Yamaha Tenere 700 2020 Service Manual
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Yamaha Tenere 700 2020 Service Manual

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Table of Contents

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2020
SERVICE MANUAL
Ténéré 700
XTZ690
XTZ690-U
BW3-F8197-E0

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Summary of Contents for Yamaha Tenere 700 2020

  • Page 1 2020 SERVICE MANUAL Ténéré 700 XTZ690 XTZ690-U BW3-F8197-E0...
  • Page 3 It is not possible to include all the knowledge of a mechanic in one manual. Therefore, any- one 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. Please refer to “BA- SIC INFORMATION”...
  • Page 4 EAS20004 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. •...
  • Page 5 EAS20005 SYMBOLS The following symbols are used in this manual for easier understanding. The following symbols are not relevant to every vehicle. SYMBOL DEFINITION SYMBOL DEFINITION Serviceable with engine mounted Gear oil Filling fluid Molybdenum disulfide oil Lubricant Brake fluid Special tool Wheel bearing grease Tightening torque...

  • Page 7: Table Of Contents

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

  • Page 9: General Information

    GENERAL INFORMATION IDENTIFICATION .................... 1-1 VEHICLE IDENTIFICATION NUMBER .............1-1 MODEL LABEL..................1-1 FEATURES...................... 1-2 MULTI-FUNCTION METER UNIT ............. 1-2 SPECIAL TOOLS .................... 1-7...

  • Page 10: Identification

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

  • Page 11: Features

    FEATURES EAS20008 FEATURES • The display units will return to factory settings in case of battery disconnection. EAS30982 EWA12423 MULTI-FUNCTION METER UNIT WARNING Be sure to stop the vehicle before making any setting changes to the multi-function meter unit. Changing settings while riding can distract the operator and increase the risk of an accident.
  • Page 12 FEATURES The fuel meter indicates the amount of fuel in the The transmission gear display shows the select- fuel tank. The segments of the fuel meter disap- ed gear. The neutral position is indicated by “–”. pear from “F” (full) towards “E” (empty) as the Clock fuel level decreases.
  • Page 13 FEATURES • The countdown tripmeter does not automati- cally reset. The ABS will be disabled until the key is turned to “OFF”, or the engine stop switch is turned to Push the top set button to switch the display in “...
  • Page 14 FEATURES Countdown tripmeter settings • “MPG”: The distance that can be traveled on To set the countdown tripmeter, select it by 1.0 Imp.gal of fuel under the current riding con- pushing the top set button. When the units stop ditions is shown. flashing, push the top and bottom set buttons si- To switch the instantaneous fuel consumption multaneously until the first digit starts flashing.
  • Page 15 FEATURES Coolant temperature Brightness control mode 1. Coolant temperature display 1. Brightness level display This display shows the coolant temperature from The brightness level of the multi-function meter 40 °C to 116 °C in 1 °C increments. unit panel can be adjusted. If the message “Hi”...

  • Page 16: Special Tools

    • For U.S.A. and Canada, use part number starting with “YM-”, “YU-”, or “ACC-”. • For others, use part number starting with “90890-”. Reference Tool name/Tool No. Illustration pages Yamaha diagnostic tool USB 3-4, 3-9, 4-49, 90890-03267 4-50, 8-34, 8-105, 8-125 Yamaha diagnostic tool (A/I)
  • Page 17 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Carburetor angle driver 2 3-10 90890-03173 Spoke nipple wrench (6–7) 3-16 90890-01521 Spoke nipple wrench (6–7) YM-01521 Steering nut wrench 3-20, 4-70 90890-01403 Exhaust flange nut wrench YU-A9472 Oil filter wrench 3-24 90890-01426 Oil filter wrench YU-38411...
  • Page 18 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Fork seal driver 4-64, 4-64, 4-64 90890-01442 Adjustable fork seal driver (36–46 mm) YM-01442 Rod puller 4-65 90890-01437 Universal damping rod bleeding tool set YM-A8703 YM-A8703 Rod puller attachment (M10 long) 4-65 90890-01578 90890-01578 Universal damping rod bleeding tool set...
  • Page 19 90890-03081 Engine compression tester YU-33223 YU-33223 Rotor holding tool 5-13, 5-16 90890-01235 Universal magneto and rotor holder YU-01235 Yamaha bond No. 1215 5-19, 5-37, 5-62, 90890-85505 5-64 (Three bond No.1215®) Valve spring compressor 5-28, 5-32 90890-04019 Valve spring compressor YM-04019 Valve spring compressor attachment (ø26)
  • Page 20 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Rotor holding tool 5-35, 5-35, 5-36, 90890-04166 5-36 Rotor holding tool YM-04166 Flywheel puller 5-35 90890-01362 Heavy duty puller YU-33270-B Digital circuit tester (CD732) 5-40, 8-130, 90890-03243 8-131, 8-132, Model 88 Multimeter with tachometer 8-133, 8-133, YU-A1927 8-133, 8-134,...
  • Page 21 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Piston ring compressor 5-74 90890-05158 Piston ring compressor YM-08037 Radiator cap tester 90890-01325 Mityvac cooling system tester kit YU-24460-A YU-24460-A Radiator cap tester adapter 90890-01352 Pressure tester adapter YU-33984 YU-33984 Mechanical seal installer (ø33) 6-13 90890-04132 Water pump seal installer (ø33)
  • Page 22 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Fuel injector pressure adapter 7-12 90890-03210 Fuel injector pressure adapter YU-03210 Fuel pressure adapter 7-13 90890-03176 Fuel pressure adapter YM-03176 OBD/ GST Leadwire kit 8-34 90890-03249 Ignition checker 8-135 90890-06754 Oppama pet–4000 spark checker YM-34487 Test harness–...

  • Page 23: Specifications

    SPECIFICATIONS GENERAL SPECIFICATIONS ................ 2-1 ENGINE SPECIFICATIONS ................2-2 CHASSIS SPECIFICATIONS ................2-7 ELECTRICAL SPECIFICATIONS ..............2-10 TIGHTENING TORQUES ................2-12 ENGINE TIGHTENING TORQUES............2-12 CHASSIS TIGHTENING TORQUES............2-13 CABLE ROUTING ..................2-15...

  • Page 24: General Specifications

    GENERAL SPECIFICATIONS EAS20013 GENERAL SPECIFICATIONS Model Model BW31 (XTZ690_EUR) BW32 (XTZ690-U) BW33 (XTZ690P-B) BW34 (XTZ690_AUS) Dimensions Overall length 2370 mm (93.3 in) Overall width 905 mm (35.6 in) Overall height 1455 mm (57.3 in) Wheelbase 1595 mm (62.8 in) Ground clearance 240 mm (9.45 in) Minimum turning radius 2.8 m (9.47 ft)

  • Page 25: Engine Specifications

    ENGINE SPECIFICATIONS EAS20014 ENGINE SPECIFICATIONS Engine Combustion cycle 4-stroke Cooling system Liquid cooled Valve train DOHC Displacement 689 cm³ Cylinder arrangement Inline Number of cylinders 2-cylinder Bore × stroke 80.0 × 68.6 mm (3.15 × 2.70 in) Compression ratio 11.5 : 1 Compression pressure 770–990 kPa/355 r/min (7.7–9.9 kgf/cm²/355 r/ min, 109.5–140.8 psi/355 r/min)
  • Page 26 ENGINE SPECIFICATIONS Coolant reservoir (up to the maximum level mark) 0.25 L (0.26 US qt, 0.22 Imp.qt) Radiator cap valve opening pressure 108.0–137.4 kPa (1.08–1.37 kgf/cm², 15.7–19.9 psi) Thermostat Valve opening temperature 80.0–84.0 °C (176.00–183.20 °F) Valve full open temperature 95.0 °C (203.00 °F) Valve lift (full open) 8.0 mm (0.31 in)
  • Page 27 ENGINE SPECIFICATIONS Valve spring Free length (intake) 40.30 mm (1.59 in) Limit 38.29 mm (1.51 in) Free length (exhaust) 41.39 mm (1.63 in) Limit 39.32 mm (1.55 in) Cylinder Bore 80.000–80.010 mm (3.1496–3.1500 in) Wear limit 80.060 mm (3.1520 in) Piston Diameter 79.970–79.985 mm (3.1484–3.1490 in)
  • Page 28 ENGINE SPECIFICATIONS Bearing color code Code 1 Blue Code 2 Black Code 3 Brown Code 4 Green Code 5 Yellow Balancer shaft journal to balancer shaft bearing clearance 0.020–0.054 mm (0.0008–0.0021 in) Clutch Clutch type Wet, multiple-disc Clutch lever free play 5.0–10.0 mm (0.20–0.39 in) Friction plate 2 thickness 2.92–3.08 mm (0.115–0.121 in)
  • Page 29 ENGINE SPECIFICATIONS Throttle body ID mark 1WS1 10 Idling condition Engine idling speed 1250–1450 r/min O2 feedback control Active Coolant temperature 85–105 °C (185–221 °F) Engine oil temperature 60–80 °C (140–176 °F) Intake vacuum 39.3–41.6 kPa (295–312 mmHg, 11.6–12.3 inHg) Difference in vacuum pressure between the cylinders 0 kPa-1.3 kPa (0 mmHg-10 mmHg, 0 inHg-0.4...

  • Page 30: Chassis Specifications

    CHASSIS SPECIFICATIONS EAS20015 CHASSIS SPECIFICATIONS Chassis Frame type Double cradle Caster angle 27.0 ° Trail 105 mm (4.1 in) Front wheel Wheel type Spoke wheel 21 × 1.85 Rim size Radial wheel runout limit 2.0 mm (0.08 in) Lateral wheel runout limit 2.0 mm (0.08 in) Rear wheel Wheel type...
  • Page 31 Limit 413.6 mm (16.28 in) Inner tube bending limit 0.2 mm (0.01 in) Recommended oil Yamaha Suspension Oil G10 Quantity (left) 624.0 cm³ (21.10 US oz, 21.96 Imp. oz) Quantity (right) 624.0 cm³ (21.10 US oz, 21.96 Imp. oz) Level 85.0 mm (3.35 in)
  • Page 32 CHASSIS SPECIFICATIONS Adjustment value from the start position (Hard) Compression damping Adjusting system Mechanical adjustable type Unit for adjustment Click Adjustment value from the start position (Soft) Adjustment value from the start position (STD) Adjustment value from the start position (Hard) Drive chain Size 525V11...

  • Page 33: Electrical Specifications

    ELECTRICAL SPECIFICATIONS EAS20016 ELECTRICAL SPECIFICATIONS Voltage System voltage 12 V Ignition system Ignition system Ignition timing (B.T.D.C.) 10.0 °/1200 r/min Engine control unit Model TBDF2B (XTZ690, XTZ690P-B) TBDF4K (XTZ690-U) Ignition coil 1.19–1.61 Ω Primary coil resistance Secondary coil resistance 8.50–11.50 kΩ Lean angle sensor output voltage Operating angle 65 °...
  • Page 34 ELECTRICAL SPECIFICATIONS ABS on/off indicator light Immobilizer system indicator light Starter motor Brush overall length limit 6.5 mm (0.26 in) Brush spring force 6.03–6.52 N (615–665 gf, 21.71–23.47 oz) Mica undercut (depth) 0.70 mm (0.03 in) Fuel sender unit 12.0–14.0 Ω Sender unit resistance (full) 118.0–122.0 Ω...

  • Page 35: Tightening Torques

    TIGHTENING TORQUES EAS20017 TIGHTENING TORQUES EAS30016 ENGINE TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Exhaust pipe nut 20 N·m (2.0 kgf·m, 15 lb·ft) Exhaust pipe bracket bolt 20 N·m (2.0 kgf·m, 15 lb·ft) Muffler bolt 47 N·m (4.7 kgf·m, 35 lb·ft) Muffler joint bolt 20 N·m (2.0 kgf·m, 15 lb·ft) Muffler protector bolt...

  • Page 36: Chassis Tightening Torques

    TIGHTENING TORQUES EAS30017 CHASSIS TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Front wheel axle 72 N·m (7.2 kgf·m, 53 lb·ft) Front wheel axle pinch bolt 21 N·m (2.1 kgf·m, 15 lb·ft) See TIP. Rear wheel sprocket nut 80 N·m (8.0 kgf·m, 59 lb·ft) Rear wheel axle nut 105 N·m (10.5 kgf·m, 77 lb·ft) Brake caliper bleed screw...
  • Page 37 TIGHTENING TORQUES Upper handlebar holder bolt 1. Tighten the upper handlebar holder bolts less than 20 N·m (2.0 kgf·m, 15 lb·ft) temporally. 2. Tighten the upper handlebar holder bolt on the front side, and then on the rear side to specified torque.

  • Page 38: Cable Routing

    CABLE ROUTING EAS20021 CABLE ROUTING Handlebar (front view) 13 14 2-15...
  • Page 39 CABLE ROUTING 1. Main switch lead 2. Frame 3. Wire harness 4. Headlight stay 5. Handlebar 6. Clutch switch lead 7. Handlebar switch lead (left) 8. Clutch cable 9. Throttle cable (accelerator cable) 10. Brake hose (front brake master cylinder to hydraulic unit) 11.
  • Page 40 CABLE ROUTING Frame (front right side view) 18 19 18 19 2-17...
  • Page 41 CABLE ROUTING 1. Oil temperature sensor connector 2. Handlebar switch coupler (right/left) 3. Main switch/immobilizer coupler 4. Radiator fan motor coupler 5. Front wheel sensor coupler 6. O sensor coupler 7. Main switch 8. Main switch lead 9. Handlebar switch lead (right) 10.
  • Page 42 CABLE ROUTING Frame and engine (right side view) 24 25 2-19...
  • Page 43 CABLE ROUTING 1. Relay unit 2. Turn signal relay 3. Radiator fan motor relay 4. Resistor coupler 5. Throttle position sensor 6. Oil pressure switch 7. O sensor 8. Rear wheel sensor lead 9. Rear brake light switch lead 10. Battery 11.
  • Page 44 CABLE ROUTING Frame (front left side view) 10 11 25 26 2-21...
  • Page 45 CABLE ROUTING 1. Horn connector O. Install the intake air pressure sensor hose until it bottoms out the intake air pressure sensor. 2. Coolant reservoir hose P. Engage the clamp by at least three notches. 3. Windshield inner panel (left) Q.
  • Page 46 CABLE ROUTING Engine (left side view) 18 19 20 21 19 20 21 15 16 17 2-23...
  • Page 47 CABLE ROUTING 1. Fuel pump coupler V. Insert the projection on the sidestand switch lead holder into the hole in the down tube. Point the end 2. Canister of the plastic band outward, and cut off the excess 3. Engine ground lead terminal end of the tie.
  • Page 48 CABLE ROUTING Frame (top view) 11 12 13 14 15 16 21 22 2-25...
  • Page 49 CABLE ROUTING 1. Rectifier/regulator 2. Hydraulic unit 3. Radiator fan motor coupler 4. Handlebar switch coupler (right /left) 5. Wire harness (to headlight assembly) 6. Main switch/immobilizer unit coupler 7. Front wheel sensor coupler 8. Fuel hose 9. Fuel pump coupler 10.
  • Page 50 CABLE ROUTING Battery and rear fender (top view) 2-27...
  • Page 51 CABLE ROUTING 1. Rear brake light switch lead 2. Negative battery terminal 3. Joint coupler 4. Fuse box 1 5. Resistor 6. Radiator fan motor relay 7. Turn signal/hazard relay 8. Relay unit 9. Fuse box 2 10. FI diagnostic tool connector 11.
  • Page 52 CABLE ROUTING Rear brake hose (right side view) 2-29...
  • Page 53 CABLE ROUTING 1. Rear brake caliper 2. Rear wheel sensor lead 3. Brake hose (hydraulic unit to rear brake caliper) 4. Brake hose (rear brake master cylinder to hydraulic unit) 5. Rear brake master cylinder 6. Swingarm A. Fasten the brake hose (hydraulic unit to rear brake caliper) and rear wheel sensor lead with the clamp.
  • Page 54 CABLE ROUTING Front brake hose (left and right side view) 2-31...
  • Page 55 CABLE ROUTING 1. Brake hose (front brake master cylinder to hydraulic unit) 2. Front wheel sensor lead 3. Brake hose (hydraulic unit to right front brake caliper) 4. Brake hose (right front brake caliper to left front brake caliper) 5. Protector –...
  • Page 56 CABLE ROUTING Hydraulic unit assembly (top and left side view) 2-33...
  • Page 57 CABLE ROUTING 1. Brake hose (hydraulic unit to rear brake caliper) 2. Brake hose (rear brake master cylinder to hydraulic unit) 3. Brake hose (front brake master cylinder to hydraulic unit) 4. Brake hose (hydraulic unit to right front brake caliper) 2-34...
  • Page 58 CABLE ROUTING Radiator (front and right side view) 2-35...
  • Page 59 CABLE ROUTING 1. Radiator inlet hose 2. Radiator 3. Radiator outlet hose 4. Radiator cap 5. Coolant reservoir hose A. Point the ends of the hose clamp inward. Make sure that the ends of the hose clamp do not contact the coolant reservoir hose. Position the hose clamp 3 mm (0.12 in) or more away from the end of the radiator inlet hose.
  • Page 60 CABLE ROUTING Radiator (left side view) 2-37...
  • Page 61 CABLE ROUTING 1. Coolant reservoir hose 2. Radiator inlet hose 3. Thermostat housing 4. Coolant reservoir cap 5. Coolant reservoir cover 6. Coolant reservoir breather hose 7. Radiator A. Fasten the coolant reservoir hose to the radiator inlet hose with the plastic locking tie. Position the coolant reservoir hose directly under the radiator inlet hose.
  • Page 62 CABLE ROUTING 2-39...

  • Page 63: Periodic Checks And Adjustments

    INTRODUCTION ..................3-1 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM ....................3-1 GENERAL MAINTENANCE AND LUBRICATION CHART .......3-1 CHECKING THE VEHICLE USING THE YAMAHA DIAGNOSTIC TOOL ......................3-4 CHECKING THE FUEL LINE ..............3-4 CHECKING THE SPARK PLUGS ............. 3-5 ADJUSTING THE VALVE CLEARANCE ..........3-6 CHECKING THE ENGINE IDLING SPEED ..........3-9...
  • Page 64 CHECKING THE COOLANT LEVEL............3-26 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 OPERATION .........3-29 CHECKING AND CHARGING THE BATTERY........

  • Page 66: Periodic Maintenance

    EAS30614 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM • Items marked with an asterisk should be performed by your Yamaha dealer because these items re- quire special tools, data, and technical skills. • From 50000 km (30000 mi), repeat the maintenance intervals starting from 10000 km (6000 mi).
  • Page 67 PERIODIC MAINTENANCE ODOMETER READING CHECK OR MAINTENANCE ANNUAL ITEM CHECK 1000 km 10000 km 20000 km 30000 km 40000 km (600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi) • Check operation. √ √ √ √ √ Clutch • Adjust. •...
  • Page 68 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) • Change (warm engine before draining). √ √ √ √ √...

  • Page 69: Checking The Vehicle Using The Yamaha Diagnostic Tool

    CHECKING THE VEHICLE USING THE • Air ducts YAMAHA DIAGNOSTIC TOOL • Fuel tank side covers Use the Yamaha diagnostic tool and check the Refer to “GENERAL CHASSIS (3)” on page vehicle according to the following procedure. 4-5. 1. Remove: 2.

  • Page 70: Checking The Spark Plugs

    PERIODIC MAINTENANCE 5. Install: • Fuel tank side covers • Air ducts • Air scoops Refer to “GENERAL CHASSIS (3)” on page 4-5. • Rider seat Refer to “GENERAL CHASSIS (1)” on page 4-1. EAS30620 4. Remove: CHECKING THE SPARK PLUGS •...

  • Page 71: Adjusting The Valve Clearance

    PERIODIC MAINTENANCE ECA13320 NOTICE Coupler holder bolt 7 N·m (0.7 kgf·m, 5.2 lb·ft) Before removing the spark plugs, blow away any dirt accumulated in the spark plug wells 13.Install: with compressed air to prevent it from falling • Intake air pressure sensor bolt into the cylinders.
  • Page 72 PERIODIC MAINTENANCE 2. Remove: Thickness gauge • Rider seat 90890-03268 Refer to “GENERAL CHASSIS (1)” on page Feeler gauge set 4-1. YU-26900-9 • Air scoops • Air ducts • Fuel tank side covers • If the valve clearance is incorrect, record the Refer to “GENERAL CHASSIS (3)”...
  • Page 73 PERIODIC MAINTENANCE 7. Adjust: 1.58 mm (0.0622 in) + 0.05 mm (0.0020 • Valve clearance in) = 1.63 mm (0.0641 in) a. Remove the valve lifter and the valve pad The valve pad number is 163. with a valve lapper. e.

  • Page 74: Checking The Engine Idling Speed

    • Hose “1” (Parts No.: 5JW-24311-00) THROTTLE BODIES” on page 7-8. • 3-way joint “2” (Parts No.: 90413-05014) a. Connect the Yamaha diagnostic tool. • Vacuum gauge hose #1 “3” (to throttle body Use the diagnostic code number “67”. Refer to “SELF-DIAGNOSTIC FUNC- •...
  • Page 75 PERIODIC MAINTENANCE • If the throttle body synchronization can not be adjusted using the bypass air screw, clean or replace the throttle bodies. • The difference in vacuum pressure between the throttle bodies should not exceed 1.33 kPa (10 mmHg). Carburetor angle driver 2 90890-03173 5.

  • Page 76: Checking The Exhaust System

    PERIODIC MAINTENANCE 5. Adjust: • Throttle grip free play Refer to “CHECKING THE THROTTLE GRIP OPERATION” on page 3-29. Throttle grip free play 3.0–5.0 mm (0.12–0.20 in) EAS30062 CHECKING THE EXHAUST SYSTEM 1. Check: • Muffler assembly “1” • Exhaust pipe “2” Cracks/damage →...

  • Page 77: Replacing The Air Filter Element And Cleaning The

    PERIODIC MAINTENANCE • Air duct cover EAS31130 REPLACING THE AIR FILTER ELEMENT AND CLEANING THE CHECK HOSE Air filter element screw 1.6 N·m (0.16 kgf·m, 1.2 lb·ft) Air duct cover screw There is an air filter check hose “1” at the bottom 1.6 N·m (0.16 kgf·m, 1.2 lb·ft) of the air filter case.

  • Page 78: Checking The Brake Operation

    PERIODIC MAINTENANCE G088888 G088889 If the specified clutch lever free play cannot be • While pushing the brake lever forward, turn the obtained on the handlebar side of the cable, use adjusting dial “1” until the brake lever is in the the adjusting nut on the engine side.

  • Page 79: Adjusting The Rear Disc Brake

    PERIODIC MAINTENANCE 2. Adjust: • Rear brake light switch Refer to “ADJUSTING THE REAR BRAKE LIGHT SWITCH” on page 3-29. EAS30634 CHECKING THE REAR BRAKE PADS The following procedure applies to all of the brake pads. 1. Operate the brake. 2.
  • Page 80 PERIODIC MAINTENANCE ECA18050 NOTICE • Bleed the brake system in the following or- der. • 1st step: Front brake calipers • 2nd step: Rear brake caliper EWA16530 WARNING Bleed the ABS whenever: • the system is disassembled. • a brake hose is loosened, disconnected or A.

  • Page 81: Checking The Brake Fluid Level

    PERIODIC MAINTENANCE EWA13110 EWA13260 WARNING WARNING After bleeding the hydraulic brake system, Never attempt to make any repairs to the check the brake operation. wheel. EAS30632 CHECKING THE BRAKE FLUID LEVEL After a tire or wheel has been changed or re- 1.

  • Page 82: Checking The Tires

    • The tire pressure and the suspension must approved by Yamaha is used on this vehicle. be adjusted according to the total weight (including cargo, rider, passenger and ac-...

  • Page 83: Checking The Wheel Bearings

    PERIODIC MAINTENANCE 1. Place the vehicle on the sidestand. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. 2. Shift the transmission into the neutral posi- tion. 3. Check: • Drive chain slack G088891 Out of specification →...

  • Page 84: Lubricating The Drive Chain

    PERIODIC MAINTENANCE EAS30645 CHECKING AND ADJUSTING THE • To maintain the proper wheel alignment, adjust STEERING HEAD both sides evenly. 1. Stand the vehicle on a level surface. • There should be no clearance between the ad- EWA13120 WARNING justing blocks and the head of adjusting bolts. Securely support the vehicle so that there is no danger of it falling over.

  • Page 85: Lubricating The Steering Head

    PERIODIC MAINTENANCE EAS30646 LUBRICATING THE STEERING HEAD Steering nut wrench 1. Lubricate: 90890-01403 • Upper bearing Exhaust flange nut wrench YU-A9472 • Lower bearing • Upper bearing cover • Lower bearing dust seal Lower ring nut (initial tightening torque) Recommended lubricant 75 N·m (7.5 kgf·m, 55 lb·ft) Lithium-soap-based grease c.

  • Page 86: Checking The Sidestand Switch

    PERIODIC MAINTENANCE EAS30652 CHECKING THE SIDESTAND SWITCH Rebound damping Refer to “CHECKING THE SWITCHES” on Adjustment value from the start page 8-129. position (Soft) EAS30653 Adjustment value from the start CHECKING THE FRONT FORK position (STD) 1. Stand the vehicle on a level surface. EWA13120 Adjustment value from the start WARNING...

  • Page 87: Checking The Rear Shock Absorber Assembly

    PERIODIC MAINTENANCE Direction “a” Compression damping is increased (suspension is harder). Direction “b” Compression damping is decreased (suspension is softer). Compression damping Adjustment value from the start 4. Wait a few seconds, and then install the bleed position (Soft) screws. Adjustment value from the start EAS30808 position (STD)
  • Page 88 PERIODIC MAINTENANCE Rebound damping Compression damping ECA13590 ECA13590 NOTICE NOTICE Never go beyond the maximum or minimum Never go beyond the maximum or minimum adjustment positions. adjustment positions. 1. Adjust: 1. Adjust: • Rebound damping • Compression damping a. Turn the adjusting screw “1” in direction a.

  • Page 89: Checking The Connecting Arms And Relay Arm

    PERIODIC MAINTENANCE ECA13361 NOTICE • Engine oil also lubricates the clutch and the wrong oil types or additives could cause clutch slippage. Therefore, do not add any chemical additives or use engine oils with a grade of “CD” or higher and do not use oils labeled “ENERGY CONSERVING II”.

  • Page 90: Measuring The Engine Oil Pressure

    PERIODIC MAINTENANCE 12.Check: • Engine oil level Refer to “CHECKING THE ENGINE OIL LEVEL” on page 3-24. 13.Install: • Engine guard Refer to “ENGINE REMOVAL” on page 5-3. EAS30810 MEASURING THE ENGINE OIL PRESSURE 1. Stand the vehicle on a level surface. b.

  • Page 91: Checking The Coolant Level

    PERIODIC MAINTENANCE Engine oil pressure Possible causes • Leaking oil passage Above specification • Faulty oil filter • Oil viscosity too high 10.Install: • Main gallery bolt • O-ring Main gallery bolt 8 N·m (0.8 kgf·m, 5.9 lb·ft) 7. Install: •...

  • Page 92: Checking The Cooling System

    PERIODIC MAINTENANCE • Use only distilled water. However, if dis- EAS30813 CHANGING THE COOLANT tilled water is not available, soft water may 1. Remove: be used. • Air scoop (right) 3. Start the engine, warm it up for several min- Refer to “GENERAL CHASSIS (3)”...
  • Page 93 PERIODIC MAINTENANCE ECA13481 NOTICE • Adding water instead of coolant lowers the antifreeze content of the coolant. If water is used instead of coolant, check, and if nec- essary, correct the antifreeze concentra- tion of the coolant. • Use only distilled water. However, if dis- tilled water is not available, soft water may be used.

  • Page 94: Checking The Front Brake Light Switch

    PERIODIC MAINTENANCE EAS30814 EWA13270 CHECKING THE FRONT BRAKE LIGHT WARNING SWITCH Damaged outer cable may cause the cable to Refer to “CHECKING THE SWITCHES” on corrode and interfere with its movement. Re- page 8-129. place damaged outer cable and inner cables as soon as possible.

  • Page 95: Checking And Charging The Battery

    PERIODIC MAINTENANCE G088895 4. Adjust: d. Tighten the locknut. • Throttle grip free play Throttle cable locknut (handlebar side) Prior to adjusting the throttle grip free play, throt- 4.3 N·m (0.43 kgf·m, 3.2 lb·ft) tle body synchronization should be adjusted properly.

  • Page 96: Replacing The License Plate Light Bulb

    PERIODIC MAINTENANCE 5. Install: • License plate light cover • License plate light unit • Lower fender cover License plate light cover nut 3.8 N·m (0.38 kgf·m, 2.8 lb·ft) Lower fender cover bolt 4.0 N·m (0.40 kgf·m, 3.0 lb·ft) EAS31831 REPLACING THE LICENSE PLATE LIGHT BULB 1.

  • Page 97: Chassis

    CHASSIS GENERAL CHASSIS (1) ................. 4-1 GENERAL CHASSIS (2) ................. 4-2 REMOVING THE SIDE COVERS ............. 4-3 REMOVING THE TAIL COVER ..............4-3 REMOVING THE ECU (engine control unit) ..........4-3 INSTALLING THE ECU (engine control unit) ..........4-3 INSTALLING THE TAIL COVER ............... 4-3 INSTALLING THE SIDE COVERS............
  • Page 98 FRONT BRAKE ..................... 4-25 INTRODUCTION ..................4-30 CHECKING THE FRONT BRAKE DISCS..........4-30 REPLACING THE FRONT BRAKE PADS ..........4-30 REMOVING THE FRONT BRAKE CALIPERS ........4-31 CHECKING THE FRONT BRAKE CALIPERS ........4-32 INSTALLING THE FRONT BRAKE CALIPERS ........4-32 REMOVING THE FRONT BRAKE MASTER CYLINDER .......4-33 CHECKING THE FRONT BRAKE MASTER CYLINDER......
  • Page 99 REAR SHOCK ABSORBER ASSEMBLY ............4-72 HANDLING THE REAR SHOCK ABSORBER ........4-73 DISPOSING OF A REAR SHOCK ABSORBER ........4-73 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY....4-73 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY ....4-73 CHECKING THE CONNECTING ARMS AND RELAY ARM ....4-73 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY ....
  • Page 100 GENERAL CHASSIS (1) EAS20026 GENERAL CHASSIS (1) Removing the seats and battery m (0.7 kgf m, 5.2 lb • • • 2.3 N m (0.23 kgf m, 1.7 lb • • • ’ Order Job/Parts to remove Remarks Passenger seat Rider seat Battery band Negative battery lead...

  • Page 101: General Chassis (1)

    GENERAL CHASSIS (2) EAS20155 GENERAL CHASSIS (2) Removing the tail/brake light assembly 4.0 N m (0.40 kgf m, 3.0 lb 11 N m (1.1 kgf m, 8.1 lb 3.8 N m (0.38 kgf m, 2.8 lb • • • • •...

  • Page 102: Removing The Side Covers

    GENERAL CHASSIS (2) EAS31264 REMOVING THE SIDE COVERS The following procedure applies to both of the side covers. 1. Remove: • Side cover “1” Remove the projections “a” on the side cover from holes “b” on the tail cover, and then remove the projections “c”...

  • Page 103: General Chassis (3)

    GENERAL CHASSIS (2) Fit the projections “a” on the side cover to the holes “b” in the tail cover, and then fit the projec- tions “c” to the grommets “d”.
  • Page 104 GENERAL CHASSIS (3) EAS20156 GENERAL CHASSIS (3) Removing the air scoops m (0.7 kgf m, 5.2 lb 3.0 N m (0.30 kgf m, 2.2 lb • • • • • • 4.0 N m (0.40 kgf m, 3.0 lb 4.0 N m (0.40 kgf m, 3.0 lb •...

  • Page 105: Removing The Air Scoops

    GENERAL CHASSIS (3) EAS31772 REMOVING THE AIR SCOOPS The following procedure applies to both of the air scoops. 1. Remove: • Air scoop “1” Remove the projections “a” on the air scoop from the holes “b”. EAS32778 INSTALLING THE FUEL TANK SIDE COVERS The following procedure applies to both of the fuel tank side covers.

  • Page 106: Installing The Air Scoops

    GENERAL CHASSIS (3) EAS31773 INSTALLING THE AIR SCOOPS The following procedure applies to both of the air scoops. 1. Install: • Air scoop “1” Fit the projections “a” on the air scoop to the holes “b”.

  • Page 107: General Chassis (4)

    GENERAL CHASSIS (4) EAS20157 GENERAL CHASSIS (4) Removing the windshields and headlight assembly 0.5 N m (0.05 kgf m, 0.37 lb • • • m (0.7 kgf m, 5.2 lb • • • 4.0 N m (0.40 kgf m, 3.0 lb •...
  • Page 108 GENERAL CHASSIS (4) Removing the windshields and headlight assembly 0.5 N m (0.05 kgf m, 0.37 lb • • • m (0.7 kgf m, 5.2 lb • • • 4.0 N m (0.40 kgf m, 3.0 lb • • • 23 N m (2.3 kgf m, 17 lb...

  • Page 109: Removing The Meter Assembly

    GENERAL CHASSIS (4) EAS33141 REMOVING THE METER ASSEMBLY 1. Remove: • Meter assembly Pull the meter assembly upward and remove the meter assembly from the headlight inner cover. EAS30141 INSTALLING THE WINDSHIELDS The following procedure applies to both of wind- shields.

  • Page 110: Front Wheel

    FRONT WHEEL EAS20028 FRONT WHEEL Removing the front wheel and brake discs m (0.8 kgf m, 5.9 lb 72 N m (7.2 kgf m, 53 lb • • • • • • 40 N m (4.0 kgf m, 30 lb •...
  • Page 111 FRONT WHEEL Disassembling the front wheel ’ Order Job/Parts to remove Remarks Oil seal Wheel bearing Spacer 4-12...

  • Page 112: Removing The Front Wheel

    FRONT WHEEL EAS30145 REMOVING THE FRONT WHEEL ECA20981 NOTICE • Keep any type of magnets (including mag- netic pick-up tools, magnetic screwdrivers, etc.) away from the front wheel sensor or front wheel sensor rotor; otherwise, the sensor or rotor may be damaged, resulting in improper performance of the ABS sys- G088896 tem.

  • Page 113: Maintenance Of The Front Wheel Sensor And Sensor Rotor

    FRONT WHEEL 3. Measure: • Wheel sensor rotor deflection Out of specification → Clean the installation surface of the wheel sensor rotor and correct the wheel sensor rotor deflection, or replace the wheel sensor rotor. Wheel sensor rotor deflection limit 0.25 mm (0.0098 in) G088897 5.

  • Page 114: Assembling The Front Wheel

    FRONT WHEEL G088899 EAS30151 EAS30152 ASSEMBLING THE FRONT WHEEL ADJUSTING THE FRONT WHEEL STATIC 1. Install: BALANCE • Wheel bearings • After replacing the tire, wheel or both, the front • Oil seals wheel static balance should be adjusted. a. Install the new wheel bearing (left side). •...
  • Page 115 FRONT WHEEL 5. Install: • Front wheel sensor • Front wheel sensor protector • Front wheel sensor lead holder “1” Front wheel sensor bolt 7 N·m (0.7 kgf·m, 5.2 lb·ft) Front wheel sensor lead holder bolt 7 N·m (0.7 kgf·m, 5.2 lb·ft) 2.
  • Page 116 FRONT WHEEL Distance “a” (between the front wheel sensor rotor and front wheel sensor) 0.7–1.6 mm (0.03–0.06 in) Measure the distance between the front wheel sensor rotor and front wheel sensor in several places in one rotation of the front wheel. Do not turn the front wheel while the thickness gauge is installed.

  • Page 117: Rear Wheel

    REAR WHEEL EAS20029 REAR WHEEL Removing the rear wheel 105 N m (10.5 kgf m, 77 lb • • • 16 N m (1.6 kgf m, 12 lb • • • m (0.7 kgf m, 5.2 lb • • • m (0.7 kgf m, 5.2 lb •...
  • Page 118 REAR WHEEL Removing the rear brake disc and rear wheel sprocket 80 N m (8.0 kgf m, 59 lb • • • 30 N m (3.0 kgf m, 22 lb • • • m (0.8 kgf m, 5.9 lb • •...
  • Page 119 REAR WHEEL Disassembling the rear wheel ’ Order Job/Parts to remove Remarks Oil seal Wheel bearing Spacer 4-20...

  • Page 120: Removing The Rear Wheel

    REAR WHEEL EAS30910 EAS30159 REMOVING THE REAR WHEEL CHECKING THE REAR WHEEL ECA21030 1. Check: NOTICE • Rear wheel axle • Keep any type of magnets (including mag- • Wheel bearings netic pick-up tools, magnetic screwdrivers, • Oil seal etc.) away from the rear wheel sensor or Refer to “CHECKING THE FRONT WHEEL”...

  • Page 121: Maintenance Of The Rear Wheel Sensor And Sensor Rotor

    REAR WHEEL 1. Check: • Rear wheel sensor Refer to “MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR” on page 4-14. 2. Check: • Rear wheel sensor rotor Refer to “MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR” G088904 on page 4-14.
  • Page 122 REAR WHEEL Rear wheel sensor rotor bolt Recommended lubricant 8 N·m (0.8 kgf·m, 5.9 lb·ft) Lithium-soap-based grease LOCTITE® Rear brake disc bolt 5. Install: 30 N·m (3.0 kgf·m, 22 lb·ft) • Collar (right) LOCTITE® • Collar (left) • Rear brake caliper “1” ECA21011 •...
  • Page 123 REAR WHEEL Out of specification → Check the wheel bear- ing for looseness, and the rear wheel sensor and sensor rotor installation conditions (warpage caused by overtorque, wrong in- stallation direction, rotor decentering, LOC- TITE® on the mounting surface of the rotor, deformation caused by an impact during ser- vice and caught foreign materials).

  • Page 124: Front Brake

    FRONT BRAKE EAS20030 FRONT BRAKE Removing the front brake pads 40 N m (4.0 kgf m, 30 lb • • • 10 N m (1.0 kgf m, 7.4 lb • • • ’ Order Job/Parts to remove Remarks The following procedure applies to both of the front brake calipers.
  • Page 125 FRONT BRAKE Removing the front brake master cylinder 1.5 N m (0.15 kgf m, 1.1 lb • • • 10 N m (1.0 kgf m, 7.4 lb • • • 1.0 N m (0.10 kgf m, 0.73 lb • • •...
  • Page 126 FRONT BRAKE Disassembling the front brake master cylinder ’ Order Job/Parts to remove Remarks Brake master cylinder kit Brake master cylinder body 4-27...
  • Page 127 FRONT BRAKE Removing the front brake calipers 40 N m (4.0 kgf m, 30 lb • • • 30 N m (3.0 kgf m, 22 lb • • • ’ Order Job/Parts to remove Remarks The following procedure applies to both of the front brake calipers.
  • Page 128 FRONT BRAKE Disassembling the front brake calipers 10 N m (1.0 kgf m, 7.4 lb • • • ’ Order Job/Parts to remove Remarks The following procedure applies to both of the front brake calipers. Brake pad clip Brake pad pin Brake pad Brake pad spring Brake pad support...

  • Page 129: Introduction

    FRONT BRAKE EAS30168 INTRODUCTION EWA14101 WARNING Disc brake components rarely require disas- sembly. Therefore, always follow these pre- ventive measures: • Never disassemble brake components un- less absolutely necessary. • If any connection on the hydraulic brake G098641 system is disconnected, the entire brake 3.

  • Page 130: Removing The Front Brake Calipers

    FRONT BRAKE 1. Measure: • Install the brake pad spring in the brake caliper • Brake pad wear “a” in the recessed portion that is near the brake Out of specification → Replace the brake pad pin. pads as a set. Brake pad lining thickness limit 4.0 mm (0.16 in) 3.

  • Page 131: Checking The Front Brake Calipers

    FRONT BRAKE EAS30173 CHECKING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers. Recommended brake component replacement schedule Brake pads If necessary Brake hoses Every four years Every two years and Brake fluid whenever the brake is A.

  • Page 132: Removing The Front Brake Master Cylinder

    FRONT BRAKE • When refilling, be careful that water does • Brake fluid delivery passages not enter the brake fluid reservoir. Water (brake master cylinder body) Obstruction → Blow out with compressed air. will significantly lower the boiling point of the brake fluid and could cause vapor lock.
  • Page 133 FRONT BRAKE EWA13540 WARNING • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. • Refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake performance.

  • Page 134: Rear Brake

    REAR BRAKE EAS20031 REAR BRAKE Removing the rear brake pads 10 N m (1.0 kgf m, 7.4 lb • • • ’ Order Job/Parts to remove Remarks Rear wheel Refer to “REAR WHEEL” on page 4-18. Brake pad clip Brake pad pin Brake pad Brake pad spring Brake caliper bleed screw...
  • Page 135 REAR BRAKE Removing the rear brake master cylinder 30 N m (3.0 kgf m, 22 lb • • • 23 N m (2.3 kgf m, 17 lb • • • 4.0 N m (0.40 kgf m, 3.0 lb • • •...
  • Page 136 REAR BRAKE Disassembling the rear brake master cylinder 18 N m (1.8 kgf m, 13 lb • • • ’ Order Job/Parts to remove Remarks Brake master cylinder yoke Brake master cylinder kit Hose joint Bushing Brake master cylinder body 4-37...
  • Page 137 REAR BRAKE Removing the rear brake caliper 30 N m (3.0 kgf m, 22 lb • • • ’ Order Job/Parts to remove Remarks Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM (ABS)” on page 3-14. Rear wheel Refer to “REAR WHEEL”...
  • Page 138 REAR BRAKE Disassembling the rear brake caliper 10 N m (1.0 kgf m, 7.4 lb • • • ’ Order Job/Parts to remove Remarks Brake pad clip Brake pad pin Brake pad Brake pad spring Brake pad support Boot Boot Brake caliper bleed screw 4-39...

  • Page 139: Introduction

    REAR BRAKE 4. Adjust: EAS30183 INTRODUCTION • Brake disc deflection EWA14101 Refer to “CHECKING THE FRONT BRAKE WARNING DISCS” on page 4-30. Disc brake components rarely require disas- sembly. Therefore, always follow these pre- Rear brake disc bolt ventive measures: 30 N·m (3.0 kgf·m, 22 lb·ft) •...

  • Page 140: Removing The Rear Brake Caliper

    REAR BRAKE • Rear brake caliper Refer to “REMOVING THE REAR WHEEL” on page 4-21. EAS30188 CHECKING THE REAR BRAKE CALIPER Recommended brake component replacement schedule Brake pads If necessary Brake hoses Every four years c. Tighten the bleed screw. Every two years and Brake fluid whenever the brake is...

  • Page 141: Removing The Rear Brake Master Cylinder

    REAR BRAKE EAS30193 REMOVING THE REAR BRAKE MASTER CYLINDER 1. Remove: • Brake hose union bolt • Brake hose gaskets • Brake hose (rear brake master cylinder to hy- draulic unit) To collect any remaining brake fluid, place a container under the master cylinder and the end 3.

  • Page 142: Installing The Rear Brake Master Cylinder

    REAR BRAKE • When refilling, be careful that water does EAS30196 INSTALLING THE REAR BRAKE MASTER not enter the brake fluid reservoir. Water CYLINDER will significantly lower the boiling point of 1. Install: the brake fluid and could cause vapor lock. •...

  • Page 143: Abs (Anti-Lock Brake System)

    ABS (ANTI-LOCK BRAKE SYSTEM) EAS20032 ABS (ANTI-LOCK BRAKE SYSTEM) Removing the hydraulic unit assembly 30 N m (3.0 kgf m, 22 lb • • • m (0.7 kgf m, 5.2 lb • • • 3.8 N m (0.38 kgf m, 2.8 lb •...
  • Page 144 ABS (ANTI-LOCK BRAKE SYSTEM) Removing the hydraulic unit assembly 30 N m (3.0 kgf m, 22 lb • • • m (0.7 kgf m, 5.2 lb • • • 3.8 N m (0.38 kgf m, 2.8 lb • • • m (0.7 kgf m, 5.2 lb •...

  • Page 145: Removing The Hydraulic Unit Assembly

    ABS (ANTI-LOCK BRAKE SYSTEM) EAS31036 REMOVING THE HYDRAULIC UNIT Do not operate the brake lever and brake pedal ASSEMBLY while removing the brake hoses. ECA21091 NOTICE ECA14530 Unless necessary, avoid removing and in- NOTICE stalling the brake hoses of the hydraulic unit When removing the brake hoses, cover the assembly.
  • Page 146 ABS (ANTI-LOCK BRAKE SYSTEM) “1”, and then temporarily tighten the union bolt for the brake hose (hydraulic unit to Do not allow any foreign materials to enter the right front brake caliper). hydraulic unit assembly or the brake hoses e. Position the brake hose (hydraulic unit to when installing the hydraulic unit assembly.

  • Page 147: Hydraulic Unit Operation Tests

    Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up • For the brake line routing confirmation, use the any spilt brake fluid immediately. diagnosis of function of the Yamaha diagnostic 6. Bleed: tool. • Brake system •...
  • Page 148 Refer to “YAMAHA DIAGNOSTIC TOOL” on respectively. page 8-34. ECA18280 6. Start the Yamaha diagnostic tool and display NOTICE the diagnosis of function screen. • Check that the pulse is felt in the brake le- 7. Select code No. 2, “Brake line routing confir- ver, brake pedal, and again in the brake le- mation”.
  • Page 149 90890-03262 Refer to “YAMAHA DIAGNOSTIC TOOL” on G088913 page 8-34. 6. Start the Yamaha diagnostic tool and display 10.After the pulsating action has stopped in the the diagnosis of function screen. brake lever, it is generated in the brake pedal 7.

  • Page 150: Checking The Abs Warning Light

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

  • Page 151: Handlebar

    HANDLEBAR EAS20033 HANDLEBAR Removing the handlebar 18 N m (1.8 kgf m, 13 lb 26 N m (2.6 kgf m, 19 lb m (0.7 kgf m, 5.2 lb • • • • • • • • • 28 N m (2.8 kgf m, 21 lb •...
  • Page 152 HANDLEBAR Removing the handlebar 18 N m (1.8 kgf m, 13 lb 26 N m (2.6 kgf m, 19 lb m (0.7 kgf m, 5.2 lb • • • • • • • • • 28 N m (2.8 kgf m, 21 lb •...

  • Page 153: Removing The Handlebar

    HANDLEBAR EAS30203 EAS30205 REMOVING THE HANDLEBAR INSTALLING THE HANDLEBAR 1. Stand the vehicle on a level surface. 1. Stand the vehicle on a level surface. EWA13120 EWA13120 WARNING WARNING Securely support the vehicle so that there is Securely support the vehicle so that there is no danger of it falling over.
  • Page 154 HANDLEBAR • Lubricate the clutch lever pivot bolt and nut Throttle cable housing bolt with the lithium-soap-based grease. 3.0 N·m (0.30 kgf·m, 2.2 lb·ft) • Fit the projection “b” on the bottom of the bolt head into the slot “c” in the bolt hole in the clutch lever holder.
  • Page 155 HANDLEBAR G088917 8. Install: 10.Install: • Handlebar grip • Throttle cable holder “1” • Grip end (left) “1” Align the throttle cable holder “1” with the edge Grip end of the front brake master cylinder. 26 N·m (2.6 kgf·m, 19 lb·ft) a.
  • Page 156 HANDLEBAR Rearview mirror (left) 17 N·m (1.7 kgf·m, 13 lb·ft) Rearview mirror (right) 17 N·m (1.7 kgf·m, 13 lb·ft) Left-hand threads Handguard bolt (grip end) 18 N·m (1.8 kgf·m, 13 lb·ft) Handguard bolt (rearview mirror) 7 N·m (0.7 kgf·m, 5.2 lb·ft) LOCTITE®...

  • Page 157: Front Fork

    FRONT FORK EAS20034 FRONT FORK Removing the front fork legs 30 N m (3.0 kgf m, 22 lb • • • 23 N m (2.3 kgf m, 17 lb • • • 20 N m (2.0 kgf m, 15 lb •...
  • Page 158 FRONT FORK Disassembling the front fork legs 15 N m (1.5 kgf m, 11 lb • • • 55 N m (5.5 kgf m, 41 lb • • • ’ Order Job/Parts to remove Remarks The following procedure applies to both of the front fork legs.
  • Page 159 FRONT FORK Disassembling the front fork legs 15 N m (1.5 kgf m, 11 lb • • • 55 N m (5.5 kgf m, 41 lb • • • ’ Order Job/Parts to remove Remarks Damper rod assembly Damper rod assembly bolt O-ring Copper washer Inner tube...

  • Page 160: Removing The Front Fork Legs

    FRONT FORK EAS31648 REMOVING THE FRONT FORK LEGS Fork spring compression tool The following procedure applies to both of the 90890-01573 front fork legs. Fork spring compression tool 1. Stand the vehicle on a level surface. YM-01573 Rod holder EWA13120 WARNING 90890-01434 Damper rod holder double ended...

  • Page 161: Checking The Front Fork Legs

    FRONT FORK G088920 4. Remove: EAS30208 CHECKING THE FRONT FORK LEGS • Outer tube The following procedure applies to both of the a. Hold the front fork leg horizontally. front fork legs. b. Securely clamp the brake caliper bracket 1. Check: in a vise with soft jaws.

  • Page 162: Assembling The Front Fork Legs

    • Inner tube’s outer surface poor handling and a loss of stability. Recommended oil Yamaha Suspension Oil G10 • When assembling the front fork leg, be sure to replace the following parts: 4. Install: –Inner tube bushing...
  • Page 163 (with the specified amount of the recom- Fork seal driver mended fork oil) 90890-01442 Adjustable fork seal driver (36–46 Recommended oil Yamaha Suspension Oil G10 YM-01442 Quantity (left) 624.0 cm³ (21.10 US oz, 21.96 Imp. oz) Quantity (right) 624.0 cm³ (21.10 US oz, 21.96 Imp.
  • Page 164 FRONT FORK • When disassembling and assembling the front fork leg, do not allow any foreign ma- Install the fork spring guide with its shorter end terial to enter the front fork. “a” pointing up “A”. 11.After filling the front fork leg, slowly stroke the damper rod “1”...

  • Page 165: Installing The Front Fork Legs

    FRONT FORK EAS30210 INSTALLING THE FRONT FORK LEGS Fork spring compression tool The following procedure applies to both of the 90890-01573 front fork legs. Fork spring compression tool YM-01573 1. Install: Rod holder • Front fork leg 90890-01434 Temporarily tighten the lower bracket pinch Damper rod holder double ended bolts.
  • Page 166 FRONT FORK Front fork cap bolt 30 N·m (3.0 kgf·m, 22 lb·ft) Upper bracket pinch bolt 23 N·m (2.3 kgf·m, 17 lb·ft) 4-67...

  • Page 167: Steering Head

    STEERING HEAD EAS20035 STEERING HEAD Removing the lower bracket 148 N m (14.8 kgf m, 110 lb • • • 1st 75 N m (7.5 kgf m, 55 lb • • • 2nd 7 N m (0.7 kgf m, 5.2 lb •...
  • Page 168 STEERING HEAD Removing the lower bracket 148 N m (14.8 kgf m, 110 lb • • • 1st 75 N m (7.5 kgf m, 55 lb • • • 2nd 7 N m (0.7 kgf m, 5.2 lb • • •...

  • Page 169: Removing The Lower Bracket

    STEERING HEAD • Bearing races EAS30213 REMOVING THE LOWER BRACKET Damage/pitting → Replace the bearings and 1. Stand the vehicle on a level surface. bearing races as a set. EWA13120 3. Replace: WARNING • Bearings Securely support the vehicle so that there is •...

  • Page 170: Installing The Steering Head

    STEERING HEAD EAS30216 INSTALLING THE STEERING HEAD Tighten each lower bracket pinch bolt to specifi- 1. Lubricate: cation in the order. • Upper bearing Pinch bolt “1” → Pinch bolt “2” → Pinch bolt “1” • Lower bearing → Pinch bolt “2”. Recommended lubricant Lithium-soap-based grease 2.

  • Page 171: Rear Shock Absorber Assembly

    REAR SHOCK ABSORBER ASSEMBLY EAS20036 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly 48 N m (4.8 kgf m, 35 lb • • • 60 N m (6.0 kgf m, 44 lb • • • 45 N m (4.5 kgf m, 33 lb •...

  • Page 172: Handling The Rear Shock Absorber

    REAR SHOCK ABSORBER ASSEMBLY EAS30826 HANDLING THE REAR SHOCK ABSORBER Pass a suitable rod “1” through the holes in the EWA13740 WARNING brackets of the passenger footrests “2” and se- cure the rod to support the vehicle. This rear shock absorber contains highly compressed nitrogen gas.

  • Page 173: Installing The Relay Arm

    REAR SHOCK ABSORBER ASSEMBLY • Install both the rear shock absorber assembly and brake hose bracket “3” using the rear shock absorber assembly bolt. • Install the rear shock absorber assembly bolt “2” so that the bolt head fits between the pro- jections “a”...

  • Page 174: Swingarm

    SWINGARM EAS20037 SWINGARM Removing the swingarm 110 N m (11 kgf m, 81 lb • • • m (0.7 kgf m, 5.2 lb • • • m (0.7 kgf m, 5.2 lb • • • m (0.7 kgf m, 5.2 lb •...
  • Page 175 SWINGARM Removing the swingarm 110 N m (11 kgf m, 81 lb • • • m (0.7 kgf m, 5.2 lb • • • m (0.7 kgf m, 5.2 lb • • • m (0.7 kgf m, 5.2 lb • •...

  • Page 176: Removing The Swingarm

    SWINGARM EAS30226 REMOVING THE SWINGARM Loosen the adjusting bolt with the engine align- 1. Stand the vehicle on a level surface. ment tool “1”. EWA13120 WARNING Securely support the vehicle so that there is Engine alignment tool no danger of it falling over. 90890-11097 Pass a suitable rod “1”...

  • Page 177: Installing The Swingarm

    SWINGARM EAS30228 INSTALLING THE SWINGARM 1. Lubricate: • Oil seals • Pivot shaft Recommended lubricant Lithium-soap-based grease 2. Install: • Bearings “1” • Oil seals “2” (to the swingarm “3”) Installed depth “a” 28.3–29.7 mm (1.11–1.17 in) Installed depth “b” 11.5–13.0 mm (0.45–0.51 in) Installed depth “c”...
  • Page 178 SWINGARM 6. Install: • Washer • Pivot shaft nut Pivot shaft nut 110 N·m (11 kgf·m, 81 lb·ft) 7. Install: • Rear wheel Refer to “REAR WHEEL” on page 4-18. 8. Adjust: • Drive chain slack Refer to “ADJUSTING THE DRIVE CHAIN SLACK”...

  • Page 179: Chain Drive

    CHAIN DRIVE EAS20038 CHAIN DRIVE Removing the drive chain 14 N m (1.4 kgf m, 10 lb • • • 10 N m (1.0 kgf m, 7.4 lb • • • m (0.9 kgf m, 6.6 lb • • • 10 N m (1.0 kgf m, 7.4 lb...
  • Page 180 CHAIN DRIVE Removing the drive chain 14 N m (1.4 kgf m, 10 lb • • • 10 N m (1.0 kgf m, 7.4 lb • • • m (0.9 kgf m, 6.6 lb • • • 10 N m (1.0 kgf m, 7.4 lb •...

  • Page 181: Removing The Drive Sprocket

    CHAIN DRIVE EAS31115 REMOVING THE DRIVE SPROCKET Loosen the drive sprocket nut before removing the rear wheel. 1. Straighten the drive sprocket nut ribs “a”. G088937 2. Loosen: • Drive sprocket nut G088938 Loosen the drive sprocket nut while pressing the 2.

  • Page 182: Checking The Drive Sprocket

    CHAIN DRIVE • Do not soak the drive chain in kerosene for EAS30231 CHECKING THE DRIVE SPROCKET more than ten minutes, otherwise the O- 1. Check: rings can be damaged. • Drive sprocket More than 1/4 tooth “a” wear → Replace the drive sprocket, drive chain, and rear wheel sprocket as a set.

  • Page 183: Installing The Drive Chain

    CHAIN DRIVE 5. Adjust: EAS30234 INSTALLING THE DRIVE CHAIN • Installed shift rod length 1. Install: a. Loosen both locknuts “1”. • Drive chain 2. Lubricate: The shift rod locknut (shift pedal side) has left- • Drive chain hand threads. Recommended lubricant b.
  • Page 184 CHAIN DRIVE Drive chain slack 43.0–48.0 mm (1.69–1.89 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. Therefore, keep the drive chain slack within the specified lim- its.

  • Page 185: Engine

    ENGINE ENGINE INSPECTION ..................5-1 MEASURE THE COMPRESSION PRESSURE........5-1 ENGINE REMOVAL ..................5-3 REMOVING THE ENGINE ................ 5-8 INSTALLING THE ENGINE............... 5-8 INSTALLING THE EXHAUST PIPE AND MUFFLER........5-9 CAMSHAFTS....................5-10 REMOVING THE IGNITION COILS ............5-13 REMOVING THE CAMSHAFTS..............5-13 CHECKING THE CAMSHAFTS ..............5-14 CHECKING THE CAMSHAFT SPROCKETS .........5-15 CHECKING THE TIMING CHAIN TENSIONER........
  • Page 186 CLUTCH ......................5-42 REMOVING THE CLUTCH ..............5-46 CHECKING THE FRICTION PLATES.............5-46 CHECKING THE CLUTCH PLATES ............5-47 CHECKING THE CLUTCH SPRINGS.............5-47 CHECKING THE CLUTCH HOUSING ............5-47 CHECKING THE CLUTCH BOSS............5-47 CHECKING THE PRESSURE PLATE ............5-47 CHECKING THE PRIMARY DRIVE GEAR..........5-47 CHECKING THE PRIMARY DRIVEN GEAR ..........5-47 CHECKING THE PULL LEVER SHAFT AND PULL ROD ......5-48 INSTALLING THE CLUTCH..............
  • Page 187 CRANKSHAFT AND BALANCER SHAFT ...........5-76 REMOVING THE BALANCER SHAFT JOURNAL BEARINGS ....5-77 REMOVING THE CRANKSHAFT JOURNAL BEARINGS ......5-77 CHECKING THE BALANCER SHAFT ASSEMBLY........5-77 CHECKING THE CRANKSHAFT ............5-79 INSTALLING THE CRANKSHAFT ............5-81 INSTALLING THE BALANCER SHAFT ASSEMBLY......5-81 TRANSMISSION.................... 5-82 REMOVING THE TRANSMISSION ............

  • Page 188: Engine Inspection

    ENGINE INSPECTION 6. Measure: EAS20041 ENGINE INSPECTION • Compression pressure Out of specification → Refer to steps (c) and EAS30249 (d). MEASURE THE COMPRESSION PRESSURE The following procedure applies to all of the cyl- inders. Due to the engine characteristics, the compres- sion pressure is different for cylinder #1 and cyl- inder #2.
  • Page 189 ENGINE INSPECTION 7. Install: • Spark plugs • Ignition coils Spark plug 13 N·m (1.3 kgf·m, 9.6 lb·ft)

  • Page 190: Engine Removal

    ENGINE REMOVAL EAS20042 ENGINE REMOVAL Removing the exhaust pipe 10 N m (1.0 kgf m, 7.4 lb • • • 11 N m (1.1 kgf m, 8.1 lb • • • 10 N m (1.0 kgf m, 7.4 lb • •...
  • Page 191 ENGINE REMOVAL Disconnecting the leads m (0.7 kgf m, 5.2 lb • • • ’ Order Job/Parts to remove Remarks Drain. Engine oil Refer to “CHANGING THE ENGINE OIL” on page 3-24. Drain. Coolant Refer to “CHANGING THE COOLANT” on page 3-27.
  • Page 192 ENGINE REMOVAL Disconnecting the leads m (0.7 kgf m, 5.2 lb • • • ’ Order Job/Parts to remove Remarks Cylinder head breather hose/Sub-wire harness/ Refer to “THROTTLE BODIES” on page 7-5. Throttle bodies Clutch cable Disconnect. Gear position sensor coupler Disconnect.
  • Page 193 ENGINE REMOVAL Removing the engine 30 N m (3.0 kgf m, 22 lb • • • 55 N m (5.5 kgf m, 41 lb • • • 30 N m (3.0 kgf m, 22 lb • • • 55 N m (5.5 kgf m, 41 lb 75 N...
  • Page 194 ENGINE REMOVAL Removing the engine 16 15 30 N m (3.0 kgf m, 22 lb • • • 55 N m (5.5 kgf m, 41 lb • • • 30 N m (3.0 kgf m, 22 lb • • • 55 N m (5.5 kgf m, 41 lb...

  • Page 195: Removing The Engine

    ENGINE REMOVAL EAS30250 REMOVING THE ENGINE 1. Loosen: • Engine mounting adjust bolt Loosen the engine mounting adjust bolt using a 1/2 inch hexagon bit socket “1” 3. Install: • Collar “14” • Engine mounting bolt (front right side) “15” Temporarily tighten the bolt.

  • Page 196: Installing The Exhaust Pipe And Muffler

    ENGINE REMOVAL Engine mounting bolt (right up- Installed depth of gasket “b” per side) 5.0 mm (0.20 in) 55 N·m (5.5 kgf·m, 41 lb·ft) 10.Tighten: • Engine bracket bolts (left and right) “13”, “18” Engine bracket bolts 30 N·m (3.0 kgf·m, 22 lb·ft) Tighten the engine bracket bolts in any order.

  • Page 197: Camshafts

    CAMSHAFTS EAS20043 CAMSHAFTS Removing the cylinder head cover 10 N m (1.0 kgf m, 7.4 lb • • • 13 N m (1.3 kgf m, 9.6 lb • • • 13 N m (1.3 kgf m, 9.6 lb • • •...
  • Page 198 CAMSHAFTS Removing the cylinder head cover 10 N m (1.0 kgf m, 7.4 lb • • • 13 N m (1.3 kgf m, 9.6 lb • • • 13 N m (1.3 kgf m, 9.6 lb • • • 4.0 N m (0.40 kgf m, 3.0 lb •...
  • Page 199 CAMSHAFTS Removing the camshafts 10 N m (1.0 kgf m, 7.4 lb • • • 10 N m (1.0 kgf m, 7.4 lb • • • m (0.7 kgf m, 5.2 lb • • • 10 N m (1.0 kgf m, 7.4 lb •...

  • Page 200: Removing The Ignition Coils

    CAMSHAFTS EAS33146 ECA13720 REMOVING THE IGNITION COILS NOTICE 1. Remove: To prevent damage to the cylinder head, • Ignition coil camshafts or camshaft caps, loosen the Refer to “CHECKING THE SPARK PLUGS” camshaft cap bolts in stages and in a criss- on page 3-5.

  • Page 201: Checking The Camshafts

    CAMSHAFTS 4. Measure: EAS30257 CHECKING THE CAMSHAFTS • Camshaft-journal-to-camshaft-cap clearance Out of specification → Measure the camshaft 1. Check: • Camshaft lobes journal diameter. Blue discoloration/pitting/scratches → Re- Camshaft-journal-to-camshaft- place the camshaft. cap clearance 2. Measure: 0.028–0.062 mm (0.0011–0.0024 • Camshaft lobe dimensions “a” and “b” Out of specification →...

  • Page 202: Checking The Camshaft Sprockets

    CAMSHAFTS EAS30266 CHECKING THE TIMING CHAIN TENSIONER 1. Check: • Timing chain tensioner Cracks/damage/rough movement → Re- place. a. Lightly press the timing chain tensioner rod into the timing chain tensioner housing by hand. G088948 While pressing the timing chain tensioner rod, 5.

  • Page 203: Installing The Camshafts

    CAMSHAFTS Rotor holding tool 90890-01235 Universal magneto and rotor holder YU-01235 EAS30269 INSTALLING THE CAMSHAFTS 1. Align: • Mark “a” on the generator rotor (with the slot “b” in the generator rotor cover) a. Turn the crankshaft counterclockwise. b. When piston #1 is at TDC, align the TDC mark “a”...
  • Page 204 CAMSHAFTS ECA19980 NOTICE • When installing the timing chain, start with the Be sure to tighten the camshaft sprocket exhaust camshaft and be sure to keep the tim- bolts to the specified torque to avoid the ing chain as tight as possible on the exhaust possibility of the bolts coming loose and side.
  • Page 205 CAMSHAFTS c. Install a new timing chain tensioner gasket “3”, the timing chain tensioner “4”, and the timing chain tensioner bolts “5” on the cyl- inder block. Be sure to install the timing chain tensioner gas- ket so that the portion “a” of the gasket is pro- truding from the upper inner side of the timing chain tensioner.

  • Page 206: Installing The Cylinder Head Cover

    • Cylinder head cover “2” Cylinder head cover bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft) • Apply Yamaha bond No.1215 “3” onto the mat- ing surfaces of the cylinder head cover gasket and cylinder head. • After installing the cylinder head cover gasket “1”...
  • Page 207 CAMSHAFTS A. Exhaust side 2. Install: • Spark plugs • Ignition coils “1” Spark plug 13 N·m (1.3 kgf·m, 9.6 lb·ft) Install the ignition coils “1” in the direction shown in the illustration. 5-20...

  • Page 208: Cylinder Head

    CYLINDER HEAD EAS20044 CYLINDER HEAD Removing the cylinder head 1st 10 N m (1.0 kgf m, 7.4 lb • • • 2nd 40 N m (4.0 kgf m, 30 lb • • • 75 N m (7.5 kgf m, 55 lb •...
  • Page 209 CYLINDER HEAD Removing the cylinder head 1st 10 N m (1.0 kgf m, 7.4 lb • • • 2nd 40 N m (4.0 kgf m, 30 lb • • • 75 N m (7.5 kgf m, 55 lb • • •...
  • Page 210 CYLINDER HEAD Removing the cylinder head 1st 10 N m (1.0 kgf m, 7.4 lb • • • 2nd 40 N m (4.0 kgf m, 30 lb • • • 75 N m (7.5 kgf m, 55 lb • • •...

  • Page 211: Removing The Cylinder Head

    CYLINDER HEAD EAS30276 REMOVING THE CYLINDER HEAD 1. Remove: • Engine bracket bolts (left) • Engine mounting bolt (left upper side) ×2 • Engine bracket (left) • Engine mounting bolt (front right side) ×6 • Collar Place a suitable stand under the engine. 2.

  • Page 212: Installing The Cylinder Head

    CYLINDER HEAD Cylinder head bolt (“1”–“6”) 1st: 10 N·m (1.0 kgf·m, 7.4 lb·ft) 2nd: 40 N·m (4.0 kgf·m, 30 lb·ft) *3rd: 20 N·m (2.0 kgf·m, 15 lb·ft) Specified angle 90° Cylinder head bolt (“7”, “8”) 10 N·m (1.0 kgf·m, 7.4 lb·ft) * Following the tightening order, loosen the bolt one by one, and then retighten it to the a.
  • Page 213 CYLINDER HEAD 5-26...

  • Page 214: Valves And Valve Springs

    VALVES AND VALVE SPRINGS EAS20045 VALVES AND VALVE SPRINGS Removing the valves and valve springs ’ Order Job/Parts to remove Remarks Cylinder head Refer to “CYLINDER HEAD” on page 5-21. Valve lifter Valve pad Valve cotter Valve spring retainer Valve spring Exhaust valve Intake valve Valve stem seal...

  • Page 215: Removing The Valves

    VALVES AND VALVE SPRINGS EAS30283 REMOVING THE VALVES Valve spring compressor The following procedure applies to all of the 90890-04019 valves and related components. Valve spring compressor YM-04019 Valve spring compressor attach- Before removing the internal parts of the cylinder ment (ø26) head (e.g., valves, valve springs, valve seats), 90890-01243...
  • Page 216 VALVES AND VALVE SPRINGS b. Install the new valve guide with the valve Valve-stem-to-valve-guide clear- guide installer “2” and valve guide remov- ance (intake) er “1”. 0.010–0.037 mm (0.0004–0.0015 Valve guide position Limit 14.8–15.2 mm (0.58–0.60 in) 0.080 mm (0.0032 in) Valve-stem-to-valve-guide clear- ance (exhaust) 0.025–0.052 mm (0.0010–0.0020...

  • Page 217: Checking The Valve Seats

    VALVES AND VALVE SPRINGS 4. Check: • Valve face Pitting/wear → Grind the valve face. • Valve stem end Mushroom shape or diameter larger than the body of the valve stem → Replace the valve. 5. Measure: • Valve stem runout Out of specification →...

  • Page 218: Checking The Valve Springs

    VALVES AND VALVE SPRINGS j. Measure the valve seat width “c” again. If the valve seat width is out of specification, reface and lap the valve seat. G088968 b. Apply molybdenum disulfide oil onto the valve stem. G088970 c. Install the valve into the cylinder head. d.
  • Page 219 VALVES AND VALVE SPRINGS 1. Deburr: Valve spring compressor • Valve stem end 90890-04019 (with an oil stone) Valve spring compressor YM-04019 Valve spring compressor attach- ment (ø26) 90890-01243 Valve spring compressor adapt- er (26 mm) YM-01253-1 2. Lubricate: • Valve stem •...

  • Page 220: Generator And Starter Clutch

    GENERATOR AND STARTER CLUTCH EAS20140 GENERATOR AND STARTER CLUTCH Removing the stator coil, generator rotor and starter clutch 32 N m (3.2 kgf m, 24 lb • • • 10 N m (1.0 kgf m, 7.4 lb • • • 10 N m (1.0 kgf m, 7.4 lb...
  • Page 221 GENERATOR AND STARTER CLUTCH Removing the stator coil, generator rotor and starter clutch 32 N m (3.2 kgf m, 24 lb • • • 10 N m (1.0 kgf m, 7.4 lb • • • 10 N m (1.0 kgf m, 7.4 lb •...

  • Page 222: Removing The Generator

    GENERATOR AND STARTER CLUTCH EAS30867 REMOVING THE GENERATOR 1. Remove: • Generator rotor bolt “1” • Washer While holding the generator rotor “2” with the ro- tor holding tool “3”, loosen the generator rotor bolt. G088977 Rotor holding tool EAS30868 REMOVING THE STARTER CLUTCH 90890-04166 1.

  • Page 223: Checking The Torque Limiter

    GENERATOR AND STARTER CLUTCH a. Install the starter clutch gear “1” onto the generator 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 re- placed.
  • Page 224 • Apply LOCTITE® to the threads of only the generator cover bolts “1” shown in the illustra- tion. 4. Apply: • Sealant (onto the stator coil lead grommet) Yamaha bond No. 1215 90890-85505 (Three bond No.1215®) 7. Connect: • Stator coil coupler • Crankshaft position sensor coupler To route the stator coil lead, refer to “CABLE...

  • Page 225: Electric Starter

    ELECTRIC STARTER EAS20052 ELECTRIC STARTER Removing the starter motor m (0.7 kgf m, 5.2 lb • • • 10 N m (1.0 kgf m, 7.4 lb • • • ’ Order Job/Parts to remove Remarks Canister Refer to “FUEL TANK” on page 7-1. Starter motor lead Disconnect.
  • Page 226 ELECTRIC STARTER Disassembling the starter motor 11 N m (1.1 kgf m, 8.1 lb • • • m (0.5 kgf m, 3.7 lb • • • ’ Order Job/Parts to remove Remarks O-ring Starter motor front cover Starter motor yoke Armature assembly Gasket Brush holder set...

  • Page 227: Checking The Starter Motor

    ELECTRIC STARTER EAS30325 CHECKING THE STARTER MOTOR Brush overall length limit 1. Check: 6.5 mm (0.26 in) • Commutator Dirt → Clean with 600 grit sandpaper. 2. Measure: • Mica undercut “a” Out of specification → Cut the mica to the proper measurement with a hacksaw blade that has been grounded to fit the commutator.

  • Page 228: Installing The Starter Motor

    ELECTRIC STARTER 2. Install: • Starter motor yoke “1” • Starter motor front cover “2” • Starter motor rear cover “3” Align the match marks “a” on the starter motor yoke with the match marks “b” on the front cover and rear covers.

  • Page 229: Clutch

    CLUTCH EAS20055 CLUTCH Removing the clutch cover and pull lever shaft m (0.7 kgf m, 5.2 lb • • • 12 N m (1.2 kgf m, 8.9 lb • • • 12 N m (1.2 kgf m, 8.9 lb • •...
  • Page 230 CLUTCH Removing the clutch cover and pull lever shaft m (0.7 kgf m, 5.2 lb • • • 12 N m (1.2 kgf m, 8.9 lb • • • 12 N m (1.2 kgf m, 8.9 lb • • • ’...
  • Page 231 CLUTCH Removing the clutch m (0.8 kgf m, 5.9 lb • • • 10 N m (1.0 kgf m, 7.4 lb • • • 95 N m (9.5 kgf m, 70 lb • • • ’ Order Job/Parts to remove Remarks Compression spring Pressure plate...
  • Page 232 CLUTCH Removing the clutch m (0.8 kgf m, 5.9 lb • • • 10 N m (1.0 kgf m, 7.4 lb • • • 95 N m (9.5 kgf m, 70 lb • • • ’ Order Job/Parts to remove Remarks Washer Clutch boss...

  • Page 233: Removing The Clutch

    CLUTCH EAS30346 REMOVING THE CLUTCH 1. Remove: • Clutch cover • 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. G088993 2.

  • Page 234: Checking The Clutch Plates

    CLUTCH EAS30352 CHECKING THE CLUTCH HOUSING 1. Check: • Clutch housing dogs Damage/pitting/wear → Deburr the clutch housing dogs or replace the clutch housing. Pitting on the clutch housing dogs will cause er- ratic clutch operation. 2. Check: A. Friction plate 1 •...

  • Page 235: Checking The Pull Lever Shaft And Pull Rod

    CLUTCH EAS30358 CHECKING THE PULL LEVER SHAFT AND Universal clutch holder PULL ROD 90890-04086 1. Check: Universal clutch holder • Pull lever shaft pinion gear teeth YM-91042 • Pull rod teeth Damage/wear → Replace the pull rod and pull lever shaft as a set. 2.
  • Page 236 CLUTCH Clutch spring bolt Clutch cover bolt 8 N·m (0.8 kgf·m, 5.9 lb·ft) 12 N·m (1.2 kgf·m, 8.9 lb·ft) Clutch cable holder bolt 12 N·m (1.2 kgf·m, 8.9 lb·ft) LOCTITE® • Apply lithium-soap-based grease onto the pull rod. • Tighten the clutch spring bolts in stages and in •...
  • Page 237 CLUTCH • After installing the clutch cable, bend the pro- jection “b” on the pull lever. 9. Adjust: • Clutch lever free play Refer to “ADJUSTING THE CLUTCH LEVER FREE PLAY” on page 3-12. Clutch lever free play 5.0–10.0 mm (0.20–0.39 in) 5-50...

  • Page 238: Shift Shaft

    SHIFT SHAFT EAS20057 SHIFT SHAFT Removing the shift shaft and stopper lever 22 N m (2.2 kgf m, 16 lb • • • ’ Order Job/Parts to remove Remarks Drain. Engine oil Refer to “CHANGING THE ENGINE OIL” on page 3-24. Drain.
  • Page 239 SHIFT SHAFT Removing the shift shaft and stopper lever 12 13 22 N m (2.2 kgf m, 16 lb • • • ’ Order Job/Parts to remove Remarks Stopper lever Stopper lever spring Collar Shift shaft spring Shift shaft spring stopper Oil seal Bearing 5-52...

  • Page 240: Checking The Shift Shaft

    SHIFT SHAFT • Hook the ends of the stopper lever spring “3” EAS30377 CHECKING THE SHIFT SHAFT onto the stopper lever “4” and the stopper lever 1. Check: spring hook “5”. • Shift shaft • Mesh the stopper lever with the shift drum seg- Bends/damage/wear →...

  • Page 241: Oil Pump

    OIL PUMP EAS20054 OIL PUMP Removing the oil pump 10 N m (1.0 kgf m, 7.4 lb • • • 12 N m (1.2 kgf m, 8.9 lb • • • 12 N m (1.2 kgf m, 8.9 lb • •...
  • Page 242 OIL PUMP Disassembling the oil pump 3.8 N m (0.38 kgf m, 2.8 lb • • • ’ Order Job/Parts to remove Remarks Oil pump cover Oil pump rotor assembly Oil pump inner rotor Oil pump outer rotor Oil pump driven sprocket Hold down the washer when removing the Circlip circlip.

  • Page 243: Checking The Sprocket And Chain

    OIL PUMP 3. Check: EAS30336 CHECKING THE SPROCKET AND CHAIN • Oil pump operation 1. Check: Rough movement → Repeat steps (1) and • Oil pump drive sprocket (2) or replace the oil pump assembly. Refer to “CHECKING THE CLUTCH HOUS- ING”...

  • Page 244: Installing The Oil Pump

    OIL PUMP 4. Check: • Oil pump operation Refer to “CHECKING THE OIL PUMP” on page 5-56. EAS30343 INSTALLING THE OIL PUMP 1. Install: • Oil pump “1” • Oil pump bolts “2” Oil pump bolt 12 N·m (1.2 kgf·m, 8.9 lb·ft) ECA20940 NOTICE After installing the oil pump drive chain and...

  • Page 245: Oil Pan

    OIL PAN EAS20177 OIL PAN Removing the oil pan 43 N m (4.3 kgf m, 32 lb • • • 10 N m (1.0 kgf m, 7.4 lb 10 N m (1.0 kgf m, 7.4 lb (11) • • • •...

  • Page 246: Removing The Oil Pan

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

  • Page 247: Crankcase

    CRANKCASE EAS20059 CRANKCASE Separating the crankcase 24 N m (2.4 kgf m, 18 lb • • • 24 N m (2.4 kgf m, 18 lb • • • 17 N m (1.7 kgf m, 13 lb • • • 10 N m (1.0 kgf m, 7.4 lb •...
  • Page 248 CRANKCASE Separating the crankcase 24 N m (2.4 kgf m, 18 lb 24 N m (2.4 kgf m, 18 lb • • • • • • 17 N m (1.7 kgf m, 13 lb • • • 10 N m (1.0 kgf m, 7.4 lb •...

  • Page 249: Disassembling The Crankcase

    ×8 (onto the crankcase mating surfaces) ×3 ×2 ×2 ×6 ×5 Yamaha bond No. 1215 90890-85505 (Three bond No.1215®) ECA20880 NOTICE Do not allow any sealant to come into con- tact with the oil gallery, crankshaft journal bearings, or balancer shaft journal bearings.
  • Page 250 CRANKCASE • Lubricate the bolts “13”–“27” threads and mat- ing surfaces with engine oil. • M9 × 80 mm bolt (×5) (bolts with washers): “1”, “3”–“6” • M9 × 90 mm bolt (×1) (bolt with washer): “2” • M8 × 70 mm bolt (×6) (bolts with new O- rings): “7”–“12”...

  • Page 251: Installing The Oil Pressure Switch

    24 N·m (2.4 kgf·m, 18 lb·ft) (onto the oil pressure switch threads) Crankcase bolts “15”–“27” 10 N·m (1.0 kgf·m, 7.4 lb·ft) Yamaha bond No. 1215 90890-85505 (Three bond No.1215®) • Tighten the bolts “7”–“16” in the tightening se- quence cast on the crankcase.
  • Page 252 CRANKCASE 10˚ 45˚ 5-65...
  • Page 253 CONNECTING RODS AND PISTONS EAS20132 CONNECTING RODS AND PISTONS Removing the connecting rods and pistons 1st 20 N m (2.0 kgf m, 15 lb • • • 2nd Specified angle 180° ’ Order Job/Parts to remove Remarks The following procedure applies to all of the connecting rods and pistons.

  • Page 254: Connecting Rods And Pistons

    CONNECTING RODS AND PISTONS • Oil ring EAS30745 REMOVING THE CONNECTING RODS AND PISTONS When removing a piston ring, open the end gap The following procedure applies to all of the con- with your fingers and lift the other side of the ring necting rods and pistons.

  • Page 255: Checking The Piston Rings

    CONNECTING RODS AND PISTONS b. If out of specification, replace the cylinder, Piston ring and replace the piston and piston rings as Top ring a set. Ring side clearance c. Measure piston skirt diameter “b” with the 0.030–0.065 mm (0.0012– micrometer.

  • Page 256: Checking The Piston Pin

    CONNECTING RODS AND PISTONS G089003 G089005 4. Calculate: a. Bottom of cylinder • Piston-pin-to-piston-pin-bore clearance b. Top of cylinder Out of specification → Replace the piston pin EAS30749 and piston as a set. CHECKING THE PISTON PIN Piston-pin-to-piston-pin-bore clearance = The following procedure applies to all of the pis- Piston pin bore inside diameter “b”...
  • Page 257 CONNECTING RODS AND PISTONS Align the projections “a” on the big end bearings with the notches “b” in the connecting rod and connecting rod cap. Install by carrying out the following procedures in order to assemble in the most suitable condition. G089006 e.
  • Page 258 CONNECTING RODS AND PISTONS • Make sure the “Y” marks “b” on the connecting rods face towards the left side of the crank- shaft. 180˚ j. After the installation, check that the sec- tion shown “a” is flush with each other by touching the surface.

  • Page 259: Installing The Connecting Rod And Piston

    CONNECTING RODS AND PISTONS • “P ”–“P ” refer to the bearings shown in the EAS30751 INSTALLING THE CONNECTING ROD AND crankshaft illustration. PISTON The following procedure applies to all of the con- necting rods and pistons. 1. Install: • Big end bearings •...
  • Page 260 CONNECTING RODS AND PISTONS b. Clean the connecting rod bolts and lubri- cate the bolt threads and seats with mo- lybdenum disulfide oil. c. After installing the big end bearing, as- semble the connecting rod and connecting rod cap without installing them onto the crankshaft.
  • Page 261 CONNECTING RODS AND PISTONS Recommended lubricant Engine oil 6. Offset: • Piston ring end gaps 45˚ 45˚ 90˚ a. 2nd ring b. Lower oil ring rail c. Upper oil ring rail d. Top ring e. Oil ring expander A. Exhaust side 9.
  • Page 262 CONNECTING RODS AND PISTONS EWA16610 WARNING If the bolt is tightened more than the speci- fied angle, do not loosen the bolt and then re- tighten it. Instead, replace the bolt with a new one and perform the procedure again. ECA20890 NOTICE Do not use a torque wrench to tighten the...

  • Page 263: Crankshaft And Balancer Shaft

    CRANKSHAFT AND BALANCER SHAFT EAS20178 CRANKSHAFT AND BALANCER SHAFT Removing the crankshaft and balancer shaft ’ Order Job/Parts to remove Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-60. Refer to “CONNECTING RODS AND PIS- Connecting rod TONS” on page 5-66. Balancer shaft assembly Balancer shaft journal lower bearing Balancer shaft journal upper bearing...

  • Page 264: Removing The Balancer Shaft Journal Bearings

    CRANKSHAFT AND BALANCER SHAFT 3. Check: EAS31072 REMOVING THE BALANCER SHAFT • Balancer shaft assembly JOURNAL BEARINGS Cracks/damage/wear → Replace the balanc- 1. Remove: er shaft assembly and journal bearings. • Balancer shaft journal lower bearings Dirt → Clean. (from the crankcase) •...
  • Page 265 CRANKSHAFT AND BALANCER SHAFT Do not put the Plastigauge® over the oil hole in the balancer shaft journal. 5. Select: • Balancer shaft journal bearings (J –J • The numbers “A” stamped into the crankcase d. Install the balancer shaft journal lower and the numbers “B”...

  • Page 266: Checking The Crankshaft

    CRANKSHAFT AND BALANCER SHAFT For example, if the crankcase J and balanc- 4. Measure: • Crankshaft-journal-to-crankshaft-journal- er shaft web J numbers are 6 and 5 respec- bearing clearance tively, then the bearing size for J Out of specification → Replace the crank- (crankcase) –...
  • Page 267 CRANKSHAFT AND BALANCER SHAFT 5. Select: • Crankshaft journal bearings (J –J • The numbers “A” stamped into the crankcase and the numbers “B” stamped into the crank- shaft web are used to determine the replace- ment crankshaft journal bearing sizes. •...

  • Page 268: Installing The Crankshaft

    CRANKSHAFT AND BALANCER SHAFT Bearing color code Model identification color Pink Code -1 Purple Code 0 White Code 1 Blue G089019 Code 2 Black 2. Install: Code 3 • Balancer shaft “1” Brown Align the punch mark “a” in the balancer drive EAS31077 gear with the punch mark “b”...

  • Page 269: Transmission

    TRANSMISSION EAS20062 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks 10 N m (1.0 kgf m, 7.4 lb • • • 12 N m (1.2 kgf m, 8.9 lb • • • ’ Order Job/Parts to remove Remarks Separate.
  • Page 270 TRANSMISSION Disassembling the main axle assembly ’ Order Job/Parts to remove 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 Main axle 5-83...
  • Page 271 TRANSMISSION Disassembling the drive axle assembly ’ Order Job/Parts to remove Remarks 1st wheel gear Collar 5th wheel gear Circlip Washer 3rd wheel gear Collar Toothed lock washer Toothed lock washer retainer 4th wheel gear Collar Washer 5-84...
  • Page 272 TRANSMISSION Disassembling the drive axle assembly ’ Order Job/Parts to remove Remarks Circlip 6th wheel gear Circlip Washer Collar 2nd wheel gear Oil seal Circlip Bearing Collar Drive axle 5-85...

  • Page 273: Removing The Transmission

    TRANSMISSION EAS30430 REMOVING THE TRANSMISSION 1. Remove: • Drive axle assembly “1” • Shift drum retainer “2” • Shift fork guide bars • Shift fork “L” and “R” • Shift drum assembly • Shift fork “C” G089022 2. Check: • Shift fork guide bar Roll the shift fork guide bar on a flat surface.

  • Page 274: Checking The Transmission

    TRANSMISSION • Transmission gear dogs Cracks/damage/rounded edges → Replace the defective gear(s). G089024 EAS30433 CHECKING THE TRANSMISSION G089025 1. Measure: • Main axle runout 4. Check: (with a centering device and dial gauge “1”) • Transmission gear engagement Out of specification → Replace the main axle. (each pinion gear to its respective wheel gear) Main axle runout limit...

  • Page 275: Installing The Transmission

    TRANSMISSION • Bearing retainer Bearing retainer bolt 12 N·m (1.2 kgf·m, 8.9 lb·ft) LOCTITE® Use a suitable pin “a” to position the bearing housing, and then install the housing until it con- tacts the cylinder. 2. Install: A. Main axle •...
  • Page 276 TRANSMISSION 4. Check: • Transmission Rough movement → Repair. Oil each gear, shaft, and bearing thoroughly. 5-89...

  • Page 277: Cooling System

    COOLING SYSTEM COOLING SYSTEM DIAGRAMS ..............6-1 RADIATOR ...................... 6-2 CHECKING THE RADIATOR..............6-4 INSTALLING THE RADIATOR..............6-4 OIL COOLER....................6-5 CHECKING THE OIL COOLER ..............6-7 CHECKING THE WATER JACKET JOINT ..........6-7 CHECKING THE THERMOSTAT.............. 6-7 INSTALLING THE OIL COOLER .............. 6-7 INSTALLING THE THERMOSTAT............

  • Page 278: Cooling System Diagrams

    COOLING SYSTEM DIAGRAMS EAS20299 COOLING SYSTEM DIAGRAMS 1. Thermostat 2. Oil cooler inlet hose 3. Oil cooler 4. Oil cooler outlet hose 5. Water jacket joint inlet hose 6. Water pump outlet pipe 7. Water pump inlet pipe 8. Radiator outlet hose 9.

  • Page 279: Radiator

    RADIATOR EAS20063 RADIATOR Removing the radiator m (0.8 kgf m, 5.9 lb • • • 1.0 N m (0.10 kgf m, 0.73 lb • • • m (0.7 kgf m, 5.2 lb • • • m (0.8 kgf m, 5.9 lb •...
  • Page 280 RADIATOR Removing the radiator m (0.8 kgf m, 5.9 lb • • • 1.0 N m (0.10 kgf m, 0.73 lb • • • m (0.7 kgf m, 5.2 lb • • • m (0.8 kgf m, 5.9 lb • •...

  • Page 281: 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 G089029 screwdriver. b. Apply the specified pressure for ten sec- onds and make sure there is no drop in pressure.

  • Page 282: Oil Cooler

    OIL COOLER EAS20064 OIL COOLER Removing the oil cooler 2.0 N m (0.20 kgf m, 1.5 lb • • • 2.0 N m (0.20 kgf m, 1.5 lb • • • 10 N m (1.0 kgf m, 7.4 lb • •...
  • Page 283 OIL COOLER Removing the oil cooler 2.0 N m (0.20 kgf m, 1.5 lb • • • 2.0 N m (0.20 kgf m, 1.5 lb • • • 10 N m (1.0 kgf m, 7.4 lb • • • 40 N m (4.0 kgf m, 30 lb •...

  • Page 284: Checking The Oil Cooler

    OIL COOLER EAS30441 CHECKING THE OIL COOLER If the accuracy of the thermostat is in doubt, re- 1. Check: place it. A faulty thermostat could cause serious • Oil cooler overheating or overcooling. Cracks/damage → Replace. 2. Check: 2. Check: •...

  • Page 285: Installing The Thermostat

    OIL COOLER Refer to “INSTALLING THE RADIATOR” on page 6-4. 5. Measure: • Radiator cap opening pressure Below the specified pressure → Replace the radiator cap. Refer to “CHECKING THE RADIATOR” on page 6-4. EAS30939 INSTALLING THE THERMOSTAT 1. Install: •...

  • Page 286: Thermostat

    THERMOSTAT EAS20065 THERMOSTAT Removing the thermostat 12 N m (1.2 kgf m, 8.9 lb • • • 2.0 N m (0.20 kgf m, 1.5 lb • • • ’ Order Job/Parts to remove Remarks Drain. Coolant Refer to “CHANGING THE COOLANT” on page 3-27.

  • Page 287: Water Pump

    WATER PUMP EAS20066 WATER PUMP Removing the water pump m (0.7 kgf m, 5.2 lb • • • 12 N m (1.2 kgf m, 8.9 lb • • • 10 N m (1.0 kgf m, 7.4 lb • • • 10 N m (1.0 kgf m, 7.4 lb...
  • Page 288 WATER PUMP Removing the water pump m (0.7 kgf m, 5.2 lb • • • 12 N m (1.2 kgf m, 8.9 lb • • • 10 N m (1.0 kgf m, 7.4 lb • • • 10 N m (1.0 kgf m, 7.4 lb m (0.7 kgf m, 5.2 lb...

  • Page 289: Disassembling The Water Pump

    WATER PUMP EAS30446 EAS30447 DISASSEMBLING THE WATER PUMP CHECKING THE WATER PUMP 1. Remove: 1. Check: • Mechanical seal (impeller side) “1” • Water pump housing (from the impeller, with a thin, flat-head • Clutch cover screwdriver) • Impeller shaft Cracks/damage/wear →...
  • Page 290 WATER PUMP Mechanical seal installer (ø33) If the surface “a” of the mechanical seal (impeller 90890-04132 side) that contacts the mechanical seal (housing Water pump seal installer (ø33) side) is dirty, clean it. YM-33221-A Middle driven shaft bearing driv- Mechanical seal (impeller side) 90890-04058 0.15 mm (0.006 in) Middle drive bearing installer 40...

  • Page 291: Installing The Clutch Cover

    WATER PUMP 3. Check: EAS31117 INSTALLING THE CLUTCH COVER • Cooling system 1. Install: Leaks → Repair or replace the faulty part. • Dowel pins “1” 4. Measure: • Clutch cover gasket “2” • Radiator cap opening pressure • Clutch cover “3” Below the specified pressure →...
  • Page 292 WATER PUMP 6-15...

  • Page 293: Fuel System

    FUEL SYSTEM FUEL TANK..................... 7-1 REMOVING THE FUEL TANK ..............7-3 REMOVING THE FUEL PUMP ..............7-3 CHECKING THE FUEL PUMP BODY............7-3 CHECKING THE CYLINDER HEAD BREATHER HOSE ......7-3 CHECKING THE ROLLOVER VALVE ............7-3 INSTALLING THE CANISTER ..............7-3 INSTALLING THE FUEL PUMP..............7-4 INSTALLING THE FUEL TANK..............7-4 THROTTLE BODIES ..................7-5 REMOVING THE THROTTLE BODIES ............
  • Page 294 FUEL TANK EAS20067 FUEL TANK Removing the fuel tank 4.0 N m (0.40 kgf m, 3.0 lb • • • m (0.7 kgf m, 5.2 lb • • • m (0.7 kgf m, 5.2 lb • • • 10 N m (1.0 kgf m, 7.4 lb •...

  • Page 295: Fuel Tank

    FUEL TANK Removing the canister ’ Order Job/Parts to remove Remarks “ ” Refer to Removing the fuel tank on page 7- Fuel tank Fuel tank breather/overflow hose (fuel tank to rollover valve) Rollover valve Fuel tank breather/overflow hose (rollover valve to canister) Canister purge hose Canister breather hose...

  • Page 296: Removing The Fuel Tank

    FUEL TANK EAS30450 ECA14721 REMOVING THE FUEL TANK NOTICE 1. Extract the fuel in the fuel tank through the • Do not drop the fuel pump or give it a fuel tank cap with a pump. strong shock. 2. Remove: •...

  • Page 297: Installing The Fuel Pump

    FUEL TANK EAS30457 INSTALLING THE FUEL TANK 1. Install: • Fuel hose ECA18420 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 298: Throttle Bodies

    THROTTLE BODIES EAS20070 THROTTLE BODIES Removing the throttle bodies 15 N m (1.5 kgf m, 11 lb • • • 3.8 N m (0.38 kgf m, 2.8 lb • • • 4.5 N m (0.45 kgf m, 3.3 lb • •...
  • Page 299 THROTTLE BODIES Removing the throttle bodies 15 N m (1.5 kgf m, 11 lb • • • 3.8 N m (0.38 kgf m, 2.8 lb • • • 4.5 N m (0.45 kgf m, 3.3 lb • • • 3.0 N m (0.30 kgf m, 2.2 lb •...
  • Page 300 THROTTLE BODIES Removing the fuel injectors m (0.5 kgf m, 3.7 lb • • • 3.5 N m (0.35 kgf m, 2.6 lb • • • 3.5 N m (0.35 kgf m, 2.6 lb • • • ’ Order Job/Parts to remove Remarks ISC (Idle Speed Control) valve plate ISC (Idle Speed Control) valve...

  • Page 301: Removing The Throttle Bodies

    THROTTLE BODIES e. Pull the air filter case rearward to remove EAS30979 REMOVING THE THROTTLE BODIES it from the throttle bodies. 1. Remove: f. Remove the throttle bodies. • Throttle bodies a. Remove the battery box bracket “1”. EAS30475 CHECKING THE INJECTORS (BEFORE REMOVING) 1.
  • Page 302 THROTTLE BODIES • Spark plugs • Air filter element • Throttle body joints • Fuel hose • Exhaust system • Cylinder head breather hose • Canister purge hoses EWA17850 WARNING If the throttle bodies are subjected to strong c. Push the lever in the direction shown in shocks or dropped during checking, replace the illustration to hold the throttle valves in them.
  • Page 303 • ISC (Idle Speed Control) valve • O-ring 2. Clean: • ISC (Idle Speed Control) valve “1” Recommended cleaning agent: 3. Install: Yamaha oil & brake cleaner • O-ring ECA21230 • ISC (Idle Speed Control) valve NOTICE • ISC (Idle Speed Control) valve plate •...

  • Page 304: Checking The Throttle Body Joints

    Connect the throttle position sensor to the wire harness. d. Remove the protective cap, and then con- nect the Yamaha diagnostic tool to cou- pler. For information about using the Yamaha diag- nostic tool, refer to the operation manual that is included with the tool.

  • Page 305: Checking The Injector Pressure

    THROTTLE BODIES 1. Install new seals onto the end of each injec- e. Open the valve on the fuel injector pres- tor. sure adapter until the specified pressure is 2. Install the fuel injectors to the fuel rail. reached. Fuel rail bolt Specific air pressure 3.5 N·m (0.35 kgf·m, 2.6 lb·ft) 490 kPa (4.9 kgf/cm...

  • Page 306: Installing The Throttle Body Joints

    THROTTLE BODIES EWA16640 WARNING Fuel tank mounting bracket bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft) Cover fuel hose connections with a cloth when disconnecting them. Residual pres- Refer to “FUEL TANK” on page 7-1. sure in the fuel lines could cause fuel to •...

  • Page 307: Installing The Throttle Bodies

    THROTTLE BODIES 45° 45° a. #1 Cylinder b. #2 Cylinder A. Left B. Right EAS30980 INSTALLING THE THROTTLE BODIES 1. Install: • Throttle bodies a. Fit the throttle bodies to the throttle body joints. b. Fit the air filter case joints to the throttle bodies.
  • Page 308 THROTTLE BODIES 7-15...

  • Page 309: 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............8-33 YAMAHA DIAGNOSTIC TOOL ...............8-34 TROUBLESHOOTING DETAILS (FAULT CODE) ........8-34 TROUBLESHOOTING DETAILS (EVENT CODE)........8-80 FUEL PUMP SYSTEM...................8-83 CIRCUIT DIAGRAM ................8-83 TROUBLESHOOTING ................8-85 IMMOBILIZER SYSTEM................
  • Page 310 ABS (ANTI-LOCK BRAKE SYSTEM)............8-97 CIRCUIT DIAGRAM ................8-97 ABS COUPLER LOCATION CHART ............8-99 MAINTENANCE OF THE ABS ECU .............8-100 ABS TROUBLESHOOTING OUTLINE..........8-100 BASIC INSTRUCTIONS FOR TROUBLESHOOTING ......8-101 BASIC PROCESS FOR TROUBLESHOOTING ........8-102 [A] CHECKING THE ABS WARNING LIGHT........8-103 [A-1] ONLY THE ABS WARNING LIGHT FAILS TO COME ON...8-103 [A-2] ALL INDICATOR LIGHTS FAIL TO COME ON ......8-103 [A-3] THE ABS WARNING LIGHT COMES ON ........8-103 [A-4] ONLY THE ABS ECU FAILS TO COMMUNICATE ......8-104...

  • Page 312: Ignition System

    IGNITION SYSTEM EAS20072 IGNITION SYSTEM EAS30490 CIRCUIT DIAGRAM...
  • Page 313 IGNITION SYSTEM 1. Main switch 8. Ignition fuse 17.Battery 18.Engine ground 19.Main fuse 23.Relay unit (diode) 26.Joint coupler 27.Sidestand switch 29.Crankshaft position sensor 32.ECU (Engine Control Unit) 33.Ignition coil #1 34.Ignition coil #2 35.Spark plug 43.Lean angle sensor 66.Gear position switch 67.Handlebar switch (right) 69.Engine stop switch C.

  • Page 314: Engine Stopping Due To Sidestand Operation

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

  • Page 315: Troubleshooting

    IGNITION SYSTEM EAS30492 TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Tail cover 3. Fuel tank side covers 4. Drive sprocket cover 5. Fuel tank NG →...
  • Page 316 IGNITION SYSTEM NG → 8. Check the engine stop switch. • The engine stop switch is faulty. Refer to “CHECKING THE • Replace the right handlebar switch. SWITCHES” on page 8-129. OK ↓ NG → 9. Check the gear position switch. Refer to “CHECKING THE GEAR Replace the gear position switch.
  • Page 317 IGNITION SYSTEM...

  • Page 318: Electric Starting System

    ELECTRIC STARTING SYSTEM EAS20073 ELECTRIC STARTING SYSTEM EAS30493 CIRCUIT DIAGRAM...
  • Page 319 ELECTRIC STARTING SYSTEM 1. Main switch 8. Ignition fuse 17.Battery 18.Engine ground 19.Main fuse 20.Starter relay 21.Starter motor 23.Relay unit (diode) 24.Starting circuit cut-off relay 26.Joint coupler 27.Sidestand switch 28.Diode 66.Gear position switch 67.Handlebar switch (right) 69.Engine stop switch 70.Start switch 73.Handlebar switch (left) 74.Clutch switch...

  • Page 320: Starting Circuit Cut-Off System Operation

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

  • Page 321: Troubleshooting

    ELECTRIC STARTING SYSTEM EAS30495 TROUBLESHOOTING The starter motor fails to turn. • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Tail cover 3. Drive chain cover NG → 1. Check the fuses. (Ignition and main) Replace the fuse(s). Refer to “CHECKING THE FUS- ES”...
  • Page 322 ELECTRIC STARTING SYSTEM NG → 9. Check the gear position switch. Refer to “CHECKING THE GEAR Replace the gear position switch. POSITION SWITCH” on page 8-139. OK ↓ NG → 10.Check the sidestand switch. Refer to “CHECKING THE Replace the sidestand switch. SWITCHES”...

  • Page 323: Charging System

    CHARGING SYSTEM EAS20074 CHARGING SYSTEM EAS30496 CIRCUIT DIAGRAM 15.Stator coil 16.Rectifier/regulator 17.Battery 18.Engine ground 19.Main fuse 8-12...

  • Page 324: Troubleshooting

    CHARGING SYSTEM EAS30497 TROUBLESHOOTING The battery is not being charged. • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Air scoop (left) NG → 1. Check the fuse. (Main) Replace the fuse. Refer to “CHECKING THE FUS- ES” on page 8-130. OK ↓...
  • Page 325 CHARGING SYSTEM 8-14...

  • Page 326: Lighting System

    LIGHTING SYSTEM EAS20075 LIGHTING SYSTEM EAS30498 CIRCUIT DIAGRAM 8-15...
  • Page 327 LIGHTING SYSTEM 1. Main switch 8. Ignition fuse 9. Signaling system fuse 10.Headlight fuse 17.Battery 18.Engine ground 19.Main fuse 26.Joint coupler 51.Meter assembly 54.Meter light 61.High beam indicator light 73.Handlebar switch (left) 75.Dimmer switch 76.Pass switch 84.Headlight assembly 85.Headlight (high beam) 86.Headlight (low beam) 87.Auxiliary light 88.License plate light...

  • Page 328: Troubleshooting

    LIGHTING SYSTEM EAS30499 TROUBLESHOOTING Any of the following fail to light: headlight (high beam), headlight (low beam), auxiliary light, license plate light, taillight, meter light or high beam indicator light. • Before troubleshooting, remove the following part(s): 1. Rider seat 2.
  • Page 329 LIGHTING SYSTEM 8-18...

  • Page 330: Signaling System

    SIGNALING SYSTEM EAS20076 SIGNALING SYSTEM EAS30500 CIRCUIT DIAGRAM 8-19...
  • Page 331 SIGNALING SYSTEM 1. Main switch 5. Parking lighting fuse 6. ABS control unit fuse 8. Ignition fuse 9. Signaling system fuse 17.Battery 18.Engine ground 19.Main fuse 22.Rear brake light switch 23.Relay unit (diode) 26.Joint coupler 29.Crankshaft position sensor 32.ECU (Engine Control Unit) 40.Coolant temperature sensor 44.Front wheel sensor 46.ABS ECU...

  • Page 332: Troubleshooting

    SIGNALING SYSTEM EAS30501 TROUBLESHOOTING • Any of the following fail to light: turn signal light, brake light or indicator light. • The horn fails to sound. • The fuel meter fails to come on. • The speedometer fails to operate. •...
  • Page 333 SIGNALING SYSTEM NG → 2. Check the entire signaling system wiring. Properly connect or replace the wiring har- Refer to “CIRCUIT DIAGRAM” on ness. page 8-19. OK ↓ Replace the horn. The brake light fails to come on. NG → 1.
  • Page 334 SIGNALING SYSTEM NG → 5. Check the entire signaling system wiring. Properly connect or replace the wiring har- Refer to “CIRCUIT DIAGRAM” on ness. page 8-19. OK ↓ Replace the meter assembly. The neutral indicator light fails to come on. NG →...
  • Page 335 SIGNALING SYSTEM The oil pressure warning light remains on after the engine is started. NG → 1. Check the entire signaling system wiring. Properly connect or replace the wiring har- Refer to “CIRCUIT DIAGRAM” on ness. page 8-19. OK ↓ NG →...
  • Page 336 SIGNALING SYSTEM The speedometer fails to operate. NG → 1. Check the front wheel sensor. Refer to “MAINTENANCE OF THE Replace the front wheel sensor. FRONT WHEEL SENSOR AND SENSOR ROTOR” on page 4-14. OK ↓ NG → 2. Check the entire front wheel sensor Properly connect or replace the wiring har- wiring.
  • Page 337 SIGNALING SYSTEM 8-26...

  • Page 338: Cooling System

    COOLING SYSTEM EAS20077 COOLING SYSTEM EAS30502 CIRCUIT DIAGRAM 8-27...
  • Page 339 COOLING SYSTEM 1. Main switch 8. Ignition fuse 13.Radiator fan motor fuse 17.Battery 18.Engine ground 19.Main fuse 26.Joint coupler 32.ECU (Engine Control Unit) 40.Coolant temperature sensor 90.Radiator fan motor relay 91.Radiator fan motor A. Wire harness B. Sub-wire harness (Refer to “SIGNALING SYSTEM”...

  • Page 340: Troubleshooting

    COOLING SYSTEM EAS30503 TROUBLESHOOTING The radiator fan motor fails to turn. • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Tail cover 3. Fuel tank NG → 1. Check the fuses. (Ignition, radiator fan motor, and main) Replace the fuse(s). Refer to “CHECKING THE FUS- ES”...
  • Page 341 COOLING SYSTEM NG → 7. Check the entire cooling system wiring. Properly connect or replace the wiring har- Refer to “CIRCUIT DIAGRAM” on ness. page 8-27. OK ↓ Replace the ECU. Refer to “REPLAC- ING THE ECU (engine control unit)” on page 8-130.

  • Page 342: Fuel Injection System

    FUEL INJECTION SYSTEM EAS20078 FUEL INJECTION SYSTEM EAS30504 CIRCUIT DIAGRAM 8-31...
  • Page 343 38.ISC (Idle Speed Control) unit 39.Intake air temperature sensor 40.Coolant temperature sensor 41.Intake air pressure sensor 43.Lean angle sensor 44.Front wheel sensor 46.ABS ECU 47.Yamaha diagnostic tool coupler 49.Fuel pump 51.Meter assembly 57.Multi-function meter 59.Engine trouble warning light 66.Gear position switch 67.Handlebar switch (right) 69.Engine stop switch...

  • Page 344: Ecu Self-Diagnostic Function

    The engine operation is not normal and the engine trouble warning light comes on. 1. Check: • Fault code number a. Check the fault code numbers that have a condition of “Malfunction” using the Yamaha diagnostic tool. b. Identify the faulty system with the fault code number.

  • Page 345: Yamaha Diagnostic Tool

    EAS30951 YAMAHA DIAGNOSTIC TOOL This model uses the Yamaha diagnostic tool to identify malfunctions. For information about using the Yamaha diagnostic tool, refer to the operation manual that is included with the tool. Yamaha diagnostic tool USB 90890-03267 Yamaha diagnostic tool (A/I) 90890-03262 A generic scan tool can also be used to identify malfunctions.
  • Page 346 FUEL INJECTION SYSTEM Parts connected to the ECU The following parts are connected to the ECU. When checking for a power short circuit, the couplers must be disconnected from all of the following parts beforehand. • Crankshaft position sensor • O sensor •...
  • Page 347 Check the locking condition of function mode of the Yamaha di- the coupler. agnostic tool. Disconnect the coupler and Condition is “Recover” → Go to check the pins (bent or broken item 6 and finish the service.
  • Page 348 Turn the main switch to “ON”, and then check the condition of the fault code using the mal- function mode of the Yamaha di- agnostic tool. Condition is “Recover” → Go to item 6 and finish the service. Condition is “Malfunction” →...
  • Page 349 Disconnect the coupler and function mode of the Yamaha di- check the pins (bent or broken agnostic tool. Condition is “Recover” → Go to terminals and locking condition of the pins).
  • Page 350 FUEL INJECTION SYSTEM [For P0108] Open circuit Between intake air pressure sensor coupler and ECU coupler: blue–blue If there is no continuity, replace the wire harness. L/R L/B Y/L P/W R/W L/Y B/R Gy/R G/Y O B/L P/W L Br/L Br/W P/L R/G G/W Gy/G...
  • Page 351 Improperly installed sensor → the fault code using the mal- Reinstall or replace the sensor. function mode of the Yamaha di- agnostic tool. Condition is “Recover” → Go to item 7 and finish the service.
  • Page 352 Check the locking condition of place the wire harness. the fault code using the mal- the coupler. function mode of the Yamaha di- Disconnect the coupler and agnostic tool. Condition is “Recover” → Go to check the pins (bent or broken terminals and locking condition item 7 and finish the service.
  • Page 353 FUEL INJECTION SYSTEM [For P0112] Ground short circuit Between intake air temperature sensor coupler and ground: brown/white–ground If there is continuity, replace the wire harness. Br/W [For P0113] Open circuit Between intake air temperature sensor coupler and ECU coupler: brown/white–brown/white If there is no continuity, replace the wire harness.
  • Page 354 Improperly installed sensor → the fault code using the mal- Reinstall or replace the sensor. function mode of the Yamaha di- agnostic tool. Condition is “Recover” → Go to item 7 and finish the service.
  • Page 355 Disconnect the coupler and function mode of the Yamaha di- check the pins (bent or broken agnostic tool. Condition is “Recover” → Go to terminals and locking condition of the pins).
  • Page 356 Improperly installed sensor → the fault code using the mal- Reinstall or replace the sensor. function mode of the Yamaha di- agnostic tool. Condition is “Recover” → Go to item 8 and finish the service.
  • Page 357 When engine is cold: the fault code using the mal- Displayed temperature is close function mode of the Yamaha di- to the ambient temperature. agnostic tool. Condition is “Recover” → Go to The displayed temperature is not close to the ambient tem- item 8 and finish the service.
  • Page 358 Check the locking condition of place the sub-wire harness. the fault code using the mal- the coupler. function mode of the Yamaha di- Disconnect the coupler and agnostic tool. Condition is “Recover” → Go to check the pins (bent or broken terminals and locking condition item 9 and finish the service.
  • Page 359 FUEL INJECTION SYSTEM [For P0122] Open circuit Between throttle position sensor coupler and ECU coupler: white–white If there is no continuity, replace the wire harness and/or sub-wire harness. L/R L/B Y/L P/W R/W L/Y B/R Gy/R G/Y O Br/L Br/W P/L R/G G/W Gy/G R/L R/B P/B...
  • Page 360 Improperly installed sensor → the fault code using the mal- Reinstall or adjust the sensor. function mode of the Yamaha di- Refer to “ADJUSTING THE agnostic tool. Condition is “Recover” → Go to THROTTLE POSITION SEN- SOR”...
  • Page 361 Improperly installed sensor → the fault code using the mal- Reinstall or replace the sensor. function mode of the Yamaha di- agnostic tool. Condition is “Recover” → Go to item 7 and finish the service.
  • Page 362 Diagnostic code No. Actuates fuel injector #1 five times at one-second intervals. Actuation The indicator on the Yamaha diagnostic tool screen comes on each time the fuel injector is actuated. Disconnect the fuel pump coupler. Check that fuel injector #1 is actuated Procedure five times by listening for the operating sound.
  • Page 363 Diagnostic code No. Actuates fuel injector #2 five times at one-second intervals. Actuation The indicator on the Yamaha diagnostic tool screen comes on each time the fuel injector is actuated. Disconnect the fuel pump coupler. Check that fuel injector #2 is actuated Procedure five times by listening for the operating sound.
  • Page 364 Check the locking condition of place the wire harness. code using the malfunction the coupler. mode of the Yamaha diagnostic Disconnect the coupler and tool. Condition is “Recover” → Go to check the pins (bent or broken terminals and locking condition item 7 and finish the service.
  • Page 365 Diagnostic code No. Actuates the cylinder-#1 ignition coil five times at one-second intervals. Actuation The indicator on the Yamaha diagnostic tool screen comes on each time the ignition coil is actuated. Check that a spark is generated five times. Procedure •...
  • Page 366 Check the condition of the fault the coupler. code using the malfunction Disconnect the coupler and mode of the Yamaha diagnostic check the pins (bent or broken tool. Condition is “Recover” → Go to terminals and locking condition of the pins).
  • Page 367 Diagnostic code No. Actuates the cylinder-#2 ignition coil five times at one-second intervals. Actuation The indicator on the Yamaha diagnostic tool screen comes on each time the ignition coil is actuated. Check that a spark is generated five times. Procedure •...
  • Page 368 Check the condition of the fault → Reinstall or replace the igni- code using the malfunction tion coil. mode of the Yamaha diagnostic tool. Condition is “Recover” → Go to item 7 and finish the service. Condition is “Malfunction” → Go to item 5.
  • Page 369 FUEL INJECTION SYSTEM Value does not increase → Go Locate the malfunction. Execute the diagnostic mode. (Code No. 07) to item A-2. Rotate the front wheel by hand and check that the indicated val- ue increases. Incorrect indication → Go to Execute the diagnostic mode.
  • Page 370 19 mph). Confirm that the fault code has a condition of “Recover” using the malfunction mode of the Yamaha diagnostic tool, and then delete the fault code. Delete this fault code even if it has a condition of “Malfunction”.
  • Page 371 FUEL INJECTION SYSTEM Improperly connected → Con- Connection of gear position Execute the diagnostic mode. switch coupler. nect the coupler securely or re- (Code No. 21) Check the locking condition of place the wire harness. When the transmission is in the coupler.
  • Page 372 19 mph). Confirm that the fault code has a condition of “Recover” using the malfunction mode of the Yamaha diagnostic tool, and then delete the fault code. Delete this fault code even if it has a condition of “Malfunction”.
  • Page 373 FUEL INJECTION SYSTEM Value does not increase → Go Locate the malfunction. Execute the diagnostic mode. (Code No. 07) to item A-2 for the front wheel Rotate the front wheel by hand sensor. and check that the indicated val- ue increases. Incorrect indication →...
  • Page 374 FUEL INJECTION SYSTEM Improperly connected → Con- Connection of ECU coupler. Execute the diagnostic mode. Check the locking condition of nect the coupler securely or re- (Code No. 21) the coupler. place the wire harness. When the clutch lever is re- Disconnect the coupler and leased with the transmission in check the pins (bent or broken...
  • Page 375 3 times and takes approximately 6 seconds each time. The in- Actuation dicator on the Yamaha diagnostic tool screen comes on during the oper- ation. Check that the ISC unit is actuated three times by listening for the operat- Procedure ing sound.
  • Page 376 3 times and takes approximately 6 seconds each time. The in- Actuation dicator on the Yamaha diagnostic tool screen comes on during the oper- ation. Check that the ISC unit is actuated three times by listening for the operat- Procedure ing sound.
  • Page 377 FUEL INJECTION SYSTEM ISC operating sound is heard → Locate the malfunction. Execute the diagnostic mode. (Code No. 54) Go to item A-2 for the compo- Fully closes the ISC (idle speed nent other than ISC (idle speed control) valve, and then fully control) unit is defective.
  • Page 378 Disconnect the coupler and function mode of the Yamaha di- check the pins (bent or broken agnostic tool. Condition is “Recover” → Go to terminals and locking condition of the pins).
  • Page 379 Between ISC (idle speed con- function mode of the Yamaha di- trol) unit coupler and sub-wire agnostic tool. Condition is “Recover” → Go to harness coupler.
  • Page 380 Delete the fault code and check Confirm that the fault code has that the engine trouble warning a condition of “Recover” using light goes off. the Yamaha diagnostic tool, and then delete the fault code. Fault code No. P0601 Fault code No. P0601 Faulty ECU memory.
  • Page 381 #1. Click the “Step up” or “Step function mode of the Yamaha di- down” button 1 time. (Clicking agnostic tool. Condition is “Recover” → Go to the “Step up” or “Step down”...
  • Page 382 Actuates the relay unit five times at one-second intervals. Actuation The indicator on the Yamaha diagnostic tool screen come on each time the relay is actuated. Check that the relay unit is actuated five times by listening for the operat- Procedure ing sound.
  • Page 383 No operating sound → Replace Check the condition of the fault the relay unit. code using the malfunction mode of the Yamaha diagnostic tool. Condition is “Recover” → Go to item 7 and finish the service. Condition is “Malfunction” → Go to item 5.
  • Page 384 Check the condition of the fault check the pins (bent or broken code using the malfunction terminals and locking condition mode of the Yamaha diagnostic of the pins). tool. Condition is “Recover” → Go to item 7 and finish the service.
  • Page 385 (loose bolts). function mode of the Yamaha di- agnostic tool. Condition is “Recover” → Go to item 7 and finish the service. Condition is “Malfunction” → Go to item 2.
  • Page 386 Between main switch and igni- the fault code using the mal- tion fuse. function mode of the Yamaha di- brown/blue–brown/blue agnostic tool. Condition is “Recover” → Go to Between ignition fuse and joint coupler.
  • Page 387 “OFF”, and then back to “ON”. Check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool. Condition is “Recover” → Go to item 6 and finish the service. Condition is “Malfunction” → Go to item 4.
  • Page 388 “OFF”, and then back to page 8-136. “ON”. Check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool. Condition is “Recover” → Go to item 6 and finish the service. Condition is “Malfunction” → Go to item 5.
  • Page 389 “Recover” using light goes off. the Yamaha diagnostic tool, and then delete the fault code. Fault code No. P2195 If fault code numbers “P2195” and “P0030” are both indicated, take the actions specified for fault code number “P0030”...
  • Page 390 Check the condition of the fault Disconnect the coupler and code using the malfunction check the pins (bent or broken mode of the Yamaha diagnostic terminals and locking condition tool. Condition is “Recover” → Go to of the pins).
  • Page 391 • “Err” is displayed on the clock display of the multi-function meter, but the engine trouble warning light does not come on. • When the Yamaha diagnostic tool is used, event code No. U0155 is displayed as a fault code. Event code No.
  • Page 392 Delete the fault code and check Confirm that the fault code has that the engine trouble warning a condition of “Recover” using light goes off. the Yamaha diagnostic tool, and then delete the fault code. Event code No. 30 Event code No. Item Latch up detected.
  • Page 393 FUEL INJECTION SYSTEM 8-82...
  • Page 394 FUEL PUMP SYSTEM EAS20081 FUEL PUMP SYSTEM EAS30513 CIRCUIT DIAGRAM 8-83...
  • Page 395 FUEL PUMP SYSTEM 1. Main switch 8. Ignition fuse 17.Battery 18.Engine ground 19.Main fuse 23.Relay unit (diode) 25.Fuel pump relay 26.Joint coupler 28.Diode 32.ECU (Engine Control Unit) 49.Fuel pump 67.Handlebar switch (right) 69.Engine stop switch C. for XTZ690 D. for XTZ690-U 8-84...
  • Page 396 FUEL PUMP SYSTEM EAS30514 TROUBLESHOOTING If the fuel pump fails to operate. • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Tail cover 3. Fuel tank NG → 1. Check the fuses. (Ignition and main) Replace the fuse(s). Refer to “CHECKING THE FUS- ES”...
  • Page 397 FUEL PUMP SYSTEM NG → 8. Check the entire fuel pump system wiring. Properly connect or replace the wiring har- Refer to “CIRCUIT DIAGRAM” on ness. page 8-83. OK ↓ Replace the ECU. Refer to “REPLAC- ING THE ECU (engine control unit)” on page 8-130.
  • Page 398 IMMOBILIZER SYSTEM EAS20084 IMMOBILIZER SYSTEM EAS30519 CIRCUIT DIAGRAM 8-87...
  • Page 399 IMMOBILIZER SYSTEM 1. Main switch 8. Ignition fuse 12.Backup fuse 14.Immobilizer unit 17.Battery 18.Engine ground 19.Main fuse 26.Joint coupler 32.ECU (Engine Control Unit) 51.Meter assembly 52.Immobilizer system indicator light C. for XTZ690 D. for XTZ690-U 8-88...
  • Page 400 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 401 IMMOBILIZER SYSTEM Parts to be replaced Main switch/immobi- Key registration re- Accessory lizer unit Standard quirement lock* and Main Immobilizer switch unit √ Standard key is lost New standard key All keys have been lost Code re-registering √ √ √ √...
  • Page 402 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 403 IMMOBILIZER SYSTEM Voiding the standard key code: If a standard key has been lost, it is possible to disable its use by re-registering the remaining standard key. Standard key registration erases the stored standard key code from the memory, thus disabling the lost standard key.
  • Page 404 IMMOBILIZER SYSTEM EAS30522 TROUBLESHOOTING When the main switch is turned to “ON”, the immobilizer system indicator light does not come on nor flashes. NG → 1. Check the fuses. (Ignition, backup, and main) Replace the fuse(s). Refer to “CHECKING THE FUS- ES”...
  • Page 405 IMMOBILIZER SYSTEM EAS30523 SELF-DIAGNOSIS FAULT CODE INDICATION When a system malfunction occurs, the immobilizer system indicator light flashes. The pattern of flash- ing also shows the fault code. Fault code Part Symptom Cause Action IMMOBILIZER Code cannot be trans- 1. Radio wave interfer- 1.
  • Page 406 IMMOBILIZER SYSTEM Fault code Part Symptom Cause Action Unidentified code is Noise interference or dis- 1. Check the wire received. connected lead/cable. harness and con- nector. 2. Replace the main switch/immobiliz- er unit. 3. Replace the ECU. Refer to “REPLAC- ING THE ECU (en- gine control unit)”...
  • Page 407 IMMOBILIZER SYSTEM 8-96...
  • Page 408 ABS (ANTI-LOCK BRAKE SYSTEM) EAS20085 ABS (ANTI-LOCK BRAKE SYSTEM) EAS30988 CIRCUIT DIAGRAM 8-97...
  • Page 409 22.Rear brake light switch 26.Joint coupler 32.ECU (Engine Control Unit) 42.Resistor unit 44.Front wheel sensor 45.Rear wheel sensor 46.ABS ECU 47.Yamaha diagnostic tool coupler 51.Meter assembly 57.Multi-function meter 64.ABS warning light 67.Handlebar switch (right) 68.Front brake light switch 69.Engine stop switch C.
  • Page 410 W P W/G (Gy) B W B W G R/B Br/W L/R L/B B/G L/R L/B R/W B 1. Front wheel sensor coupler 2. Rear wheel sensor coupler 3. Yamaha diagnostic tool coupler 4. ABS ECU coupler 5. Meter assembly coupler 8-99...
  • Page 411 Previous malfunctions can be checked since the ABS ECU also stores the mal- function history. The fault codes recorded in the ABS ECU can be checked using the Yamaha diagnostic tool. When the service is finished, check the normal operation of the vehicle, and then delete the fault code(s). For in- formation about deleting the fault codes, refer to “[B-3] DELETING THE FAULT CODES”...
  • Page 412 Since all malfunctions are recorded after they are detect- ed, 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 413 Can communicate [A-5] ABS ECU and FI ECU The battery voltage is low. • Return to [A]. fail to communicate. The connection with the Yamaha • diagnostic tool is defective. The wire harness is defective. • [B-2] Diagnose by the fault [B-3] Delete the fault codes.
  • Page 414 EAS31134 [A-3] THE ABS WARNING LIGHT COMES ON Connect the Yamaha diagnostic tool to the Yamaha diagnostic tool coupler and execute functional di- agnosis. (For information about how to execute functional diagnosis, refer to the operation manual that is included with the tool.) Check that communication with the ABS ECU is possible.
  • Page 415 Check for continuity between the black terminal of the ABS ECU coupler and ground. If there is no continuity, the wire harness is defective. Replace the wire harness. • Open circuit in the wire harness between the ABS ECU coupler and the Yamaha diagnostic tool cou- pler.
  • Page 416 Connecting the Yamaha diagnostic tool Remove the rider seat. Refer to “GENERAL CHASSIS (1)” on page 4-1. Remove the protective cap, and then connect the Yamaha diagnostic tool to the coupler. Refer to “YAMAHA DIAGNOSTIC TOOL” on page 8-34. Details about the displayed fault codes are shown in the following chart. Refer to this chart and check the vehicle.
  • Page 417 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Item Symptom Check point Rear wheel sensor (abnor- Rear wheel sensor signal is • Foreign material adhered mal pulse period) not received properly. (The around the rear wheel sen- pulse period is abnormal while the vehicle is traveling.) •...
  • Page 418 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Item Symptom Check point Brake light switch or tail/ Brake light signal is not re- • Defective signaling system brake light ceived properly while the ve- (tail/brake light or brake hicle is traveling. (Brake light light switch) circuit, or front or rear brake •...
  • Page 419 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Item Symptom Check point Rear wheel ABS (intermit- • Pulses from the rear wheel • Incorrect installation of the tent wheel speed pulses or sensor are received inter- rear wheel sensor (for fault incorrect depressurization) mittently while the vehicle code No.
  • Page 420 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Item Symptom Check point Hydraulic unit assembly (de- Abnormality is detected in • Defective battery fective ABS solenoid and the solenoid or motor power • Defective coupler between ABS motor power supply cir- supply circuit in the hydraulic the battery and the hydrau- cuits)
  • Page 421 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Item Front wheel sensor (intermittent pulses or no pulses) Front wheel sensor signal is not received properly. (Pulses are not re- Symptom ceived or are received intermittently while the vehicle is traveling.) Order Item/components and probable cause Check or maintenance job Foreign material adhered around the front Check the surface of the sensor rotor and wheel sensor...
  • Page 422 ABS (ANTI-LOCK BRAKE SYSTEM) • Vehicle possibly ridden on uneven roads. Fault code No. Item Front wheel sensor (abnormal pulse period) Front wheel sensor signal is not received properly. (The pulse period Symptom is abnormal while the vehicle is traveling.) Order Item/components and probable cause Check or maintenance job Foreign material adhered around the front...
  • Page 423 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Item Rear wheel sensor (abnormal pulse period) Rear wheel sensor signal is not received properly. (The pulse period Symptom is abnormal while the vehicle is traveling.) Order Item/components and probable cause Check or maintenance job Defective rear wheel sensor or incorrect Check the wheel sensor for damage and the installed installation of the sensor...
  • Page 424 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Item Front wheel sensor (open or short circuit) Symptom Open or short circuit is detected in the front wheel sensor. Order Item/components and probable cause Check or maintenance job Defective front wheel sensor or hydraulic If the above items were performed and no malfunctions unit assembly were found, the wheel sensor or hydraulic unit assembly...
  • Page 425 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Item Rear wheel sensor (open or short circuit) Symptom Open or short circuit is detected in the rear wheel sensor. Order Item/components and probable cause Check or maintenance job Defective rear wheel sensor or hydraulic If the above items were performed and no malfunctions unit assembly were found, the wheel sensor or hydraulic unit assembly...
  • Page 426 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Item Rear wheel sensor (missing pulses) Rear wheel sensor signal is not received properly. (Missing pulses are Symptom detected in the signal while the vehicle is traveling.) Order Item/components and probable cause Check or maintenance job Foreign material adhered around the rear Check the surface of the sensor rotor and wheel sensor wheel sensor...
  • Page 427 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Item Brake light switch or tail/brake light Brake light signal is not received properly while the vehicle is travel- Symptom ing (Brake light circuit, or front or rear brake light switch circuit). Order Item/components and probable cause Check or maintenance job Open or short circuit in the wire harness •...
  • Page 428 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. 32 Fault code No. Hydraulic unit assembly (short circuit in ABS solenoid power supply Item circuit) Short circuit is detected in the solenoid power supply circuit in the hy- Symptom draulic unit assembly. Order Item/components and probable cause Check or maintenance job Defective hydraulic unit assembly...
  • Page 429 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. 41 Fault code No. Front wheel ABS (intermittent wheel speed pulses or incorrect de- Item pressurization) • Pulses from the front wheel sensor are received intermittently while the vehicle is traveling. Symptom • Front wheel will not recover from the locking tendency even though the signal is transmitted from the ABS ECU to reduce the hydraulic pressure.
  • Page 430 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Rear wheel ABS (intermittent wheel speed pulses or incorrect depres- Item surization) • Pulses from the rear wheel sensor are received intermittently while the vehicle is traveling. (for fault code No. 42) Symptom •...
  • Page 431 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. 44 Fault code No. Item Rear wheel sensor (missing pulses) Rear wheel sensor signal is not received properly. (Missing pulses are Symptom detected in the signal while the vehicle is traveling.) Order Item/components and probable cause Check or maintenance job Foreign material adhered around the rear Check the surface of the sensor rotor and wheel sensor...
  • Page 432 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Vehicle system power supply (voltage of ABS ECU power supply is Item low) Power voltage supplied to the ABS ECU in the hydraulic unit assem- Symptom bly is too low. Order Item/components and probable cause Check or maintenance job Defective battery Recharge or replace the battery.
  • Page 433 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. 56 Fault code No. Item Hydraulic unit assembly (abnormal internal power supply) Abnormality is detected in the power supply circuit in the hydraulic Symptom unit assembly. Order Item/components and probable cause Check or maintenance job Defective hydraulic unit assembly Replace the hydraulic unit assembly.
  • Page 434 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Item Front wheel sensor power supply (voltage of power supply is low) Power voltage supplied from the ABS ECU to the front wheel sensor is Symptom too low. Order Item/components and probable cause Check or maintenance job Defective ABS ECU Replace the ABS ECU.
  • Page 435 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 is Symptom too low. Order Item/components and probable cause Check or maintenance job Defective hydraulic unit assembly Replace the hydraulic unit assembly.
  • Page 436 EAS31139 [B-3] DELETING THE FAULT CODES To delete the fault codes, use the Yamaha diagnostic tool. For information about deleting the fault codes, refer to the operation manual of the Yamaha diagnostic tool. Check that all the displayed fault codes are deleted.
  • Page 437 ABS (ANTI-LOCK BRAKE SYSTEM) EAS33280 TROUBLESHOOTING FOR THE ABS CANCEL FUNCTION Perform this troubleshooting when the ABS cancel function does not operate, or to check if the ABS cancel function operates. Before performing this troubleshooting, perform the basic troubleshooting. Refer to “BASIC PROCESS FOR TROUBLESHOOTING”...
  • Page 438 ELECTRICAL COMPONENTS EAS20089 ELECTRICAL COMPONENTS 1. Main switch/Immobilizer unit 2. Intake air temperature sensor 3. Front brake light switch 4. Clutch switch 5. Rectifier/regulator 6. Ignition coil 7. Gear position switch 8. Battery 9. Lean angle sensor 10. Fuse box 1 11.
  • Page 439 ELECTRICAL COMPONENTS 1. Hydraulic unit assembly 2. Intake air pressure sensor 3. Fuel pump 4. Main fuse 5. Starter relay 6. Relay unit (diode) 7. ECU (Engine Control Unit) 8. Rear wheel sensor 9. Turn signal/hazard relay 10. Radiator fan motor relay 11.
  • Page 440 ELECTRICAL COMPONENTS EAS30549 CHECKING THE SWITCHES Check each switch for continuity with the digital circuit tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. Br/L Br/R Br/R Br/L G G/W W/G B/W R/W L/W Y Br/W L/R PUSH...
  • Page 441 ELECTRICAL COMPONENTS EAS30551 Amperage CHECKING THE FUSES Fuses Q’ty rating The following procedure applies to all of the fus- Spare 20 A ECA13680 Spare 10 A NOTICE Spare 7.5 A To avoid a short circuit, always set the main Spare 2.0 A switch to “OFF”...
  • Page 442 ELECTRICAL COMPONENTS 1. Remove: 8. Lubricate: • Rider seat • Battery terminals Refer to “GENERAL CHASSIS (1)” on page Recommended lubricant 4-1. Dielectric grease 2. Disconnect: • Battery leads 9. Install: (from the battery terminals) • Rider seat ECA13640 Refer to “GENERAL CHASSIS (1)” on page NOTICE 4-1.
  • Page 443 ELECTRICAL COMPONENTS Starting circuit cut-off relay 2. Negative battery terminal 3. Positive tester probe 4. Negative tester probe Result Continuity (between “3” and “4”) R/W L/W L/W L/Y R/W L/G B/R B/Y Sb/W EAS30794 CHECKING THE TURN SIGNAL/HAZARD RELAY 1. Check: 1.
  • Page 444 ELECTRICAL COMPONENTS Turn signal/hazard relay output voltage DC 12V a. Connect the digital circuit tester to the turn signal/hazard relay terminal as shown. Digital circuit tester (CD732) 90890-03243 Model 88 Multimeter with ta- chometer a. Disconnect the diode from the wire har- YU-A1927 ness.
  • Page 445 ELECTRICAL COMPONENTS c. Check the relay unit (diode) for continuity. Continuity d. Check the relay unit (diode) for no continu- Positive tester probe ity. black/yellow “1” Negative tester probe EAS30558 CHECKING THE IGNITION COILS sky blue “2” The following procedure applies to all of the igni- No continuity Positive tester probe tion coils.
  • Page 446 ELECTRICAL COMPONENTS Digital circuit tester (CD732) 90890-03243 Model 88 Multimeter with ta- chometer YU-A1927 • Negative tester probe Ignition coil terminal “1” • Positive tester probe G089051 Spark plug terminal “2” 2. Ignition coil c. Turn the main switch to “ON”. d.
  • Page 447 ELECTRICAL COMPONENTS Gy B G089053 b. Measure the crankshaft position sensor c. Set the main switch to “ON”. resistance. d. Turn the lean angle sensor to 65°. e. Measure the lean angle sensor output EAS30561 voltage. CHECKING THE LEAN ANGLE SENSOR 1.
  • Page 448 ELECTRICAL COMPONENTS 2. Check: Digital circuit tester (CD732) • Stator coil resistance 90890-03243 Out of specification → Replace the stator coil. Model 88 Multimeter with ta- chometer Stator coil resistance YU-A1927 0.128–0.192 Ω a. Connect the digital circuit tester to the sta- •...
  • Page 449 ELECTRICAL COMPONENTS Coolant temperature sensor re- sistance 2510–2780 Ω at 20 °C (2510– 2780 Ω at 68 °F) Coolant temperature sensor re- sistance 210–221 Ω at 100 °C (210–221 Ω at 212 °F) a. Connect the digital circuit tester to the b.
  • Page 450 ELECTRICAL COMPONENTS • Gear position switch EWA16690 WARNING Refer to “CRANKCASE” on page 5-60. • Handle the throttle position sensor with 2. Check: special care. • Gear position switch Out of specification → Replace the gear posi- • Never subject the throttle position sensor to strong shocks.
  • Page 451 ELECTRICAL COMPONENTS O Y/W W Sb EAS30681 CHECKING THE FUEL INJECTORS The following procedure applies to all of the fuel injectors. 1. Remove: • Fuel injector Refer to “THROTTLE BODIES” on page 7-5. 2. Check: • Fuel injector resistance Out of specification → Replace the fuel injec- tor.
  • Page 452 ELECTRICAL COMPONENTS 8-141...

  • Page 453: Appendix

    APPENDIX SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE....9-1 SELF-DIAGNOSTIC FUNCTION TABLE (FOR FUEL INJECTION SYSTEM)....................9-1 SELF-DIAGNOSTIC FUNCTION TABLE (FOR IMMOBILIZER SYSTEM)....................9-7 DIAGNOSTIC CODE: SENSOR OPERATION TABLE ......9-8 DIAGNOSTIC CODE: ACTUATOR OPERATION TABLE ......9-10 EVENT CODE TABLE...................9-12...

  • Page 454: Self-Diagnostic Function And Diagnostic Code Table

    SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE EAS20311 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE EAS32705 SELF-DIAGNOSTIC FUNCTION TABLE (FOR FUEL INJECTION SYSTEM) For details of the fault code, refer to “TROUBLESHOOTING METHOD” on page 8-33. Fault code Probable cause of Fail-safe system op- Item Vehicle symptom malfunction...
  • Page 455 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Fault code Probable cause of Fail-safe system op- Item Vehicle symptom malfunction eration P0112 [P0112] Intake air [P0112] Low voltage Engine is difficult to The intake air tem- P0113 temperature sensor of the intake air tem- start.
  • Page 456 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Fault code Probable cause of Fail-safe system op- Item Vehicle symptom malfunction eration P0122 [P0122] Throttle posi- [P0122] Low voltage Engine idling speed is Change in the throttle P0123 tion sensor (open or of the throttle position high.
  • Page 457 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Fault code Probable cause of Fail-safe system op- Item Vehicle symptom malfunction eration P0335 Crankshaft position • Defective coupler Engine cannot be Does not operate. sensor (no normal between crankshaft started. ISC feedback is not signals are received position sensor and carried out.
  • Page 458 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Fault code Probable cause of Fail-safe system op- Item Vehicle symptom malfunction eration P0507 • Component other • Defective speed Engine idling speed is ISC learning is not than ISC (idle speed sensor. high. carried out.
  • Page 459 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Fault code Probable cause of Fail-safe system op- Item Vehicle symptom malfunction eration P0601 Faulty ECU memory. • Malfunction in ECU. Engine cannot be Engine cannot be (When this malfunc- started. started. tion is detected in the Engine response is Ignition and injection ECU, the fault code...

  • Page 460: Self-Diagnostic Function Table (For Immobilizer System)

    SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Fault code Probable cause of Fail-safe system op- Item Vehicle symptom malfunction eration P1602 Malfunction in ECU • Open or short cir- Engine idling speed is feedback learning internal circuit (mal- cuit in wire harness unstable.

  • Page 461: Diagnostic Code: Sensor Operation Table

    SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE EAS32425 DIAGNOSTIC CODE: SENSOR OPERATION TABLE Diagnostic Item Tool display Procedure code No. Throttle position sensor sig- • Fully closed position 11–21 Check with throttle valves fully closed. • Fully open position 96–106 Check with throttle valves fully open.
  • Page 462 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Diagnostic Item Tool display Procedure code No. Gear position switch and Operate the transmission, clutch switch clutch lever, and sidestand. • Transmission is in gear or the clutch lever released • Clutch lever is squeezed with the transmission in gear and when the side- stand is retracted...

  • Page 463: Diagnostic Code: Actuator Operation Table

    Check that a spark is gener- coil five times at one-second ated five times. intervals. • Connect an ignition check- The indicator on the Yamaha diagnostic tool screen come on each time the ignition coil is actuated. Cylinder-#2 ignition coil...
  • Page 464 This operation is performed ing for the operating sound. 3 times and takes approxi- mately 6 seconds each time. The indicator on the Yamaha diagnostic tool screen come on during the operation. 9-11...

  • Page 465: Event Code Table

    EVENT CODE TABLE EAS20316 EVENT CODE TABLE Item Symptom Possible cause Remarks U0155 CAN communication Communication be- • Defective meter cou- Perform the checks error (with the meter) tween the ECU and pler and ECU coupler and maintenance jobs the meter is not possi- •...
  • Page 466 EVENT CODE TABLE Item Symptom Possible cause Remarks sensor Correction value re- • Open or short circuit • If a fault code is indi- mains at upper limit in the wire harness cated, perform the (Correction value re- during O feedback between the sensor checks and mainte-...
  • Page 467 EVENT CODE TABLE Item Symptom Possible cause Remarks Difficult/unable to start Engine starting diffi- • Empty fuel tank • If a fault code is indi- engine cult/unable condition • Defective fuel injec- cated, perform the detected tion system checks and mainte- •...
  • Page 468 Yellow/Blue 43. Lean angle sensor Yellow/White 44. Front wheel sensor 45. Rear wheel sensor 46. ABS ECU 47. Yamaha diagnostic tool coupler 48. Fuel sender 49. Fuel pump 50. Oil pressure switch 51. Meter assembly 52. Immobilizer system indicator light 53.
  • Page 471 XTZ690/XTZ690-U 2020 XTZ690/XTZ690-U 2020 XTZ690/XTZ690-U 2020 XTZ690/XTZ690-U 2020 XTZ690/XTZ690-U 2020 WIRING DIAGRAM SCHÉMA DE CÂBLAGE SCHALTPLAN SCHEMA ELETTRICO DIAGRAMA ELÉCTRICO R/B L W G/W B/L L R/B P/L Br/L W/G R/G L/R L/B Y/L L/Y B/R G/Y Gy/R G/B R/L R/L R/G W/G Br/L P/L Br/L Br/W P/L R/G G/W...
  • Page 472 XTZ690/XTZ690-U 2020 XTZ690/XTZ690-U 2020 XTZ690/XTZ690-U 2020 XTZ690/XTZ690-U 2020 XTZ690/XTZ690-U 2020 WIRING DIAGRAM SCHÉMA DE CÂBLAGE SCHALTPLAN SCHEMA ELETTRICO DIAGRAMA ELÉCTRICO (Gy) (Gy) PUSH FREE FREE PUSH (Gy) (Gy) (Gy) (Gy) (Gy) (Gy) (Gy)

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