecting rod bolt while check- ing that the sections shown “a”...
Page 339 CONNECTING RODS AND PISTONS 6. Offset: • Piston ring end gaps 90˚ 90˚ 9. Install: 45˚ • Connecting rod caps • Connecting rod bolts a. Top ring b. 2nd ring • Make sure the “Y” marks “a” on the connecting c.
Page 340 CONNECTING RODS AND PISTONS Connecting rod bolt (1st) 20 Nm (2.0 m·kgf, 14 ft·lbf) b. Put a mark “1” on the corner of the connecting rod bolt “2” and the connecting rod cap “3”. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ c. Tighten the connecting rod bolts further to reach the specified angle 175–185.
Page 341: Crankshaft And Balancer Shaft
CRANKSHAFT AND BALANCER SHAFT EAS20178 CRANKSHAFT AND BALANCER SHAFT Removing the crankshaft and balancer shaft Order Job/Parts to remove Q’ty Remarks Lower crankcase Refer to “CRANKCASE” on page 5-56. Refer to “REMOVING THE CONNECTING Connecting rod RODS AND PISTONS” on page 5-61. Balancer shaft Balancer shaft journal lower bearing Balancer shaft journal upper bearing...
Page 342: Removing The 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 343 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 344: 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 345: Installing The Crankshaft
CRANKSHAFT AND BALANCER SHAFT e. Install the balancer shaft journal lower bear- for all of the bearings. ings “1” into the lower crankcase and assem- For example, if the crankcase “J ” and bal- ble the crankcase halves. ancer shaft web “J ”...
Page 346: Installing The Balancer Assembly
CRANKSHAFT AND BALANCER SHAFT crankcase. • Be sure to install each crankshaft journal bear- ings in its original place. EAS31172 INSTALLING THE BALANCER ASSEMBLY 1. Install: • Balancer shaft journal upper bearings (into the upper crankcase) • Balancer shaft journal lower bearings (into the lower crankcase) •...
Page 347: Transmission
TRANSMISSION EAS20062 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...
Page 348 TRANSMISSION Disassembling the main axle assembly Order Job/Parts to remove Q’ty Remarks 2nd pinion gear Toothed lock washer Toothed lock washer retainer 6th pinion gear Collar Washer Circlip 3rd pinion gear Circlip Washer 5th pinion gear Collar Bearing housing Bearing Main axle 5-77...
Page 349 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 350 TRANSMISSION Disassembling the drive axle assembly Order Job/Parts to remove Q’ty Remarks Collar Bearing Circlip Drive axle 5-79...
Page 351: 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 352 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 353 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 354 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 355 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 356: Radiator
RADIATOR EAS20063 RADIATOR Removing the radiator 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • 0.5 Nm (0.05 m kgf, 0.36 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) 9 Nm (0.9 m...
Page 357: 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 358 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 359: Oil Cooler
OIL COOLER EAS20064 OIL COOLER Removing the oil cooler 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 35 Nm (3.5 m kgf, 25 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Coolant reservoir Refer to “RADIATOR” on page 6-1. Muffler assembly Refer to “ENGINE REMOVAL”...
Page 360: Checking The Oil Cooler
OIL COOLER 3. Fill: EAS30441 CHECKING THE OIL COOLER • Cooling system 1. Check: (with the specified amount of the recom- • Oil cooler mended coolant) Cracks/damage  Replace. Refer to “CHANGING THE COOLANT” on 2. Check: page 3-27. • Oil cooler inlet hose •...
Page 361: Thermostat
THERMOSTAT EAS20065 THERMOSTAT Removing the thermostat assembly 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Muffler assembly Refer to “ENGINE REMOVAL” on page 5-3. Drain. Coolant Refer to “CHANGING THE COOLANT” on page 3-27.
Page 362: 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 363: Water Pump
WATER PUMP EAS20066 WATER PUMP Removing the water pump 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Drain. Coolant Refer to “CHANGING THE COOLANT” on page 3-27. Water pump inlet hose Disconnect. Water pump assembly...
Page 364 WATER PUMP Disassembling the water pump 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Water pump housing cover O-ring Circlip Water pump driven gear Washer Impeller shaft Mechanical seal Bearing Oil seal...
Page 365: 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 366 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 367: Fuel System
FUEL SYSTEM FUEL TANK ......................7-1 REMOVING THE FUEL TANK ..............7-2 REMOVING THE FUEL PUMP ..............7-2 CHECKING THE FUEL PUMP BODY............7-2 CHECKING THE FUEL PUMP OPERATION..........7-2 INSTALLING THE FUEL PUMP..............7-2 INSTALLING THE FUEL TANK..............7-3 THROTTLE BODIES ..................7-4 CHECKING THE INJECTORS (BEFORE REMOVING) ......7-7 REMOVING THE FUEL HOSE (FUEL RAIL SIDE) ........7-7 REMOVING THE INJECTORS ..............7-7 CHECKING THE INJECTORS ..............7-7...
Page 368: Fuel Tank
FUEL TANK EAS20067 FUEL TANK Removing the fuel tank 7 Nm (0.7 m kgf, 5.1 ft Ibf) 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 4.0 Nm (0.40 m kgf, 2.9 ft Ibf) •...
Page 369: Removing The Fuel Tank
FUEL TANK 4. Remove: EAS30450 REMOVING THE FUEL TANK • Fuel tank 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. Do not set the fuel tank down so that the instal- 2. Remove: lation surface of the fuel pump is directly under •...
Page 370: Installing The Fuel Tank
FUEL TANK ening sequence as shown. A. Forward EAS30457 INSTALLING THE FUEL TANK 1. Connect: • Fuel hose (fuel tank side) ECA17500 NOTICE When installing the fuel hose, make sure that it is securely connected, and that the fuel hose connector cover on the fuel hose is in the correct position, otherwise the fuel hose will not be properly installed.
Page 371 THROTTLE BODIES EAS20070 THROTTLE BODIES Removing the throttle bodies 4.5 Nm (0.45 m kgf, 3.3 ft Ibf) • • 3.0 Nm (0.30 m kgf, 2.2 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Fuel tank front cover/Front side panel/Front side Refer to “GENERAL CHASSIS (2)”...
Page 372 THROTTLE BODIES Removing the sensors 3.5 Nm (0.35 m kgf, 2.5 ft Ibf) • • 3.5 Nm (0.35 m kgf, 2.5 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Negative pressure hose Hose joint Intake air pressure sensor 2 Intake air pressure sensor 1 Throttle position sensor Accelerator position sensor...
Page 373 THROTTLE BODIES Removing the injectors 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Throttle bodies/Throttle body joint Refer to “THROTTLE BODIES” on page 7-4. Fuel rail Injector Injector coupler...
Page 374: Throttle Bodies
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 375 • 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 376: Replacing The Throttle Bodies
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 377: Checking The Fuel Pressure
THROTTLE BODIES the fuel rail joint “2”, and then connect an air side cowling compressor “3” to the adapter. Refer to “GENERAL CHASSIS (2)” on page b. Connect the pressure gauge “4” to the injec- 4-6. tor pressure adapter “1”. •...
Page 378: Installing The Fuel Hose (Fuel Rail Side)
THROTTLE BODIES or equivalent coverings. d. Start the engine. e. Measure the fuel pressure. EAS30485 ADJUSTING THE THROTTLE POSITION Faulty  Replace the fuel pump. SENSOR Fuel line pressure at idling EWA16690 300–390 kPa (3.0–3.9 kgf/cm², WARNING 43.5–56.6 psi) • Handle the throttle position sensor with special care.
Page 379: Adjusting The Accelerator Position Sensor
THROTTLE BODIES SELECT ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ g. Press the “TCS” button “1” to select the diag- nostic mode “DIAG” “3” or the CO adjustment EAS30486 mode “CO”. ADJUSTING THE ACCELERATOR POSITION SENSOR EWA16700 WARNING • Handle the accelerator position sensor with DIAG special care.
Page 380 THROTTLE BODIES display. Accelerator position sensor screw 3.5 Nm (0.35 m·kgf, 2.5 ft·lbf) SELECT h. Press the “TCS” button “1” to select the diag- nostic mode “DIAG” “3” or the CO adjustment mode “CO”. n. Turn the throttle grip to the fully open position. o.
Page 381 THROTTLE BODIES 7-14...
Page 382: Air Induction System
AIR INDUCTION SYSTEM EAS20071 AIR INDUCTION SYSTEM 7-15...
Page 383 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 384 AIR INDUCTION SYSTEM Removing the air cut-off valve assembly and reed valves 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Fuel tank front cover/Front side panel/Front side Refer to “GENERAL CHASSIS (2)”...
Page 385 AIR INDUCTION SYSTEM Removing the air cut-off valve assembly and reed valves 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Reed valve assembly 2 Reed valve plate 7-18...
Page 386: Checking The Air Induction System
AIR INDUCTION SYSTEM Cracks/damage  Replace the reed valve EAS30488 CHECKING THE AIR INDUCTION SYSTEM assembly. Air injection 3. Measure: The air induction system burns unburned ex- • Reed valve bending limit “a” haust gases by injecting fresh air (secondary air) Out of specification ...
Page 387 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 388 AIR INDUCTION SYSTEM 7-21...
Page 389: Electrical System
CIRCUIT DIAGRAM .................8-27 TROUBLESHOOTING ................8-29 FUEL INJECTION SYSTEM................8-31 CIRCUIT DIAGRAM .................8-31 ECU SELF-DIAGNOSTIC FUNCTION.............8-33 TROUBLESHOOTING METHOD.............8-35 DIAGNOSTIC MODE ................8-36 YAMAHA DIAGNOSTIC TOOL ..............8-37 TROUBLESHOOTING DETAILS .............8-38 FUEL PUMP SYSTEM..................8-77 CIRCUIT DIAGRAM .................8-77 TROUBLESHOOTING ................8-79 IMMOBILIZER SYSTEM.................8-81 CIRCUIT DIAGRAM .................8-81 GENERAL INFORMATION ..............8-83 PARTS REPLACEMENT AND KEY CODE REGISTRATION REQUIREMENTS..................8-83...
Page 390 ABS (ANTI-LOCK BRAKE SYSTEM)............8-91 CIRCUIT DIAGRAM .................8-91 ABS COMPONENTS CHART ..............8-93 ABS COUPLER LOCATION CHART ............8-95 MAINTENANCE OF THE ABS ECU ............8-97 ABS TROUBLESHOOTING OUTLINE.............8-97 BASIC INSTRUCTIONS FOR TROUBLESHOOTING ......8-98 BASIC PROCESS FOR TROUBLESHOOTING ........8-99 [A] CHECKING THE ABS WARNING LIGHT.........8-100 [A-1] ONLY THE ABS WARNING LIGHT FAILS TO COME ON....8-100 [A-2] THE ABS WARNING LIGHT AND OTHER INDICATOR LIGHTS FAIL TO COME ON ..............8-100...
Page 392: Ignition System
IGNITION SYSTEM EAS20072 IGNITION SYSTEM EAS30490 CIRCUIT DIAGRAM...
Page 393 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 27.ECU (engine control unit) 28.Ignition coil #1 29.Ignition coil #2 30.Ignition coil #3 31.Spark plug 39.Crankshaft position sensor 44.Lean angle sensor 66.Gear position switch...
Page 394: Engine Stopping Due To Sidestand Operation
IGNITION SYSTEM EAS30491 ENGINE STOPPING DUE TO SIDESTAND OPERATION When the engine is running and the transmission is in gear, the engine will stop if the sidestand is moved down. This is because the electric current from the ignition coils does not flow to the ECU when both the gear position switch (neutral circuit) and sidestand switch are set to “OFF”, thereby preventing the spark plugs from producing a spark.
Page 395: Troubleshooting
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 396 IGNITION SYSTEM 9. Check the gear position switch. Refer to “CHECKING THE GEAR Replace the gear position switch. POSITION SWITCH” on page NG 8-147. OK 10.Check the sidestand switch. Refer to “CHECKING THE Replace the sidestand switch. NG SWITCHES” on page 8-127. OK...
Page 397 IGNITION SYSTEM...
Page 398: Electric Starting System
ELECTRIC STARTING SYSTEM EAS20073 ELECTRIC STARTING SYSTEM EAS30493 CIRCUIT DIAGRAM...
Page 399 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 66.Gear position switch 69.Handlebar switch (right) 71.Start/engine stop switch 76.Handlebar switch (left) 77.Clutch switch...
Page 400: Starting Circuit Cut-Off System Operation
ELECTRIC STARTING SYSTEM EAS30494 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the main switch is turned to “ON” and the “ ” side of the start/engine stop switch is pushed, the starter motor can only operate if at least one of the following conditions is met: •...
Page 401 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 402: Troubleshooting
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 403 ELECTRIC STARTING SYSTEM 9. Check the gear position switch. Refer to “CHECKING THE GEAR Replace the gear position switch. POSITION SWITCH” on page NG 8-147. OK 10.Check the sidestand switch. Refer to “CHECKING THE Replace the sidestand switch. NG SWITCHES” on page 8-127. OK...
Page 404: Charging System
CHARGING SYSTEM EAS20074 CHARGING SYSTEM EAS30496 CIRCUIT DIAGRAM 8-13...
Page 405 CHARGING SYSTEM 1. AC magneto 2. Rectifier/regulator 4. Main fuse 15.Battery 16.Engine ground 8-14...
Page 406: Troubleshooting
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 407 CHARGING SYSTEM 8-16...
Page 408: Lighting System
LIGHTING SYSTEM EAS20075 LIGHTING SYSTEM EAS30498 CIRCUIT DIAGRAM 8-17...
Page 409 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 27.ECU (engine control unit) 52.Meter assembly 55.Meter light 61.High beam indicator light 76.Handlebar switch (left) 83.Dimmer/pass switch 88.Headlight control unit 89.Headlight (high beam) 90.Headlight (low beam) 91.Auxiliary light (right)
Page 410: Troubleshooting
LIGHTING SYSTEM EAS30499 TROUBLESHOOTING Any of the following fail to light: headlight, high beam indicator light, taillight, license light or meter light. • Before troubleshooting, remove the following part(s): 1. Fuel tank front cover/Front side panel/Front side cowling 2. Passenger seat/Rider seat 3.
Page 411 LIGHTING SYSTEM 8-20...
Page 412: Signaling System
SIGNALING SYSTEM EAS20076 SIGNALING SYSTEM EAS30500 CIRCUIT DIAGRAM 8-21...
Page 413 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 27.ECU (engine control unit) 41.Coolant temperature sensor 46.Rear wheel sensor 47.ABS ECU (electronic control unit) 52.Meter assembly 54.Neutral indicator light 56.Tachometer 57.Multi-function meter 58.Oil level warning light...
Page 414: Troubleshooting
SIGNALING SYSTEM EAS30501 TROUBLESHOOTING • Any of the following fail to light: turn signal light, brake light or an indicator light. • The horn fails to sound. • Before troubleshooting, remove the following part(s): 1. Fuel tank front cover/Front side panel/Front side cowling 2.
Page 415 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 416 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 417 SIGNALING SYSTEM 2. Check the entire signaling system’s wiring. Properly connect or repair the signaling Refer to “CIRCUIT DIAGRAM” on system’s wiring. NG page 8-21. OK Replace the ECU or meter assembly. Refer to “REPLACING THE ECU (en- gine control unit)” on page 8-132. The speedometer fails to operate.
Page 418: Cooling System
COOLING SYSTEM EAS20077 COOLING SYSTEM EAS30502 CIRCUIT DIAGRAM 8-27...
Page 419 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 27.ECU (engine control unit) 41.Coolant temperature sensor 95.Radiator fan motor relay 96.Radiator fan motor 8-28...
Page 420: Troubleshooting
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. Throttle bodies 1. Check the fuses. (Main, ignition and radiator fan) Replace the fuse(s).
Page 421 COOLING SYSTEM 8-30...
Page 422: Fuel Injection System
FUEL INJECTION SYSTEM EAS20078 FUEL INJECTION SYSTEM EAS30504 CIRCUIT DIAGRAM 8-31...
Page 423 44.Lean angle sensor 46.Rear wheel sensor 47.ABS ECU (electronic control unit) 48.Throttle servo motor 49.Accelerator position sensor 50.Throttle position sensor 51.Yamaha diagnostic tool coupler 52.Meter assembly 57.Multi-function meter 59.Engine trouble warning light 66.Gear position switch 68.Fuel pump 69.Handlebar switch (right) 70.Drive mode switch...
Page 424: Ecu Self-Diagnostic Function
FUEL INJECTION SYSTEM EAS30505 ECU SELF-DIAGNOSTIC FUNCTION The ECU is equipped with a self-diagnostic function in order to ensure that the fuel injection system is operating normally. If this function detects a malfunction in the system, it immediately operates the en- gine under substitute characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the system.
Page 425 FUEL INJECTION SYSTEM ECU detects an abnormal signal from a sensor If the ECU detects an abnormal signal from a sensor while the vehicle is being driven, the ECU illumi- nates the engine trouble warning light and provides the engine with alternate operating instructions that are appropriate for the type of malfunction.
Page 426: Troubleshooting Method
FUEL INJECTION SYSTEM The engine operation is not normal, but the EAS30506 TROUBLESHOOTING METHOD engine trouble warning light does not come The engine operation is not normal and the engine trouble warning light comes on. 1. Check the operation of the following sensors 1.
Page 427: Diagnostic Mode
FUEL INJECTION SYSTEM EAS30507 DIAGNOSTIC MODE Setting the diagnostic mode 1. Turn the main switch to “OFF”. 2. Disconnect the wire harness coupler from the fuel pump. 3. Simultaneously press and hold the “TCS” button “1” and “RESET” button “2”, turn the main switch to “ON”, and continue to press the buttons for 8 seconds or more.
Page 428: Yamaha Diagnostic Tool
9. Connect the wire harness coupler to the fuel pump. EAS30951 YAMAHA DIAGNOSTIC TOOL This model uses the Yamaha diagnostic tool to identify malfunctions. For information about using the Yamaha diagnostic tool, refer to the operation manual that is included with the tool. Yamaha diagnostic tool 90890-03231...
Page 429: Troubleshooting Details
However, the diagnostic tool cannot be used to freely change the basic vehicle functions, such as ad- justing the ignition timing. Connecting the Yamaha diagnostic tool Remove the protective cap “1”, and then connect the Yamaha diagnostic tool “2” to the coupler. Lg/L Lg/W L Br When the Yamaha diagnostic tool is connected to the vehicle, the operation of the multi-function meter and indicators will be different from the normal operation.
Page 430 FUEL INJECTION SYSTEM Fault code No. Crankshaft position sensor: no normal signals are received from Item the crankshaft position sensor. Improperly connected  Con- Connection of crankshaft posi- Crank the engine. tion sensor coupler. nect the coupler securely or Fault code number is not dis- played ...
Page 431 FUEL INJECTION SYSTEM Fault code No. Item Intake air pressure sensor 1: open or short circuit detected. Meter display Displays the intake air pressure. Procedure Operate the throttle while pushing the “ ” side of the start/engine stop switch. (If the display value changes, the performance is OK.) Item Probable cause of Maintenance job...
Page 432 FUEL INJECTION SYSTEM Fault code No. Item Intake air pressure sensor 1: open or short circuit detected. Defective intake air pressure Execute the diagnostic mode. Turn the main switch to “ON”. sensor 1. (Code No. 03) Fault code number is not dis- played ...
Page 433 FUEL INJECTION SYSTEM Fault code No. Intake air pressure sensor 1: hose system malfunction (clogged or Item detached hose). Defective intake air pressure Execute the diagnostic mode. sensor 1. (Code No. 03) When engine is stopped: Atmospheric pressure at the current altitude and weather conditions is indicated.
Page 434 FUEL INJECTION SYSTEM Fault code No. Item Throttle position sensor: open or short circuit detected. Improperly connected  Con- Connection of throttle position Turn the main switch to “ON”. sensor coupler. nect the coupler securely or Fault code number is not dis- played ...
Page 435 FUEL INJECTION SYSTEM Fault code No. Item Throttle position sensor: open or short circuit detected. Malfunction in ECU. Replace the ECU. Refer to “REPLACING THE ECU (engine control unit)” on page 8-132. Fault code No. Sidestand switch: a break or disconnection of the black/red lead of Item the ECU is detected.
Page 436 FUEL INJECTION SYSTEM Fault code No. Sidestand switch: a break or disconnection of the black/red lead of Item the ECU is detected. Defective sidestand switch. Execute the diagnostic mode. Turn the main switch to “ON”, (Code No. 20) and then extend and retract the Shift the transmission into gear.
Page 437 FUEL INJECTION SYSTEM Fault code No. Intake air pressure sensor 1 or intake air pressure sensor 2: when Item the main switch is turned to “ON”, the intake air pressure sensor 1 voltage and intake air pressure sensor 2 voltage differ greatly. Defective intake air pressure Execute the diagnostic mode.
Page 438 FUEL INJECTION SYSTEM Fault code No. Item Coolant temperature sensor: open or short circuit detected. Open or short circuit  Replace Wire harness continuity. Turn the main switch to “ON”. the wire harness. Fault code number is not dis- played  Service is finished. Between coolant temperature sensor coupler and ECU cou- Fault code number is displayed...
Page 439 FUEL INJECTION SYSTEM Fault code No. Item Intake air temperature sensor: open or short circuit detected. Improperly connected  Con- Connection of wire harness Turn the main switch to “ON”. ECU coupler. nect the coupler securely or Fault code number is not dis- played ...
Page 440 FUEL INJECTION SYSTEM Fault code No. Item sensor: no normal signals are received from the O sensor. sensor. Improperly installed sensor  Installed condition of O Start the engine, warm it up, Reinstall or replace the sensor. and then race it, or execute the diagnostic mode.
Page 441 FUEL INJECTION SYSTEM Fault code No. Item Intake air pressure sensor 2: open or short circuit detected. Fail-safe system Able to start engine Able to drive vehicle Diagnostic code No. Meter display Displays the intake air pressure. Procedure Operate the throttle while pushing the “ ”...
Page 442 FUEL INJECTION SYSTEM Fault code No. Item Intake air pressure sensor 2: open or short circuit detected. Defective intake air pressure Execute the diagnostic mode. Turn the main switch to “ON”. sensor 2. (Code No. 04) Fault code number is not dis- played ...
Page 443 FUEL INJECTION SYSTEM Fault code No. Intake air pressure sensor 2: hose system malfunction (clogged or Item detached hose). Clogged or detached hose  Condition of intake air pressure Start the engine and let it idle for sensor 2 hose. Repair or replace the sensor approximately 5 seconds.
Page 444 FUEL INJECTION SYSTEM Fault code No. Item Latch up detected. The vehicle has overturned. Raise the vehicle upright. Turn the main switch to “ON”, then to “OFF”, and then back to “ON”. Fault code number is not dis- played  Service is finished. Fault code number is displayed ...
Page 445 FUEL INJECTION SYSTEM Fault code No. Cylinder-#1 ignition coil: open or short circuit detected in the pri- Item mary lead of the cylinder-#1 ignition coil. Improperly connected  Con- Connection of wire harness Start the engine and let it idle for ECU coupler.
Page 446 FUEL INJECTION SYSTEM Fault code No. Cylinder-#2 ignition coil: open or short circuit detected in the pri- Item mary lead of the cylinder-#2 ignition coil. Improperly connected  Con- Connection of cylinder-#2 igni- Start the engine and let it idle for tion coil coupler.
Page 447 FUEL INJECTION SYSTEM Fault code No. Cylinder-#3 ignition coil: open or short circuit detected in the pri- Item mary lead of the cylinder-#3 ignition coil. Item Probable cause of Maintenance job Confirmation of service com- malfunction and check pletion Improperly connected  Con- Connection of cylinder-#3 igni- Start the engine and let it idle for tion coil coupler.
Page 448 FUEL INJECTION SYSTEM Fault code No. Item Injector: open or short circuit detected. Actuation Actuates injector #1 five times at one-second intervals. Illuminates the engine trouble warning light. Procedure Check that injector #1 is actuated five times by listening for the operating sound.
Page 449 FUEL INJECTION SYSTEM Fault code No. Item Injector: open or short circuit detected. Open or short circuit  Replace Wire harness continuity. Execute the diagnostic mode. the wire harness. (Code Nos. 36, 37, 38) No operating sound  Go to Between injector coupler and ECU coupler.
Page 450 FUEL INJECTION SYSTEM Fault code No. Item Lean angle sensor: open or short circuit detected. Open or short circuit  Replace Wire harness continuity. Turn the main switch to “ON”, the wire harness. then to “OFF”, and then back to Between lean angle sensor cou- “ON”.
Page 451 FUEL INJECTION SYSTEM Fault code No. Rear wheel sensor: no normal signals are received from the rear wheel sensor. Item B Neutral switch: open or short circuit is detected. C Clutch switch: open or short circuit is detected. Value does not increase  Go Locate the malfunction.
Page 452 FUEL INJECTION SYSTEM Fault code No. Rear wheel sensor: no normal signals are received from the rear wheel sensor. Item B Neutral switch: open or short circuit is detected. C Clutch switch: open or short circuit is detected. Malfunction in ECU. Replace the ECU.
Page 453 FUEL INJECTION SYSTEM Fault code No. Rear wheel sensor: no normal signals are received from the rear wheel sensor. Item B Neutral switch: open or short circuit is detected. C Clutch switch: open or short circuit is detected. Value does not increase  Go Locate the malfunction.
Page 454 FUEL INJECTION SYSTEM Fault code No. Rear wheel sensor: no normal signals are received from the rear wheel sensor. Item B Neutral switch: open or short circuit is detected. C Clutch switch: open or short circuit is detected. Defective relay unit. Check the relay unit.
Page 455 FUEL INJECTION SYSTEM Fault code No. Rear wheel sensor: no normal signals are received from the rear wheel sensor. Item B Neutral switch: open or short circuit is detected. C Clutch switch: open or short circuit is detected. Fail-safe system Able to start engine Able to drive vehicle Diagnostic code No.
Page 456 FUEL INJECTION SYSTEM Fault code No. A Rear wheel sensor: no normal signals are received from the rear wheel sensor. Item B Neutral switch: open or short circuit is detected. C Clutch switch: open or short circuit is detected. Improperly connected  Con- Connection of clutch switch cou- Execute the diagnostic mode.
Page 457 FUEL INJECTION SYSTEM Fault code No. Rear wheel sensor: no normal signals are received from the rear wheel sensor. Item B Neutral switch: open or short circuit is detected. C Clutch switch: open or short circuit is detected. Defective clutch switch. Check the clutch switch.
Page 458 FUEL INJECTION SYSTEM Fault code No. Fuel system voltage: incorrect voltage supplied to the fuel injector Item and fuel pump. Improperly connected  Con- Connection of relay unit coupler. Start the engine and let it idle for Check the locking condition of nect the coupler securely or approximately 5 seconds.
Page 459 FUEL INJECTION SYSTEM Fault code No. EEPROM fault code number: an error is detected while reading or Item writing on EEPROM. Meter display EEPROM fault code display • 00 (no history) • 01–03: Cylinder fault code number (history exists) If more than one cylinder is defective, the display switches every two seconds to show the cylinder fault code numbers of all defective cylin- ders in a repeating cycle.
Page 460 FUEL INJECTION SYSTEM Fault code No. EEPROM fault code number: an error is detected while reading or Item writing on EEPROM. “11” is indicated in diagnostic Turn the main switch to “OFF”. Turn the main switch to “ON”. mode (code No. 60). EEPROM Fault code number is not dis- played ...
Page 461 FUEL INJECTION SYSTEM Fault code No. Item Accelerator position sensor: open or short circuit detected. Fail-safe system Able/Unable to start engine Able/Unable to drive vehicle Diagnostic code No. 14, 15 Meter display Accelerator position sensor signal 1 • 12–22 (fully closed position) •...
Page 462 FUEL INJECTION SYSTEM Fault code No. Item Accelerator position sensor: open or short circuit detected. Defective accelerator position Check accelerator position sen- Turn the main switch to “ON”. sensor. sor signal 1. Fault code number is not dis- played  Service is finished. Execute the diagnostic mode.
Page 463 FUEL INJECTION SYSTEM Fault code No. Item YCC-T drive system: malfunction detected. Abnormality  Replace the Check the electronic throttle Turn the main switch to “ON”. valve fuse. electronic throttle valve fuse. Fault code number is not dis- played  Service is finished. Fault code number is displayed ...
Page 464 FUEL INJECTION SYSTEM Fault code No. 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 8-98. If the ABS warning light is off, perform the following procedure.
Page 465 The fault code can also be deleted by activating the diag- nostic mode and selecting diag- nostic code number “63”. 89 (Yamaha diagnostic tool) Fault code No. Err (multi-function meter display) Multi-function meter: signals cannot be transmitted between the Item ECU and the multi-function meter.
Page 466 FUEL INJECTION SYSTEM 89 (Yamaha diagnostic tool) Fault code No. Err (multi-function meter display) Multi-function meter: signals cannot be transmitted between the Item ECU and the multi-function meter. Improperly connected  Con- Connection of wire harness Turn the main switch to “ON”.
Page 467 FUEL INJECTION SYSTEM 8-76...
Page 468 FUEL PUMP SYSTEM EAS20081 FUEL PUMP SYSTEM EAS30513 CIRCUIT DIAGRAM 8-77...
Page 469 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 27.ECU (engine control unit) 68.Fuel pump 69.Handlebar switch (right) 71.Start/engine stop switch 8-78...
Page 470 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 471 FUEL PUMP SYSTEM 8-80...
Page 472 IMMOBILIZER SYSTEM EAS20084 IMMOBILIZER SYSTEM EAS30519 CIRCUIT DIAGRAM 8-81...
Page 473 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 27.ECU (engine control unit) 52.Meter assembly 53.Immobilizer system indicator light 57.Multi-function meter 8-82...
Page 474 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 475 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 476 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 477 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 478 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 8-131.
Page 479 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 480 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 481 IMMOBILIZER SYSTEM 8-90...
Page 482 ABS (ANTI-LOCK BRAKE SYSTEM) EAS20085 ABS (ANTI-LOCK BRAKE SYSTEM) EAS30843 CIRCUIT DIAGRAM 8-91...
Page 483 22.Relay unit 23.Starting circuit cut-off relay 27.ECU (engine control unit) 45.Front wheel sensor 46.Rear wheel sensor 47.ABS ECU (electronic control unit) 51.Yamaha diagnostic tool coupler 52.Meter assembly 57.Multi-function meter 64.ABS warning light 69.Handlebar switch (right) 71.Start/engine stop switch 73.Front brake light switch 74.Rear brake light switch...
Page 484 ABS (ANTI-LOCK BRAKE SYSTEM) EAS30525 ABS COMPONENTS CHART 8-93...
Page 485 ABS (ANTI-LOCK BRAKE SYSTEM) 1. Hydraulic unit assembly 2. Fuse box 3 3. ABS test 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 8-94...
Page 486 ABS (ANTI-LOCK BRAKE SYSTEM) EAS30844 ABS COUPLER LOCATION CHART 8-95...
Page 487 ABS (ANTI-LOCK BRAKE SYSTEM) 1. Meter assembly coupler 2. Rear wheel sensor coupler 3. ABS ECU coupler 4. ABS test coupler 5. Front wheel sensor coupler 8-96...
Page 488 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-...
Page 489 Since all malfunctions are recorded after they are detected, it is possible to check the recorded malfunction data by utilizing the Yamaha diagnostic tool when the ABS ECU has entered the self-diagnosis mode.
Page 490 • 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 491 EAS31162 [A-3] THE ABS WARNING LIGHT COMES ON Connect the Yamaha diagnostic tool to the ABS test coupler and execute functional diagnosis. (For in- formation about how to execute functional diagnosis, refer to the operation manual that is included with the tool.)
Page 492 ABS test coupler. (CANL) EAS31165 [B-1] MALFUNCTION ARE CURRENTLY DETECTED When the Yamaha diagnostic tool is connected to the ABS test coupler, the fault codes will be displayed on the computer screen. • A fault code is displayed. [B-2] •...
Page 493 Once all the work is complete, delete the fault codes. [B-3] • When the Yamaha diagnostic tool is connected to the vehicle, the operation of the multi-function me- ter and indicators will be different from the normal operation.
Page 494 ABS (ANTI-LOCK BRAKE SYSTEM) B. Recovered malfunction A. Detected malfunction 4. ECU The types of the control units are displayed. (e.g., FI, ABS) 5. Item The item names of the detected malfunction are displayed. 6. Condition The current conditions are displayed. (Detected/Recovered) 7.
Page 495 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code Item Symptom Check point Front wheel sensor (abnor- Front wheel sensor signal is • Foreign material adhered mal pulse period) not received properly. (The around the front wheel sen- pulse period is abnormal • Incorrect installation of the while the vehicle is traveling.) front wheel •...
Page 496 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code Item Symptom Check point Rear wheel sensor (missing Rear wheel sensor signal is • Foreign material adhered pulses) not received properly. (Miss- around the rear wheel sen- ing pulses are detected in • Incorrect installation of the the signal while the vehicle is traveling.) rear wheel...
Page 497 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code Item Symptom Check point Front wheel ABS (intermit- • Pulses from the front wheel • Incorrect installation of the tent wheel speed pulses or sensor are received inter- front wheel sensor • Incorrect rotation of the incorrect depressurization) mittently while the vehicle is traveling.
Page 498 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code Item Symptom Check point Hydraulic unit assembly Abnormality is detected in • Defective battery • Defective coupler between (defective ABS solenoid and the solenoid or motor power ABS motor power supply cir- supply circuit in the hydraulic the battery and the hydrau- cuits) unit assembly.
Page 499 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Item Front wheel sensor (intermittent pulses or no pulses) Front wheel sensor signal is not received properly. (Pulses are not Symptom received or are received intermittently while the vehicle is travel- ing.) Order Item/components and probable cause Check or maintenance job Defective front wheel sensor or incorrect Check the wheel sensor for damage and the installed...
Page 500 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Item Front wheel sensor (abnormal pulse period) Front wheel sensor signal is not received properly. (The pulse Symptom period is abnormal while the vehicle is traveling.) Order Item/components and probable cause Check or maintenance job Incorrect installation of the front wheel Check the components for looseness, distortion, and bends.
Page 501 ABS (ANTI-LOCK BRAKE SYSTEM) • If the rear brake ABS operates continuously for 20 seconds or more, fault code No. 27 will be record- ed. If the rear brake ABS operates continuously for 36 seconds or more, fault code No. 14 will be re- corded.
Page 502 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 the coupler for any pins that may be pulled out. Defective coupler between the rear wheel •...
Page 503 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 Foreign material adhered around the front Check the surface of the sensor rotor and wheel sensor wheel sensor...
Page 504 ABS (ANTI-LOCK BRAKE SYSTEM) If pulse gaps are detected when the vehicle is traveling at a speed of 30 km/h (19 mi/h) or more, fault code No. 18 will be recorded. If the vehicle is traveling at a speed of 29 km/h (18 mi/h) or less, fault code No.
Page 505 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 506 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 507 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 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 Incorrect installation of the front wheel Check the components for looseness, distortion, and bends.
Page 509 ABS (ANTI-LOCK BRAKE SYSTEM) 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. 52) •...
Page 510 ABS (ANTI-LOCK BRAKE SYSTEM) 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 Recharge or replace the battery.
Page 511 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 •...
Page 512 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Item Rear wheel sensor power supply (voltage of power supply is low) Power voltage supplied from the ABS ECU to the rear wheel sensor Symptom is too low. Order Item/components and probable cause Check or maintenance job •...
Page 513 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 514 ELECTRICAL COMPONENTS EAS20089 ELECTRICAL COMPONENTS 8-123...
Page 515 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 516 ELECTRICAL COMPONENTS 8-125...
Page 517 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 518 ELECTRICAL COMPONENTS EAS30549 CHECKING THE SWITCHES Br/W B/Y W/R B W/G Br B/R B/L B/L Br/W 8-127...
Page 519 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 8-128...
Page 520 ELECTRICAL COMPONENTS Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. ECA14371 NOTICE Never insert the tester probes into the coupler terminal slots. Always insert the probes from the opposite end “a”...
Page 521 ELECTRICAL COMPONENTS keep flammable products and your hands EAS30550 CHECKING THE BULBS AND BULB away from the bulb until it has cooled down. SOCKETS ECA14381 Check each bulb and bulb socket for damage or NOTICE wear, proper connections, and also for continuity •...
Page 522 ELECTRICAL COMPONENTS 1. Check: 3. Replace: • Bulb socket (for continuity) • Blown fuse (with the pocket tester) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ No continuity  Replace. a. Set the main switch to “OFF”. b. Install a new fuse of the correct amperage Pocket tester rating.
Page 523 ELECTRICAL COMPONENTS 4. Install: ECA13661 NOTICE • Rider seat/Passenger seat • This is a VRLA (Valve Regulated Lead Acid) Refer to “GENERAL CHASSIS (1)” on page battery. Never remove the sealing caps be- 4-1. cause the balance between cells will not be EAS31006 maintained and battery performance will REPLACING THE ECU (engine control unit)
Page 524 ELECTRICAL COMPONENTS ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect a pocket tester to the battery termi- 5. Charge: nals. • Battery (refer to the appropriate charging method) • Positive tester probe  positive battery terminal EWA13300 • Negative tester probe  WARNING negative battery terminal Do not quick charge a battery.
Page 525 ELECTRICAL COMPONENTS g. Measure the battery open-circuit voltage after leaving the battery unused for more than 30 minutes. 12.8 V or more --- Charging is complete. 12.7 V or less --- Recharging is required. Under 12.0 V --- Replace the battery. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...
Page 526 ELECTRICAL COMPONENTS Starter relay 8. Check: 1. Positive battery terminal • Battery terminals 2. Negative battery terminal Dirt  Clean with a wire brush. 3. Positive tester probe Loose connection  Connect properly. 4. Negative tester probe 9. Lubricate: • Battery terminals Relay operation Recommended lubricant Continuity...
Page 527 ELECTRICAL COMPONENTS Relay unit (fuel pump relay) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester (DC 20 V) to the turn signal/hazard relay terminal as shown. Pocket tester 90890-03112 Analog pocket tester YU-03112-C • Positive tester probe blue/red “1” • Negative tester probe Ground 1.
Page 528 ELECTRICAL COMPONENTS Continuity Positive tester probe sky blue “1” Negative tester probe black/yellow “2” No continuity Positive tester probe black/yellow “2” Negative tester probe sky blue “1” Continuity b. Turn the main switch to “ON”. Positive tester probe c. Measure the turn signal/hazard relay output sky blue “1”...
Page 529 ELECTRICAL COMPONENTS unit terminal as shown. nition coil as shown. c. Check the relay unit (diode) for continuity. Pocket tester d. Check the relay unit (diode) for no continuity. 90890-03112 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Analog pocket tester YU-03112-C EAS30558 CHECKING THE IGNITION COILS The following procedure applies to all of the igni- •...
Page 530 ELECTRICAL COMPONENTS b. Measure the crankshaft position sensor re- 2. Ignition coil sistance. c. Turn the main switch to “ON”. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ d. Measure the ignition spark gap “a”. e. Crank the engine by pushing the “ ” side of EAS30561 the start/engine stop switch and gradually in- CHECKING THE LEAN ANGLE SENSOR crease the spark gap until a misfire occurs.
Page 531 ELECTRICAL COMPONENTS EAS30566 CHECKING THE STATOR COIL 1. Disconnect: • Stator coil coupler (from the wire harness) 2. Check: • Stator coil resistance Out of specification  Replace the stator coil. Stator coil resistance 0.152–0.228  (W-W) c. Set the main switch to “ON”. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...
Page 532 ELECTRICAL COMPONENTS on page 8-140. b. Connect the pocket tester (DC 20 V) to the battery as shown. Rectifier/regulator input voltage above 14 V at 5000 r/min Pocket tester 90890-03112 Analog pocket tester ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ YU-03112-C a. Set the engine tachometer to the ignition coil of cylinder #1.
Page 533 ELECTRICAL COMPONENTS c. Measure the horn resistance. b. Measure the oil level switch resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Check: • Horn sound EAS30573 CHECKING THE FUEL SENDER Faulty sound  Replace. 1. Disconnect: • Fuel pump coupler EAS30846 CHECKING THE ENGINE OIL LEVEL (from the fuel pump) SWITCH 2.
Page 534 ELECTRICAL COMPONENTS EAS30575 CHECKING THE OIL LEVEL WARNING LIGHT This model is equipped with a self-diagnosis de- vice for the oil level detection circuit. 1. Check: • Oil level warning light “1” (Turn the main switch to “ON”.) Warning light comes on for a few seconds, then goes off ...
Page 535 ELECTRICAL COMPONENTS EAS30578 CHECKING THE COOLANT TEMPERATURE SENSOR 1. Remove: • Coolant temperature sensor Refer to “CYLINDER HEAD” on page 5-19. EWA14130 WARNING • Handle the coolant temperature sensor with special care. • Never subject the coolant temperature sen- sor to strong shocks. If the coolant temper- ature sensor is dropped, replace it.
Page 536 ELECTRICAL COMPONENTS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Resistance a. Connect the pocket tester (  1 k) to the 1.08–2.52 k throttle position sensor terminals as shown. Pocket tester ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester (  1 k) to the ac- 90890-03112 Analog pocket tester celerator position sensor terminals as shown.
Page 537 ELECTRICAL COMPONENTS tle servo motor. • Positive tester probe  Air induction system solenoid terminal “1” • Negative tester probe  Do not use old batteries to operate the throttle Air induction system solenoid terminal “2” servo motor. c. Measure the air induction system solenoid re- sistance.
Page 538 ELECTRICAL COMPONENTS • Positive tester probe Intake air temperature sensor re- pink (wire harness color) (intake air pressure sistance sensor 1) 5400–6600 @0 C (32 F) pink/white (wire harness color) (intake air pres- Intake air temperature sensor re- sure sensor 2) •...
Page 539 ELECTRICAL COMPONENTS Pocket tester 90890-03112 Analog pocket tester YU-03112-C Result Neutral position Continuity Positive tester probe sky blue “1” EAS30681 Negative tester probe CHECKING THE FUEL INJECTORS Sensor terminal “a” The following procedure applies to all of the fuel 1st position injectors.
Page 540 ELECTRICAL COMPONENTS 8-149...
Page 541: 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 542: 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 543: Poor Medium-And-High-Speed Performance
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 544: Overcooling
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 545: Troubleshooting At The Abs Warning Light
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 546: Self-Diagnostic Function And Diagnostic Code Table
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE EAS20116 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE EAS31118 SELF-DIAGNOSTIC FUNCTION TABLE • The fault code numbers 51–56 cannot be displayed on the meter. The pattern of the immobilizer sys- tem indicator light flashing shows the fault code. •...
Page 547: Communication Error With The Meter
Front wheel sensor: no normal signals are received from the front wheel sensor. Engine idling stop EAS31119 COMMUNICATION ERROR WITH THE METER Fault code No. Item 89 (Yamaha diagnostic tool) Multi-function meter: signals cannot be transmitted between the ECU and Err (multi-function meter dis- the multi-function meter. play) EAS31120...
Page 548 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Diagnostic Item Meter display Procedure code No. Rear wheel vehicle speed Rear wheel speed pulse Check that the number pulses 0–999 increases when the rear wheel is rotated. The number is cumulative and does not reset each time the wheel is stopped.
Page 549 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Diagnostic Item Meter display Procedure code No. gear position switch and Operate the transmission, clutch switch clutch lever, and sidestand. • Transmission is in neutral • Transmission is in gear or the clutch lever released •...
Page 550: Diagnostic Code: Actuator Operation Table
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Diagnostic Item Meter display Procedure code No. Malfunction code reinstate- ment (for fault code No. 24, 42 only) • No malfunction code — • Malfunction code exists Fault code 24, 42 To reinstate, set the •...
Page 551 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Diagnostic Item Actuation Procedure code No. Injector #3 Actuates the injector #3 five Check that injector #3 is times at one-second inter- actuated five times by listen- vals. ing for the operating sound. Illuminates the engine trou- ble warning light.
Page 552: Event Code Table
EVENT CODE TABLE EAS20164 EVENT CODE TABLE The event code numbers listed below cannot be displayed on the meter. To display the event code numbers, use the Yamaha diagnostic tool. Item Symptom Possible causes Note Intake air pres- Brief abnormality...
Page 553 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 D67, and check upper limit for tained at the upper – Clogged throttle body the ISC maintenance adjustment) limit...
Page 554 EVENT CODE TABLE 9-13...
Page 555: Wiring Diagram
Yellow/Red 49. Accelerator position sensor B. Sub-wire harness (Injector #2) Yellow/White 50. Throttle position sensor C. Sub-wire harness (Coolant 51. Yamaha diagnostic tool cou- temperature sensor) pler D. Negative battery sub-wire har- 52. Meter assembly ness 53. Immobilizer system indicator light 54.
Page 559 MT09TRA/MT09TRAF 2015 MT09TRA/MT09TRAF 2015 MT09TRA/MT09TRAF 2015 MT09TRA/MT09TRAF 2015 MT09TRA/MT09TRAF 2015 SCHÉMA DE CÂBLAGE SCHEMA ELETTRICO WIRING DIAGRAM SCHALTPLAN DIAGRAMA ELÉCTRICO...
Page 560 MT09TRA/MT09TRAF 2015 MT09TRA/MT09TRAF 2015 MT09TRA/MT09TRAF 2015 MT09TRA/MT09TRAF 2015 MT09TRA/MT09TRAF 2015 SCHÉMA DE CÂBLAGE SCHEMA ELETTRICO WIRING DIAGRAM SCHALTPLAN DIAGRAMA ELÉCTRICO...

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Tracer mt09traf

Yamaha TRACER MT09TRA Service Manual

Table of Contents

Specifications

Periodic Checks and Adjustments

Chassis

General Chassis (1)

General Chassis (2)

General Chassis (3)

Front Wheel

Front Brake

Rear Brake

Abs (Anti-Lock Brake System)

Handlebar

Front Fork

Steering Head

Rear Shock Absorber Assembly

Swingarm

Chain Drive

Engine

Engine Inspection

Engine Removal

Camshafts

Cylinder Head

Valves and Valve Springs

Generator and Starter Clutch

Clutch

Shift Shaft

Oil Pump

Oil Pan

Crankcase

Connecting Rods and Pistons

Crankshaft and Balancer Shaft

Transmission

Cooling System

Radiator

Oil Cooler

Thermostat

Water Pump

Quick Links

Chapters

Troubleshooting

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Summary of Contents for Yamaha TRACER MT09TRA