Yamaha MBK X-MAX 300 2017 Service Manual
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Yamaha MBK X-MAX 300 2017 Service Manual

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Table of Contents

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2017
SERVICE MANUAL
X-MAX 300
EVOLIS 300
CZD300-A
CZD300-AH
B74-F8197-E0

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Summary of Contents for Yamaha MBK X-MAX 300 2017

  • Page 1 2017 SERVICE MANUAL X-MAX 300 EVOLIS 300 CZD300-A CZD300-AH B74-F8197-E0...
  • Page 3 This manual was produced by the PT Yamaha Indonesia Motor Manufacturing Ltd. primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a me- chanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
  • Page 4 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 TROUBLESHOOTING...

  • Page 9: General Information

    GENERAL INFORMATION IDENTIFICATION .................... 1-1 VEHICLE IDENTIFICATION NUMBER .............1-1 MODEL LABEL..................1-1 FEATURES...................... 1-2 MULTI-FUNCTION DISPLAY..............1-2 SPECIAL TOOLS .................... 1-8...

  • Page 10: Identification

    IDENTIFICATION EAS20007 IDENTIFICATION EAS30002 VEHICLE IDENTIFICATION NUMBER The vehicle identification number “1” is stamped into the frame. EAS30003 MODEL LABEL The model label “1” is affixed to the inside of the storage box.

  • Page 11: Features

    FEATURES • information display EAS20008 FEATURES For the UK: To switch the displays between kilo- EAS30618 MULTI-FUNCTION DISPLAY meters and miles, turn the main switch to “ON” while pushing the “INFO” switch, and then con- tinue to push the “INFO” switch for eight sec- onds.
  • Page 12 FEATURES The fuel meter indicates the amount of fuel in the Tripmeter display fuel tank. The segments of the fuel meter disap- pear from “F” (full) towards “E” (empty) as the fuel level decreases. When the last segment of the fuel meter starts flashing, refuel as soon as possible.
  • Page 13 FEATURES Time tripmeter “Time” Oil change tripmeter “Oil Trip” 1. Time tripmeter 1. Oil change indicator “Oil” 2. Oil change tripmeter The time tripmeter displays the time that has elapsed while the main switch was in the “ON” The oil change tripmeter shows the distance position since it was last reset.
  • Page 14 FEATURES The V-belt replacement indicator “V-Belt” will display “Consumption_ _._ km/L” or “Consump- flash every 20000 km (12000 mi) to indicate that tion_ _._ L/100 km” and average speed display the V-belt should be replaced. “Average” in the following order: After replacing the V-belt, reset the V-belt re- Air-temp →...
  • Page 15 FEATURES Air temperature display Traction control system mode display 1. Air temperature display 1. Traction control system mode display 2. Icy road warning indicator “ ” This display shows the current status of the trac- tion control system. This display shows the air temperature from –10 °C to 50 °C in 1 °C increments.
  • Page 16 FEATURES The average speed “Average_ _ _kmh” or “Av- erage_ _ _MPH” (for the UK) is displayed. After resetting the average fuel consumption, “_ The average speed is the total distance divided _._” will be shown until the vehicle has traveled by the total time (with the main switch in the “ON”...
  • Page 17 • For U.S.A. and Canada, use part numbers starting with “YM-”, “YU-”, or “ACC-”. • For others, use part numbers starting with “90890-”. Reference Tool name/Tool No. Illustration pages Yamaha diagnostic tool USB 3-4, 3-7, 3-8, 90890-03256 4-68, 4-69, 7-17, 7-17, 7-18, 7-18, 8-34, 8-88,...
  • Page 18 90890-03081 Engine compression tester YU-33223 YU-33223 Camshaft sprocket stopper 5-17, 5-20 90890-04182 Camshaft sprocket stopper YM-04182 Yamaha bond No. 1215 5-20, 5-51, 5-63 90890-85505 (Three bond No.1215®) Valve spring compressor 5-27, 5-31 90890-04019 Valve spring compressor YM-04019 Valve spring compressor attachment...

  • Page 19: Special Tools

    SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Piston pin puller set 5-33 90890-01304 Piston pin puller YU-01304 YU-01304 Rotor holding tool 5-40, 5-45 90890-01235 Universal magneto and rotor holder YU-01235 Rotor holding tool 5-40, 5-40, 5-44, 90890-04166 5-45, 5-49, 5-49, Rotor holding tool 5-50, 5-51 YM-04166...
  • Page 20 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Sheave fixed block 5-40, 5-43 90890-04135 Sheave fixed bracket YM-04135 Oil seal guide (40mm) 5-43 90890-01590 Sliding sheave guide 40mm YM-01590 ø40 Flywheel puller 5-49 90890-01404 Flywheel puller YM-01404 Rotor puller bolt M14 X L80 5-49 90890-04183 M14×P1.5...
  • Page 21 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Radiator cap tester 6-4, 6-5 90890-01325 Mityvac cooling system tester kit YU-24460-A YU-24460-A Radiator cap tester adapter 31mm 6-4, 6-5 90890-05375 Radiator cap tester adapter 31mm YM-05375 Mechanical seal installer 6-10 90890-04145 ø30 ø10 Middle driven shaft bearing driver...
  • Page 22 SPECIAL TOOLS 1-13...

  • Page 23: Specifications

    SPECIFICATIONS GENERAL SPECIFICATIONS ................ 2-1 ENGINE SPECIFICATIONS ................2-2 CHASSIS SPECIFICATIONS ................2-7 ELECTRICAL SPECIFICATIONS ..............2-9 TIGHTENING TORQUES ................2-11 ENGINE TIGHTENING TORQUES............2-11 CHASSIS TIGHTENING TORQUES............2-11 CABLE ROUTING ..................2-13...

  • Page 24: General Specifications

    GENERAL SPECIFICATIONS EAS20013 GENERAL SPECIFICATIONS Model Model B741 (CZD300-A_EUR/GLP/HRV/MTQ/TUR/ ZAF) B742 (CZD300-A_EUR) B743 (CZD300-AH) B749 (CZD300-A_EUR) Dimensions Overall length 2185 mm (86.0 in) Overall width 775 mm (30.5 in) Overall height 1415/1465 mm (55.7/57.7 in) Wheelbase 1540 mm (60.6 in) Ground clearance 135 mm (5.31 in) Minimum turning radius...

  • Page 25: Engine Specifications

    ENGINE SPECIFICATIONS EAS20014 ENGINE SPECIFICATIONS Engine Combustion cycle 4-stroke Cooling system Liquid cooled Valve train SOHC Displacement 292 cm³ Number of cylinders Single cylinder Bore × stroke 70.0 × 75.9 mm (2.76 × 2.99 in) Compression ratio 10.9 : 1 Compression pressure 783–1008 kPa/860 r/min (7.8–10.1 kgf/cm²/860 r/min, 111.4–143.4 psi/860 r/min)
  • Page 26 ENGINE SPECIFICATIONS 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 74.0–78.0 °C (165.20–172.40 °F) Valve full open temperature 90.0 °C (194.00 °F) Valve lift (full open) 7.0 mm (0.28 in) Water pump Water pump type Single suction centrifugal pump Impeller shaft tilt limit 0.15 mm (0.006 in)
  • Page 27 ENGINE SPECIFICATIONS Valve-stem-to-valve-guide clearance (exhaust) 0.025–0.052 mm (0.0010–0.0020 in) Limit 0.100 mm (0.0039 in) Valve stem runout 0.010 mm (0.0004 in) Valve spring Free length (intake) 35.87 mm (1.41 in) Limit 34.07 mm (1.34 in) Free length (exhaust) 35.87 mm (1.41 in) Limit 34.07 mm (1.34 in) Cylinder...
  • Page 28 ENGINE SPECIFICATIONS Code 4 Green Code 5 Yellow Code 6 Pink Balancer shaft runout limit 0.030 mm (0.0012 in) Clutch Clutch type Dry, centrifugal, shoe Automatic centrifugal clutch Clutch shoe thickness 3.0 mm (0.12 in) Limit 1.5 mm (0.06 in) Clutch housing inside diameter 150.0 mm (5.91 in) Limit...
  • Page 29 ENGINE SPECIFICATIONS Exhaust gas sampling point Muffler tail pipe 0.0–1.0 % Fuel line pressure (at idle) 220–300 kPa (2.2–3.0 kgf/cm², 31.9–43.5 psi) Throttle grip free play 3.0–5.0 mm (0.12–0.20 in)

  • Page 30: Chassis Specifications

    CHASSIS SPECIFICATIONS EAS20015 CHASSIS SPECIFICATIONS Chassis Frame type Backbone Caster angle 26.5 ° Trail 95 mm (3.7 in) Front wheel Wheel type Cast wheel J15M/C × MT3.5 Rim size Rim material Aluminum Radial wheel runout limit 1.0 mm (0.04 in) Lateral wheel runout limit 1.0 mm (0.04 in) Rear wheel...
  • Page 31 Hydraulic damper Fork spring free length 348.3 mm (13.71 in) Limit 341.3 mm (13.44 in) Recommended oil Yamaha Suspension Oil G10 Quantity (left) 235.0 cm³ (7.95 US oz, 8.29 Imp.oz) Quantity (right) 235.0 cm³ (7.95 US oz, 8.29 Imp.oz) Level (left) 155 mm (6.1 in)

  • Page 32: Electrical Specifications

    Ignition system Ignition system Advancer type Digital Ignition timing (B.T.D.C.) 10.0 °/1600 r/min Engine control unit Model/manufacturer B740/PT. YAMAHA MOTOR ELECTRONICS INDONESIA Ignition coil Minimum ignition spark gap 6.0 mm (0.24 in) 2.16–2.64 Ω Primary coil resistance Secondary coil resistance 8.64–12.96 kΩ...
  • Page 33 ELECTRICAL SPECIFICATIONS Engine trouble warning light ABS warning light Smart key system indicator light Traction control system indicator light Starter motor Power output 0.40 kW 0.063–0.077 Ω Armature coil resistance Brush overall length 7.0 mm (0.28 in) Limit 3.00 mm (0.12 in) Brush spring force 6.08–9.12 N (620–930 gf, 21.89–32.83 oz) Commutator diameter...

  • Page 34: Tightening Torques

    TIGHTENING TORQUES EAS20017 TIGHTENING TORQUES EAS30016 ENGINE TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Exhaust pipe nut 15 N·m (1.5 kgf·m, 11 lb·ft) Clamp bolt 20 N·m (2.0 kgf·m, 15 lb·ft) Muffler bolt 53 N·m (5.3 kgf·m, 39 lb·ft) Muffler protector bolt 8 N·m (0.8 kgf·m, 5.9 lb·ft) Muffler cap bolt...

  • Page 35: Chassis Tightening Torques

    TIGHTENING TORQUES EAS30017 CHASSIS TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Upper handlebar holder bolt 21 N·m (2.1 kgf·m, 15 lb·ft) Front brake caliper bolt 35 N·m (3.5 kgf·m, 26 lb·ft) Brake caliper bleed screw 6 N·m (0.6 kgf·m, 4.4 lb·ft) Front wheel axle nut 52 N·m (5.2 kgf·m, 38 lb·ft) Rear brake caliper bolt...

  • Page 36: Cable Routing

    CABLE ROUTING EAS20021 CABLE ROUTING Handlebar (front view) 2-13...
  • Page 37 CABLE ROUTING 1. Front brake hose (front brake master cylinder to hydraulic unit) 2. Rear brake hose (rear brake master cylinder to hydraulic unit) 3. Handlebar switch lead (left handlebar switch) 4. Throttle cable (decelerator cable) 5. Throttle cable (accelerator cable) 6.
  • Page 38 CABLE ROUTING Handlebar (left side view) 2-15...
  • Page 39 CABLE ROUTING 1. Rear brake hose (rear brake master cylinder to hydraulic unit) 2. Handlebar switch lead (left handlebar switch) 3. Throttle cable (decelerator cable) 4. Throttle cable (accelerator cable) 5. Front brake hose (front brake master cylinder to hydraulic unit) 6.
  • Page 40 CABLE ROUTING Steering (left side view) 2-17...
  • Page 41 CABLE ROUTING 1. Front brake hose (hydraulic unit to front brake caliper) 2. Front wheel sensor lead 3. Wire harness 4. Starter motor lead 5. Throttle cable (decelerator cable) 6. Throttle cable (accelerator cable) 7. Sidestand switch lead 8. Fuel tank cap lid lock cable 9.
  • Page 42 CABLE ROUTING Frame (left side view) 2-19...
  • Page 43 CABLE ROUTING 1. Throttle cable (decelerator cable) 2. Throttle cable (accelerator cable) 3. Seat lock cable 4. Starter motor lead 5. Wire harness 6. Smart key unit 7. Rear wheel sensor lead 8. Ignition coil 9. Frame ground 10. Sidestand switch 11.
  • Page 44 CABLE ROUTING Frame (top view) 2-21...
  • Page 45 CABLE ROUTING 1. Fuel tank cap lid lock cable 2. ISC (Idle Speed Control) unit coupler 3. Coolant temperature sensor coupler 4. Throttle body sensor assembly coupler 5. Seat lock cable 6. AC magneto lead 7. Starter motor lead 8. Engine ground lead 9.
  • Page 46 CABLE ROUTING Radiator (front and left view) 2-23...
  • Page 47 CABLE ROUTING 1. Radiator rear cover 2. Coolant reservoir hose 3. Radiator outlet hose 4. Radiator inlet hose 5. Radiator filler hose 6. Radiator fan motor lead 7. Coolant reservoir breather hose A. Fasten the coolant reservoir hose with the holder on the radiator rear cover.
  • Page 48 CABLE ROUTING Radiator (right side view) 2-25...
  • Page 49 CABLE ROUTING 1. Thermostat 2. Cooling system air bleed hose 3. Canister purge hose 4. Fuel tank breather hose (rollover valve to canister) 5. Coolant reservoir hose 6. Radiator filler hose 7. Radiator outlet hose 8. Radiator inlet hose 9. Fuel tank overflow tray A.
  • Page 50 CABLE ROUTING Tail/brake light (left side view) 2-27...
  • Page 51 CABLE ROUTING 1. Wire harness 2. Tail/brake light lead (right tail/brake light) 3. Tail/brake light lead (left tail/brake light) 4. License plate light lead 5. Frame A. Route the wire harness through the hole in the rear lower cowling assembly. Align the tape on the wire harness with the hole.
  • Page 52 CABLE ROUTING Air filter case (top view) 2-29...
  • Page 53 CABLE ROUTING 1. Cylinder head breather hose 2. Air filter case joint 3. Transmission case breather hose 4. Air filter case A. Install the cylinder head breather hose with its paint mark facing upward and completely onto the hose fitting. B.
  • Page 54 CABLE ROUTING Hydraulic unit (top and left/right side view) 2-31...
  • Page 55 CABLE ROUTING 1. Front brake hose (hydraulic unit to front brake caliper) 2. Rear brake hose (hydraulic unit to rear brake caliper) 3. Rear brake hose (rear brake master cylinder to hydraulic unit) 4. Front brake hose (front brake master cylinder to hydraulic unit) 5.
  • Page 56 CABLE ROUTING Battery (front side view) 2-33...
  • Page 57 CABLE ROUTING 1. ABS test coupler 2. Negative battery lead 3. Positive battery lead 4. Battery 5. Yamaha diagnostic tool coupler 6. Starter relay 7. Fuse box 2 8. Fuse box 1 9. Battery band 10. ABS test coupler lead A.
  • Page 58 CABLE ROUTING Battery (rear view) 2-35...
  • Page 59 CABLE ROUTING 1. Headlight lead 2. Wire harness 3. Starter relay lead 4. Meter assembly coupler A. Route the wire harness through the guide. 2-36...
  • Page 60 CABLE ROUTING Front fork (right side view) 2-37...
  • Page 61 CABLE ROUTING 1. Front brake hose (hydraulic unit to front brake caliper) 2. Front wheel sensor A. Fasten the front brake hose (hydraulic unit to front brake caliper) and front wheel sensor with the clamp in the area shown in the illustration. B.
  • Page 62 CABLE ROUTING Fuel tank (right side view) 2-39...
  • Page 63 CABLE ROUTING 1. Canister purge hose 2. Fuel hose 3. Canister 4. Fuel tank breather hose (fuel tank to rollover valve) 5. Rollover valve 6. Cooling system air bleed hose 7. Fuel tank breather hose (rollover valve to canister) 8. Fuel tank 9.
  • Page 64 CABLE ROUTING Fuel tank (top view) 2-41...
  • Page 65 CABLE ROUTING 1. Fuel tank overflow hose 2. Fuel tank 3. Canister 4. Canister purge hose A. Face the paint mark on the fuel tank overflow hose upward. B. Fasten the canister purge hose with the holder. Align the holder with the paint mark on the canister purge hose.
  • Page 66 CABLE ROUTING Rear brake (right side view) 2-43...
  • Page 67 CABLE ROUTING 1. Rear wheel sensor lead 2. Rear brake hose (hydraulic unit to rear brake caliper) A. Route the rear wheel sensor lead through the guide on the V-belt case air filter element cover. Position the rearside edge of the tape on the lead in the area shown in the illustration.
  • Page 68 CABLE ROUTING 2-45...

  • Page 69: 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 PLUG ............... 3-4 ADJUSTING THE VALVE CLEARANCE ..........3-5 CHECKING THE ENGINE IDLING SPEED ..........3-7...
  • Page 70 ADJUSTING THE HEADLIGHT BEAM ...........3-25...

  • Page 72: Periodic Maintenance

    UK, a mileage-based maintenance, is performed instead. • From 50000 km (30000 mi), repeat the maintenance intervals starting from 10000 km (6000 mi). • Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
  • Page 73 PERIODIC MAINTENANCE CHECK OR MAINTENANCE ODOMETER READINGS ANNUAL ITEM X 1000 km CHECK X 1000 mi Pre air filter ele- √ √ • Clean. ment Sub air filter ele- √ √ • Replace. ment Air filter case √ √ √ √...
  • Page 74 PERIODIC MAINTENANCE CHECK OR MAINTENANCE ODOMETER READINGS ANNUAL ITEM X 1000 km CHECK X 1000 mi • Check coolant level and vehi- √ √ √ √ √ cle for coolant leakage. 24 * Cooling system • Change. Every 3 years When the V-belt replacement indicator flashes 25 * V-belt •...

  • Page 75: Checking The Vehicle Using The Yamaha Diagnostic Tool

    EAS32024 CHECKING THE VEHICLE USING THE • Battery cover assembly YAMAHA DIAGNOSTIC TOOL Refer to “GENERAL CHASSIS (1)” on page Use the Yamaha diagnostic tool and check the 4-1. vehicle according to the following procedure. 1. Remove: EAS30619 CHECKING THE FUEL LINE •...

  • Page 76: Adjusting The Valve Clearance

    PERIODIC MAINTENANCE 2. Remove: 7. Install: • Spark plug cap • Spark plug “1” • Spark plug • Spark plug cap ECA13330 NOTICE Spark plug 13 N·m (1.3 kgf·m, 9.6 lb·ft) Before removing the spark plug, blow away any dirt accumulated in the spark plug well with compressed air to prevent it from falling •...
  • Page 77 PERIODIC MAINTENANCE • Muffler assembly Refer to “ENGINE REMOVAL” on page 5-7. • Cylinder head cover Refer to “CYLINDER HEAD” on page 5-13. 2. Remove: • Crankshaft end cover “1” • Timing mark accessing bolt “2” c. Measure the valve clearance with a thick- ness gauge “1”.

  • Page 78: Checking The Engine Idling Speed

    Refer to “CLEANING THE ISC (IDLE SPEED CONTROL) UNIT AND THROTTLE BODY” on page 7-15. a. Connect the Yamaha diagnostic tool. Refer to the following table for the available Use the diagnostic code number “67”. valve pads.

  • Page 79: Checking The Exhaust System

    For more information, refer to the opera- 4-16. tion manual of the Yamaha diagnostic tool. • Footrest board assembly Refer to “GENERAL CHASSIS (5)” on page 1. Connect the Yamaha diagnostic tool to the 4-13. connector. For information about connecting the Yamaha diagnostic tool, refer to...

  • Page 80: Replacing The Air Filter Element And Cleaning The

    PERIODIC MAINTENANCE • Lower side covers Refer to “GENERAL CHASSIS (4)” on page 4-10. • Meter assembly Refer to “GENERAL CHASSIS (3)” on page 4-7. • Front cowling assemblies Refer to “GENERAL CHASSIS (2)” on page 4-4. • Battery Refer to “GENERAL CHASSIS (1)” on page 3.

  • Page 81: Cleaning The V-Belt Case Air Filter Element

    PERIODIC MAINTENANCE Air filter case cover screw 1.2 N·m (0.12 kgf·m, 0.88 lb·ft) ECA20480 NOTICE Never operate the engine without the air filter element installed. Unfiltered air will cause rapid wear of engine parts and may damage the engine. Operating the engine without the air filter element will also affect throttle body 3.

  • Page 82: Checking The Brake Operation

    PERIODIC MAINTENANCE 1. Operate the brake. V-belt case air duct bolt 2. Check: 7 N·m (0.7 kgf·m, 5.2 lb·ft) • Rear brake pad V-belt case air filter element cov- Wear indicators “a” almost touch the brake er bolt disc → Replace the brake pads and brake 7 N·m (0.7 kgf·m, 5.2 lb·ft) pad shims as a set.

  • Page 83: Checking The Front Brake Hoses

    PERIODIC MAINTENANCE 3. Hold the vehicle upright and apply the front brake several times. 4. Check: • Brake hoses Brake fluid leakage → Replace the damaged hose. Refer to “FRONT BRAKE” on page 4-38 and “ABS (ANTI-LOCK BRAKE SYSTEM)” on page 4-63.

  • Page 84: Checking The Wheels

    PERIODIC MAINTENANCE • the system is disassembled. f. Fully squeeze the brake lever and hold it in • a brake hose is loosened, disconnected or position. replaced. g. Loosen the bleed screw. • the brake fluid level is very low. •...

  • Page 85: Checking The Tires

    PERIODIC MAINTENANCE • Lateral wheel runout EWA13190 WARNING Refer to “CHECKING THE FRONT WHEEL” It is dangerous to ride with a worn-out tire. on page 4-29 and “CHECKING THE REAR When the tire tread reaches the wear limit, re- WHEEL” on page 4-35. place the tire immediately.

  • Page 86: Checking The Wheel Bearings

    1. Stand the vehicle on a level surface. en if a tire combination other than one EWA13120 approved by Yamaha is used on this vehicle. WARNING Securely support the vehicle so that there is Front tire no danger of it falling over.

  • Page 87: Lubricating The Steering Head

    PERIODIC MAINTENANCE Refer to “STEERING HEAD” on page 4-87. e. Install the rubber washer. f. Install the upper ring nut. g. Finger tighten the upper ring nut, then align the slots of both ring nuts. If neces- sary, hold the lower ring nut and tighten the upper ring nut until their slots are aligned.

  • Page 88: Lubricating The Levers

    PERIODIC MAINTENANCE 3. Hold the vehicle upright and apply the front EAS30648 LUBRICATING THE LEVERS brake. Lubricate the pivoting point and metal-to-metal 4. Check: moving parts of the levers. • Front fork operation Push down hard on the handlebar several Recommended lubricant times and check if the front fork rebounds Silicone grease...

  • Page 89: Checking The Engine Oil Level

    PERIODIC MAINTENANCE • Always adjust both rear shock absorber as- EAS30656 CHECKING THE ENGINE OIL LEVEL semblies evenly. Uneven adjustment can 1. Stand the vehicle on a level surface. result in poor handling and loss of stability. • Place the vehicle on the centerstand. Spring preload •...

  • Page 90: Changing The Engine Oil

    PERIODIC MAINTENANCE c. Install the oil filter element and oil filter el- EAS30657 CHANGING THE ENGINE OIL ement cover. 1. Start the engine, warm it up for several min- utes, and then turn it off. Oil filter element cover bolt 2.

  • Page 91: Changing The Final Transmission Oil

    PERIODIC MAINTENANCE b. Start the engine and keep it idling until en- 5. Install: gine oil starts to seep from the oil check • Final transmission oil drain bolt bolt. If no engine oil comes out after one (along with the copper washer minute, turn the engine off so that it will not Final transmission oil drain bolt seize.

  • Page 92: Checking The Cooling System

    PERIODIC MAINTENANCE • Thermostat assembly “8” • Water pump inlet hose “9” • Water pump outlet pipe “10” Cracks/tears → Replace. Refer to “RADIATOR” on page 6-2, “THER- MOSTAT” on page 6-6 and “WATER PUMP” on page 6-8. ECA13470 NOTICE •...
  • Page 93 PERIODIC MAINTENANCE • Lower side covers 5. Remove: Refer to “GENERAL CHASSIS (4)” on page • Coolant drain bolt (radiator side) “1” 4-10. (along with the O-ring) • Radiator cover • Coolant drain bolt (water pump side) “2” Refer to “GENERAL CHASSIS (5)” on page (along with the copper washer) 4-13.
  • Page 94 PERIODIC MAINTENANCE Coolant is potentially harmful and should be handled with special care. EWA13040 WARNING • If coolant splashes in your eyes, thorough- ly wash them with water and consult a doc- tor. • If coolant splashes on your clothes, quickly wash it away with water and then with soap and water.

  • Page 95: Replacing The V-Belt

    PERIODIC MAINTENANCE 1. Check: EAS31188 REPLACING THE V-BELT • Outer cable 1. Remove: Damage → Replace. • Storage box 2. Check: Refer to “GENERAL CHASSIS (4)” on page • Cable operation 4-10. Rough movement → Lubricate. • Air filter case Refer to “AIR FILTER CASE”...

  • Page 96: Checking The Switches, Lights And Signals

    PERIODIC MAINTENANCE Faulty → Refer to “CHECKING THE SWITCHES” on page 8-127 and “CHECK- ING THE BULBS AND BULB SOCKETS” in “BASIC INFORMATION” (separate volume). EAS30664 ADJUSTING THE HEADLIGHT BEAM 1. Adjust: • Headlight beam (vertically) a. Turn the adjusting bolt “1”. 4.

  • Page 97: Chassis

    CHASSIS GENERAL CHASSIS (1) ................. 4-1 INSTALLING THE BATTERY BAND............4-2 REMOVING THE BATTERY COVER ASSEMBLY ........4-2 INSTALLING THE BATTERY COVER ASSEMBLY........4-2 DISASSEMBLING THE BATTERY COVER ASSEMBLY ......4-3 ASSEMBLING THE BATTERY COVER ASSEMBLY ....... 4-3 ADJUSTING THE WINDSHIELD HEIGHT..........4-3 GENERAL CHASSIS (2) ................. 4-4 REMOVING THE FRONT COWLING ASSEMBLIES .......
  • Page 98 FRONT WHEEL..................... 4-27 REMOVING THE FRONT WHEEL............4-29 DISASSEMBLING THE FRONT WHEEL..........4-29 CHECKING THE FRONT WHEEL ............4-29 MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR....................4-30 ASSEMBLING THE FRONT WHEEL............4-30 ADJUSTING THE FRONT WHEEL STATIC BALANCE ......4-31 INSTALLING THE FRONT WHEEL (FRONT BRAKE DISC)....
  • Page 99 ABS (ANTI-LOCK BRAKE SYSTEM)............4-63 REMOVING THE HYDRAULIC UNIT ASSEMBLY .........4-65 CHECKING THE HYDRAULIC UNIT ASSEMBLY........4-65 INSTALLING THE HYDRAULIC UNIT ASSEMBLY........4-65 HYDRAULIC UNIT OPERATION TESTS..........4-67 CHECKING THE ABS WARNING LIGHT ..........4-70 HANDLEBAR ....................4-71 ADJUSTING THE HANDLEBAR POSITION...........4-74 REMOVING THE UPPER HANDLEBAR COVER........4-74 REMOVING THE HANDLEBAR..............4-74 CHECKING THE HANDLEBAR ..............4-75 INSTALLING THE HANDLEBAR ............
  • Page 100 GENERAL CHASSIS (1) EAS20026 GENERAL CHASSIS (1) Removing the battery cover assembly and windshield 0.5 N m (0.05 kgf m, 0.37 lb • • • 1.8 N m (0.18 kgf m, 1.3 lb • • • m (0.8 kgf m, 5.9 lb •...

  • Page 101: General Chassis (1)

    GENERAL CHASSIS (1) EAS32305 EAS32307 INSTALLING THE BATTERY BAND INSTALLING THE BATTERY COVER 1. Install: ASSEMBLY • Battery band “1” 1. Install: • Battery cover assembly “1” Install the battery band with the arrow mark “a” pointing up. a. Fit the projections “a” on the battery cover assembly into the grommets.

  • Page 102: Disassembling The Battery Cover Assembly

    GENERAL CHASSIS (1) EAS32308 DISASSEMBLING THE BATTERY COVER ASSEMBLY 1. Remove the battery cover screws and quick fastener. 2. Remove the projections “a” on the battery front cover “1” from the holes “b” in the battery rear cover “2”. 3. Install: •...

  • Page 103: General Chassis (2)

    GENERAL CHASSIS (2) EAS20155 GENERAL CHASSIS (2) Removing the front cowlings 4.0 N m (0.40 kgf m, 3.0 lb • • • 1.8 N m (0.18 kgf m, 1.3 lb • • • 1.8 N m (0.18 kgf m, 1.3 lb •...

  • Page 104: Removing The Front Cowling Assemblies

    GENERAL CHASSIS (2) EAS32310 REMOVING THE FRONT COWLING ASSEMBLIES The following procedure applies to both of the front cowling assemblies. 1. Remove: • Front cowling assembly “1” b. Install the front cowling assembly bolt, screws, and quick fasteners, and then tighten the bolt and screws to specifica- tion.

  • Page 105: General Chassis (3)

    GENERAL CHASSIS (2) 1. Fit the projections “a” on the front upper cowl- ing “1” into the holes “b” in the front lower cowling “2”. 2. Install the front cowling screws and clamp, and then tighten the screws to specification. Front cowling screw 1.8 N·m (0.18 kgf·m, 1.3 lb·ft) 3.
  • Page 106 Refer to “GENERAL CHASSIS (2)” on page Front cowling assemblies 4-4. Headlight assembly Headlight unit coupler Disconnect. Headlight unit cover Headlight unit Meter assembly panel molding Starter relay Fuse box 1 Fuse box 2 Yamaha diagnostic tool coupler Battery box...
  • Page 107 GENERAL CHASSIS (3) Removing the headlight unit and meter assembly 1.8 N m (0.18 kgf m, 1.3 lb • • • m (0.8 kgf m, 5.9 lb • • • m (0.7 kgf m, 5.2 lb • • • 1.8 N m (0.18 kgf m, 1.3 lb •...

  • Page 108: Removing The Meter Assembly Panel Molding

    GENERAL CHASSIS (3) EAS32314 REMOVING THE METER ASSEMBLY PANEL MOLDING 1. Remove: • Meter assembly panel molding “1” Remove the projections “a” on the meter assem- bly panel molding from the holes “b” in the meter assembly panel. EAS32315 INSTALLING THE METER ASSEMBLY PANEL MOLDING 1.

  • Page 109: General Chassis (4)

    GENERAL CHASSIS (4) EAS20157 GENERAL CHASSIS (4) Removing the storage box and side covers m (0.9 kgf m, 6.6 lb • • • m (0.9 kgf m, 6.6 lb • • • 1.8 N m (0.18 kgf m, 1.3 lb •...

  • Page 110: Removing The Upper Side Covers

    GENERAL CHASSIS (4) EAS32316 REMOVING THE UPPER SIDE COVERS The following procedure applies to both of the upper side covers. 1. Remove: • Upper side cover “1” b. Install the quick fasteners. EAS32318 REMOVING THE LOWER CENTER COVER 1. Remove: •...

  • Page 111: Removing The Lower Side Covers

    GENERAL CHASSIS (4) a. Fit the projections “a” on the lower center 1. Install: cover into the holes “b” in the lower side • Lower side cover “1” cover. a. Fit the projections “a” on the lower side b. Install the lower center cover screws, and cover into the grommets “b”.

  • Page 112: General Chassis (5)

    GENERAL CHASSIS (5) EAS20158 GENERAL CHASSIS (5) Removing the footrest boards and bottom cover 3.8 N m (0.38 kgf m, 2.8 lb • • • m (0.9 kgf m, 6.6 lb • • • m (0.9 kgf m, 6.6 lb •...
  • Page 113 GENERAL CHASSIS (5) Removing the footrest boards and bottom cover 3.8 N m (0.38 kgf m, 2.8 lb • • • m (0.9 kgf m, 6.6 lb • • • m (0.9 kgf m, 6.6 lb • • • 3.8 N m (0.38 kgf m, 2.8 lb •...

  • Page 114: Disassembling The Footrest Board Assemblies

    GENERAL CHASSIS (5) EAS32326 DISASSEMBLING THE FOOTREST BOARD ASSEMBLIES The following procedure applies to both of the footrest board assemblies. 1. Remove the footrest board screws and clamps. 2. Remove the projections “a” on the footrest board molding “1” from the holes “b” in the footrest board “2”.

  • Page 115: General Chassis (6)

    GENERAL CHASSIS (6) EAS20159 GENERAL CHASSIS (6) Removing the leg shield assembly 3.8 N m (0.38 kgf m, 2.8 lb • • • m (0.9 kgf m, 6.6 lb • • • m (0.9 kgf m, 6.6 lb • • •...
  • Page 116 GENERAL CHASSIS (6) Removing the leg shield assembly 3.8 N m (0.38 kgf m, 2.8 lb • • • m (0.9 kgf m, 6.6 lb • • • m (0.9 kgf m, 6.6 lb • • • 1.8 N m (0.18 kgf m, 1.3 lb •...
  • Page 117 GENERAL CHASSIS (6) Disassembling the leg shield assembly 1.0 N m (0.10 kgf m, 0.73 lb • • • 1.8 N m (0.18 kgf m, 1.3 lb • • • 1.8 N m (0.18 kgf m, 1.3 lb • • •...

  • Page 118: Removing The Fuel Tank Cap Lid Cover

    GENERAL CHASSIS (6) EAS32349 REMOVING THE FUEL TANK CAP LID COVER 1. Remove: • Fuel tank cap lid cover “1” b. Install the fuel tank cap lid cover screw, and then tighten the screw to specification. Fuel tank cap lid cover screw 1.8 N·m (0.18 kgf·m, 1.3 lb·ft) a.

  • Page 119: General Chassis (7)

    GENERAL CHASSIS (6) a. Fit the projections “a” on the upper center cover into the holes “b” in the leg shield. b. Install the quick fasteners. 4-20...
  • Page 120 GENERAL CHASSIS (7) EAS20193 GENERAL CHASSIS (7) Removing the seat and seat hinge m (0.7 kgf m, 5.2 lb • • • 12 N m (1.2 kgf m, 8.9 lb • • • 25 N m (2.5 kgf m, 18 lb •...

  • Page 121: Installing The Seat Damper

    GENERAL CHASSIS (7) EAS32331 INSTALLING THE SEAT DAMPER 1. Install: • Seat damper “1” Install the seat damper so that the rod “a” is pointing downward as shown in the illustration. 4-22...

  • Page 122: General Chassis (8)

    GENERAL CHASSIS (8) EAS20194 GENERAL CHASSIS (8) Removing the rear upper cowlings and rear lower cowling assembly 1.8 N m (0.18 kgf m, 1.3 lb • • • m (0.9 kgf m, 6.6 lb • • • 23 N m (2.3 kgf m, 17 lb •...
  • Page 123 GENERAL CHASSIS (8) Disassembling the rear lower cowling assembly 1.8 N m (0.18 kgf m, 1.3 lb • • • 1.8 N m (0.18 kgf m, 1.3 lb • • • 1.8 N m (0.18 kgf m, 1.3 lb • •...

  • Page 124: Removing The Rear Center Cover

    GENERAL CHASSIS (8) b. Fit the projections “c” on the rear center EAS32351 REMOVING THE REAR CENTER COVER cover into the holes “d” in the tail/brake 1. Remove: light cover. • Rear center cover “1” c. Fit the holes “e” in the rear center cover to the projection “f”...

  • Page 125: Installing The Rear Upper Cowlings

    GENERAL CHASSIS (8) EAS32353 INSTALLING THE REAR UPPER COWLINGS The following procedure applies to both of the rear upper cowlings. 1. Install: • Rear upper cowling “1” a. Fit the projection “a” on the rear upper cowling into the hole “b” in the rear lower cowling.

  • Page 126: Front Wheel

    FRONT WHEEL EAS20028 FRONT WHEEL Removing the front wheel and brake disc 52 N m (5.2 kgf m, 38 lb m (0.7 kgf m, 5.2 lb • • • • • • m (0.7 kgf m, 5.2 lb • • •...
  • Page 127 FRONT WHEEL Disassembling the front wheel ’ Order Job/Parts to remove Remarks Oil seal Wheel bearing (left) Spacer Wheel bearing (right) 4-28...

  • Page 128: Removing The Front Wheel

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

  • Page 129: Maintenance Of The Front Wheel Sensor And Sensor Rotor

    FRONT WHEEL Radial wheel runout limit 1.0 mm (0.04 in) Lateral wheel runout limit 1.0 mm (0.04 in) 2. Check: • Front wheel sensor rotor “1” Cracks/damage/scratches → Replace the front wheel sensor rotor. Iron powder/dust/solvent → Clean. 4. Check: When cleaning the wheel sensor rotor, be care- •...

  • Page 130: Adjusting The Front Wheel Static Balance

    FRONT WHEEL Front brake disc bolt 23 N·m (2.3 kgf·m, 17 lb·ft) LOCTITE® Front wheel sensor rotor bolt 8 N·m (0.8 kgf·m, 5.9 lb·ft) LOCTITE® ECA21011 NOTICE • Do not drop the wheel sensor rotor or sub- b. Install the spacer. ject it to shocks.
  • Page 131 FRONT WHEEL 4. Install: 7. Measure: • Front wheel • Distance “a” • Collars (between the front wheel sensor rotor “1” and • Front wheel axle front wheel sensor “2”) Out of specification → Check the wheel bear- • Front wheel axle nut ing for looseness, and the front wheel sensor and sensor rotor installation conditions Install the front wheel with the mark “a”...
  • Page 132 FRONT WHEEL EWA13500 WARNING Make sure the brake hose is routed properly. 4-33...

  • Page 133: Rear Wheel

    REAR WHEEL EAS20029 REAR WHEEL Removing the rear wheel and brake disc m (0.7 kgf m, 5.2 lb • • • 10 N m (1.0 kgf m, 7.4 lb • • • m (0.8 kgf m, 5.9 lb • • •...

  • Page 134: Removing The Rear Wheel (Disc)

    REAR WHEEL • The rear wheel sensor cannot be disassem- EAS30156 REMOVING THE REAR WHEEL (DISC) bled. Do not attempt to disassemble it. If ECA21030 faulty, replace with a new one. NOTICE • Keep any type of magnets (including mag- •...

  • Page 135: Installing The Rear Wheel (Rear Brake Disc)

    REAR WHEEL 2. Check: EAS30165 INSTALLING THE REAR WHEEL (REAR • Rear brake disc BRAKE DISC) Refer to “CHECKING THE REAR BRAKE 1. Install: DISC” on page 4-57. • Rear wheel sensor rotor “1” 3. Install: • Rear brake disc “2” •...
  • Page 136 REAR WHEEL 4-37...
  • Page 137 FRONT BRAKE EAS20030 FRONT BRAKE Removing the front brake pads m (0.7 kgf m, 5.2 lb • • • 35 N m (3.5 kgf m, 26 lb • • • m (0.6 kgf m, 4.4 lb • • • 35 N m (3.5 kgf m, 26 lb •...
  • Page 138 FRONT BRAKE Removing the front brake master cylinder 11 N m (1.1 kgf m, 8.1 lb • • • 1.5 N m (0.15 kgf m, 1.1 lb • • • m (0.6 kgf m, 4.4 lb • • • 29 N m (2.9 kgf m, 21 lb •...

  • Page 139: Front Brake

    FRONT BRAKE Removing the front brake master cylinder 11 N m (1.1 kgf m, 8.1 lb • • • 1.5 N m (0.15 kgf m, 1.1 lb • • • m (0.6 kgf m, 4.4 lb • • • 29 N m (2.9 kgf m, 21 lb •...
  • Page 140 FRONT BRAKE Disassembling the front brake master cylinder ’ Order Job/Parts to remove Remarks Brake master cylinder kit Brake master cylinder body 4-41...
  • Page 141 FRONT BRAKE Removing the front brake caliper m (0.7 kgf m, 5.2 lb • • • 35 N m (3.5 kgf m, 26 lb • • • 35 N m (3.5 kgf m, 26 lb • • • 29 N m (2.9 kgf m, 21 lb •...
  • Page 142 FRONT BRAKE Disassembling the front brake caliper m (0.6 kgf m, 4.4 lb • • • ’ Order Job/Parts to remove Remarks Brake pad clip Brake pad pin Brake pad (inner) Brake pad (outer) Brake pad spring Front brake caliper bracket Brake caliper piston Brake caliper piston dust seal Brake caliper piston seal...

  • Page 143: Introduction

    FRONT BRAKE e. Measure the runout 1.5 mm (0.06 in) be- EAS30168 INTRODUCTION low the edge of the brake disc. EWA14101 WARNING Disc brake components rarely require disas- sembly. Therefore, always follow these pre- ventive measures: • Never disassemble brake components un- less absolutely necessary.

  • Page 144: Replacing The Front Brake Pads

    FRONT BRAKE d. Measure the brake disc runout. e. If out of specification, repeat the adjust- ment steps until the brake disc runout is within specification. f. If the brake disc runout cannot be brought within specification, replace the brake disc.

  • Page 145: Removing The Front Brake Caliper

    FRONT BRAKE EAS31328 REMOVING THE FRONT BRAKE CALIPER The longer tangs “a” of the brake pad spring must point in the direction of the brake caliper Before removing the brake caliper, drain the piston. brake fluid from the entire brake system. 1.

  • Page 146: Checking The Front Brake Caliper

    FRONT BRAKE 2. Check: • Brake caliper bracket Cracks/damage → Replace. EAS30174 ASSEMBLING THE FRONT BRAKE CALIPER EWA13621 WARNING • Before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. b. Remove the brake caliper piston dust •...

  • Page 147: Removing The Front Brake Master Cylinder

    FRONT BRAKE ECA13540 NOTICE Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. 5. Bleed: • Brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM (ABS)” on page 3-12. 6. Check: 2.

  • Page 148: Checking The Front Brake Master Cylinder

    FRONT BRAKE Specified brake fluid DOT 4 EAS30182 INSTALLING THE FRONT BRAKE MASTER CYLINDER 1. Install: • Front brake master cylinder assembly • Front brake master cylinder holder “1” Front brake master cylinder hold- EAS30725 CHECKING THE FRONT BRAKE MASTER er bolt CYLINDER 11 N·m (1.1 kgf·m, 8.1 lb·ft)
  • Page 149 FRONT BRAKE • Turn the handlebar to the left and right to make sure the brake hose does not touch other parts (e.g., wire harness, cables, leads). Correct if necessary. 6. Check: • Brake lever operation Soft or spongy feeling → Bleed the brake sys- tem.

  • Page 150: Rear Brake

    REAR BRAKE EAS20031 REAR BRAKE Removing the rear brake pads m (0.6 kgf m, 4.4 lb • • • 35 N m (3.5 kgf m, 26 lb • • • ’ Order Job/Parts to remove Remarks Rear brake caliper Brake pad clip Brake pad pin Brake pad (inner) Brake pad (outer)
  • Page 151 REAR BRAKE Removing the rear brake master cylinder 11 N m (1.1 kgf m, 8.1 lb • • • 1.5 N m (0.15 kgf m, 1.1 lb • • • m (0.6 kgf m, 4.4 lb • • • m (0.6 kgf m, 4.4 lb •...
  • Page 152 REAR BRAKE Removing the rear brake master cylinder 11 N m (1.1 kgf m, 8.1 lb • • • 1.5 N m (0.15 kgf m, 1.1 lb • • • m (0.6 kgf m, 4.4 lb • • • m (0.6 kgf m, 4.4 lb •...
  • Page 153 REAR BRAKE Disassembling the rear brake master cylinder ’ Order Job/Parts to remove Remarks Brake master cylinder kit Brake master cylinder body 4-54...
  • Page 154 REAR BRAKE Removing the rear brake caliper 29 N m (2.9 kgf m, 21 lb • • • 35 N m (3.5 kgf m, 26 lb • • • ’ Order Job/Parts to remove Remarks Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM (ABS)”...
  • Page 155 REAR BRAKE Disassembling the rear brake caliper 31 N m (3.1 kgf m, 23 lb • • • m (0.6 kgf m, 4.4 lb • • • 23 N m (2.3 kgf m, 17 lb • • • ’ Order Job/Parts to remove Remarks Brake pad clip...

  • Page 156: Introduction

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

  • Page 157: Removing The Rear Brake Caliper

    REAR BRAKE 2. Install: Rear brake caliper bolt • Brake pad spring 35 N·m (3.5 kgf·m, 26 lb·ft) • Brake pad shims • Brake pads 4. Check: • Brake fluid level Always install new brake pads, brake pad shims Below the minimum level mark “a” → Add the and brake pad spring as a set.

  • Page 158: Disassembling The Rear Brake Caliper

    REAR BRAKE 1. Check: EAS30187 DISASSEMBLING THE REAR BRAKE • Brake caliper piston “1” CALIPER Rust/scratches/wear → Replace the brake 1. Remove: caliper piston. • Brake caliper piston “1” • Brake caliper cylinder “2” • Brake caliper piston dust seal “2” Scratches/wear →...

  • Page 159: Installing The Rear Brake Caliper

    REAR BRAKE EAS30190 INSTALLING THE REAR BRAKE CALIPER Specified brake fluid 1. Install: DOT 4 • Rear brake caliper “1” (temporarily) EWA13540 WARNING • Brake hose gaskets “2” • Use only the designated brake fluid. Other • Rear brake hose “3” brake fluids may cause the rubber seals to •...

  • Page 160: Removing The Rear Brake Master Cylinder

    REAR BRAKE EAS30193 REMOVING THE REAR BRAKE MASTER CYLINDER Before removing the rear brake master cylinder, drain the brake fluid from the entire brake sys- tem. 1. Remove: • Rear brake hose union bolt “1” • Brake hose gaskets “2” •...
  • Page 161 REAR BRAKE 2. Install: • When refilling, be careful that water does not enter the brake master cylinder reser- • Brake hose gaskets “1” voir. Water will significantly lower the boil- • Rear brake hose “2” ing point of the brake fluid and could cause •...
  • Page 162 ABS (ANTI-LOCK BRAKE SYSTEM) EAS20032 ABS (ANTI-LOCK BRAKE SYSTEM) Removing the hydraulic unit assembly 29 N m (2.9 kgf m, 21 lb • • • m (0.7 kgf m, 5.2 lb • • • 29 N m (2.9 kgf m, 21 lb •...
  • Page 163 ABS (ANTI-LOCK BRAKE SYSTEM) Removing the hydraulic unit assembly 29 N m (2.9 kgf m, 21 lb • • • m (0.7 kgf m, 5.2 lb • • • 29 N m (2.9 kgf m, 21 lb • • • m (0.7 kgf m, 5.2 lb •...

  • Page 164: Abs (Anti-Lock Brake System)

    ABS (ANTI-LOCK BRAKE SYSTEM) EAS30197 REMOVING THE HYDRAULIC UNIT Do not operate the brake levers while removing ASSEMBLY 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 165 ABS (ANTI-LOCK BRAKE SYSTEM) d. Position the rear brake hose (hydraulic ECA21110 NOTICE unit to rear brake caliper) “3” so that its Do not remove the rubber plugs or bolts projection “c” contacts the rear brake hose (M10 × 1.25) installed in the brake hose union (rear brake master cylinder to hydraulic bolt holes before installing the hydraulic unit unit) “4”, and then temporarily tighten the...

  • Page 166: Hydraulic Unit Operation Tests

    • For the brake line routing confirmation, use the • When refilling, be careful that water does diagnosis mode of the Yamaha diagnostic tool. not enter the brake fluid reservoir. Water • Before performing the brake line routing confir-...
  • Page 167 Yamaha diagnostic tool (A/I) 90890-03254 “ON” and “OFF” on the tool screen indicate when the brakes are being applied and released 6. Start the Yamaha diagnostic tool and display respectively. the diagnosis mode screen. 7. Select code No. 2, “Brake line routing confir- ECA22080 mation”.
  • Page 168 ABS ECU and that the wheels are not rotating. 1. Place the vehicle on a centerstand. 6. Start the Yamaha diagnostic tool and display 2. Turn the main switch to “OFF”. the diagnosis mode screen. 3. Remove: 7.

  • Page 169: Checking The Abs Warning Light

    12.Turn the main switch to “OFF”. 10.After the pulsating action has stopped in the 13.Remove the Yamaha diagnostic tool from the front brake lever, it is generated in the rear ABS test coupler, and then install the protec- brake lever “1” and continues for a few sec- tive cap.

  • Page 170: Handlebar

    HANDLEBAR EAS20033 HANDLEBAR Removing the rearview mirror and handlebar cover 4.0 N m (0.40 kgf m, 3.0 lb • • • 22 N m (2.2 kgf m, 16 lb • • • 22 N m (2.2 kgf m, 16 lb •...
  • Page 171 HANDLEBAR Removing the handlebar m (0.7 kgf m, 5.2 lb • • • 21 N m (2.1 kgf m, 15 lb • • • 1.8 N m (0.18 kgf m, 1.3 lb • • • 11 N m (1.1 kgf m, 8.1 lb •...
  • Page 172 HANDLEBAR Removing the handlebar m (0.7 kgf m, 5.2 lb • • • 21 N m (2.1 kgf m, 15 lb • • • 1.8 N m (0.18 kgf m, 1.3 lb • • • 11 N m (1.1 kgf m, 8.1 lb •...

  • Page 173: Adjusting The Handlebar Position

    HANDLEBAR EAS31396 ECA18300 ADJUSTING THE HANDLEBAR POSITION NOTICE 1. Remove: First, tighten the bolts on the front side of the • Upper handlebar cover handlebar holder, and then on the rear side. Refer to “REMOVING THE UPPER HAN- DLEBAR COVER” on page 4-74. 2.

  • Page 174: Checking The Handlebar

    HANDLEBAR 2. Remove: • The upper handlebar holders should be in- • Handlebar grip “1” stalled with the punch mark “d” facing forward. • Align the punch mark “e” on the handlebar with the inner edge of the upper surface of the right Blow compressed air between the handlebar lower handlebar holder.
  • Page 175 HANDLEBAR 6. Install: • Handlebar switch (left) “1” Handlebar switch screw (left han- dlebar switch) 2.3 N·m (0.23 kgf·m, 1.7 lb·ft) • Align the projection “a” on the left handlebar switch with the hole “b” in the handlebar. • First, tighten the front screw, then the rear screw.

  • Page 176: Installing The Upper Handlebar Cover

    HANDLEBAR b. Slide the handlebar grip over the left end of the handlebar. There should be 0.5–4.0 mm (0.02–0.16 in) of clearance “c” between the upper handlebar cov- Make sure that the distance “a” between the end er and handlebar switch. of the left handlebar switch and the end of the handlebar grip is 0 mm (0 in).

  • Page 177: Front Fork

    FRONT FORK EAS20034 FRONT FORK Removing the front fork legs 23 N m (2.3 kgf m, 17 lb • • • 30 N m (3.0 kgf m, 22 lb • • • m (0.9 kgf m, 6.6 lb • • •...
  • Page 178 FRONT FORK Removing the front fork legs 23 N m (2.3 kgf m, 17 lb • • • 30 N m (3.0 kgf m, 22 lb • • • m (0.9 kgf m, 6.6 lb • • • 1.8 N m (0.18 kgf m, 1.3 lb m (0.9 kgf...
  • Page 179 FRONT FORK Disassembling the front fork legs 30 N m (3.0 kgf m, 22 lb • • • ’ Order Job/Parts to remove Remarks The following procedure applies to both of the front fork legs. Front fork cap bolt O-ring Spacer Spring seat Fork spring...
  • Page 180 FRONT FORK Disassembling the front fork legs 30 N m (3.0 kgf m, 22 lb • • • ’ Order Job/Parts to remove Remarks Damper rod ring Rebound spring Inner tube Oil flow stopper Oil flow stopper spring Inner tube bushing Oil seal Washer Outer tube bushing...

  • Page 181: Removing The Front Fork Legs

    FRONT FORK EAS30206 REMOVING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. 2.

  • Page 182: Checking The Front Fork Legs

    FRONT FORK b. Securely clamp the brake caliper bracket in a vise with soft jaws. c. Separate the inner tube from the outer tube by pulling the inner tube forcefully but carefully. ECA14190 NOTICE • Excessive force will damage the oil seal and bushing.
  • Page 183 • Inner tube’s outer surface Fit the damper rod ring into the damper rod Recommended oil groove so that the side of the ring with the pro- Yamaha fork oil 10WT jections is facing in the direction shown in the il- lustration. 4. Install: •...
  • Page 184 FRONT FORK Fork seal driver weight 90890-01184 Replacement hammer YM-A9409-7 Fork seal driver attachment (ø33) 90890-01368 Replacement 33 mm YM-A9409-4 7. Install: • Outer tube bushing “1” • Washer “2” (with the fork seal driver attachment “3” and fork seal driver weight “4”) Fork seal driver weight 90890-01184 Replacement hammer...

  • Page 185: Installing The Front Fork Legs

    INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the Recommended oil front fork legs. Yamaha Suspension Oil G10 1. Install: Quantity (left) • Front fork leg 235.0 cm³ (7.95 US oz, 8.29 Temporarily tighten the lower bracket pinch Imp.oz)

  • Page 186: Steering Head

    STEERING HEAD EAS20035 STEERING HEAD Removing the lower bracket 91 N m (9.1 kgf m, 67 lb • • • m (0.7 kgf m, 5.2 lb • • • 1st 48 N m (4.8 kgf m, 35 lb • • •...
  • Page 187 STEERING HEAD Removing the lower bracket 91 N m (9.1 kgf m, 67 lb • • • m (0.7 kgf m, 5.2 lb • • • 1st 48 N m (4.8 kgf m, 35 lb • • • *2nd 14 N m (1.4 kgf m, 10 lb •...

  • Page 188: Removing The Lower Bracket

    STEERING HEAD a. Remove the bearing races from the steer- EAS30213 REMOVING THE LOWER BRACKET ing head pipe “1” with a long rod “2” and 1. Stand the vehicle on a level surface. hammer. EWA13120 b. Remove the bearing race “3” from the low- WARNING er bracket with a floor chisel “4”...
  • Page 189 STEERING HEAD 2. Install: • Lower ring nut “1” • Rubber washer “2” • Upper ring nut “3” • Lock washer “4” Refer to “CHECKING AND ADJUSTING THE STEERING HEAD” on page 3-15. 3. Install: • Front brake hose holder “1” Front brake hose holder bolt 7 N·m (0.7 kgf·m, 5.2 lb·ft) While holding the front brake hose holder so that...

  • Page 190: Rear Shock Absorber Assemblies And Swingarm

    REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM EAS20189 REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM Removing the rear shock absorber assemblies and swingarm m (0.7 kgf m, 5.2 lb • • • 30 N m (3.0 kgf m, 22 lb • • •...

  • Page 191: Removing The Rear Shock Absorber Assemblies

    REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM EAS31227 EAS31230 REMOVING THE REAR SHOCK ABSORBER CHECKING THE SWINGARM ASSEMBLIES 1. Check: 1. Stand the vehicle on a level surface. • Swingarm Bends/cracks/damage → Replace. EWA13120 WARNING 2. Check: Securely support the vehicle so that there is •...
  • Page 192 REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM • Rear wheel axle nut “2” (temporarily tighten) • Swingarm mounting bolt (upper side) “3” (temporarily tighten) • Swingarm mounting bolt (lower side) “4” (temporarily tighten) 4. Tighten: • Rear wheel axle nut “2” •...

  • Page 193: Engine

    ENGINE LUBRICATION SYSTEM CHART AND DIAGRAMS........5-1 ENGINE OIL LUBRICATION CHART ............5-1 LUBRICATION DIAGRAMS ..............5-2 ENGINE INSPECTION ..................5-5 MEASURING THE COMPRESSION PRESSURE........5-5 CHECKING THE BREATHER HOSES .............5-6 ENGINE REMOVAL ..................5-7 INSTALLING THE ENGINE..............5-11 CONNECTING THE LEADS ..............5-11 INSTALLING THE EXHAUST PIPE AND MUFFLER......5-12 CYLINDER HEAD..................
  • Page 194 V-BELT AUTOMATIC TRANSMISSION ............5-37 REMOVING THE PRIMARY FIXED SHEAVE ........5-40 REMOVING THE SECONDARY SHEAVE ..........5-40 DISASSEMBLING THE SECONDARY SHEAVE........5-40 CHECKING THE CLUTCH HOUSING ............5-41 CHECKING THE CLUTCH SHOES ............5-41 CHECKING THE V-BELT................5-41 CHECKING THE PRIMARY SHEAVE ............5-41 CHECKING THE PRIMARY SHEAVE WEIGHTS........
  • Page 195 CRANKSHAFT ....................5-65 REMOVING THE CRANKSHAFT JOURNAL BEARINGS ......5-67 CHECKING THE CRANKSHAFT AND CONNECTING ROD ....5-67 CHECKING THE BALANCER SHAFT ASSEMBLY........5-70 INSTALLING THE CONNECTING ROD ..........5-70 INSTALLING THE CRANKSHAFT JOURNAL BEARINGS.....5-71 INSTALLING THE CRANKSHAFT ASSEMBLY AND BALANCER SHAFT ASSEMBLY ................5-72 TRANSMISSION....................

  • Page 196: Lubrication System Chart And Diagrams

    LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20298 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS32362 ENGINE OIL LUBRICATION CHART 1. Oil strainer 2. Oil pump (feed) 3. Oil filter element 4. Relief valve assembly 5. Main gallery 6. Crankshaft 7. To piston 8. Camshaft 9.

  • Page 197: Lubrication Diagrams

    LUBRICATION SYSTEM CHART AND DIAGRAMS EAS32363 LUBRICATION DIAGRAMS 1. Oil filter element 2. Engine oil check bolt...
  • Page 198 LUBRICATION SYSTEM CHART AND DIAGRAMS 4 5 1 1. Oil strainer (feed) 2. Oil strainer (scavenge) 3. Crankshaft 4. Oil pump (scavenge) 5. Oil pump (feed)
  • Page 199 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Camshaft 2. Crankshaft 3. Oil pump (scavenge) 4. Oil pump (feed) 5. Relief valve assembly 6. Oil filter element...

  • Page 200: Engine Inspection

    ENGINE INSPECTION EAS20041 ENGINE INSPECTION Compression pressure 783–1008 kPa/860 r/min (7.8– EAS30249 10.1 kgf/cm²/860 r/min, 111.4– MEASURING THE COMPRESSION 143.4 psi/860 r/min) PRESSURE a. Turn the main switch to “ON”. b. With the throttle wide open, crank the en- Insufficient compression pressure will result in a gine until the reading on the compression loss of performance.

  • Page 201: Checking The Breather Hoses

    ENGINE INSPECTION 9. Connect: • Spark plug cap 10.Install: • Storage box Refer to “GENERAL CHASSIS (4)” on page 4-10. EAS31742 CHECKING THE BREATHER HOSES 1. Remove: • Storage box Refer to “GENERAL CHASSIS (4)” on page 4-10. 2. Check: •...

  • Page 202: Engine Removal

    ENGINE REMOVAL EAS20042 ENGINE REMOVAL Removing the muffler and exhaust pipe m (0.8 kgf m, 5.9 lb • • • 53 N m (5.3 kgf m, 39 lb • • • 20 N m (2.0 kgf m, 15 lb • •...
  • Page 203 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 3-19. Drain. Coolant Refer to “CHANGING THE COOLANT” on page 3-21.
  • Page 204 ENGINE REMOVAL Disconnecting the leads m (0.7 kgf m, 5.2 lb • • • ’ Order Job/Parts to remove Remarks Thermostat assembly Refer to “THERMOSTAT” on page 6-6. Fuel injector Refer to “FUEL INJECTOR” on page 7-8. Air filter case joint Refer to “AIR FILTER CASE”...
  • Page 205 ENGINE REMOVAL Removing the engine 45 N m (4.5 kgf m, 33 lb • • • 30 N m (3.0 kgf m, 22 lb • • • 23 N m (2.3 kgf m, 17 lb • • • 45 N m (4.5 kgf m, 33 lb •...

  • Page 206: Installing The Engine

    ENGINE REMOVAL EAS30251 INSTALLING THE ENGINE Engine mounting bolt (rear side) 1. Lubricate: 45 N·m (4.5 kgf·m, 33 lb·ft) • Engine bracket bolt “1” Engine mounting bolt (front side) 45 N·m (4.5 kgf·m, 33 lb·ft) Recommended lubricant Lithium-soap-based grease 7. Install: •...

  • Page 207: Installing The Exhaust Pipe And Muffler

    ENGINE REMOVAL EAS30252 INSTALLING THE EXHAUST PIPE AND MUFFLER 1. Install: • Exhaust gasket “1” (to the cylinder head) Install the exhaust gasket with its projections “a” facing toward the cylinder head. 5-12...

  • Page 208: Cylinder Head

    • • • * Apply Yamaha bond No.1215 (90890-85505). ** Following the tightening order, loosen the bolt one by one, and then retighten it to the specific torque (after loosening the bolt, retighten it before loosening the next bolt). ’...
  • Page 209 • • • * Apply Yamaha bond No.1215 (90890-85505). ** Following the tightening order, loosen the bolt one by one, and then retighten it to the specific torque (after loosening the bolt, retighten it before loosening the next bolt). ’...
  • Page 210 • • • * Apply Yamaha bond No.1215 (90890-85505). ** Following the tightening order, loosen the bolt one by one, and then retighten it to the specific torque (after loosening the bolt, retighten it before loosening the next bolt). ’...
  • Page 211 • • • * Apply Yamaha bond No.1215 (90890-85505). ** Following the tightening order, loosen the bolt one by one, and then retighten it to the specific torque (after loosening the bolt, retighten it before loosening the next bolt). ’...

  • Page 212: Removing The Cylinder Head

    CYLINDER HEAD EAS30276 REMOVING THE CYLINDER HEAD 1. Remove: • Crankshaft end cover • Timing mark accessing bolt 2. Align: • Mark “a” on the generator rotor (with the slots “b” in the generator rotor cover) a. Turn the crankshaft clockwise. b.

  • Page 213: Checking The Camshaft Sprocket

    CYLINDER HEAD • Cylinder head water jacket Mineral deposits/rust → Eliminate. 3. Measure: • Cylinder head warpage Out of specification → Resurface the cylinder head. Warpage limit 0.05 mm (0.0020 in) a. Place a straightedge “1” and a thickness a. 1/4 tooth gauge “2”...
  • Page 214 CYLINDER HEAD a. Install the timing chain onto the camshaft Cylinder head nut sprocket, then the camshaft sprocket onto 1st: 16 N·m (1.6 kgf·m, 12 lb·ft) the camshaft, and then finger tighten the *2nd: 16 N·m (1.6 kgf·m, 12 lb·ft), camshaft sprocket bolts.
  • Page 215 • The mark “b” on the timing chain tensioner should face in the direction shown in the illus- tration. • Apply Yamaha bond No. 1215 to the threads of the timing chain tensioner bolts. Yamaha bond No. 1215 90890-85505 (Three bond No.1215®)
  • Page 216 CYLINDER HEAD Bracket bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft) While holding the bracket 1 so that the bracket 1 the portion “a” of the cylinder head, tighten the bolt to specification. 5-21...

  • Page 217: Camshaft

    CAMSHAFT EAS20043 CAMSHAFT Removing the rocker arms and camshaft 10 N m (1.0 kgf m, 7.4 lb • • • 12 N m (1.2 kgf m, 8.9 lb • • • m (0.8 kgf m, 5.9 lb • • • ’...

  • Page 218: Removing The Camshaft

    CAMSHAFT 3. Measure: EAS30256 REMOVING THE CAMSHAFT • Camshaft runout 1. Remove: Out of specification → Replace the camshaft • Camshaft assembly “1” assembly. Camshaft runout limit Screw the M6 bolts “2” into the threaded end of 0.030 mm (0.0012 in) the camshaft assembly, and then pull out the camshaft.

  • Page 219: Installing The Camshaft

    CAMSHAFT 2. Check: 5. Calculate: • Rocker arm shaft • Rocker-arm-to-rocker-arm-shaft clearance Blue discoloration/excessive wear/pitting/ scratches → Replace or check the lubrication Calculate the clearance by subtracting the rock- system. er arm shaft outside diameter from the rocker 3. Measure: arm inside diameter.
  • Page 220 CAMSHAFT • Before installing the rocker arm shaft retainer, make sure that the notches “a” in the rocker arm shafts face inward. • While holding the rocker arm shaft retainer so that the portion “b” of the retainer contact the cylinder head, tighten the bolt to specification.

  • Page 221: 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 5-13. Camshaft/Rocker arms Refer to “CAMSHAFT” on page 5-22. Valve pad Valve cotter Valve spring retainer Valve spring...

  • Page 222: Removing The Valves

    VALVES AND VALVE SPRINGS EAS30283 REMOVING THE VALVES The following procedure applies to all of the valves and related components. Before removing the internal parts of the cylinder head (e.g., valves, valve springs, valve seats), make sure the valves properly seal. 1.
  • Page 223 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 11.98–12.02 mm (0.471–0.473 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 224: 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 225: Checking The Valve Springs

    VALVES AND VALVE SPRINGS j. Measure the valve seat width again. If the valve seat width is out of specification, re- face and lap the valve seat. EAS30286 CHECKING THE VALVE SPRINGS The following procedure applies to all of the valve springs.
  • Page 226 VALVES AND VALVE SPRINGS • Valve stem seal “2” (with the recommended lubricant) Install the valve cotters by compressing the valve spring with the valve spring compressor Recommended lubricant and the valve spring compressor attachment “2”. Engine oil Valve spring compressor 90890-04019 Valve spring compressor YM-04019...

  • Page 227: Cylinder And Piston

    CYLINDER AND PISTON EAS20046 CYLINDER AND PISTON Removing the cylinder and piston ’ Order Job/Parts to remove Remarks Cylinder head Refer to “CYLINDER HEAD” on page 5-13. Water pump outlet pipe Refer to “WATER PUMP” on page 6-8. Timing chain guide (exhaust side) Cylinder Cylinder gasket Dowel pin...

  • Page 228: Removing The Piston

    CYLINDER AND PISTON EAS30289 REMOVING THE PISTON When removing a piston ring, open the end gap 1. Remove: with your fingers and lift the other side of the ring • Piston pin clips “1” over the piston crown. • Piston pin “2” •...

  • Page 229: Checking The Piston Rings

    CYLINDER AND PISTON Piston ring Top ring Ring side clearance 0.030–0.065 mm (0.0012– 0.0026 in) Side clearance limit 0.115 mm (0.0045 in) 2nd ring Ring side clearance 0.020–0.055 mm (0.0008– 0.0022 in) b. 8.0 mm (0.31 in) from the bottom edge of the Side clearance limit piston 0.115 mm (0.0045 in)

  • Page 230: Checking The Piston Pin

    CYLINDER AND PISTON 4. Calculate: Piston ring • Piston-pin-to-piston-pin-bore clearance Top ring Out of specification → Replace the piston pin End gap limit and piston as a set. 0.50 mm (0.0197 in) Piston-pin-to-piston-pin-bore clearance = 2nd ring Piston pin bore diameter “b” - End gap limit Piston pin outside diameter “a”...
  • Page 231 CYLINDER AND PISTON • When installing a piston pin clip, make sure 5. Install: that the clip ends “b” are positioned away from • Dowel pins the cutout “c” in the piston as shown in the illus- • Cylinder gasket tration.

  • Page 232: V-Belt Automatic Transmission

    V-BELT AUTOMATIC TRANSMISSION EAS20050 V-BELT AUTOMATIC TRANSMISSION Removing the V-belt case 10 N m (1.0 kgf m, 7.4 lb • • • (12) m (0.7 kgf m, 5.2 lb • • • ’ Order Job/Parts to remove Remarks Refer to “GENERAL CHASSIS (4)” on page Storage box 4-10.
  • Page 233 V-BELT AUTOMATIC TRANSMISSION Removing the V-belt, primary sliding sheave assembly and secondary sheave assembly 85 N m (8.5 kgf m, 63 lb • • • 75 N m (7.5 kgf m, 55 lb • • • 115 N m (11.5 kgf m, 85 lb •...
  • Page 234 V-BELT AUTOMATIC TRANSMISSION Disassembling the secondary sheave assembly ® * Apply Shell dolium grease R Order Job/Parts to remove ’ Remarks Secondary sheave nut Clutch carrier assembly Compression spring Spring seat 1 Spring seat 2 Guide pin Collar Secondary sliding sheave O-ring Oil seal Bearing...

  • Page 235: Removing The Primary Fixed Sheave

    V-BELT AUTOMATIC TRANSMISSION EAS32357 ECA21820 REMOVING THE PRIMARY FIXED SHEAVE NOTICE 1. Remove: Do not remove the secondary sheave nut at • Primary fixed sheave bolt “1” this stage. • Washer • Primary fixed sheave “2” While holding the secondary sheave with the ro- tor holding tool “2”, loosen the secondary While holding the primary fixed sheave with the sheave nut one full turn with the locknut wrench...

  • Page 236: Checking The Clutch Housing

    V-BELT AUTOMATIC TRANSMISSION Clutch shoe thickness 3.0 mm (0.12 in) Limit 1.5 mm (0.06 in) EAS30313 CHECKING THE CLUTCH HOUSING 1. Check: • Clutch housing Damage/wear → Replace. 2. Measure: • Clutch housing inside diameter “a” EAS30315 CHECKING THE V-BELT Out of specification →...

  • Page 237: Checking The Primary Sheave Weights

    V-BELT AUTOMATIC TRANSMISSION • Collar Cracks/damage/wear → Replace the primary sliding sheave, primary fixed sheave, and collar as a set. EAS30317 CHECKING THE PRIMARY SHEAVE WEIGHTS The following procedure applies to all of the pri- mary sheave weights. 1. Check: 4.

  • Page 238: Assembling The Primary Fixed Sheave

    V-BELT AUTOMATIC TRANSMISSION Recommended lubricant Recommended lubricant Shell dolium grease R® Shell dolium grease R® Do not apply grease to the inner surface “a” of the secondary fixed sheave “2”. If any grease gets on the inner surface of the secondary fixed sheave, be sure to wipe it off thoroughly.

  • Page 239: Installing The Primary Sheave, V-Belt And Secondary Sheave

    V-BELT AUTOMATIC TRANSMISSION • Cam 2. Install: • Oil seal “1” (into the primary sliding sheave “2”) Installed depth “a” 0–0.4mm (0–0.02 in) 2. Tighten: • Secondary sheave nut “1” Secondary sheave nut 85 N·m (8.5 kgf·m, 63 lb·ft) While holding the secondary sheave with the ro- tor holding tool “2”, tighten the secondary EAS31234 INSTALLING THE PRIMARY SHEAVE, V-...
  • Page 240 V-BELT AUTOMATIC TRANSMISSION Rotor holding tool Install the V-belt in the primary sheave (when the 90890-04166 pulley is at its widest position) and in the second- Rotor holding tool ary sheave (when the pulley is at its narrowest YM-04166 position), and make sure the V-belt is tight. 7.

  • Page 241: Generator And Starter Clutch

    (7.5 kgf m, 55 lb • • • • • • * Apply Yamaha bond No.1215 (90890-85505). ’ Order Job/Parts to remove Remarks Refer to “GENERAL CHASSIS (1)” on page Battery cover assembly 4-1. Refer to “GENERAL CHASSIS (2)” on page Front cowling assemblies 4-4.
  • Page 242 9.6 lb 75 N m (7.5 kgf m, 55 lb • • • • • • * Apply Yamaha bond No.1215 (90890-85505). ’ Order Job/Parts to remove Remarks Crankshaft position sensor coupler Disconnect. Stator coil coupler Disconnect. Crankshaft end cover...
  • Page 243 75 N m (7.5 kgf m, 55 lb • • • • • • * Apply Yamaha bond No.1215 (90890-85505). ’ Order Job/Parts to remove Remarks Starter clutch idle gear shaft Starter clutch idle gear Generator rotor assembly Woodruff key...

  • Page 244: Removing The Generator

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

  • Page 245: Installing The Starter Clutch

    GENERATOR AND STARTER CLUTCH • Starter clutch gear Rotor holding tool Burrs/chips/roughness/wear → Replace the 90890-04166 defective part(s). Rotor holding tool 3. Check: YM-04166 • Starter clutch gear contact surfaces Damage/pitting/wear → Replace the starter clutch gear. 4. Check: • Starter clutch operation a.
  • Page 246 • Sealant • Stator coil coupler (onto the stator coil lead grommet) • Crankshaft position sensor coupler Yamaha bond No. 1215 To route the stator coil/crankshaft position sen- 90890-85505 sor lead, refer to “CABLE ROUTING” on page (Three bond No.1215®) 2-13.

  • Page 247: Electric Starter

    ELECTRIC STARTER EAS20052 ELECTRIC STARTER Removing the starter motor 10 N m (1.0 kgf m, 7.4 lb • • • 3.5 N m (0.35 kgf m, 2.6 lb • • • ’ Order Job/Parts to remove Remarks Refer to “GENERAL CHASSIS (4)” on page Storage box 4-10.
  • Page 248 ELECTRIC STARTER Disassembling the starter motor 1.5 N m (0.15 kgf m, 1.1 lb • • • 3.5 N m (0.35 kgf m, 2.6 lb • • • ’ Order Job/Parts to remove Remarks Starter motor front cover Gasket Oil seal Bearing Armature assembly Circlip...

  • Page 249: Checking The Starter Motor

    ELECTRIC STARTER EAS30325 CHECKING THE STARTER MOTOR Digital circuit tester (CD732) 1. Check: 90890-03243 • Commutator Model 88 Multimeter with ta- Dirt → Clean with 600 grit sandpaper. chometer YU-A1927 2. Measure: • Commutator diameter “a” Out of specification → Replace the starter Armature coil resistance motor.

  • Page 250: Assembling The Starter Motor

    ELECTRIC STARTER Connect the starter motor lead to the starter mo- tor so that the lead is parallel to the starter motor axis “a”. 7. Check: • Gear teeth Damage/wear → Replace the gear. 8. Check: • Bearing • Oil seal Damage/wear →...

  • Page 251: Oil Pump

    OIL PUMP EAS20054 OIL PUMP Removing the oil pump assembly 10 N m (1.0 kgf m, 7.4 lb • • • ’ Order Job/Parts to remove Remarks Refer to “GENERAL CHASSIS (1)” on page Battery cover assembly 4-1. Refer to “GENERAL CHASSIS (2)” on page Front cowling assemblies 4-4.
  • Page 252 OIL PUMP Removing the oil pump assembly 10 N m (1.0 kgf m, 7.4 lb • • • ’ Order Job/Parts to remove Remarks Water pump inlet hose/water pump outlet pipe Refer to “WATER PUMP” on page 6-8. Refer to “GENERATOR AND STARTER Generator rotor assembly/Starter clutch gear CLUTCH”...
  • Page 253 OIL PUMP Disassembling the oil pump assembly m (0.7 kgf m, 5.2 lb • • • 11 8 ’ Order Job/Parts to remove Remarks Oil pump housing cover Dowel pin Oil pump outer rotor (scavenge) Oil pump inner rotor (scavenge) Oil pump housing (scavenge) Washer Dowel pin...

  • Page 254: Checking The Oil Strainer

    OIL PUMP EAS30340 CHECKING THE OIL STRAINER 1. Check: • Oil strainer (feed) Damage → Replace. Contaminants → Clean with solvent. EAS30337 CHECKING THE OIL PUMP 1. Check: • Oil pump driven gear • Oil pump housings EAS30785 • Oil pump housing cover CHECKING THE OIL PUMP DRIVE CHAIN Cracks/damage/wear →...

  • Page 255: Installing The Oil Pump

    OIL PUMP A. Scavenge B. Feed 3. Check: • Oil pump operation Refer to “CHECKING THE OIL PUMP” on page 5-59. EAS30343 INSTALLING THE OIL PUMP 1. Install: • Oil pump assembly Oil pump bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft) ECA13890 NOTICE After tightening the bolts, make sure the oil...

  • Page 256: Crankcase

    CRANKCASE EAS20059 CRANKCASE Separating the crankcase 10 N m (1.0 kgf m, 7.4 lb • • • 10 N m (1.0 kgf m, 7.4 lb • • • 10 N m (1.0 kgf m, 7.4 lb • • • 20 N m (2.0 kgf m, 15 lb •...
  • Page 257 CRANKCASE Separating the crankcase 10 N m (1.0 kgf m, 7.4 lb • • • 10 N m (1.0 kgf m, 7.4 lb • • • 10 N m (1.0 kgf m, 7.4 lb • • • 20 N m (2.0 kgf m, 15 lb •...

  • Page 258: Disassembling The Crankcase

    3. Apply: 3. Check: • Sealant • Crankcase (onto the crankcase mating surfaces) Cracks/damage → Replace. Yamaha bond No. 1215 • Oil delivery passages Obstruction → Blow out with compressed air. 90890-85505 (Three bond No.1215®) EAS30391 CHECKING THE TIMING CHAIN AND TIMING...
  • Page 259 CRANKCASE 4. Install: • Dowel pins • Crankcase (left) • Crankcase bolts Crankcase bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft) • Thoroughly wipe off any sealant that protrudes from between the left crankcase and the right crankcase. • Tighten each bolt 1/4 of a turn at a time, in stag- es and in a crisscross pattern.

  • Page 260: Crankshaft

    CRANKSHAFT EAS20061 CRANKSHAFT Removing the crankshaft assembly and balancer shaft assembly ’ Order Job/Parts to remove Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-61. Crankshaft assembly Balancer shaft assembly Crankshaft journal bearing (left crankcase side) Crankshaft journal bearing (right crankcase side) Oil seal Bearing...
  • Page 261 CRANKSHAFT Removing the connecting rod 1st 18 N m (1.8 kgf m, 13 lb • • • 2nd Specified angle 180° ’ Order Job/Parts to remove Remarks Connecting rod cap Big end lower bearing Connecting rod Big end upper bearing 5-66...

  • Page 262: Removing The Crankshaft Journal Bearings

    CRANKSHAFT EAS30419 REMOVING THE CRANKSHAFT JOURNAL BEARINGS The following procedure applies to both of the crankshaft journal bearings. 1. Remove: • Crankshaft assembly • Balancer shaft assembly • Crankshaft journal bearings “1” Remove the crankshaft journal bearings using 2. Check: the pressure tool “2”.
  • Page 263 CRANKSHAFT 4. Select: d. Assemble the connecting rod halves. • Big end bearings (P • Do not move the connecting rod or crankshaft until the clearance measurement has been The numbers “A” stamped into the crankshaft completed. web and the numbers “B” on the connecting rods •...
  • Page 264 CRANKSHAFT Bearing color code Code 1 Blue Code 2 Black Code 3 Brown Code 4 Green 5. Measure: d. Measure the crankshaft journal bearing in- • Crankshaft-journal-to-crankshaft-journal side diameter “b” of each crankshaft jour- bearing clearance. nal bearing. Out of specification → Replace the crank- Crankshaft journal bearing inside shaft journal bearings.

  • Page 265: Checking The Balancer Shaft Assembly

    CRANKSHAFT • J –J refer to the bearings shown in the crank- Bearing color code shaft illustration. Code 0 White Code 1 Blue Code 2 Black Code 3 Brown Code 4 Green Code 5 Yellow Code 6 Pink EAS31142 CHECKING THE BALANCER SHAFT ASSEMBLY 1.

  • Page 266: Installing The Crankshaft Journal Bearings

    CRANKSHAFT • Make sure the “Y” marks “c” on the connecting rods face towards the left side of the crank- shaft. • Make sure the characters “d” on both the con- necting rod and connecting rod cap are aligned. • Make sure that the projection “e” on the con- necting rod cap faces the same direction as the “Y”...

  • Page 267: Installing The Crankshaft Assembly And Balancer Shaft Assembly

    CRANKSHAFT Crankshaft metal installation base set 90890-04181 Crankshaft metal installation base set YM-04181 a. Set the bearing installer “1” on the crank- case. 2. Measure: • Align the mark “a” on the bearing installer with • Install depth of crankshaft journal bearings the punch mark “b”...

  • Page 268: Transmission

    TRANSMISSION EAS20062 TRANSMISSION Removing the transmission 20 N m (2.0 kgf m, 15 lb • • • 20 N m (2.0 kgf m, 15 lb • • • ’ Order Job/Parts to remove Remarks Drain. Final transmission oil Refer to “CHANGING THE FINAL TRANS- MISSION OIL”...
  • Page 269 TRANSMISSION Removing the transmission 20 N m (2.0 kgf m, 15 lb • • • 20 N m (2.0 kgf m, 15 lb • • • ’ Order Job/Parts to remove Remarks Final transmission oil filler cap Final transmission oil drain bolt Transmission case cover Transmission case cover gasket Dowel pin...

  • Page 270: Checking The Transmission

    TRANSMISSION EAS30433 CHECKING THE TRANSMISSION 1. Check: • Transmission gears Blue discoloration/pitting/wear → Replace the defective gear(s). • Transmission gear dogs Cracks/damage/rounded edges → Replace the defective gear(s). 2. Check: • Transmission gear engagement (each pinion gear to its respective wheel gear) Incorrect →...

  • Page 271: Cooling System

    COOLING SYSTEM COOLING SYSTEM DIAGRAMS ..............6-1 RADIATOR ...................... 6-2 CHECKING THE RADIATOR..............6-4 INSTALLING THE RADIATOR..............6-4 THERMOSTAT ....................6-6 CHECKING THE THERMOSTAT ASSEMBLY ......... 6-7 INSTALLING THE THERMOSTAT ASSEMBLY ........6-7 WATER PUMP....................6-8 DISASSEMBLING THE WATER PUMP..........6-10 CHECKING THE WATER PUMP ............6-10 ASSEMBLING THE WATER PUMP............

  • Page 272: Cooling System Diagrams

    COOLING SYSTEM DIAGRAMS EAS20299 COOLING SYSTEM DIAGRAMS 1. Water pump inlet hose 2. Thermostat assembly 3. Radiator inlet hose 4. Cooling system air bleed hose 5. Radiator outlet hose 6. Water pump outlet pipe 7. Water pump assembly...

  • Page 273: Radiator

    RADIATOR EAS20063 RADIATOR Removing the radiator m (0.8 kgf m, 5.9 lb • • • m (0.7 kgf m, 5.2 lb • • • m (0.7 kgf m, 5.2 lb • • • 1.6 N m (0.16 kgf m, 1.2 lb •...
  • Page 274 RADIATOR Removing the radiator m (0.8 kgf m, 5.9 lb • • • m (0.7 kgf m, 5.2 lb • • • m (0.7 kgf m, 5.2 lb • • • 1.6 N m (0.16 kgf m, 1.2 lb • •...

  • Page 275: 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, flathead screwdriver. b. Apply the specified pressure for ten sec- onds and make sure there is no drop in pressure.
  • Page 276 RADIATOR 3. Fill: • Cooling system (with the specified amount of the recom- mended coolant) Refer to “CHANGING THE COOLANT” on page 3-21. 4. Check: • Cooling system Leaks → Repair or replace any faulty part. a. Attach the radiator cap tester “1” and radi- ator cap tester adapter “2”...

  • Page 277: Thermostat

    THERMOSTAT EAS20065 THERMOSTAT Removing the thermostat assembly m (0.9 kgf m, 6.6 lb • • • ’ Order Job/Parts to remove Remarks Refer to “GENERAL CHASSIS (1)” on page Battery cover assembly 4-1. Refer to “GENERAL CHASSIS (2)” on page Front cowling assemblies 4-4.

  • Page 278: Checking The Thermostat Assembly

    THERMOSTAT EAS31248 CHECKING THE THERMOSTAT ASSEMBLY 1. Check: • Thermostat “1” Does not open at 74–78 °C (165–172 °F) → 0.5 mm (0.02 in) 7 mm Replace. (0.28 in) 76˚C 90˚C (169˚F) (194˚F) A. Fully closed B. Fully open If the accuracy of the thermostat is in doubt, re- place it.

  • Page 279: Water Pump

    WATER PUMP EAS20066 WATER PUMP Removing the water pump 10 N m (1.0 kgf m, 7.4 lb • • • (10) 10 N m (1.0 kgf m, 7.4 lb • • • 10 N m (1.0 kgf m, 7.4 lb •...
  • Page 280 WATER PUMP Removing the water pump 10 N m (1.0 kgf m, 7.4 lb • • • (10) 10 N m (1.0 kgf m, 7.4 lb • • • 10 N m (1.0 kgf m, 7.4 lb • • • ’...

  • Page 281: Disassembling The Water Pump

    WATER PUMP EAS30446 DISASSEMBLING THE WATER PUMP 1. Remove: • Water pump seal “1” Remove the water pump seal from the outside of the generator cover “2”. A. Push down 3. Mechanical seal installer 4. Middle driven shaft bearing driver EAS30447 CHECKING THE WATER PUMP 1.
  • Page 282 WATER PUMP • Generator cover “1” 5. Measure: • Radiator cap opening pressure Generator cover bolt Below the specified pressure → Replace the 10 N·m (1.0 kgf·m, 7.4 lb·ft) radiator cap. Refer to “CHECKING THE RADIATOR” on page 6-4. • Align the projections “a” and “b” on the water pump with the respective projections “a”...

  • Page 283: Fuel System

    FUEL SYSTEM FUEL TANK..................... 7-1 REMOVING THE FUEL TANK ..............7-5 REMOVING THE FUEL PUMP ..............7-5 REMOVING THE FUEL FILTER ............... 7-5 CHECKING THE FUEL PUMP BODY............7-5 CHECKING THE FUEL FILTER..............7-5 CHECKING THE ROLLOVER VALVE ............7-5 INSTALLING THE FUEL FILTER.............. 7-6 INSTALLING THE FUEL PUMP..............7-6 INSTALLING THE FUEL TANK..............7-6 CHECKING THE FUEL PRESSURE ............7-7...

  • Page 284: Fuel Tank

    FUEL TANK EAS20067 FUEL TANK Removing the fuel tank 16 N m (1.6 kgf m, 12 lb • • • 4.0 N m (0.40 kgf m, 3.0 lb • • • ’ Order Job/Parts to remove Remarks Refer to “GENERAL CHASSIS (1)” on page Battery 4-1.
  • Page 285 FUEL TANK Removing the fuel tank 16 N m (1.6 kgf m, 12 lb • • • 4.0 N m (0.40 kgf m, 3.0 lb • • • ’ Order Job/Parts to remove Remarks Thermostat assembly Refer to “THERMOSTAT” on page 6-6. Cylinder head Refer to “CYLINDER HEAD”...
  • Page 286 FUEL TANK Removing the canister m (0.7 kgf m, 5.2 lb • • • ’ Order Job/Parts to remove Remarks Refer to “GENERAL CHASSIS (1)” on page Battery 4-1. Refer to “GENERAL CHASSIS (2)” on page Front cowling assemblies 4-4. Refer to “GENERAL CHASSIS (3)”...
  • Page 287 FUEL TANK Removing the canister m (0.7 kgf m, 5.2 lb • • • ’ Order Job/Parts to remove Remarks Canister purge hose Canister bracket Canister Canister breather hose...

  • Page 288: Removing The Fuel Tank

    FUEL TANK • Fuel filter “2” EAS30450 REMOVING THE FUEL TANK • O-ring “3” 1. Extract the fuel in the fuel tank through the a. Unhook the projections “a” on fuel filter fuel tank cap with a pump. holder from the fuel pump, and then slide 2.

  • Page 289: Installing The Fuel Filter

    FUEL TANK • Always use a new fuel pump gasket. • When installing the fuel pump gasket, make sure that there is no foreign material between the gasket and the surrounding parts. • The gasket lip “a” shall face toward the fuel pump.

  • Page 290: Checking The Fuel Pressure

    FUEL TANK • To install the fuel hose, slide the fuel hose con- nector cover “1” on each end of the hose in the Before removing the hose, place a few rags in direction of the arrow shown. the area under where it will be removed. b.

  • Page 291: Fuel Injector

    FUEL INJECTOR EAS20191 FUEL INJECTOR Removing the fuel injector 12 N m (1.2 kgf m, 8.9 lb • • • m (0.7 kgf m, 5.2 lb • • • ’ Order Job/Parts to remove Remarks Refer to “GENERAL CHASSIS (1)” on page Battery cover assembly 4-1.

  • Page 292: Removing The Fuel Hose

    FUEL INJECTOR EAS31250 EAS31617 REMOVING THE FUEL HOSE INSTALLING THE FUEL INJECTOR 1. Disconnect: 1. Install: • Fuel hose • O-ring “1” EWA17610 (to the fuel injector) WARNING • Fuel injector “2” Cover fuel hose connections with a cloth when disconnecting them. Residual pres- Fuel injector bolt sure in the fuel lines could cause fuel to 12 N·m (1.2 kgf·m, 8.9 lb·ft)
  • Page 293 FUEL INJECTOR 2. Install: • Fuel hose holder “1” Fuel hose holder bolt 7 N·m (0.7 kgf·m, 5.2 lb·ft) While holding the fuel hose holder so that the portion “a” of the holder contacts the portion “b” of the cylinder head cover. 7-10...

  • Page 294: Air Filter Case

    AIR FILTER CASE EAS20068 AIR FILTER CASE Removing the air filter case 10 N m (1.0 kgf m, 7.4 lb • • • 1.2 N m (0.12 kgf m, 0.88 lb • • • 1.2 N m (0.12 kgf m, 0.88 lb •...

  • Page 295: Installing The Air Filter Case

    AIR FILTER CASE EAS31618 INSTALLING THE AIR FILTER CASE 1. Install: • Air filter case joint “1” (to the air filter case “2”) • Apply Three Bond 1521 “3” onto the mating surfaces of the air filter case joint and air filter case.

  • Page 296: Throttle Body

    THROTTLE BODY EAS20070 THROTTLE BODY Removing the throttle body m (0.5 kgf m, 3.7 lb 3.0 N m (0.30 kgf m, 2.2 lb • • • • • • 12 N m (1.2 kgf m, 8.9 lb • • • 12 N m (1.2 kgf m, 8.9 lb...
  • Page 297 THROTTLE BODY Removing the throttle body m (0.5 kgf m, 3.7 lb • • • 3.0 N m (0.30 kgf m, 2.2 lb • • • 12 N m (1.2 kgf m, 8.9 lb • • • 12 N m (1.2 kgf m, 8.9 lb •...

  • Page 298: Removing The Throttle Body

    THROTTLE BODY EAS30979 EAS31254 REMOVING THE THROTTLE BODY CLEANING THE ISC (IDLE SPEED 1. Remove: CONTROL) UNIT AND THROTTLE BODY • Throttle body 1. Remove the throttle body from the vehicle. ECA20500 NOTICE Before removing the throttle body, disconnect Do not remove the throttle body sensor as- the throttle cables, canister purge hose, and sembly from the throttle body.
  • Page 299 THROTTLE BODY Recommended cleaning agent Yamaha oil & brake cleaner ECA21790 NOTICE • Be sure to use the recommended cleaning agent. • Do not spray the cleaning agent directly onto the ISC unit or throttle body and do not immerse them in the cleaning agent.
  • Page 300 9-1. • ISC valve position Use the diagnostic code number “54”. Refer to “SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE” on page 9-1. Yamaha diagnostic tool USB 90890-03256 Yamaha diagnostic tool (A/I) 90890-03254 12.Reset: • A/F control learning values Use the diagnostic code number “87”.

  • Page 301: Replacing The Throttle Body

    9-1. • ISC valve position Use the diagnostic code number “54” Refer to “SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE” on page 9-1. Yamaha diagnostic tool USB 90890-03256 Yamaha diagnostic tool (A/I) 90890-03254 4. Reset: • A/F control learning values Use the diagnostic code number “87”.
  • Page 302 THROTTLE BODY 7-19...

  • Page 303: Electrical System

    TROUBLESHOOTING ................8-21 COOLING SYSTEM..................8-27 CIRCUIT DIAGRAM ................8-27 TROUBLESHOOTING ................8-29 FUEL INJECTION SYSTEM................8-31 CIRCUIT DIAGRAM ................8-31 ECU SELF-DIAGNOSTIC FUNCTION............8-33 TROUBLESHOOTING METHOD............8-33 YAMAHA DIAGNOSTIC TOOL ...............8-34 TROUBLESHOOTING DETAILS ............8-34 FUEL PUMP SYSTEM...................8-77 CIRCUIT DIAGRAM ................8-77 TROUBLESHOOTING ................8-79...
  • Page 304 ABS (ANTI-LOCK BRAKE SYSTEM)............8-81 CIRCUIT DIAGRAM ................8-81 ABS COUPLER LOCATION CHART ............8-83 MAINTENANCE OF THE ABS ECU ............8-84 ABS TROUBLESHOOTING OUTLINE............8-84 BASIC INSTRUCTIONS FOR TROUBLESHOOTING ......8-85 BASIC PROCESS FOR TROUBLESHOOTING ........8-86 [A] CHECKING THE ABS WARNING LIGHT..........8-87 [A-1] ONLY THE ABS WARNING LIGHT FAILS TO COME ON.....

  • Page 306: Ignition System

    IGNITION SYSTEM EAS20072 IGNITION SYSTEM EAS30490 CIRCUIT DIAGRAM...
  • Page 307 IGNITION SYSTEM 1. Crankshaft position sensor 6. Main switch 10.Backup fuse 11.Main fuse 22.Battery 24.Main fuse 2 30.Sidestand switch 44.ECU (Engine Control Unit) 45.Ignition coil 46.Spark plug 54.Engine ground 67.Frame ground...

  • Page 308: Troubleshooting

    IGNITION SYSTEM EAS30492 TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). • Before troubleshooting, remove the following part(s): 1. Battery cover assembly 2. Storage box 3. Lower side cover 4. Exhaust pipe NG → 1. Check the fuse. (Main, main 2, backup) Replace the fuse(s).
  • Page 309 IGNITION SYSTEM NG → 8. Check the main switch. Refer to “CHECKING THE Replace the main switch. SWITCHES” on page 8-127. OK ↓ NG → 9. Check the sidestand switch. Refer to “CHECKING THE Replace the sidestand switch. SWITCHES” on page 8-127. OK ↓...

  • Page 310: Electric Starting System

    ELECTRIC STARTING SYSTEM EAS20073 ELECTRIC STARTING SYSTEM EAS30493 CIRCUIT DIAGRAM...
  • Page 311 ELECTRIC STARTING SYSTEM 6. Main switch 11.Main fuse 13.Signaling system fuse 22.Battery 24.Main fuse 2 25.Starter relay 26.Starter motor 28.Diode 3 29.Starting circuit cut-off relay 30.Sidestand switch 31.Handlebar switch (right) 32.Start/engine stop switch 35.Front brake light switch 67.Frame ground 70.Handlebar switch (left) 74.Rear brake light switch...

  • Page 312: Starting Circuit Cut-Off System Operation

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

  • Page 313: Troubleshooting

    ELECTRIC STARTING SYSTEM EAS30495 TROUBLESHOOTING The starter motor fails to turn. • Before troubleshooting, remove the following part(s): 1. Battery cover assembly 2. Front cowlings 3. Footrest board assemblies 4. Lower side cover NG → 1. Check the fuses. (Main, main 2 and signaling sys- tem) Replace the fuse(s).
  • Page 314 ELECTRIC STARTING SYSTEM NG → 8. Check the main switch. Refer to “CHECKING THE Replace the main switch. SWITCHES” on page 8-127. OK ↓ NG → 9. Check the sidestand switch. Refer to “CHECKING THE Replace the sidestand switch. SWITCHES” on page 8-127. OK ↓...
  • Page 315 ELECTRIC STARTING SYSTEM 8-10...

  • Page 316: Charging System

    CHARGING SYSTEM EAS20074 CHARGING SYSTEM EAS30496 CIRCUIT DIAGRAM 8-11...
  • Page 317 CHARGING SYSTEM 2. AC magneto 3. Rectifier/regulator 22.Battery 24.Main fuse 2 67.Frame ground 8-12...

  • Page 318: Troubleshooting

    CHARGING SYSTEM EAS30497 TROUBLESHOOTING The battery is not being charged. • Before troubleshooting, remove the following part(s): 1. Battery cover assembly 2. Lower side cover (left) 3. Radiator cover 4. Exhaust pipe NG → 1. Check the fuse. (Main 2) Replace the fuse.
  • Page 319 CHARGING SYSTEM 8-14...

  • Page 320: Lighting System

    LIGHTING SYSTEM EAS20075 LIGHTING SYSTEM EAS30498 CIRCUIT DIAGRAM 8-15...
  • Page 321 LIGHTING SYSTEM 6. Main switch 10.Backup fuse 11.Main fuse 17.Answer back fuse 22.Battery 24.Main fuse 2 44.ECU (Engine Control Unit) 54.Engine ground 60.License plate light 61.Tail/brake light assembly (right) 63.Tail/brake light (right) 64.Tail/brake light assembly (left) 66.Tail/brake light (left) 67.Frame ground 70.Handlebar switch (left) 71.Dimmer switch 77.Headlight assembly...

  • Page 322: Troubleshooting

    LIGHTING SYSTEM EAS30499 TROUBLESHOOTING Any of the following fail to light: headlight, auxiliary light, high beam indicator light, tail/brake light, li- cense plate light, meter light or storage box light. • Before troubleshooting, remove the following part(s): 1. Battery cover assembly 2.
  • Page 323 LIGHTING SYSTEM NG → 6. Check the entire lighting system wiring. Properly connect or replace the wire har- Refer to “CIRCUIT DIAGRAM” on ness. page 8-15. OK ↓ Replace the ECU, meter assembly, tail/brake light assembly, storage box light or headlight assembly. Refer to “REPLACING THE ECU (Engine Con- trol Unit)”...

  • Page 324: Signaling System

    SIGNALING SYSTEM EAS20076 SIGNALING SYSTEM EAS30500 CIRCUIT DIAGRAM 8-19...
  • Page 325 SIGNALING SYSTEM 1. Crankshaft position sensor 6. Main switch 10.Backup fuse 11.Main fuse 12.ABS control unit fuse 13.Signaling system fuse 16.Diode 1 19.Turn signal light and hazard fuse 22.Battery 24.Main fuse 2 31.Handlebar switch (right) 33.Hazard switch 35.Front brake light switch 36.Coolant temperature sensor 44.ECU (Engine Control Unit) 48.Fuel sender...

  • Page 326: Troubleshooting

    SIGNALING SYSTEM EAS30501 TROUBLESHOOTING • Any of the following fail to light: turn signal lights, tail/brake light or indicator lights. • The horn fails to sound. • The fuel meter fails to flash. • The speedometer fails to operate. • The instantaneous fuel consumption meter fails to operation. •...
  • Page 327 SIGNALING SYSTEM Checking the signaling system The horn fails to sound. NG → 1. Check the horn switch. The horn switch is faulty. Replace the left Refer to “CHECKING THE handlebar switch. SWITCHES” on page 8-127. OK ↓ NG → 2.
  • Page 328 SIGNALING SYSTEM NG → 3. Check the hazard switch. The hazard switch is faulty. Replace the Refer to “CHECKING THE right handlebar switch. SWITCHES” on page 8-127. OK ↓ NG → 4. Check the turn signal/hazard relay. Refer to “CHECKING THE TURN Replace the turn signal/hazard relay.
  • Page 329 SIGNALING SYSTEM NG → 2. Check the entire wheel sensor wir- Properly connect or replace the wire har- ing. ness. Refer to TIP. OK ↓ Replace the hydraulic unit assembly, ECU or meter assembly. Replace if there is an open or short circuit. •...
  • Page 330 SIGNALING SYSTEM The fuel meter fails to operate. NG → 1. Check the fuel sender. Refer to “CHECKING THE FUEL Replace the fuel pump. SENDER” on page 8-135. OK ↓ NG → 2. Check the entire signaling system wiring. Properly connect or replace the wire har- Refer to “CIRCUIT DIAGRAM”...
  • Page 331 SIGNALING SYSTEM 8-26...

  • Page 332: Cooling System

    COOLING SYSTEM EAS20077 COOLING SYSTEM EAS30502 CIRCUIT DIAGRAM 8-27...
  • Page 333 COOLING SYSTEM 6. Main switch 9. Radiator fan motor fuse 10.Backup fuse 11.Main fuse 13.Signaling system fuse 22.Battery 24.Main fuse 2 36.Coolant temperature sensor 44.ECU (Engine Control Unit) 52.Radiator fan motor relay 53.Radiator fan motor 54.Engine ground 67.Frame ground 8-28...

  • Page 334: Troubleshooting

    COOLING SYSTEM EAS30503 TROUBLESHOOTING • Before troubleshooting, remove the following part(s): 1. Battery cover assembly 2. Front cowling assemblies 3. Lower side covers 4. Radiator cover NG → 1. Check the fuses. (Main, main 2, signaling system ra- diator fan motor and backup) Replace the fuse(s).
  • Page 335 COOLING SYSTEM NG → 7. Check the entire cooling system’s wiring. Properly connect or replace the wire har- Refer to “CIRCUIT DIAGRAM” on ness. page 8-27. OK ↓ Replace the ECU. Refer to “REPLACING THE ECU (En- gine Control Unit)” on page 8-128. 8-30...

  • Page 336: Fuel Injection System

    FUEL INJECTION SYSTEM EAS20078 FUEL INJECTION SYSTEM EAS30504 CIRCUIT DIAGRAM 8-31...
  • Page 337 37.Throttle body sensor assembly 38.Throttle position sensor 39.Intake air pressure sensor 40.Intake air temperature sensor 41.O sensor 42.Lean angle sensor 43.Yamaha diagnostic tool coupler 44.ECU (Engine Control Unit) 45.Ignition coil 46.Spark plug 47.Fuel injector 51.ISC (Idle Speed Control) unit 52.Radiator fan motor relay 53.Radiator fan motor...

  • Page 338: 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 339: 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 90890-03256 Yamaha diagnostic tool (A/I) 90890-03254 A generic scan tool can also be used to identify malfunctions.
  • Page 340 Reinstall the throttle body. fault code using the malfunction Refer to “THROTTLE BODY” on mode of the Yamaha diagnostic page 7-13. tool. Condition is “Recover” → Go to item 3 and finish the service.
  • Page 341 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. P0107, P0108 ECA20500 NOTICE Do not remove the throttle body sensor assembly from the throttle body.
  • Page 342 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 343 FUEL INJECTION SYSTEM Fault code No. P0107, P0108 No normal signals are received from the intake air pressure sensor. [P0107] Intake air pressure sensor: open or ground short circuit de- Item tected. [P0108] Intake air pressure sensor: open or power short circuit de- tected.
  • Page 344 Improperly installed sensor → the fault code using the mal- Reinstall the throttle body. function mode of the Yamaha di- Refer to “THROTTLE BODY” on agnostic tool. Condition is “Recover” → Go to page 7-13.
  • Page 345 When engine is stopped: the fault code using the mal- Atmospheric pressure at the function mode of the Yamaha di- current altitude and weather agnostic tool. Condition is “Recover” → Go to conditions is indicated.
  • Page 346 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 347 FUEL INJECTION SYSTEM Fault code No. P0112, P0113 No normal signals are received from the intake air temperature sen- sor. Item [P0112] Intake air temperature sensor: ground short circuit detected. [P0113] Intake air temperature sensor: open or power short circuit detected.
  • Page 348 Improperly installed sensor → the fault code using the mal- Reinstall the throttle body. function mode of the Yamaha di- Refer to “THROTTLE BODY” on agnostic tool. Condition is “Recover” → Go to page 7-13.
  • Page 349 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 350 FUEL INJECTION SYSTEM Fault code No. P0117, P0118 No normal signals are received from the coolant temperature sensor. [P0117] Coolant temperature sensor: ground short circuit detected. Item [P0118] Coolant temperature sensor: open or power short circuit de- tected. 1. Coolant temperature sensor 2.
  • Page 351 Improperly installed sensor → the fault code using the mal- Reinstall or replace the sensor. function mode of the Yamaha di- Refer to “CYLINDER HEAD” on agnostic tool. Condition is “Recover” → Go to page 5-13.
  • 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 Turn the main switch to “ON”, the wire harness. and then check the condition of the fault code using the mal- function mode of the Yamaha di- agnostic tool. Condition is “Recover” → Go to item 7 and finish the service.
  • Page 354 FUEL INJECTION SYSTEM Fault code No. P0122, P0123 No normal signals are received from the throttle position sensor. [P0122] Throttle position sensor: open or ground short circuit de- Item tected. [P0123] Throttle position sensor: open or power short circuit detect- [For P0122] Open circuit Between throttle body sensor assembly coupler and ECU coupler: blue–blue If there is no continuity, replace the wire harness.
  • Page 355 Improperly installed sensor → the fault code using the mal- Reinstall the throttle body. function mode of the Yamaha di- Refer to “THROTTLE BODY” on agnostic tool. Condition is “Recover” → Go to page 7-13.
  • Page 356 Improperly installed sensor → the fault code using the mal- Reinstall or replace the sensor. function mode of the Yamaha di- Refer to “CYLINDER HEAD” on agnostic tool. Condition is “Recover” → Go to page 5-13.
  • Page 357 Diagnostic code No. Actuates fuel injector five times at one-second intervals. Actuation The “check” indicator on the Yamaha diagnostic tool screen comes on each time the fuel injector is actuated. Disconnect the fuel pump coupler. Check that fuel injector is actuated Procedure five times by listening for the operating sound.
  • Page 358 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 359 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 360 Ignition coil: no normal signals are received from the ignition circuit. Actuates the ignition coil five times at one-second intervals. Actuation The “check” indicator on the Yamaha diagnostic tool screen comes on each time the ignition coil is actuated. Check that a spark is generated five times.
  • Page 361 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 6 and finish the service.
  • Page 362 Between radiator fan motor re- the fault code using the mal- lay coupler and ECU coupler. function mode of the Yamaha di- white/yellow–white/yellow agnostic tool. Condition is “Recover” → Go to Between radiator fan motor re- lay and signaling system fuse.
  • Page 363 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. 8-58...
  • Page 364 Actuates and fully closes the ISC valve, then opens it to the standby opening position. This operation takes approximately 3 seconds until it is Action completed. The “check” indicator on the Yamaha diagnostic tool screen come on. Procedure The ISC unit vibrates when the ISC valve operates. Probable cause of malfunc-...
  • Page 365 10 seconds. THROTTLE BODY” on page Check the condition of the fault 7-15. code using the malfunction mode of the Yamaha diagnostic tool. Condition is “Recover” → Go to item A-9 and finish the service. Condition is “Malfunction” → Go to item A-5.
  • Page 366 Actuates and fully closes the ISC valve, then opens it to the standby opening position. This operation takes approximately 3 seconds until it is Action completed. The “check” indicator on the Yamaha diagnostic tool screen come on. Procedure The ISC unit vibrates when the ISC valve operates. Probable cause of malfunc-...
  • Page 367 10 seconds. light goes off. Confirm that the fault code has a condition of “Recover” using the Yamaha diagnostic tool, and then delete the fault code. Fault code No. P0511 Fault code No. P0511 Item ISC (Idle Speed Control) unit: ISC unit does not operate.
  • Page 368 Check the locking condition of place the wire harness. the fault code using the mal- the coupler. function mode of the Yamaha Disconnect the coupler and diagnostic tool. Condition is “Recover” → Go to check the pins (bent or broken terminals and locking condition item 6 and finish the service.
  • Page 369 8-11. Check the condition of the fault Defective rectifier/regulator or code using the malfunction stator coil assembly → Replace. mode of the Yamaha diagnostic Defective connection in the tool. charging system circuit → Prop- Condition is “Recover” → Go to erly connect or replace the wire item 2 and finish the service.
  • Page 370 CO Refer to “ADJUSTING THE EX- the fault code using the mal- concentration. HAUST GAS VOLUME” on function mode of the Yamaha di- page 3-8. agnostic tool. Condition is “Recover” → Go to After this adjustment is made, turn the main switch to “OFF”.
  • Page 371 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. P0657 Fault code No. P0657...
  • Page 372 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. P1601 Fault code No. P1601 No normal signals are received from the sidestand switch.
  • Page 373 ECU coupler. Check the condition of the fault blue/yellow–blue/yellow code using the malfunction Between starting circuit cut-off mode of the Yamaha diagnostic relay coupler and sidestand tool. Condition is “Recover” → Go to switch coupler. blue/green–blue/green item 7 and finish the service.
  • Page 374 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 375 FUEL INJECTION SYSTEM Fault code No. P1604, P1605 [P1604] Lean angle sensor: ground short circuit detected. Item [P1605] Lean angle sensor: open or power short circuit detected. [For P1604] Ground short circuit Between lean angle sensor coupler and ground: yellow/green–ground If there is continuity, replace the wire harness.
  • Page 376 Check the condition of the fault An indicated value is out of the code using the malfunction specified range. → Replace the mode of the Yamaha diagnostic lean angle sensor. tool. Condition is “Recover” → Go to item 6 and finish the service.
  • Page 377 ING” on page 8-85. If the ABS warning light is off, perform the following procedure. Use the monitoring function of the Yamaha diagnostic tool to check the rear wheel speed pulse. For information about us- ing the Yamaha diagnostic tool, refer to the operation manual that is included with the tool.
  • Page 378 BRAKE SYSTEM)” on page 4-63. 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. 8-73...
  • Page 379 Check the condition of the fault Reinstall or replace the sensor. code using the malfunction Refer to “CYLINDER HEAD” on mode of the Yamaha diagnostic page 5-13. tool. Condition is “Recover” → Go to item 8 and finish the service.
  • Page 380 Between O sensor coupler and Check the condition of the fault code using the malfunction ECU coupler. mode of the Yamaha diagnostic gray/red–gray/red tool. Condition is “Recover” → Go to item 8 and finish the service. Condition is “Malfunction” → Go to item 5.
  • Page 381 FUEL INJECTION SYSTEM 8-76...
  • Page 382 FUEL PUMP SYSTEM EAS20081 FUEL PUMP SYSTEM EAS30513 CIRCUIT DIAGRAM 8-77...
  • Page 383 FUEL PUMP SYSTEM 6. Main switch 10.Backup fuse 11.Main fuse 22.Battery 24.Main fuse 2 31.Handlebar switch (right) 32.Start/engine stop switch 44.ECU (Engine Control Unit) 49.Fuel pump 50.Fuel pump relay 54.Engine ground 67.Frame ground 8-78...
  • Page 384 FUEL PUMP SYSTEM EAS30514 TROUBLESHOOTING If the fuel pump fails to operate. • Before troubleshooting, remove the following part(s): 1. Battery cover assembly 2. Front cowling assemblies 3. Lower side covers 4. Bottom cover assembly 5. Leg shield assembly NG → 1.
  • Page 385 FUEL PUMP SYSTEM 8-80...
  • Page 386 ABS (ANTI-LOCK BRAKE SYSTEM) EAS20085 ABS (ANTI-LOCK BRAKE SYSTEM) EAS30843 CIRCUIT DIAGRAM 8-81...
  • Page 387 ABS (ANTI-LOCK BRAKE SYSTEM) 6. Main switch 10.Backup fuse 11.Main fuse 12.ABS control unit fuse 13.Signaling system fuse 20.ABS solenoid fuse 21.ABS motor fuse 22.Battery 24.Main fuse 2 31.Handlebar switch (right) 35.Front brake light switch 44.ECU (Engine Control Unit) 54.Engine ground 55.Front wheel sensor 56.Rear wheel sensor 57.Joint connector...
  • Page 388 ABS (ANTI-LOCK BRAKE SYSTEM) EAS30844 ABS COUPLER LOCATION CHART G L Br Y W W/L W/B G/BBr/R B B W/LG/B L/R B/L G Y/W P/W Dg G/Y Y/B Y/B Br/W L/R L/B B/W (Gy) 1. ABS test coupler 2. ABS ECU coupler 3.
  • Page 389 The following troubleshooting describes the problem identification and service method using the Yamaha diagnostic tool. For information about using the Yamaha diagnostic tool, refer to “[B-2] DIAG- NOSIS USING THE FAULT CODES” on page 8-88. For troubleshooting items other than the following items, follow the normal service method.
  • Page 390 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 391 The main fuse is blown. • The meter assembly circuit is • defective. The connection with the Yamaha [A-3] The ABS warning light comes • Cannot communicate diagnostic tool is defective. Return to [A]. Connect the Yamaha •...
  • Page 392 EAS31162 [A-3] THE ABS WARNING LIGHT COMES ON Connect the Yamaha diagnostic tool to the ABS test coupler and execute functional diagnosis. (For in- formation about how to execute functional diagnosis, refer to the operation manual that is included with the tool.)
  • Page 393 Replace the hydraulic unit assembly. EAS31165 [B-1] MALFUNCTION ARE CURRENTLY DETECTED When the Yamaha diagnostic tool is connected to the ABS test coupler, the fault codes will be displayed on the computer screen. • A fault code is displayed. [B-2] •...
  • Page 394 Details about the displayed fault codes are shown in the following chart. Refer to this chart and check the vehicle. Once all the work is complete, delete the fault codes. [B-3] Check the inspection points after terminating the connection with the Yamaha diagnostic tool and turn- ing the main switch off. Fault code table Record all of the fault codes displayed and inspect the check points.
  • Page 395 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Item Symptom Check point Front wheel sensor (open or Open or short circuit is de- • Defective coupler between short circuit) tected in the front wheel sen- the front wheel sensor and sor. the hydraulic unit assembly •...
  • Page 396 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Item Symptom Check point Brake light switch or brake Brake light signal is not re- • Defective signaling system light ceived properly while the ve- (brake light or brake light hicle is traveling. (Brake light switch) circuit, or front or rear brake •...
  • Page 397 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 398 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 399 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 Defective sensor rotor or incorrect instal- Check the surface of the sensor rotor for damage.
  • Page 400 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. 13, 26 • If the front brake ABS operates continuously for 20 seconds or more, fault code No. 26 will be record- ed. If the front brake ABS operates continuously for 36 seconds or more, fault code No. 13 will be re- corded.
  • Page 401 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 sensor rotor or incorrect instal- Check the surface of the sensor rotor for damage.
  • Page 402 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 Open or short circuit in the wire harness •...
  • Page 403 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 Open or short circuit in the wire harness •...
  • Page 404 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. 17, 45 If pulse gaps are detected when the vehicle is traveling at a speed of 30 km/h (19 mi/h) or more, fault code No. 17 will be recorded. If the vehicle is traveling at a speed of 29 km/h (18 mi/h) or less, fault code No.
  • Page 405 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 Defective sensor rotor or incorrect instal- Check the surface of the sensor rotor for damage.
  • Page 406 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. 31 Turn the main switch to “OFF” before disconnecting or connecting a coupler. Fault code No. Item Hydraulic unit assembly (abnormal ABS solenoid power supply) Power is not supplied to the solenoid circuit in the hydraulic unit as- Symptom sembly.
  • Page 407 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Item Hydraulic unit assembly (abnormal ABS motor power supply) Power is not supplied to the motor circuit in the hydraulic unit assem- Symptom bly. Order Item/components and probable cause Check or maintenance job Defective coupler between the battery •...
  • Page 408 ABS (ANTI-LOCK BRAKE SYSTEM) 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 409 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 410 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 Incorrect installation of the rear wheel Check the components for looseness, distortion, and bends.
  • Page 411 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. 53 Turn the main switch to “OFF” before disconnecting or connecting a coupler. 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.
  • Page 412 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Hydraulic unit assembly (defective ABS solenoid and ABS motor Item power supply circuits) Abnormality is detected in the solenoid or motor power supply circuit Symptom in the hydraulic unit assembly. Order Item/components and probable cause Check or maintenance job Defective hydraulic unit assembly If the above items were performed and no malfunctions...
  • Page 413 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. 63 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 Short circuit in the wire harness between •...
  • Page 414 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. 64 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 Short circuit in the wire harness between •...
  • Page 415 EAS31167 [B-3] DELETING THE FAULT CODES To delete the fault codes, use the Yamaha diagnostic tool. For information about deleting the fault codes, refer to the operation manual of the Yamaha diagnostic tool. Check that all the displayed fault codes are deleted.
  • Page 416 SMART KEY SYSTEM EAS20201 SMART KEY SYSTEM EAS31452 CIRCUIT DIAGRAM 8-111...
  • Page 417 SMART KEY SYSTEM 4. Request switch 5. Main switch solenoid 6. Main switch 7. Smart key unit 8. Buzzer 10.Backup fuse 11.Main fuse 13.Signaling system fuse 17.Answer back fuse 19.Turn signal light and hazard fuse 22.Battery 24.Main fuse 2 30.Sidestand switch 31.Handlebar switch (right) 33.Hazard switch 44.ECU (Engine Control Unit)
  • Page 418 SMART KEY SYSTEM EAS31453 TROUBLESHOOTING Vehicle power does not turn on. (Meter light and tail/brake light do not come on.) Engine does not start even though vehicle power is turned on. Seat does not open. (Vehicle power is turned on.) Left front storage box does not open.
  • Page 419 SMART KEY SYSTEM NG → 6. Check the entire smart key sys- tem’s wiring. Properly connect or replace the wire har- Refer to “CIRCUIT DIAGRAM” on ness. page 8-111. OK ↓ Replace the smart key unit. Checking the smart key system Before checking the smart key system, make sure that the smart key is located within the operating range of the smart key system and that the key is turned on.
  • Page 420 SMART KEY SYSTEM NG → 3. Check for continuity in the commu- nication line between the ECU and Replace the wire harness. the smart key unit (blue/red – blue/ red). OK ↓ • Replace the ECU. Refer to “REPLACING THE ECU (Engine Control Unit)”...
  • Page 421 SMART KEY SYSTEM Answer back function does not operate. NG → 1. Check the vehicle power. Refer to “Checking the vehicle pow- Repair or replace any defective parts. er” on page 8-113. OK ↓ NG → 2. Check the buzzer operation. Refer to “CHECKING THE BUZZ- Replace the buzzer.
  • Page 422 SMART KEY SYSTEM EAS31534 SMART KEY SYSTEM SELF-DIAGNOSIS The smart key system is equipped with a self-diagnostic function. If a malfunction is detected in the sys- tem, the malfunction will be indicated by the flash pattern of the smart key indicator light “ ”. The smart key indicator light “...
  • Page 423 SMART KEY SYSTEM SMART KEY SYSTEM SELF-DIAGNOSIS If a communication error between the ECU and the smart key unit is detected, the following fault code numbers will be displayed on the meter to indicate the location of the malfunction. These fault code numbers are not stored in the memory of the ECU. Note all of the displayed fault code numbers, and then check the vehicle.
  • Page 424 SMART KEY SYSTEM EAS31535 SMART KEY SYSTEM EMERGENCY MODE If the smart key is lost or if it cannot be used due a discharged battery or malfunction, this mode can be used to turn on the smart key system. The emergency mode operation will be canceled if the respective steps are not carried out within the time set for each operation.
  • Page 425 SMART KEY SYSTEM Release the main switch after the smart key indicator light “ ” flashes 1 time. → The first digit of the identification number has been set as 1. → Push and hold the main switch again. → Release the main switch after the smart key indicator light “...
  • Page 426 SMART KEY SYSTEM 1. Place the smart key “1” that will be registered within 80 cm (31.5 in) “a” of the main switch. 2. Perform steps 1–5 in “SMART KEY SYSTEM EMERGENCY MODE” on page 8-119. 3. While the smart key indicator light “ ” is on for 10 seconds, push the main switch “1” for 5 seconds until buzzer sounds once.
  • Page 427 SMART KEY SYSTEM EAS31537 DISABLING A SMART KEY If a smart key is lost or stolen, the smart key can be disabled. 1. Place all of the smart keys “1” 300 cm (118.1 in) “a” or more away from the vehicle or lock the com- munication.
  • Page 428 SMART KEY SYSTEM EAS32347 DISABLING THE POWER-ON ALARM 1. Place the smart key “1” that will be registered within 80 cm (31.5 in) “a” of the main switch. 2. Push the main switch and the smart key indicator light will come on for approximately 4 seconds. 3.
  • Page 429 SMART KEY SYSTEM EAS31719 REPLACEMENT PARTS LIST When replacing the parts, refer to the following sections. • Refer to “SMART KEY SYSTEM EMERGENCY MODE” on page 8-119. • Refer to “REGISTERING A SMART KEY” on page 8-120. • Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-128. Required item Replacement parts (when when replacing...
  • Page 430 ELECTRICAL COMPONENTS EAS20089 ELECTRICAL COMPONENTS 1. Smart key unit 19.Crankshaft position sensor 2. Coolant temperature sensor 20.Rear wheel sensor 3. Main switch 4. Front brake light switch 5. Rear brake light switch 6. ABS ECU 7. Turn signal/hazard relay 8. Battery 9.
  • Page 431 ELECTRICAL COMPONENTS 1,2,3,4 1. Throttle body sensor assembly 2. Throttle position sensor 3. Intake air pressure sensor 4. Intake air temperature sensor 5. ISC (Idle Speed Control) unit 6. Fuel injector 7. Spark plug 8. Starting circuit cut-off relay 9. Diode 1 10.Fuel pump relay 11.Fuse box 1 12.Starter relay...
  • Page 432 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. Y Br Y R R/Y Br/L Br/R Br/W OPEN Br/L R/Y PASS...
  • Page 433 Turn the main switch to “OFF”. 9-1. b. Install a new fuse of the correct amperage rating. Yamaha diagnostic tool USB c. Set on the switches to verify if the electri- 90890-03256 cal circuit is operational. Yamaha diagnostic tool (A/I) d.
  • Page 434 ELECTRICAL COMPONENTS 2. Disconnect: 10.Install: • Battery leads • Battery cover assembly (from the battery terminals) Refer to “GENERAL CHASSIS (1)” on page 4-1. ECA13640 NOTICE EAS30553 First, disconnect the negative battery lead CHECKING THE RELAYS “1”, and then positive battery lead “2”. Check each switch for continuity with the digital circuit tester.
  • Page 435 ELECTRICAL COMPONENTS Starter relay 2. Negative battery terminal 3. Positive tester probe 4. Negative tester probe Result Continuity L/W G/Y (between “3” and “4”) EAS30794 CHECKING THE TURN SIGNAL/HAZARD RELAY 1. Check: 1. Positive battery terminal • Turn signal/hazard relay input voltage 2.
  • Page 436 ELECTRICAL COMPONENTS Turn signal/hazard relay output Diode 1 voltage Continuity Positive tester probe → brown/ DC 12V red “1” Negative tester probe → brown/ a. Connect the digital circuit tester to the turn blue “2” signal/hazard relay terminal as shown. No continuity Positive tester probe →...
  • Page 437 ELECTRICAL COMPONENTS Br/W 2. Ignition coil A. Diode 1 B. Diode 2 c. Turn the main switch to “ON”. C. Diode 3 d. Measure the ignition spark gap “a”. e. Crank the engine by “ ” side of the start/ a.
  • Page 438 ELECTRICAL COMPONENTS Primary coil resistance 2.16–2.64 Ω a. Disconnect the ignition coil connectors from the ignition coil terminals. b. Connect the digital circuit tester to the igni- tion coil as shown. Digital circuit tester (CD732) 90890-03243 b. Measure the secondary coil resistance. Model 88 Multimeter with ta- chometer EAS30561...
  • Page 439 ELECTRICAL COMPONENTS EAS30560 EWA13810 CHECKING THE CRANKSHAFT POSITION WARNING SENSOR • A wire that is used as a jumper lead must 1. Disconnect: have at least the same capacity of the bat- • Crankshaft position sensor coupler tery lead, otherwise the jumper lead may (from the wire harness) burn.
  • Page 440 ELECTRICAL COMPONENTS 2. Check: • Fuel sender resistance Out of specification → Replace the fuel pump assembly. Fuel sender Sender unit resistance (full) 10.0–14.0 Ω Sender unit resistance (empty) 267.0–273.0 Ω b. Measure the stator coil resistance. a. Connect the digital circuit tester to the fuel sender terminals as shown.
  • Page 441 ELECTRICAL COMPONENTS Fuel meter comes on for a few seconds, then • Never subject the coolant temperature sen- goes off → Fuel meter is OK. sor to strong shocks. If the coolant tem- Fuel meter does not come on → Replace the perature sensor is dropped, replace it.
  • Page 442 ELECTRICAL COMPONENTS EAS30681 CHECKING THE FUEL INJECTOR Digital circuit tester (CD732) 1. Check: 90890-03243 • Fuel injector resistance Model 88 Multimeter with ta- Out of specification → Replace the fuel injec- chometer YU-A1927 tor. Resistance • Positive tester probe → 12.2 Ω...
  • Page 443 ELECTRICAL COMPONENTS b. Connect the digital circuit tester to the main switch solenoid as shown. Digital circuit tester (CD732) 90890-03243 Model 88 Multimeter with ta- chometer YU-A1927 • Positive tester probe → red/white “1” • Negative tester probe → black “2” c.
  • Page 444 ELECTRICAL COMPONENTS 8-139...

  • Page 445: Troubleshooting

    TROUBLESHOOTING SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE....9-1 SELF-DIAGNOSTIC FUNCTION TABLE ..........9-1 DIAGNOSTIC CODE: SENSOR OPERATION TABLE ......9-8 DIAGNOSTIC CODE: ACTUATOR OPERATION TABLE ......9-9 EVENT CODE TABLE...................9-11...

  • Page 446: Self-Diagnostic Function And Diagnostic Code Table

    SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE EAS20116 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE EAS31118 SELF-DIAGNOSTIC FUNCTION TABLE For details of the fault code, refer to “TROUBLESHOOTING METHOD” on page 8-33. Fault code Probable cause of Fail-safe system op- Item Vehicle symptom malfunction eration P0106...
  • Page 447 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 448 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 449 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 between crankshaft started. (no normal signals are position sensor and received from the ECU.
  • Page 450 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Fault code Probable cause of Fail-safe system op- Item Vehicle symptom malfunction eration P0507 ISC valve • Defective front Engine idling speed is Idle speed control is (stuck fully open) wheel sensor. high. not carried out. •...
  • Page 451 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Fault code Probable cause of Fail-safe system op- Item Vehicle symptom malfunction eration P0560 Charging voltage is • Battery overcharg- Engine is difficult to feedback is not abnormal. ing (defective rectifi- start. carried out. er/regulator).
  • Page 452 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Fault code Probable cause of Fail-safe system op- Item Vehicle symptom malfunction eration P1604 [P1604] Lean angle [P1604] Low voltage Engine cannot be When engine is run- P1605 sensor (ground short of the lean angle sen- started.

  • Page 453: Diagnostic Code: Sensor Operation Table

    SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE EAS31120 DIAGNOSTIC CODE: SENSOR OPERATION TABLE Diagnostic Item Tool display Procedure code No. Throttle position sensor sig- • Fully closed position 13–21 Check with throttle valve fully closed. • Fully open position 97–107 Check with throttle valve fully open.

  • Page 454: Diagnostic Code: Actuator Operation Table

    0–254 [-] — A/F control learning data era- To erase the ECU learning sure ECU learning data has been data, click the Yamaha diag- erased. nostic tool “Actuator Check” button three times in 5 sec- ECU learning data has not onds.
  • Page 455 The “check” indicator on the erating sound. Yamaha diagnostic tool screen comes on each time the relay is actuated. Headlight Actuates the headlight five Check that the headlight is times at five-second inter- on five times.

  • Page 456: Event Code Table

    EVENT CODE TABLE EAS20164 EVENT CODE TABLE Item Symptom Possible cause Remarks Intake air pressure sen- Brief abnormality de- Same as for fault code Perform the checks and tected in intake air pres- number P0107 and maintenance jobs for sure sensor P0108 fault code number P0107 and P0108.
  • Page 457 EVENT CODE TABLE Item Symptom Possible cause Remarks ISC (idle speed control) Correction value re- Low engine idling • Execute the diagnos- (Correction value re- mains at upper limit speed tic mode (diagnostic mains at upper limit) while the engine is •...
  • Page 458 Yellow/White 39. Intake air pressure sensor 40. Intake air temperature sensor 41. O sensor 42. Lean angle sensor 43. Yamaha diagnostic tool coupler 44. ECU (Engine Control Unit) 45. Ignition coil 46. Spark plug 47. Fuel injector 48. Fuel sender 49.
  • Page 461 CZD300-A/CZD300-AH 2017 CZD300-A/CZD300-AH 2017 CZD300-A/CZD300-AH 2017 CZD300-A/CZD300-AH 2017 CZD300-A/CZD300-AH 2017 WIRING DIAGRAM SCHÉMA DE CÂBLAGE SCHALTPLAN SCHEMA ELETTRICO DIAGRAMA ELÉCTRICO Br/L Br/R L/W G/Y Br/R Br/L OPEN Br/LBr/L R/W W Br/R B/L B/L Y/B Y Y/G LOCK Br/L R/Y R/Y Br/L Y/L B/W Br/WGy/R R/B B/L W/R B W/B O...
  • Page 462 CZD300-A/CZD300-AH 2017 CZD300-A/CZD300-AH 2017 CZD300-A/CZD300-AH 2017 CZD300-A/CZD300-AH 2017 CZD300-A/CZD300-AH 2017 WIRING DIAGRAM SCHÉMA DE CÂBLAGE SCHALTPLAN SCHEMA ELETTRICO DIAGRAMA ELÉCTRICO OPEN LOCK 17 18 19 20 21 37 38 39 40 TRIP INFO PASS (Gy) 84 85 86 87 88 89...

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