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Yamaha N MAX GPD150-A 2015 Service Manual

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2015
SERVICE MANUAL
GPD150-A
2DP-F8197-E0

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Summary of Contents for Yamaha N MAX GPD150-A 2015

  • Page 1 2015 SERVICE MANUAL GPD150-A 2DP-F8197-E0...
  • Page 2 EAS20002 GPD150-A SERVICE MANUAL ©2015 by PT Yamaha Indonesia Motor Manufacturing First edition, July 2015 All rights reserved. Any reproduction or unauthorized use without the written permission of PT Yamaha Indonesia Motor Manufacturing is expressly prohibited.
  • Page 3 This manual was produced by the PT Yamaha Indonesia Motor Manufacturing 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 ENGINE SERIAL NUMBER ..............1-1 FEATURES...................... 1-2 OUTLINE OF THE FI SYSTEM ..............1-2 FI SYSTEM....................1-3 OUTLINE OF THE ABS................1-4 ABS COMPONENT FUNCTIONS ............. 1-8 ABS OPERATION ...................1-13 ABS WARNING LIGHT AND OPERATION..........

  • Page 10: Identification

    IDENTIFICATION EAS20007 IDENTIFICATION EAS30002 VEHICLE IDENTIFICATION NUMBER The vehicle identification number “1” is stamped into the frame. EAS30004 ENGINE SERIAL NUMBER The engine serial number “1” is stamped into the crankcase.

  • Page 11: Features

    FEATURES EAS20008 FEATURES EAS30005 OUTLINE OF THE FI SYSTEM The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature. In the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the combustion chamber is created by the volume of the intake air and the fuel that is metered by the jet used in the respective carburetor.

  • Page 12: Fi System

    FEATURES EAS30617 FI SYSTEM The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the fuel pressure that is applied to the fuel injector at a certain level. Accordingly, when the energizing signal from the ECU energizes the fuel injector, the fuel passage opens, causing the fuel to be injected into the intake manifold only during the time the passage remains open.

  • Page 13: Outline Of The Abs

    EAS30683 OUTLINE OF THE ABS 1. The Yamaha ABS (anti-lock brake system) features an electronic control system, which acts on the front and rear brakes independently. 2. The ABS features a compact and lightweight design to help maintain the basic maneuverability of the vehicle.
  • Page 14 FEATURES The operation of the Yamaha ABS brakes is the same as conventional brakes on other vehicles, with a front brake lever for operating the front brake and a rear brake lever for operating the rear brake. When wheel lock is detected during braking, hydraulic control is performed by the hydraulic system on the front and rear brakes independently.
  • Page 15 FEATURES Wheel slip and hydraulic control The ABS ECU calculates the wheel speed of each wheel according to the rotation signal received from the front and rear wheel sensors. In addition, the ABS ECU calculates the vehicle chassis speed and the rate of speed reduction based on the wheel speed values.
  • Page 16 Slip ratio b. Brake force Electronic ABS features The Yamaha ABS (anti-lock brake system) has been developed with the most advanced electronic technology. The ABS control is processed with good response under various vehicle travel conditions. The ABS also includes a highly developed self-diagnosis function. The ABS detects any problem con- dition and allows normal braking even if the ABS is not operating properly.

  • Page 17: Abs Component Functions

    FEATURES ABS block diagram 1. Rear brake master cylinder 9. Buffer chamber 2. Hydraulic unit assembly 10. Rear brake caliper 3. Front brake master cylinder 11. Rear wheel sensor 4. Inlet solenoid valve 12. ABS warning light 5. ABS motor 13.
  • Page 18 FEATURES 3. At low speed 7. Voltage 4. At high speed 8. Time 5. Wheel sensor 6. Wheel sensor rotor ABS warning light The ABS warning light “1” comes on to warn the rider if a malfunction in the ABS occurs. When the main switch is turned to “ON”, the ABS warning light comes on to check the electrical circuit and the system function (ABS self-diagnosis), and goes off when the vehicle is operated (the function check is properly completed at a speed of 10 km/h [6 mi/h]).
  • Page 19 FEATURES Hydraulic unit assembly The hydraulic unit assembly “1” is composed of hydraulic control valves (each with a outlet solenoid valve and inlet solenoid valve), buffer chambers, hydraulic pumps, an ABS motor, and ABS ECU. The hydraulic unit adjusts the front and rear wheel brake fluid pressure to control the wheel speed according to signals transmitted from the ABS ECU.
  • Page 20 FEATURES 3. Brake caliper 4. ABS motor 3. When the ABS ECU sends a signal to stop reducing the hydraulic pressure, the outlet solenoid valve “2” closes and the brake fluid is pressurized again. The inlet solenoid valve “1” controls the hydraulic pressure difference between the brake fluid in the upper brake lines (brake master cylinder side) and the brake fluid in the lower brake lines (brake caliper side).
  • Page 21 FEATURES 1. Battery 15. ABS ECU 2. AC magneto 16. ABS motor relay 3. Rectifier/regulator 17. Solenoid relay 4. Main fuse 18. Front brake outlet solenoid 5. ABS motor fuse 19. Front brake inlet solenoid 6. ABS solenoid fuse 20. Rear brake outlet solenoid 7.

  • Page 22: Abs Operation

    FEATURES • The ABS performs a self-diagnosis test for a few seconds each time the vehicle first starts off after the main switch was turned on. During this test, a “clicking” noise can be heard from front side, and if the front brake lever or rear brake lever is even slightly operated, a vibration can be felt at the levers, but these do not indicate a malfunction.
  • Page 23 FEATURES 1. Brake master cylinder 8. Brake caliper 2. Brake light switch 9. Wheel sensor 3. ABS motor 10. ABS ECU 4. Hydraulic pump 11. ABS warning light 5. Buffer chamber 12. Brake fluid pressure 6. Outlet solenoid valve 13. Time 7.
  • Page 24 FEATURES 1. Brake master cylinder 8. Brake caliper 2. Brake light switch 9. Wheel sensor 3. ABS motor 10. ABS ECU 4. Hydraulic pump 11. ABS warning light 5. Buffer chamber 12. Brake fluid pressure 6. Outlet solenoid valve 13. Time 7.

  • Page 25: Abs Warning Light And Operation

    FEATURES 1. Brake master cylinder 8. Brake caliper 2. Brake light switch 9. Wheel sensor 3. ABS motor 10. ABS ECU 4. Hydraulic pump 11. ABS warning light 5. Buffer chamber 12. Brake fluid pressure 6. Outlet solenoid valve 13. Time 7.
  • Page 26 FEATURES ABS function EWA18300 WARNING • When hydraulic control is performed by the ABS, the brake system alerts the rider that the wheels have a tendency to lock by generating a reaction-force pulsating action in the front brake lever or rear brake lever. When the ABS is activated, the grip between the road surface and tires is close to the limit.

  • Page 27: Instrument Functions

    FEATURES Clock EAS30682 INSTRUMENT FUNCTIONS Multi-function meter unit 1. Clock The clock uses a 12-hour time system. 1. Fuel meter [To set the clock] 2. Clock 1. Turn the key to “ON”. 3. Speedometer 2. Push the “SELECT” button and “RESET” but- 4.
  • Page 28 FEATURES • an oil change tripmeter and fuel level warning indicator “ ” flash eight times, then go off for approximately 3 seconds. • a V-belt replacement tripmeter If this occurs, check the electrical circuit. • an oil change indicator •...
  • Page 29 FEATURES The instantaneous fuel consumption display can Oil change tripmeter mode be set to either “km/L” or “L/100 km”. • “km/L”: The distance that can be traveled on 1.0 L of fuel under the current riding conditions is shown. • “L/100 km”: The amount of fuel necessary to travel 100 km under the current riding condi- tions is shown.
  • Page 30 FEATURES The V-belt replacement indicator “V-BELT” will flash at every 25000 km (15500 mi) thereafter to indicate that the V-belt should be replaced. After replacing the V-belt, reset the V-belt re- placement tripmeter and the V-belt replacement indicator. To reset them both, select the V-belt replacement tripmeter, and then push the “RE- SET”...

  • Page 31: Important Information

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

  • Page 32: Bearings And Oil Seals

    IMPORTANT INFORMATION EAS30010 EAS30012 BEARINGS AND OIL SEALS RUBBER PARTS Install bearings “1” and oil seals “2” so that the Check rubber parts for deterioration during in- manufacturer’s marks or numbers are visible. spection. Some of the rubber parts are sensitive When installing oil seals, lubricate the oil seal to gasoline, flammable oil, grease, etc.

  • Page 33: Basic Service Information

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

  • Page 34: Electrical System

    BASIC SERVICE INFORMATION ECA16760 EAS30014 NOTICE ELECTRICAL SYSTEM Be sure to connect the battery leads to the correct battery terminals. Reversing the bat- Electrical parts handling tery lead connections could damage the ECA16600 NOTICE electrical components. Never disconnect a battery lead while the en- gine is running;...
  • Page 35 BASIC SERVICE INFORMATION ECA16620 Checking the electrical system NOTICE Handle electrical components with special Before checking the electrical system, make care, and do not subject them to strong sure that the battery voltage is at least 12 V. shocks. ECA14371 ECA16630 NOTICE NOTICE...
  • Page 36 BASIC SERVICE INFORMATION 2. Check: Checking the connections • Lead Check the leads, couplers, and connectors for • Coupler stains, rust, moisture, etc. • Connector 1. Disconnect: Moisture → Dry with an air blower. • Lead Rust/stains → Connect and disconnect sev- •...
  • Page 37 BASIC SERVICE INFORMATION • As a quick remedy, use a contact revitalizer available at most part stores. 4. Connect: • Lead • Coupler • Connector • When connecting a coupler or connector, push both sections of the coupler or connector to- gether until they are connected securely.
  • Page 38 BASIC SERVICE INFORMATION 1-29...
  • Page 39 Tappet adjusting tool 90890-01311 Six piece tappet set YM-A5970 YM-A5970 ø8 ø9 ø10 ø3 ø4 Yamaha diagnostic tool 3-7, 3-8, 4-65, 90890-03231 4-67, 7-14, 7-14, 8-28, 8-69, 8-90 Steering nut wrench 3-15, 3-16, 4-85 90890-01403 Exhaust flange nut wrench YU-A9472...
  • Page 40 Compression gauge 90890-03081 90890-03081 Engine compression tester YU-33223 YU-33223 Extension 90890-04136 Camshaft wrench 5-13, 5-17 90890-04162 Camshaft wrench YM-04162 Yamaha bond No. 1215 5-16, 5-64 90890-85505 (Three bond No.1215®) Slide hammer bolt 5-19 90890-01085 Slide hammer bolt 8 mm YU-01083-2 1-31...
  • Page 41 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Weight 5-19 90890-01084 Weight YU-01083-3 YU-01083-3 Valve spring compressor 5-23, 5-28 90890-04019 Valve spring compressor YM-04019 Valve spring compressor attachment 5-23, 5-28 90890-04108 Valve spring compressor adapter 22 mm YM-04108 Valve guide remover (ø5) 5-24 90890-04097 Valve guide remover (5.0 mm)

  • Page 42: Special Tools

    SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Rotor holding tool 5-38, 5-43, 5-49, 90890-01235 5-49 Universal magneto and rotor holder YU-01235 Rotor holding tool 5-38, 5-38, 5-42, 90890-04166 5-42 YM-04166 Socket wrench (39 mm) 5-38, 5-42 90890-01493 Sheave spring compressor 5-38, 5-41 90890-04134 Sheave spring compressor...
  • Page 43 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Digital circuit tester 5-52, 8-106, 90890-03174 8-109 Model 88 Multimeter with tachometer YU-A1927 Crankcase separating tool 5-62 90890-01135 Crankcase separator YU-01135-B Crankshaft installer pot 5-63 90890-01274 Installing pot YU-90058 YU-90058/YU-90059 Crankshaft installer bolt 5-63 90890-01275 Bolt...
  • Page 44 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Spacer (crankshaft installer) 5-63 90890-04081 Pot spacer YM-91044 YM-91044 Radiator cap tester 6-3, 6-3 90890-01325 Mityvac cooling system tester kit YU-24460-A YU-24460-A Radiator cap tester adapter 90890-01352 Pressure tester adapter YU-33984 YU-33984 Mechanical seal installer 90890-04145 ø30...
  • Page 45 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Pressure gauge 90890-03153 Pressure gauge YU-03153 Fuel pressure adapter 6.3mm 90890-03227 Ignition checker 8-105 90890-06754 Oppama pet–4000 spark checker YM-34487 1-36...
  • Page 46 SPECIAL TOOLS 1-37...

  • Page 47: Specifications

    SPECIFICATIONS GENERAL SPECIFICATIONS ................ 2-1 ENGINE SPECIFICATIONS ................2-2 CHASSIS SPECIFICATIONS ................2-7 ELECTRICAL SPECIFICATIONS ..............2-9 TIGHTENING TORQUES ................2-11 GENERAL TIGHTENING TORQUE SPECIFICATIONS ......2-11 ENGINE TIGHTENING TORQUES ............2-12 CHASSIS TIGHTENING TORQUES ............2-15 LUBRICATION POINTS AND LUBRICANT TYPES ........2-19 ENGINE ....................2-19 LUBRICATION SYSTEM CHART AND DIAGRAMS........2-21 ENGINE OIL LUBRICATION CHART .............2-21 LUBRICATION DIAGRAMS ..............2-23...

  • Page 48: General Specifications

    GENERAL SPECIFICATIONS EAS20013 GENERAL SPECIFICATIONS Model Model 2DP5 Dimensions Overall length 1955 mm (77.0 in) Overall width 740 mm (29.1 in) Overall height 1115 mm (43.9 in) Seat height 765 mm (30.1 in) Wheelbase 1350 mm (53.1 in) Ground clearance 135 mm (5.31 in) Minimum turning radius 2000 mm (78.7 in)

  • Page 49: Engine Specifications

    ENGINE SPECIFICATIONS EAS20014 ENGINE SPECIFICATIONS Engine Engine type Liquid cooled 4-stroke, SOHC Displacement 155 cm³ Cylinder arrangement Single cylinder Bore × stroke 58.0 × 58.7 mm (2.28 × 2.31 in) Compression ratio 10.5 : 1 Standard compression pressure (at sea level) 1800 kPa/860 r/min (18.0 kgf/cm²/860 r/min, 256.0 psi/860 r/min) Minimum–Maximum...
  • Page 50 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) Radiator core Width 158.6 mm (6.24 in) Height 142.0 mm (5.59 in)
  • Page 51 ENGINE SPECIFICATIONS Valve stem diameter (intake) 4.975–4.990 mm (0.1959–0.1965 in) Limit 4.920 mm (0.1937 in) Valve stem diameter (exhaust) 4.960–4.975 mm (0.1953–0.1959 in) Limit 4.925 mm (0.1939 in) Valve guide inside diameter (intake) 5.000–5.012 mm (0.1969–0.1973 in) Limit 5.050 mm (0.1988 in) Valve guide inside diameter (exhaust) 5.000–5.012 mm (0.1969–0.1973 in) Limit...
  • Page 52 ENGINE SPECIFICATIONS Piston ring Top ring Ring type Barrel End gap (installed) 0.10–0.25 mm (0.0039–0.0098 in) Limit 0.50 mm (0.0197 in) Ring side clearance 0.030–0.065 mm (0.0012–0.0026 in) Limit 0.115 mm (0.0045 in) 2nd ring Ring type Taper End gap (installed) 0.35–0.50 mm (0.0138–0.0197 in) Limit 0.85 mm (0.0335 in)
  • Page 53 ENGINE SPECIFICATIONS Fuel injector Model/quantity 5D78 00/1 Throttle body Type/quantity AC28/1 ID mark 2DP1 00 Fuel injection sensor 228–342 Ω Crankshaft position sensor resistance Intake air pressure sensor output voltage 3.88–4.12 V at 101.3 kPa (3.88–4.12 V at 1.01 kgf/cm², 3.88–4.12 V at 14.7 psi) 5700.0–6300.0 Ω...

  • Page 54: Chassis Specifications

    CHASSIS SPECIFICATIONS EAS20015 CHASSIS SPECIFICATIONS Chassis Frame type Underbone Caster angle 26.00° Trail 92 mm (3.6 in) Front wheel Wheel type Cast wheel 13M/C × MT3.00 Rim size Rim material Aluminum Wheel travel 100 mm (3.9 in) Radial wheel runout limit 1.0 mm (0.04 in) Lateral wheel runout limit 1.0 mm (0.04 in)
  • Page 55 CHASSIS SPECIFICATIONS Master cylinder inside diameter 11.00 mm (0.43 in) Caliper cylinder inside diameter 33.34 mm (1.31 in) Specified brake fluid YAMAHA GENUINE BRAKE FLUID (DOT 4) Rear brake Type Single disc brake Operation Left hand operation Rear disc brake Disc outside diameter ×...

  • Page 56: Electrical Specifications

    ELECTRICAL SPECIFICATIONS EAS20016 ELECTRICAL SPECIFICATIONS Voltage System voltage 12 V Ignition system Ignition system Advancer type Digital Ignition timing (B.T.D.C.) 5.0°/1600 r/min 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 57 ELECTRICAL SPECIFICATIONS Limit 3.50 mm (0.14 in) Brush spring force 3.92–5.88 N (400–600 gf, 14.11–21.17 oz) Commutator diameter 17.6 mm (0.69 in) Limit 16.6 mm (0.65 in) Mica undercut (depth) 1.35 mm (0.05 in) Starter relay Amperage 50.0 A 54.00–66.00 Ω Coil resistance Horn Horn type...

  • Page 58: Tightening Torques

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

  • Page 59: Engine Tightening Torques

    Cylinder head cover breather plate 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf) bolt Valve clearance adjusting screw 7 Nm (0.7 m·kgf, 5.1 ft·lbf) locknut Yamaha Timing chain tensioner bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) bond No. 1215 Timing chain guide bolt (intake side) 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
  • Page 60 1.2 Nm (0.12 m·kgf, 0.87 ft·lbf) Air filter case duct cover screw 1.2 Nm (0.12 m·kgf, 0.87 ft·lbf) AC magneto rotor nut 80 Nm (8.0 m·kgf, 58 ft·lbf) Yamaha Crankcase cover bolt 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf) bond No. 1215 Crankcase cover bolt 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
  • Page 61 TIGHTENING TORQUES Cylinder head tightening sequence: 2-14...

  • Page 62: Chassis Tightening Torques

    TIGHTENING TORQUES EAS30017 CHASSIS TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Engine bracket nut 52 Nm (5.2 m·kgf, 38 ft·lbf) Engine mounting nut (front right 68 Nm (6.8 m·kgf, 49 ft·lbf) side) Engine mounting bolt (front left side) 68 Nm (6.8 m·kgf, 49 ft·lbf) Engine mounting nut (rear side) 68 Nm (6.8 m·kgf, 49 ft·lbf)
  • Page 63 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Battery cover screw 1.8 Nm (0.18 m·kgf, 1.3 ft·lbf) Storage box bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Seat hinge bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Rear fender bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Front brake master cylinder holder 11 Nm (1.1 m·kgf, 8.0 ft·lbf) bolt...
  • Page 64 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Front brake hose union bolt (brake 29 Nm (2.9 m·kgf, 21 ft·lbf) caliper side) Brake caliper bleed screw 6 Nm (0.6 m·kgf, 4.3 ft·lbf) Front brake hose guide bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Front wheel axle nut 40 Nm (4.0 m·kgf, 29 ft·lbf) Front brake hose holder bolt...
  • Page 65 TIGHTENING TORQUES Steering column ring nut 1. Tighten the lower ring nut 38 Nm (3.8 m·kgf, 27 ft·lbf) with a torque wrench and the steering nut wrench, and then loosen the nut 1/4 turn. 2. Tighten the lower ring nut 16 Nm (1.6 m·kgf, 12 ft·lbf) with a torque wrench and the steering nut wrench.

  • Page 66: Lubrication Points And Lubricant Types

    Oil pump shaft O-ring (fuel injector) Starter wheel and bearing Starter clutch idle gear inner surface Drive axle and bearings Crankshaft threads and conical spring washer outer mating surface Yamaha bond Timing chain tensioner bolts No.1215® Yamaha bond Crankcase mating surfaces No.1215®...
  • Page 67 LUBRICATION POINTS AND LUBRICANT TYPES 2-20...

  • Page 68: Lubrication System Chart And Diagrams

    LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20019 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS30020 ENGINE OIL LUBRICATION CHART 2-21...
  • Page 69 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil strainer 2. Oil pump assembly 3. Crankshaft 4. Oil nozzle 5. Camshaft 2-22...

  • Page 70: Lubrication Diagrams

    LUBRICATION SYSTEM CHART AND DIAGRAMS EAS30021 LUBRICATION DIAGRAMS 2-23...
  • Page 71 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil strainer 2. Oil pump assembly 3. Camshaft 2-24...
  • Page 72 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-25...
  • Page 73 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil strainer 2. Oil pump assembly 3. Crankshaft 4. Rocker arm/Valve stem end 2-26...

  • Page 74: Cooling System Diagrams

    COOLING SYSTEM DIAGRAMS EAS20020 COOLING SYSTEM DIAGRAMS 2-27...
  • Page 75 COOLING SYSTEM DIAGRAMS 1. Radiator cap 2. Coolant reservoir hose 3. Radiator 4. Radiator inlet hose 5. Radiator outlet hose 6. Thermostat assembly 7. Water pump inlet hose 8. Water pump assembly 2-28...

  • Page 76: Cable Routing

    CABLE ROUTING EAS20021 CABLE ROUTING Handlebar (front view) 2-29...
  • Page 77 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. Rear brake light switch lead 4. Throttle cable (decelerator cable) 5. Throttle cable (accelerator cable) 6.
  • Page 78 CABLE ROUTING Handlebar (left side view) 2-31...
  • Page 79 CABLE ROUTING 1. Rear brake hose (rear brake master cylinder to hydraulic unit) 2. Rear brake light switch lead 3. Throttle cable (decelerator cable) 4. Throttle cable (accelerator cable) 5. Handlebar switch coupler (left handlebar switch) 6. Wire harness 7. Front brake hose (front brake master cylinder to hydraulic unit) 8.
  • Page 80 CABLE ROUTING Front frame (front and left side view) 2-33...
  • Page 81 CABLE ROUTING 1. Main switch lead 2. Rectifier/regulator 3. Meter assembly lead 4. Turn signal relay 5. Turn signal relay lead 6. Headlight lead 7. Auxiliary light lead 8. Front turn signal light lead (front left turn signal light) 9. Front wheel sensor lead 10.
  • Page 82 CABLE ROUTING Front fork (rear and right side view) 2-35...
  • Page 83 CABLE ROUTING 1. Horn lead 2. Front brake hose holder 3. Horn 4. Front wheel sensor 5. Front brake caliper 6. Front brake hose (hydraulic unit to front brake caliper) 7. Front wheel sensor lead A. Route the front brake hose (hydraulic unit to front brake caliper) through the guide.
  • Page 84 CABLE ROUTING Frame (left side view) 2-37...
  • Page 85 12. Starter motor sub-wire harness 13. Engine ground lead 14. Ignition coil lead 15. Positive battery lead 16. Negative battery lead Yamaha diagnostic tool lead 18. ABS test coupler lead 19. ECU lead 20. Fuse box 1 21. Fuse box 2 A.
  • Page 86 CABLE ROUTING Frame (right side view) 2-39...
  • Page 87 CABLE ROUTING 1. Coolant temperature sensor lead 2. Throttle body sensor assembly lead 3. Starter motor lead 4. ISC (Idle Speed Control) unit lead 5. AC magneto lead 6. Fuel injector lead 7. O sensor lead 8. VVA (variable valve actuator) solenoid lead 9.
  • Page 88 CABLE ROUTING Frame (top view) 2-41...
  • Page 89 3. Fuse box 1 4. Fuse box 2 5. Fuel tank overflow tray 6. Negative battery lead 7. ABS test coupler lead Yamaha diagnostic tool lead 9. Storage box 10. Tail/brake light assembly lead 11. Seat lock cable 12. ABS test coupler...
  • Page 90 CABLE ROUTING Hydraulic unit (top and right side view) 2-43...
  • Page 91 CABLE ROUTING 1. Hydraulic unit assembly 2. Main switch lead 3. Rear brake hose (hydraulic unit to rear brake caliper) 4. Rear brake hose (rear brake master cylinder to hydraulic unit) 5. Front brake hose (front brake master cylinder to hydraulic unit) 6.
  • Page 92 CABLE ROUTING Rear brake (right side view) 2-45...
  • Page 93 CABLE ROUTING 1. Rear brake caliper 2. Rear wheel sensor 3. Rear wheel sensor lead 4. Radiator 5. Coolant reservoir hose 6. Rear brake hose (hydraulic unit to rear brake caliper) 7. Swingarm 8. Rear brake hose bracket 9. Rear brake hose holder 10.
  • Page 94 CABLE ROUTING Fuel tank (right side view) 2-47...
  • Page 95 CABLE ROUTING 1. Rear brake hose (hydraulic unit to rear brake caliper) 2. Rear wheel sensor lead 3. Fuel hose 4. Fuel tank overflow hose 5. Center lower cover 6. Coolant reservoir hose 7. Coolant reservoir breather hose 8. Fuel hose holder 9.
  • Page 96 CABLE ROUTING Fuel tank (top and bottom view) 2-49...
  • Page 97 CABLE ROUTING 1. Coolant reservoir cap 2. Coolant reservoir breather hose 3. Coolant reservoir hose 4. Fuel hose A. Install the coolant reservoir cap as shown in the illustration. B. Align the white paint mark on the hose with the projection on the coolant reservoir.
  • Page 98 CABLE ROUTING Radiator (top and right side view) 2-51...
  • Page 99 CABLE ROUTING 1. Water pump 2. Water pump inlet hose 3. Thermostat assembly 4. Radiator outlet hose 5. Radiator 6. Coolant reservoir hose 7. Radiator inlet hose A. Install the hose completely onto the hose fitting. B. Face the white paint mark on the hose to the left. –...
  • Page 100 CABLE ROUTING Air filter case (top and left side view) 2-53...
  • Page 101 CABLE ROUTING 1. Cylinder head breather hose 2. V-belt case breather hose 3. Air filter case A. Face the white paint mark on the hose upward. B. Point the ends of the hose clamp upward. C. Install the hose completely onto the hose fitting. –...
  • Page 102 CABLE ROUTING 2-55...

  • Page 103: Periodic Checks And Adjustments

    PERIODIC CHECKS AND ADJUSTMENTS PERIODIC MAINTENANCE ................3-1 INTRODUCTION ..................3-1 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM ....................3-1 GENERAL MAINTENANCE AND LUBRICATION CHART ....... 3-1 CHECKING THE FUEL LINE ..............3-4 CHECKING THE FUEL FILTER ..............3-4 CHECKING THE SPARK PLUG ...............
  • Page 104 CHECKING THE SWITCHES, LIGHTS AND SIGNALS ......3-24 ADJUSTING THE HEADLIGHT BEAM ...........3-24...

  • Page 106: Periodic Maintenance

    • From 20000 km (12000 mi), repeat the maintenance intervals starting from 4000 km (2400 mi). • Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
  • Page 107 PERIODIC MAINTENANCE ODOMETER READING (whichever comes first) CHECK OR MAINTENANCE ANNUAL ITEM 1000 km 4000 km 8000 km 12000 km 16000 km CHECK (600 mi) (2400 mi) (4800 mi) (7200 mi) (9600 mi) V-belt case air fil- • Clean. √ √...
  • Page 108 PERIODIC MAINTENANCE ODOMETER READING (whichever comes first) CHECK OR MAINTENANCE ANNUAL ITEM 1000 km 4000 km 8000 km 12000 km 16000 km CHECK (600 mi) (2400 mi) (4800 mi) (7200 mi) (9600 mi) Moving parts and √ √ √ √ √...

  • Page 109: Checking The Fuel Line

    PERIODIC MAINTENANCE EAS30619 CHECKING THE FUEL LINE 1. Remove: • Front side cover (right) Refer to “GENERAL CHASSIS (2)” on page 4-4. • Footrest board assembly (right) Refer to “GENERAL CHASSIS (5)” on page 4-12. 2. Check: • Fuel hose “1” 3.

  • Page 110: Adjusting The Valve Clearance

    PERIODIC MAINTENANCE 5. Clean: 8. Install: • Spark plug • Footrest board assembly (right) (with a spark plug cleaner or wire brush) Refer to “GENERAL CHASSIS (5)” on page 6. Measure: 4-12. • Spark plug gap “a” • Front side cover (right) (with a wire thickness gauge) Refer to “GENERAL CHASSIS (2)”...
  • Page 111 PERIODIC MAINTENANCE 3. Move: c. Measure the valve clearance with a thickness • Water pump assembly “1” gauge “1”. Out of specification → Adjust. Move the water pump assembly in the direction shown in the illustration. ▲ ▲▲▲ ▲ ▲▲▲ ▲...

  • Page 112: Checking The Engine Idling Speed

    ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect the Yamaha diagnostic tool. Use the diagnostic code number “67”. Refer to “SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE” on page 9-5. Yamaha diagnostic tool 90890-03231 ▲ ▲▲▲...

  • Page 113: Adjusting The Exhaust Gas Volume

    Yamaha diagnostic tool. For more information, refer to the opera- tion manual of the Yamaha diagnostic tool. 1. Connect the Yamaha diagnostic tool to the 2. Check: connector. For information about connecting • Air filter element the Yamaha diagnostic tool, refer to Damage →...

  • Page 114: Cleaning The V-Belt Case Air Filter Element And Cleaning The Check Hose

    PERIODIC MAINTENANCE • Storage box EAS31704 CLEANING THE V-BELT CASE AIR FILTER Refer to “GENERAL CHASSIS (4)” on page ELEMENT AND CLEANING THE CHECK 4-9. HOSE 2. Check: • Cylinder head breather hose “1” Check the V-belt case air filter check hose “1” •...

  • Page 115: Checking And Charging The Battery

    PERIODIC MAINTENANCE • The air filter needs more frequent service if you Drive on the road, operate the front and rear are riding in unusually wet or dusty areas. brakes separately and check to see if the brakes • After cleaning, gently squeeze the V-belt case are operating properly.

  • Page 116: Checking The Front Brake Hoses

    CHECKING THE FRONT BRAKE HOSES 1. Check: Specified brake fluid • Brake hoses “1” YAMAHA GENUINE BRAKE Cracks/damage → Replace. FLUID (DOT 4) 2. Check: • Brake hose holder • Brake hose guide Loose →...

  • Page 117: Bleeding The Hydraulic Brake System

    PERIODIC MAINTENANCE 3. Hold the vehicle upright and apply the rear brake several times. 4. Check: • Brake hoses Brake fluid leakage → Replace the brake hose. Refer to “REAR BRAKE” on page 4-49 and “ABS (ANTI-LOCK BRAKE SYSTEM)” on page 4-61.

  • Page 118: Checking The Wheels

    PERIODIC MAINTENANCE EWA13181 WARNING Brake caliper bleed screw 6 Nm (0.6 m·kgf, 4.3 ft·lbf) • The tire pressure should only be checked and regulated when the tire temperature m. Fill the brake master cylinder reservoir to the equals the ambient air temperature. proper level with the specified brake fluid.

  • Page 119: Checking The Wheel Bearings

    STEERING HEAD en if a tire combination other than one 1. Stand the vehicle on a level surface. approved by Yamaha is used on this vehicle. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over.
  • Page 120 PERIODIC MAINTENANCE Place the vehicle on a suitable stand so that the front wheel elevated. 2. Check: • Steering head Grasp the handlebar and gently rock the han- dlebar. Binding/looseness → Adjust the steering head. 3. Remove: c. Loosen the lower ring nut 1/4 of a turn, and •...

  • Page 121: Lubricating The Steering Head

    PERIODIC MAINTENANCE EAS30651 LUBRICATING THE SIDESTAND Steering nut wrench Lubricate the pivoting point, metal-to-metal mov- 90890-01403 ing parts, and spring contact point of the side- Exhaust flange nut wrench YU-A9472 stand. Recommended lubricant Upper ring nut Lithium-soap-based grease 75 Nm (7.5 m·kgf, 54 ft·lbf) EAS30856 CHECKING THE CENTERSTAND ▲...

  • Page 122: Checking The Rear Shock Absorber Assemblies

    PERIODIC MAINTENANCE • Before checking the engine oil level, wait a few minutes until the oil has settled. • Do not screw the dipstick in when inspecting the oil level. EAS30808 CHECKING THE REAR SHOCK ABSORBER ASSEMBLIES The following procedure applies to both of the rear shock absorber assemblies.
  • Page 123 PERIODIC MAINTENANCE • Engine oil drain bolt “2” Oil strainer cover (along with the gasket “3”) 32 Nm (3.2 m·kgf, 23 ft·lbf) ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 6.

  • Page 124: Checking The Coolant Level

    PERIODIC MAINTENANCE b. Start the engine and keep it idling until engine 3. Start the engine, warm it up for several min- oil starts to seep from the oil check bolt. If no utes, and then turn it off. engine oil comes out after one minute, turn 4.
  • Page 125 PERIODIC MAINTENANCE EWA13030 WARNING A hot radiator is under pressure. Therefore, do not remove the radiator cap when the en- gine is hot. Scalding hot fluid and steam may be blown out, which could cause serious in- jury. When the engine has cooled, open the radiator cap as follows: Place a thick rag or a towel over the radiator cap and slowly turn the radiator cap counter-...
  • Page 126 • Coolant reservoir hose 11.Fill: • Cooling system (with the specified amount of the recom- mended coolant) Recommended antifreeze YAMAHA GENUINE COOLANT Mixing ratio 1:1 (antifreeze: water) Radiator (including all routes) 14.Install: 0.46 L (0.49 US qt, 0.40 Imp.qt) • Coolant reservoir cap “1”...

  • Page 127: Changing The Final Transmission Oil

    PERIODIC MAINTENANCE • Front side cover (right) Final transmission oil Refer to “GENERAL CHASSIS (2)” on page Type 4-4. Motor oil SAE 10W-30 type SE or higher or Gear oil SAE 85W GL-3 EAS31187 CHANGING THE FINAL TRANSMISSION OIL Quantity 1.

  • Page 128: Checking The Brake Light Switches

    PERIODIC MAINTENANCE Faulty → Refer to “CHECKING THE 2. Disassemble: • Secondary sheave assembly SWITCHES” on page 8-95. Refer to “V-BELT AUTOMATIC TRANSMIS- EAS30660 SION” on page 5-34. CHECKING AND LUBRICATING THE 3. Lubricate: CABLES • Spring seat“1” The following procedure applies to all of the in- •...
  • Page 129 PERIODIC MAINTENANCE 3. Check: EWA17990 WARNING • Throttle grip free play “a” Out of specification → Adjust. After adjusting the throttle grip free play, start the engine and turn the handlebars to Throttle grip free play the right and to the left to ensure that this 3.0–5.0 mm (0.12–0.20 in) does not cause the engine idling speed to change.
  • Page 130 PERIODIC MAINTENANCE 3-25...

  • Page 131: Chassis

    CHASSIS GENERAL CHASSIS (1) ................. 4-1 REMOVING THE BATTERY COVER ............4-2 INSTALLING THE BATTERY COVER ............4-2 REMOVING THE ECU (engine control unit) ..........4-2 INSTALLING THE ECU (engine control unit) ..........4-2 GENERAL CHASSIS (2) ................. 4-4 REMOVING THE TAIL/BRAKE LIGHT OUTER COVER ......4-5 INSTALLING THE TAIL/BRAKE LIGHT OUTER COVER......
  • Page 132 FRONT WHEEL.....................4-25 REMOVING THE FRONT WHEEL............4-27 DISASSEMBLING THE FRONT WHEEL ..........4-27 CHECKING THE FRONT WHEEL ............4-27 MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR ..................4-28 ASSEMBLING THE FRONT WHEEL ............4-28 ADJUSTING THE FRONT WHEEL STATIC BALANCE ......4-29 INSTALLING THE FRONT WHEEL (FRONT BRAKE DISC)....4-30 REAR WHEEL ....................4-33 REMOVING THE REAR WHEEL (DISC) ..........4-34 CHECKING THE REAR WHEEL.............4-34...
  • Page 133 HANDLEBAR ....................4-69 REMOVING THE UPPER HANDLEBAR COVER ASSEMBLY ....4-72 DISASSEMBLING THE UPPER HANDLEBAR COVER ASSEMBLY ....................4-72 REMOVING THE HANDLEBAR ..............4-72 CHECKING THE HANDLEBAR ..............4-72 INSTALLING THE HANDLEBAR ............4-72 ASSEMBLING THE UPPER HANDLEBAR COVER ASSEMBLY ..4-75 INSTALLING THE UPPER HANDLEBAR COVER ASSEMBLY .....4-75 FRONT FORK....................
  • Page 134 GENERAL CHASSIS (1) EAS20026 GENERAL CHASSIS (1) Removing the battery and ECU 1.8 Nm (0.18 m kgf, 1.3 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Seat Open. Battery cover Negative battery lead Disconnect. Positive battery lead Disconnect. Battery ECU coupler Disconnect.

  • Page 135: General Chassis (1)

    GENERAL CHASSIS (1) EAS31677 REMOVING THE BATTERY COVER 1. Remove: • Battery cover “1” b. Install the battery cover screws, and then tighten the screws to specification. Battery cover screw ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼...

  • Page 136: General Chassis (2)

    GENERAL CHASSIS (1)
  • Page 137 GENERAL CHASSIS (2) EAS20155 GENERAL CHASSIS (2) Removing the grab bar and front side covers 17 Nm (1.7 m kgf, 12 ft Ibf) • • 1.8 Nm (0.18 m kgf, 1.3 ft Ibf) • • 1.8 Nm (0.18 m kgf, 1.3 ft Ibf) •...

  • Page 138: Removing The Tail/Brake Light Outer Cover

    GENERAL CHASSIS (2) EAS31681 REMOVING THE TAIL/BRAKE LIGHT OUTER COVER 1. Remove: • Tail/brake light outer cover “1” b. Install the tail/brake light outer cover screws, and then tighten the screws to specification. Tail/brake light outer cover screw 1.8 Nm (0.18 m·kgf, 1.3 ft·lbf) ▼...

  • Page 139: General Chassis (3)

    GENERAL CHASSIS (2) ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Fit the projections “a” on the front side cowl- ing into the grommets “b”. b. Install the front side cover screws, and then tighten the screw to specification.
  • Page 140 GENERAL CHASSIS (3) EAS20156 GENERAL CHASSIS (3) Removing the fuel tank cover and seat assembly 1.8 Nm (0.18 m kgf, 1.3 ft Ibf) • • 1.8 Nm (0.18 m kgf, 1.3 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...

  • Page 141: Removing The Fuel Tank Cover

    GENERAL CHASSIS (3) EAS31685 REMOVING THE FUEL TANK COVER 1. Remove: • Fuel tank cover “1” ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Slide the fuel tank cover forward and fit the projections “a”...

  • Page 142: General Chassis (4)

    GENERAL CHASSIS (4) EAS20157 GENERAL CHASSIS (4) Removing the rear side covers and storage box 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 1.8 Nm (0.18 m kgf, 1.3 ft Ibf) • • 1.8 Nm (0.18 m kgf, 1.3 ft Ibf) •...
  • Page 143 GENERAL CHASSIS (4) Removing the rear side covers and storage box 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 1.8 Nm (0.18 m kgf, 1.3 ft Ibf) • • 1.8 Nm (0.18 m kgf, 1.3 ft Ibf) • •...

  • Page 144: Removing The Rear Side Cover Assembly

    GENERAL CHASSIS (4) EAS31687 REMOVING THE REAR SIDE COVER ASSEMBLY The following procedure applies to both of the rear side cover assembly. 1. Remove: • Rear side cover assembly “1” b. Install the quick fasteners, screw, and bolt, and then tighten the screw and bolts to spec- ification.

  • Page 145: General Chassis (5)

    GENERAL CHASSIS (5) EAS20158 GENERAL CHASSIS (5) Removing the bottom cover, center lower cover and footrest board 1.8 Nm (0.18 m kgf, 1.3 ft Ibf) • • 3.8 Nm (0.38 m kgf, 2.8 ft Ibf) • • 3.8 Nm (0.38 m kgf, 2.8 ft Ibf) •...
  • Page 146 GENERAL CHASSIS (5) Removing the bottom cover, center lower cover and footrest board 1.8 Nm (0.18 m kgf, 1.3 ft Ibf) • • 3.8 Nm (0.38 m kgf, 2.8 ft Ibf) • • 3.8 Nm (0.38 m kgf, 2.8 ft Ibf) •...

  • Page 147: Installing The Sidestand

    GENERAL CHASSIS (5) EAS31732 EAS31690 INSTALLING THE SIDESTAND INSTALLING THE FOOTREST BOARD 1. Install: ASSEMBLY • Sidestand “1” 1. Install: • Inner spring “2” • Footrest board assembly “1” • Outer spring “3” Sidestand nut 24 Nm (2.4 m·kgf, 17 ft·lbf) Make sure that the hooked end “a”...

  • Page 148: General Chassis (6)

    GENERAL CHASSIS (5) 4-15...
  • Page 149 GENERAL CHASSIS (6) EAS20159 GENERAL CHASSIS (6) Removing the meter assembly 3.8 Nm (0.38 m kgf, 2.8 ft Ibf) 1.8 Nm (0.18 m kgf, 1.3 ft Ibf) • • • • 0.4 Nm (0.04 m kgf, 0.29 ft Ibf) • •...

  • Page 150: Removing The Front Upper Cowling Assembly

    GENERAL CHASSIS (6) EAS31692 REMOVING THE FRONT UPPER COWLING ASSEMBLY 1. Remove: • Front upper cowling assembly “1” b. Install the front upper cowling assembly screw, and then tighten the screw to specifi- cation. Front upper cowling assembly ▼ ▼▼▼ ▼...

  • Page 151: General Chassis (7)

    GENERAL CHASSIS (6) Slide the front upper panel in the direction shown in the illustration, fit the projections “a” on the panel into the holes “b” in the front upper cowling, and fit the projections “c” on the cowling into the holes “d” in the panel. 4-18...
  • Page 152 GENERAL CHASSIS (7) EAS20193 GENERAL CHASSIS (7) Removing the front cowling assembly 1.8 Nm (0.18 m kgf, 1.3 ft Ibf) • • 1.8 Nm (0.18 m kgf, 1.3 ft Ibf) • • 1.8 Nm (0.18 m kgf, 1.3 ft Ibf) •...
  • Page 153 GENERAL CHASSIS (7) Removing the front cowling assembly 1.8 Nm (0.18 m kgf, 1.3 ft Ibf) • • 1.8 Nm (0.18 m kgf, 1.3 ft Ibf) • • 1.8 Nm (0.18 m kgf, 1.3 ft Ibf) • • 1.8 Nm (0.18 m kgf, 1.3 ft Ibf) •...

  • Page 154: Removing The Front Cowling Assembly

    GENERAL CHASSIS (7) EAS31278 REMOVING THE FRONT COWLING ASSEMBLY 1. Remove: • Front cowling assembly “1” b. Install the front cowling assembly screws, and then tighten the screws to specification. Front cowling assembly screw × ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼...

  • Page 155: Installing The Front Side Cowling

    GENERAL CHASSIS (7) EAS31697 INSTALLING THE FRONT SIDE COWLING The following procedure applies to both of the front side cowling. 1. Install: • Front side cowling “1” ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼...

  • Page 156: General Chassis (8)

    GENERAL CHASSIS (8) EAS20194 GENERAL CHASSIS (8) Removing the leg shield 3.5 Nm (0.35 m kgf, 2.5 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS (1)” on page Battery 4-1.

  • Page 157: Installing The Key Shutter

    GENERAL CHASSIS (8) EAS31700 INSTALLING THE KEY SHUTTER 1. Install: • Key shutter “1” Key shutter screw 3.5 Nm (0.35 m·kgf, 2.5 ft·lbf) While holding the key shutter so that it contacts the leg shield “2”, tighten the key shutter screw “3”...
  • Page 158 FRONT WHEEL EAS20028 FRONT WHEEL Removing the front wheel and brake disc 40 Nm (4.0 m kgf, 29 ft Ibf) • • 35 Nm (3.5 m kgf, 25 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...
  • Page 159 FRONT WHEEL Disassembling the front wheel Order Job/Parts to remove Q’ty Remarks Oil seal Wheel bearing Spacer 4-26...

  • Page 160: 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 161: Maintenance Of The Front Wheel Sensor And Sensor Rotor

    FRONT WHEEL • Lateral wheel runout “2” 1. Check: Over the specified limits → Replace. • Front wheel sensor “1” Cracks/bends/distortion → Replace. Radial wheel runout limit Iron powder/dust → Clean. 1.0 mm (0.04 in) Lateral wheel runout limit 1.0 mm (0.04 in) 2.

  • Page 162: Adjusting The Front Wheel Static Balance

    FRONT WHEEL b. When the front wheel stops, put an “X ” mark at the bottom of the wheel. Use a socket “4” that matches the diameter of the wheel bearing outer race. c. Turn the front wheel 90° so that the “X ”...

  • Page 163: Installing The Front Wheel (Front Brake Disc)

    FRONT WHEEL Front wheel sensor rotor bolt 8 Nm (0.8 m·kgf, 5.8 ft·lbf) LOCTITE® Front brake disc bolt 23 Nm (2.3 m·kgf, 17 ft·lbf) LOCTITE® ECA21011 NOTICE • Do not drop the wheel sensor rotor or sub- b. Turn the front wheel 90° so that the heavy ject it to shocks.
  • Page 164 FRONT WHEEL Out of specification → Check the wheel bear- 4. Install: • Front wheel ing for looseness, and the front wheel sensor • Collars and sensor rotor installation conditions (war- • Front wheel axle page caused by overtorque, wrong installa- tion direction, rotor decentering, LOCTITE®...
  • Page 165 FRONT WHEEL While holding the front brake hose guide and front wheel sensor lead holder so that the por- tions “a” of the guide and holder contact the front fork outer tube, tighten the bolts to specification. 4-32...

  • Page 166: Rear Wheel

    REAR WHEEL EAS20029 REAR WHEEL Removing the rear wheel and brake disc 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • 23 Nm (2.3 m kgf, 17 ft Ibf) • • 23 Nm (2.3 m kgf, 17 ft Ibf) •...

  • Page 167: Removing The Rear Wheel (Disc)

    REAR WHEEL • Keep any type of magnets (including mag- EAS30156 REMOVING THE REAR WHEEL (DISC) netic pick-up tools, magnetic screwdrivers, ECA22870 etc.) away from the rear wheel sensor rotor. NOTICE • Do not drop or shock the wheel sensor ro- •...
  • Page 168 REAR WHEEL 2. Check: • Rear brake disc Refer to “CHECKING THE REAR BRAKE DISC” on page 4-55. 4-35...
  • Page 169 FRONT BRAKE EAS20030 FRONT BRAKE Removing the front brake pads 6 Nm (0.6 m kgf, 4.3 ft Ibf) • • 35 Nm (3.5 m kgf, 25 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Front wheel sensor lead holder Front brake caliper Brake pad clip Brake pad pin...
  • Page 170 FRONT BRAKE Removing the front brake master cylinder 11 Nm (1.1 m kgf, 8.0 ft Ibf) • • 1.5 Nm (0.15 m kgf, 1.1 ft Ibf) • • 29 Nm (2.9 m kgf, 21 ft Ibf) • • 6 Nm (0.6 m kgf, 4.3 ft Ibf) •...

  • Page 171: Front Brake

    FRONT BRAKE Removing the front brake master cylinder 11 Nm (1.1 m kgf, 8.0 ft Ibf) • • 1.5 Nm (0.15 m kgf, 1.1 ft Ibf) • • 29 Nm (2.9 m kgf, 21 ft Ibf) • • 6 Nm (0.6 m kgf, 4.3 ft Ibf) •...
  • Page 172 FRONT BRAKE Disassembling the front brake master cylinder Order Job/Parts to remove Q’ty Remarks Brake master cylinder kit Brake master cylinder body 4-39...
  • Page 173 FRONT BRAKE Removing the front brake caliper 29 Nm (2.9 m kgf, 21 ft Ibf) • • 35 Nm (3.5 m kgf, 25 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM”...
  • Page 174 FRONT BRAKE Disassembling the front brake caliper 6 Nm (0.6 m kgf, 4.3 ft Ibf) • • Order Job/Parts to remove Q’ty 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 175: Introduction

    FRONT BRAKE e. Measure the runout 1.5 mm (0.06 in) below EAS30168 INTRODUCTION 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 176: Replacing The Front Brake Pads

    FRONT BRAKE A. Inner d. Measure the brake disc runout. B. Outer e. If out of specification, repeat the adjustment steps until the brake disc runout is within 2. Install: specification. • Brake pad spring “1” f. If the brake disc runout cannot be brought •...

  • Page 177: Removing The Front Brake Caliper

    FRONT BRAKE 5. Check: • Brake lever operation Soft or spongy feeling → Bleed the brake sys- tem. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-12. EAS31328 REMOVING THE FRONT BRAKE CALIPER Before removing the brake caliper, drain the ▲...

  • Page 178: Checking The Front Brake Caliper

    Every two years and brake caliper piston seals. Piston dust seal Every two years Specified brake fluid Brake hose Every four years YAMAHA GENUINE BRAKE Every two years and FLUID (DOT 4) Brake fluid whenever the brake is disassembled EAS30934 INSTALLING THE FRONT BRAKE CALIPER 1.

  • Page 179: Removing The Front Brake Master Cylinder

    (with the specified amount of the specified Refer to “BLEEDING THE HYDRAULIC brake fluid) BRAKE SYSTEM” on page 3-12. Specified brake fluid EAS30179 YAMAHA GENUINE BRAKE REMOVING THE FRONT BRAKE MASTER FLUID (DOT 4) CYLINDER EWA13540 WARNING Before removing the front brake master cylinder, •...

  • Page 180: Checking The Front Brake Master Cylinder

    FRONT BRAKE Specified brake fluid YAMAHA GENUINE BRAKE FLUID (DOT 4) EAS30182 INSTALLING THE FRONT BRAKE MASTER CYLINDER 1. Install: • Brake master cylinder • Brake master cylinder holder “1” EAS30725 CHECKING THE FRONT BRAKE MASTER Front brake master cylinder hold-...
  • Page 181 BRAKE SYSTEM” on page 3-12. • Brake master cylinder reservoir (with the specified amount of the specified brake fluid) Specified brake fluid YAMAHA GENUINE BRAKE FLUID (DOT 4) EWA13540 WARNING • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance.
  • Page 182 REAR BRAKE EAS20031 REAR BRAKE Removing the rear brake pads 35 Nm (3.5 m kgf, 25 ft Ibf) • • 6 Nm (0.6 m kgf, 4.3 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Rear brake caliper Brake pad clip Brake pad pin Brake pad (inner) Brake pad (outer)
  • Page 183 REAR BRAKE Removing the rear brake master cylinder 11 Nm (1.1 m kgf, 8.0 ft Ibf) • • 1.5 Nm (0.15 m kgf, 1.1 ft Ibf) • • 6 Nm (0.6 m kgf, 4.3 ft Ibf) • • 29 Nm (2.9 m kgf, 21 ft Ibf) •...

  • Page 184: Rear Brake

    REAR BRAKE Removing the rear brake master cylinder 11 Nm (1.1 m kgf, 8.0 ft Ibf) • • 1.5 Nm (0.15 m kgf, 1.1 ft Ibf) • • 6 Nm (0.6 m kgf, 4.3 ft Ibf) • • 29 Nm (2.9 m kgf, 21 ft Ibf) •...
  • Page 185 REAR BRAKE Disassembling the rear brake master cylinder Order Job/Parts to remove Q’ty Remarks Brake master cylinder kit Brake master cylinder body 4-52...
  • Page 186 REAR BRAKE Removing the rear brake caliper 35 Nm (3.5 m kgf, 25 ft Ibf) • • 29 Nm (2.9 m kgf, 21 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM”...
  • Page 187 REAR BRAKE Disassembling the rear brake caliper 6 Nm (0.6 m kgf, 4.3 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Brake pad clip Brake pad pin Brake pad (inner) Brake pad (outer) Brake pad spring Brake caliper bracket Brake caliper piston Brake caliper piston dust seal Brake caliper piston seal...

  • Page 188: Introduction

    REAR BRAKE EAS30183 INTRODUCTION Brake disc thickness limit EWA14101 4.0 mm (0.16 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 189: Removing The Rear Brake Caliper

    REAR BRAKE ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ A. Inner 3. Install: B. Outer • Brake pad pin 2. Install: • Brake pad clips • Brake pad spring •...

  • Page 190: Disassembling The Rear Brake Caliper

    REAR BRAKE b. Remove the brake caliper piston dust seal and brake caliper piston seal. Put the end of the brake hose into a container ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲...

  • Page 191: Assembling The Rear Brake Caliper

    4. Fill: and brake caliper piston seal. • Brake master cylinder reservoir (with the specified amount of the specified brake fluid) Specified brake fluid YAMAHA GENUINE BRAKE Specified brake fluid FLUID (DOT 4) YAMAHA GENUINE BRAKE FLUID (DOT 4) EAS30190...

  • Page 192: Removing The Rear Brake Master Cylinder

    • Never use solvents on internal brake com- ponents. Specified brake fluid YAMAHA GENUINE BRAKE FLUID (DOT 4) EAS30196 INSTALLING THE REAR BRAKE MASTER CYLINDER 1. Install: •...
  • Page 193 • Align the edge “b” of the brake master cylinder Specified brake fluid holder with the edge “c” of the stay on the han- YAMAHA GENUINE BRAKE dlebar as shown in the illustration. FLUID (DOT 4) • First, tighten the upper bolt, then the lower bolt.

  • Page 194: Abs (Anti-Lock Brake System)

    ABS (ANTI-LOCK BRAKE SYSTEM) EAS20032 ABS (ANTI-LOCK BRAKE SYSTEM) Removing the hydraulic unit assembly 29 Nm (2.9 m kgf, 21 ft Ibf) • • 29 Nm (2.9 m kgf, 21 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...
  • Page 195 ABS (ANTI-LOCK BRAKE SYSTEM) Removing the hydraulic unit assembly 29 Nm (2.9 m kgf, 21 ft Ibf) • • 29 Nm (2.9 m kgf, 21 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...

  • Page 196: Removing The Hydraulic Unit Assembly

    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 197 Position the pipe sections of the brake hoses at Specified brake fluid a 30° angle from the line “a” as shown in the il- YAMAHA GENUINE BRAKE lustration, and then tighten the brake hose union FLUID (DOT 4) bolts to specification.

  • Page 198: Hydraulic Unit Operation Tests

    6. Removing the protective cap “1”, and then • Brake line routing confirmation: this test connect the Yamaha diagnostic tool to the checks the function of the ABS after the sys- Yamaha diagnostic tool coupler (4P).
  • Page 199 ABS (ANTI-LOCK BRAKE SYSTEM) 7. Start the Yamaha diagnostic tool and display the diagnosis mode screen. 8. Select code No. 2, “Brake line routing confir- mation”. 9. Click “Action” “1”, and then operate the front brake lever “2” and rear brake lever “3” simul- taneously.
  • Page 200 ABS (ANTI-LOCK BRAKE SYSTEM) 1. Place the vehicle on a center stand. 7. Start the Yamaha diagnostic tool and display 2. Turn the main switch to “OFF”. the diagnosis mode screen. 3. Open the seat. 8. Select code No. 1, “ABS reaction-force con- 4.

  • Page 201: Checking The Abs Warning Light

    13.Turn the main switch to “OFF”. 14.Remove the Yamaha diagnostic tool from the Yamaha diagnostic tool coupler, and then in- stall the protective cap. 15.Turn the main switch to “ON”.
  • Page 202 HANDLEBAR EAS20033 HANDLEBAR Removing the rearview mirror and handlebar cover 22 Nm (2.2 m kgf, 16 ft Ibf) • • 22 Nm (2.2 m kgf, 16 ft Ibf) • • 1.8 Nm (0.18 m kgf, 1.3 ft Ibf) • • 1.8 Nm (0.18 m kgf, 1.3 ft Ibf)
  • Page 203 HANDLEBAR Removing the handlebar 2.5 Nm (0.25 m kgf, 1.8 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 11 Nm (1.1 m kgf, 8.0 ft Ibf) • • 21 Nm (2.1 m kgf, 15 ft Ibf) •...
  • Page 204 HANDLEBAR Removing the handlebar 2.5 Nm (0.25 m kgf, 1.8 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 11 Nm (1.1 m kgf, 8.0 ft Ibf) • • 21 Nm (2.1 m kgf, 15 ft Ibf) •...

  • Page 205: Handlebar

    HANDLEBAR EAS31622 REMOVING THE UPPER HANDLEBAR While holding the grip end, loosen the grip end COVER ASSEMBLY bolt. 1. Remove: • Upper handlebar cover assembly “1” 3. Remove: ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼...
  • Page 206 HANDLEBAR • The upper handlebar holders should be in- Rear brake master cylinder hold- stalled with the punch mark “b” facing forward. er bolt 11 Nm (1.1 m·kgf, 8.0 ft·lbf) • Install the brake master cylinder holder with the “UP” mark “a” facing up. •...
  • Page 207 HANDLEBAR Grip end bolt (left) Handlebar switch screw (right) 7 Nm (0.7 m·kgf, 5.1 ft·lbf) 2.3 Nm (0.23 m·kgf, 1.7 ft·lbf) Throttle cable holder bolt (han- dlebar switch side) 2.5 Nm (0.25 m·kgf, 1.8 ft·lbf) • Align the projection “a” on the grip end with the Grip end bolt (right) slot “b”...

  • Page 208: Assembling The Upper Handlebar Cover Assembly

    HANDLEBAR EAS31623 INSTALLING THE UPPER HANDLEBAR Front brake master cylinder hold- COVER ASSEMBLY er bolt 1. Install: 11 Nm (1.1 m·kgf, 8.0 ft·lbf) • Upper handlebar cover assembly “1” ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼...

  • Page 209: Front Fork

    FRONT FORK EAS20034 FRONT FORK Removing the front fork legs 53 Nm (5.3 m kgf, 38 ft Ibf) • • 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • Order Job/Parts to remove Q’ty...
  • Page 210 FRONT FORK Disassembling the front fork legs 23 Nm (2.3 m kgf, 17 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front fork legs. Front fork cap clip Front fork cap O-ring Fork spring Dust seal...

  • Page 211: 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 212: Checking The Front Fork Legs

    FRONT FORK EAS30209 ASSEMBLING THE FRONT FORK LEGS T-handle The following procedure applies to both of the 90890-01326 front fork legs. T-handle 3/8" drive 60 cm long YM-01326 EWA13660 WARNING • Make sure the oil levels in both front fork legs are equal.
  • Page 213 FRONT FORK 3. Lubricate: • Inner tube’s outer surface Recommended oil Fork oil 10W or equivalent 4. Install: • Inner tube (in the outer tube) 5. Install: • Copper washer 2. Install: • Front fork damper rod bolt “1” • Oil seal “1” (with the fork seal driver attachment “2”...
  • Page 214 FRONT FORK 7. Install: • Dust seal “1” (with the fork seal driver attachment “2” and fork seal driver weight “3”) Fork seal driver weight 90890-01367 Replacement hammer YM-A9409-7 Fork seal driver attachment (ø30) 90890-01400 10.Before measuring the fork oil level, wait ten minutes until the oil has settled and the air bubbles have dispersed.

  • Page 215: Installing The Front Fork Legs

    FRONT FORK EAS30210 INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Remove: • Front side cover • Refer to “GENERAL CHASSIS (2)” on page 4-4. 2. Install: • Front fork leg “1” Temporarily tighten the lower bracket pinch bolts.

  • Page 216: Steering Head

    STEERING HEAD EAS20035 STEERING HEAD Removing the lower bracket 63 Nm (6.3 m kgf, 46 ft Ibf) • • 75 Nm (7.5 m kgf, 54 ft Ibf) • • 1st 38 Nm (3.8 m kgf, 27 ft Ibf) • • 2nd 16 Nm (1.6 m kgf, 12 ft Ibf)
  • Page 217 STEERING HEAD Removing the lower bracket 63 Nm (6.3 m kgf, 46 ft Ibf) • • 75 Nm (7.5 m kgf, 54 ft Ibf) • • 1st 38 Nm (3.8 m kgf, 27 ft Ibf) • • 2nd 16 Nm (1.6 m kgf, 12 ft Ibf) •...

  • Page 218: Removing The Lower Bracket

    STEERING HEAD 3. Replace: EAS30213 REMOVING THE LOWER BRACKET • Bearings 1. Stand the vehicle on a level surface. • Bearing races EWA13120 ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼...
  • Page 219 STEERING HEAD 4. Install: • Horn bracket “1” • Apply lithium-soap-based grease to each part. • Horn “2” • Be sure to install the upper bearing so that the marks “a” on the bearing are facing upward. Horn bracket bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Horn bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
  • Page 220 STEERING HEAD 4-87...

  • Page 221: 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 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 57 Nm (5.7 m kgf, 41 ft Ibf) • •...
  • Page 222 REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM Removing the rear shock absorber assemblies and swingarm 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 57 Nm (5.7 m kgf, 41 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...

  • Page 223: Removing The Swingarm

    REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM 1. Check: EAS31228 REMOVING THE SWINGARM • Rear wheel sensor ECA22880 Refer to “MAINTENANCE OF THE FRONT NOTICE WHEEL SENSOR AND SENSOR ROTOR” Keep any type of magnets (including mag- on page 4-28. netic pick-up tools, magnetic screwdrivers, 2.
  • Page 224 REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM • Spacer “5” • Swingarm mounting bolt (lower side) “4” (to the swingarm “6”) (temporarily tighten) 4. Tighten: Bearing retaining plate bolt • Rear wheel axle nut “2” 7 Nm (0.7 m·kgf, 5.1 ft·lbf) •...
  • Page 225 REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM Distance “a” (between the wheel sensor rotor and swingarm (edge of the wheel sensor installation hole)) 18.92–19.60 mm (0.74–0.77 in) 7. Install: • Rear wheel sensor Rear wheel sensor bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) ECA22910 NOTICE Make sure there are no foreign materials in...
  • Page 226 REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM 4-93...

  • Page 227: Engine

    ENGINE ENGINE INSPECTION ..................5-1 MEASURING THE COMPRESSION PRESSURE ........5-1 ENGINE REMOVAL ..................5-3 INSTALLING THE ENGINE............... 5-7 CONNECTING THE LEADS ..............5-8 INSTALLING THE MUFFLER ..............5-8 CYLINDER HEAD.................... 5-9 REMOVING THE CYLINDER HEAD............5-13 CHECKING THE CYLINDER HEAD ............5-13 CHECKING THE CAMSHAFT SPROCKET ..........5-14 CHECKING THE TIMING CHAIN TENSIONER........5-14 CHECKING THE DECOMPRESSION SYSTEM........5-15...
  • Page 228 V-BELT AUTOMATIC TRANSMISSION ............5-34 REMOVING THE PRIMARY SHEAVE ............5-38 REMOVING THE SECONDARY SHEAVE ..........5-38 DISASSEMBLING THE SECONDARY SHEAVE........5-38 CHECKING THE CLUTCH HOUSING ............5-39 CHECKING THE CLUTCH SHOES ............5-39 CHECKING THE V-BELT ................5-39 CHECKING THE PRIMARY SHEAVE ............5-39 CHECKING THE PRIMARY SHEAVE WEIGHTS........5-40 CHECKING THE PRIMARY SHEAVE SLIDERS ........5-40 CHECKING THE SECONDARY SHEAVE ..........5-40 ASSEMBLING THE PRIMARY SHEAVE ..........5-40...
  • Page 229 CRANKSHAFT ....................5-60 DISASSEMBLING THE CRANKCASE............5-62 REMOVING THE CRANKSHAFT ASSEMBLY ........5-62 CHECKING THE CRANKSHAFT ASSEMBLY........5-62 CHECKING THE CRANKCASE ..............5-63 CHECKING THE BEARING ..............5-63 CHECKING THE OIL PUMP DRIVE GEAR ..........5-63 INSTALLING THE CRANKSHAFT ............5-63 ASSEMBLING THE CRANKCASE............5-64 INSTALLING THE CENTERSTAND ............5-64...

  • Page 230: Engine Inspection

    ENGINE INSPECTION 7. Measure: EAS20041 ENGINE INSPECTION • Compression pressure Out of specification → Refer to steps (c) and EAS30249 (d). MEASURING THE COMPRESSION PRESSURE Standard compression pressure (at sea level) Insufficient compression pressure will result in a 1800 kPa/860 r/min (18.0 loss of performance.
  • Page 231 ENGINE INSPECTION When tightening the spark plug, make sure that the inside “a” of the spark plug wrench “2” does not contact the portion “b” of the spark plug. 9. Connect: • Spark plug cap To route the spark plug lead, refer to “CON- NECTING THE LEADS”...

  • Page 232: Engine Removal

    ENGINE REMOVAL EAS20042 ENGINE REMOVAL Removing the muffler 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • 53 Nm (5.3 m kgf, 38 ft Ibf) • • 53 Nm (5.3 m kgf, 38 ft Ibf) • • 15 Nm (1.5 m kgf, 11 ft Ibf) •...
  • Page 233 ENGINE REMOVAL Disconnecting the leads 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Drain. Engine oil Refer to “CHANGING THE ENGINE OIL” on page 3-17. Drain. Coolant Refer to “CHANGING THE COOLANT” on page 3-19.
  • Page 234 ENGINE REMOVAL Disconnecting the leads 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Muffler Refer to “ENGINE REMOVAL” on page 5-3. Refer to “REAR SHOCK ABSORBER AS- Rear wheel sensor SEMBLIES AND SWINGARM” on page 4-88.
  • Page 235 ENGINE REMOVAL Removing the engine 21 Nm (2.1 m kgf, 15 ft Ibf) • • 16 Nm (1.6 m kgf, 12 ft Ibf) • • 68 Nm (6.8 m kgf, 49 ft Ibf) • • 21 Nm (2.1 m kgf, 15 ft Ibf) •...

  • Page 236: Installing The Engine

    ENGINE REMOVAL EAS30251 INSTALLING THE ENGINE 1. Install: • Collars “1” • Stopper “2” (to the engine “3”) 2. Install: • Spacer “4” • Dampers “5” (to the engine bracket “6”) ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼...

  • Page 237: Connecting The Leads

    ENGINE REMOVAL 2. Connect: • Spark plug cap “1” Route the spark plug lead between the VVA (variable valve actuator) solenoid “2” and the water pump inlet hose “3”. Make sure that the spark plug lead does not contact the VVA (vari- able valve actuator) solenoid or water pump inlet hose.

  • Page 238: Cylinder Head

    15 Nm (1.5 m kgf, 11 ft Ibf) 25 Nm (2.5 m kgf, 18 ft Ibf) • • • • Yamaha * Apply bond No.1215 (90890-85505). Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS (1)” on page Battery 4-1.
  • Page 239 11 ft Ibf) 25 Nm (2.5 m kgf, 18 ft Ibf) • • • • Yamaha * Apply bond No.1215 (90890-85505). Order Job/Parts to remove Q’ty Remarks Air filter case Refer to “AIR FILTER CASE” on page 7-7. Fuel injector Refer to “FUEL INJECTOR”...
  • Page 240 15 Nm (1.5 m kgf, 11 ft Ibf) 25 Nm (2.5 m kgf, 18 ft Ibf) • • • • Yamaha * Apply bond No.1215 (90890-85505). Order Job/Parts to remove Q’ty Remarks Coolant temperature sensor VVA (variable valve actuator) solenoid coupler Disconnect.
  • Page 241 11 ft Ibf) 25 Nm (2.5 m kgf, 18 ft Ibf) • • • • Yamaha * Apply bond No.1215 (90890-85505). Order Job/Parts to remove Q’ty Remarks Cylinder head cover breather plate Cylinder head cover breather plate gasket Oil seal...

  • Page 242: Removing The Cylinder Head

    CYLINDER HEAD 3. Remove: EAS30276 REMOVING THE CYLINDER HEAD • Cylinder head 1. Align: • “I” mark “a” on the AC magneto rotor • Loosen the bolts and nuts in the proper se- (with the match mark “b” on the right crank- quence as shown.

  • Page 243: Checking The Camshaft Sprocket

    CYLINDER HEAD ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Place a straightedge “1” and a thickness gauge “2” across the cylinder head. a. 1/4 tooth b. Correct 1. Timing chain roller 2.

  • Page 244: Checking The Decompression System

    CYLINDER HEAD e. Install the timing chain tensioner plug. • Tighten the cylinder head nuts and bolts in the proper tightening sequence as shown and ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲...
  • Page 245 Refer to the installation steps above. the tabs “a” on the gasket are protruding in the directions shown in the illustration. • 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 246 CYLINDER HEAD Install the oil seal so that it is facing in the direc- tion shown in the illustration. Press the oil seal into the cylinder head cover using a suitable di- ameter socket “3”. 6. Tighten: • Camshaft sprocket bolt “1” Camshaft sprocket bolt 30 Nm (3.0 m·kgf, 22 ft·lbf) 9.

  • Page 247: Camshaft

    CAMSHAFT EAS20043 CAMSHAFT Removing the rocker arms and camshaft 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks...

  • Page 248: Removing The Camshaft

    CAMSHAFT 2. Measure: EAS30256 REMOVING THE CAMSHAFT • Camshaft lobe dimensions “a” and “b” 1. Loosen: Out of specification → Replace the camshaft. • Adjusting screws (intake/exhaust) 2. Remove: Camshaft lobe dimensions • Camshaft assembly “1” Lobe height (Intake) 32.211–32.311 mm (1.2681– Slide hammer bolt 1.2721 in) 90890-01085...

  • Page 249: Checking The Rocker Arms And Rocker Arm Shafts

    CAMSHAFT 4. Check: 4. Measure: • Camshaft oil passage • Rocker arm shaft outside diameter “a” Obstruction → Blow out with compressed air. Out of specification → Replace. Rocker arm shaft outside diame- EAS30259 CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS 9.966–9.976 mm (0.3924–0.3928 The following procedure applies to all of the rocker arms and rocker arm shafts.
  • Page 250 CAMSHAFT b. While pushing intake rocker arm 1 “2” and in- Recommended lubricant take rocker arm 2 “3” in the direction of the ar- Camshaft row shown in the illustration, install the Molybdenum disulfide oil camshaft assembly. Camshaft bearing Engine oil Install the camshaft with the punch mark “a”...

  • Page 251: Valves And Valve Springs

    VALVES AND VALVE SPRINGS EAS20045 VALVES AND VALVE SPRINGS Removing the valves and valve springs Order Job/Parts to remove Q’ty Remarks Cylinder head Refer to “CYLINDER HEAD” on page 5-9. Camshaft/Rocker arms Refer to “CAMSHAFT” on page 5-18. Valve cotter Valve spring retainer Valve spring Intake valve...

  • Page 252: 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 253 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 remover ance (intake) “1”. 0.010–0.037 mm (0.0004–0.0015 Valve guide position Limit 9.9–10.3 mm (0.39–0.41 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 254: 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 255: Checking The Valve Springs

    VALVES AND VALVE SPRINGS j. Measure the valve seat width again. If the valve seat width is out of specification, reface and lap the valve seat. ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲...

  • Page 256: Installing The Valves

    VALVES AND VALVE SPRINGS • Valve stem seal “2” (with the recommended lubricant) Recommended lubricant Engine oil b. Installed length 3. Measure: • Valve spring tilt “a” Out of specification → Replace the valve spring. 5. Install: Spring tilt (intake) •...
  • Page 257 VALVES AND VALVE SPRINGS Install the valve cotters by compressing the valve spring with the valve spring compressor and the valve spring compressor attachment “2”. Valve spring compressor 90890-04019 Valve spring compressor YM-04019 Valve spring compressor attach- ment 90890-04108 Valve spring compressor adapt- er 22 mm YM-04108 7.

  • Page 258: Cylinder And Piston

    CYLINDER AND PISTON EAS20046 CYLINDER AND PISTON Removing the cylinder and piston 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Cylinder head Refer to “CYLINDER HEAD” on page 5-9. Timing chain guide (exhaust side) Cylinder Cylinder gasket Dowel pin...

  • Page 259: 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 260: Checking The Piston Rings

    CYLINDER AND PISTON EAS30292 CHECKING THE PISTON RINGS 1. Measure: • Piston ring side clearance Out of specification → Replace the piston and piston rings as a set. Before measuring the piston ring side clearance, eliminate any carbon deposits from the piston ring grooves and piston rings.

  • Page 261: Checking The Piston Pin

    CYLINDER AND PISTON Piston ring Top ring End gap (installed) 0.10–0.25 mm (0.0039–0.0098 Limit 0.50 mm (0.0197 in) 2nd ring End gap (installed) 0.35–0.50 mm (0.0138–0.0197 3. Measure: Limit • Piston pin bore diameter “b” Out of specification → Replace the piston. 0.85 mm (0.0335 in) Oil ring End gap (installed)
  • Page 262 CYLINDER AND PISTON • Upper oil ring rail “3” 3. Lubricate: • 2nd ring “4” • Piston • Top ring “5” • Piston rings • Cylinder (with the recommended lubricant) Be sure to install the piston rings so that the manufacturer marks face up.

  • Page 263: V-Belt Automatic Transmission

    V-BELT AUTOMATIC TRANSMISSION EAS20050 V-BELT AUTOMATIC TRANSMISSION Removing the V-belt case 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • (10) 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...
  • Page 264 V-BELT AUTOMATIC TRANSMISSION Removing the V-belt case 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • (10) 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks When removing the V-belt case gasket, cut...
  • Page 265 V-BELT AUTOMATIC TRANSMISSION Removing the V-belt, primary sheave and secondary sheave 45 Nm (4.5 m kgf, 33 ft Ibf) • • 49 Nm (4.9 m kgf, 35 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Primary fixed sheave nut Conical spring washer Washer Primary fixed sheave...
  • Page 266 V-BELT AUTOMATIC TRANSMISSION Disassembling the secondary sheave 55 Nm (5.5 m kgf, 40 ft Ibf) • • ® * Apply Shell dolium grease R Order Job/Parts to remove Q’ty Remarks Secondary sheave nut Clutch carrier assembly Compression spring Spring seat Guide pin Collar Secondary sliding sheave...

  • Page 267: Removing The Primary Sheave

    V-BELT AUTOMATIC TRANSMISSION EAS30310 ECA21820 REMOVING THE PRIMARY SHEAVE NOTICE 1. Remove: Do not remove the secondary sheave nut at • Primary fixed sheave nut “1” this stage. • Conical spring washer • Washer • Primary fixed sheave “2” While holding the secondary sheave with the ro- tor holding tool “2”, loosen the secondary sheave nut one full turn with the socket wrench While holding the primary fixed sheave with the...

  • Page 268: Checking The Clutch Housing

    V-BELT AUTOMATIC TRANSMISSION Clutch shoe thickness 4.0 mm (0.16 in) Limit 2.5 mm (0.10 in) EAS30313 CHECKING THE CLUTCH HOUSING 1. Check: • Clutch housing Damage/wear → Replace. 2. Measure: EAS30315 • Clutch housing inside diameter “a” CHECKING THE V-BELT Out of specification →...

  • Page 269: Checking The Primary Sheave Weights

    V-BELT AUTOMATIC TRANSMISSION EAS30317 CHECKING THE PRIMARY SHEAVE WEIGHTS The following procedure applies to all of the pri- mary sheave weights. 1. Check: • Primary sheave weight Cracks/damage/wear → Replace. 2. Measure: • Primary sheave weight outside diameter “a” Out of specification → Replace. 4.

  • Page 270: Installing The Primary Sheave, V-Belt And Secondary Sheave

    V-BELT AUTOMATIC TRANSMISSION • Compression spring • Clutch carrier assembly • Secondary sheave nut “1” • Install the sheave spring compressor “2” and sheave fixed block “3” onto the secondary sheave as shown. Then, compress the spring, and install the secondary sheave nut. •...
  • Page 271 V-BELT AUTOMATIC TRANSMISSION Secondary sheave nut When installing the primary sliding sheave as- 55 Nm (5.5 m·kgf, 40 ft·lbf) sembly, hold the cam to prevent the primary sheave weights from falling out of the primary sliding sheave. While holding the secondary sheave with the ro- tor holding tool “2”, tighten the secondary sheave nut with the socket wrench “3”.
  • Page 272 V-BELT AUTOMATIC TRANSMISSION • Install the conical spring washer with the mark “a” facing outward. • Install the V-belt in the primary sheave (when the pulley is at its widest position) and in the secondary sheave (when the pulley is at its narrowest position), and make sure the V-belt is tight.

  • Page 273: Starter Clutch

    7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • Yamaha *Apply bond No. 1215 (90890-85505). Order Job/Parts to remove Q’ty Remarks Cylinder head Refer to “CYLINDER HEAD” on page 5-9. Refer to “V-BELT AUTOMATIC TRANSMIS- Secondary sheave assembly SION”...
  • Page 274 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 11 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • Yamaha *Apply bond No. 1215 (90890-85505). Order Job/Parts to remove Q’ty Remarks Circlip Bearing Timing chain guide stopper Timing chain...

  • Page 275: Checking The Starter Wheel

    STARTER CLUTCH EAS31236 EAS31237 CHECKING THE STARTER WHEEL CHECKING THE TIMING CHAIN 1. Check: 1. Check: • Bearing • Timing chain Damage/wear → Replace. Damage/stiffness → Replace the timing 2. Check: chain and camshaft sprocket as a set. • Starter clutch idle gear •...

  • Page 276: Ac Magneto

    AC MAGNETO EAS20190 AC MAGNETO Removing the stator coil assembly 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) 80 Nm (8.0 m kgf, 58 ft Ibf) • • • • Order Job/Parts to remove Q’ty...
  • Page 277 AC MAGNETO Removing the stator coil assembly 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) 80 Nm (8.0 m kgf, 58 ft Ibf) • • • • Order Job/Parts to remove Q’ty Remarks AC magneto rotor...

  • Page 278: Removing The Ac Magneto

    AC MAGNETO EAS31239 REMOVING THE AC MAGNETO 1. Remove: • AC magneto rotor nut “1” • Washer While holding the AC magneto rotor “2” with the rotor holding tool “3”, loosen the AC magneto ro- tor nut. Rotor holding tool EAS31240 INSTALLING THE AC MAGNETO 90890-01235...

  • Page 279: Electric Starter

    ELECTRIC STARTER EAS20052 ELECTRIC STARTER Removing the starter motor 3.5 Nm (0.35 m kgf, 2.5 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS (4)” on page Flap 4-9.
  • Page 280 ELECTRIC STARTER Disassembling the starter motor 1.5 Nm (0.15 m kgf, 1.1 ft Ibf) • • 2.5 Nm (0.25 m kgf, 1.8 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Starter motor front cover Gasket Armature assembly Brush holder set Starter motor rear cover 5-51...

  • Page 281: Checking The Starter Motor

    ELECTRIC STARTER EAS30325 ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ CHECKING THE STARTER MOTOR a. Measure the armature assembly resistances 1. Check: with the digital circuit tester. • Commutator Dirt →...

  • Page 282: Assembling The Starter Motor

    ELECTRIC STARTER Brush spring force Starter motor sub-wire harness 3.92–5.88 N (400–600 gf, 14.11– bolt 21.17 oz) 3.5 Nm (0.35 m·kgf, 2.5 ft·lbf) Install the starter motor sub-wire harness to the starter motor so that the harness is parallel to the starter motor axis “a”.

  • Page 283: Oil Pump

    7.2 ft Ibf) • • 32 Nm (3.2 m kgf, 23 ft Ibf) • • Yamaha * Apply bond No. 1215 (90890-85505). Order Job/Parts to remove Q’ty Remarks Stator coil assembly Refer to “AC MAGNETO” on page 5-47. Oil strainer cover...
  • Page 284 OIL PUMP Disassembling the oil pump 1.0 Nm (0.10 m kgf, 0.72 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Oil pump housing cover Oil pump driven gear Oil pump rotor assembly Oil pump inner rotor Oil pump outer rotor Oil pump housing 5-55...

  • Page 285: Checking The Oil Strainer

    OIL PUMP EAS30340 CHECKING THE OIL STRAINER 1. Check: • Oil strainer Damage → Replace. Contaminants → Clean with solvent. EAS30337 CHECKING THE OIL PUMP 1. Check: • Oil pump drive gear • Oil pump driven gear EAS30342 • Oil pump housing ASSEMBLING THE OIL PUMP •...
  • Page 286 TRANSMISSION EAS20062 TRANSMISSION Removing the transmission 20 Nm (2.0 m kgf, 14 ft Ibf) • • 19 Nm (1.9 m kgf, 14 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Muffler Refer to “ENGINE REMOVAL” on page 5-3. Radiator cover Refer to “RADIATOR”...
  • Page 287 TRANSMISSION Removing the transmission 20 Nm (2.0 m kgf, 14 ft Ibf) • • 19 Nm (1.9 m kgf, 14 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Main axle assembly Primary driven gear Main axle Drive axle 1st wheel gear Circlip Primary drive gear...

  • Page 288: 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 3. Install: (each pinion gear to its respective wheel •...
  • Page 289 CRANKSHAFT EAS20061 CRANKSHAFT Removing the crankshaft 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 20 Nm (2.0 m kgf, 14 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Engine...
  • Page 290 CRANKSHAFT Removing the crankshaft 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 20 Nm (2.0 m kgf, 14 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Centerstand Crankcase (left) Dowel pin...

  • Page 291: Crankshaft

    CRANKSHAFT EAS31241 ECA20630 DISASSEMBLING THE CRANKCASE NOTICE 1. Remove: • To protect the end of the crankshaft, place • Crankcase bolts an appropriate sized socket between the crankcase separating tool bolt and the Loosen each bolt 1/4 of a turn at a time, in stag- crankshaft.

  • Page 292: Checking The Crankcase

    CRANKSHAFT EAS31244 CHECKING THE BEARING 1. Check: • Bearing Clean and lubricate the bearings, and then rotate the inner race with your finger. Rough movement → Replace. EAS31245 CHECKING THE OIL PUMP DRIVE GEAR 1. Check: • Oil pump drive gear 3.

  • Page 293: Assembling The Crankcase

    1. Thoroughly clean all the gasket mating sur- faces and crankcase mating surfaces. 2. Apply: • Sealant (onto the crankcase mating surfaces) Yamaha bond No. 1215 90890-85505 (Three bond No.1215®) Do not allow any sealant to come into contact with the oil gallery.
  • Page 294 CRANKSHAFT 5-65...

  • Page 295: Cooling System

    COOLING SYSTEM RADIATOR ...................... 6-1 CHECKING THE RADIATOR ..............6-3 INSTALLING THE RADIATOR ..............6-3 THERMOSTAT ....................6-5 CHECKING THE THERMOSTAT ASSEMBLY ......... 6-6 INSTALLING THE THERMOSTAT ASSEMBLY ........6-6 WATER PUMP....................6-7 DISASSEMBLING THE WATER PUMP............ 6-9 CHECKING THE WATER PUMP .............. 6-9 ASSEMBLING THE WATER PUMP............

  • Page 296: Radiator

    RADIATOR EAS20063 RADIATOR Removing the radiator 7 Nm (0.7 m kgf, 5.1 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...
  • Page 297 RADIATOR Removing the radiator 7 Nm (0.7 m kgf, 5.1 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...

  • Page 298: 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 seconds and make sure there is no drop in pressure.
  • Page 299 RADIATOR 3. Measure: • Radiator cap opening pressure Below the specified pressure → Replace the radiator cap. Refer to “CHECKING THE RADIATOR” on page 6-3. 4. Install: • Rear brake hose holder (front side) “1” Rear brake hose holder bolt (front side) 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Make sure that the projection “a”...
  • Page 300 THERMOSTAT EAS20065 THERMOSTAT Removing the thermostat assembly 9 Nm (0.9 m kgf, 6.5 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Drain. Coolant Refer to “CHANGING THE COOLANT” on page 3-19. Refer to “GENERAL CHASSIS (2)” on page Front side cover (right) 4-4.

  • Page 301: Thermostat

    T H E R M O S T A T 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) 74 – 78˚C 90˚C (165 –...

  • Page 302: Water Pump

    WATER PUMP EAS20066 WATER PUMP Removing the water pump 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Drain. Coolant Refer to “CHANGING THE COOLANT” on page 3-19. Refer to “GENERAL CHASSIS (2)” on page Front side cover (left) 4-4.
  • Page 303 WATER PUMP Disassembling the water pump 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Water pump housing cover Water pump housing gasket Circlip Impeller shaft Water pump seal...

  • Page 304: Disassembling The Water Pump

    WATER PUMP EAS30446 DISASSEMBLING THE WATER PUMP 1. Remove: • Water pump seal “1” Remove the water pump seal from the inside of the water pump housing “2”. A. Push down 3. Mechanical seal installer 4. Middle driven shaft bearing driver EAS30447 CHECKING THE WATER PUMP 1.
  • Page 305 WATER PUMP Water pump assembly bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) • Align the projection “a” on the impeller shaft with the slit “b” on the camshaft sprocket bolt. • Lubricate the O-ring with a thin coat of lithium- soap-based grease.
  • Page 306 WATER PUMP 6-11...

  • Page 307: Fuel System

    FUEL SYSTEM FUEL TANK..................... 7-1 REMOVING THE FUEL TANK ..............7-2 REMOVING THE FUEL PUMP ..............7-2 REMOVING THE FUEL FILTER ............... 7-2 CHECKING THE FUEL PUMP BODY............7-2 CHECKING THE FUEL FILTER ..............7-2 INSTALLING THE FUEL FILTER .............. 7-2 INSTALLING THE FUEL PUMP ..............

  • Page 308: Fuel Tank

    FUEL TANK EAS20067 FUEL TANK Removing the fuel tank 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 4.0 Nm (0.40 m kgf, 2.9 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS (2)” on page Front side covers 4-4.

  • Page 309: Removing The Fuel Tank

    FUEL TANK EAS30450 EAS31376 REMOVING THE FUEL TANK REMOVING THE FUEL FILTER 1. Extract the fuel in the fuel tank through the 1. Remove: fuel tank cap with a pump. • Fuel filter “1” 2. Disconnect: • Fuel sender coupler Remove the projections “a”...

  • Page 310: Installing The Fuel Pump

    FUEL TANK b. Install the fuel tank overflow tray and fuel tank EAS30456 INSTALLING THE FUEL PUMP cover “3”. To install the fuel tank cover, refer 1. Install: to “GENERAL CHASSIS (3)” on page 4-7. • Fuel pump gasket “1” c.
  • Page 311 FUEL TANK • Footrest board assembly (right) Refer to “INSTALLING THE FUEL TANK” on Refer to “GENERAL CHASSIS (5)” on page page 7-3. 4-12. ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲...

  • Page 312: Fuel Injector

    FUEL INJECTOR EAS20191 FUEL INJECTOR Removing the fuel injector 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS (1)” on page Battery 4-1. Refer to “GENERAL CHASSIS (2)” on page Front side covers 4-4.

  • Page 313: Removing The Fuel Hose

    FUEL INJECTOR EAS31250 REMOVING THE FUEL HOSE Fuel injector bolt 1. Disconnect: 10 Nm (1.0 m·kgf, 7.2 ft·lbf) • Fuel hose EWA17610 WARNING • Lubricate the O-ring with engine oil. Cover fuel hose connections with a cloth • Align the projection “a” on the fuel injector when disconnecting them.

  • Page 314: Air Filter Case

    AIR FILTER CASE EAS20068 AIR FILTER CASE Removing the air filter case 1.2 Nm (0.12 m kgf, 0.87 ft Ibf) • • 3.0 Nm (0.30 m kgf, 2.2 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) 1.2 Nm (0.12 m kgf, 0.87 ft Ibf) •...
  • Page 315 AIR FILTER CASE Removing the air filter case 1.2 Nm (0.12 m kgf, 0.87 ft Ibf) • • 3.0 Nm (0.30 m kgf, 2.2 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) 1.2 Nm (0.12 m kgf, 0.87 ft Ibf) •...

  • Page 316: Installing The Air Filter Case

    AIR FILTER CASE EAS31618 INSTALLING THE AIR FILTER CASE 1. Install: • Hose “1” (to the air filter case joint “2”) • Clamp “3” • Apply Three bond 1521 “4” onto the mating surfaces of the hose and air filter case joint. •...

  • Page 317: Throttle Body

    THROTTLE BODY EAS20070 THROTTLE BODY Removing the throttle body 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • 3.0 Nm (0.30 m kgf, 2.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...
  • Page 318 THROTTLE BODY Removing the throttle body 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • 3.0 Nm (0.30 m kgf, 2.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...

  • Page 319: Removing The Throttle Body

    THROTTLE BODY 2. Remove: EAS30979 REMOVING THE THROTTLE BODY • Screw “1” 1. Remove: • ISC (Idle Speed Control) unit holder “2” • Throttle body • ISC (Idle Speed Control) unit “3” ECA20500 ECA21780 NOTICE NOTICE Do not remove the throttle body sensor as- Because the force of the spring may push sembly from the throttle body.
  • Page 320 • Do not allow water to enter the ISC unit and do not allow foreign materials to adhere to Recommended cleaning agent the assembly. Yamaha oil & brake cleaner • Do not touch the terminals of the coupler directly. ECA21790 •...

  • Page 321: Replacing The Throttle Body

    THROTTLE BODY Yamaha diagnostic tool 90890-03231 12.Place the vehicle on the centerstand so that the rear wheel is elevated. 13.Check: • Engine idling speed Start the engine, warm it up, and then mea- sure the engine idling speed. Within specifi- cation →...
  • Page 322 THROTTLE BODY • Align the projection “a” on the throttle body with the slot “b” in the intake manifold. • Align the projection “c” on the intake manifold “1” with slot “d” in the intake manifold clamp “2”. 7-15...

  • Page 323: Electrical System

    TROUBLESHOOTING ................8-17 SIGNALING SYSTEM ...................8-19 CIRCUIT DIAGRAM ................8-19 TROUBLESHOOTING ................8-21 FUEL INJECTION SYSTEM................8-25 CIRCUIT DIAGRAM ................8-25 ECU SELF-DIAGNOSTIC FUNCTION ............8-27 TROUBLESHOOTING METHOD ............8-27 YAMAHA DIAGNOSTIC TOOL ...............8-28 TROUBLESHOOTING DETAILS ............8-31 FUEL PUMP SYSTEM...................8-57 CIRCUIT DIAGRAM ................8-57 TROUBLESHOOTING ................8-59...
  • Page 324 ABS (ANTI-LOCK BRAKE SYSTEM)............8-61 CIRCUIT DIAGRAM ................8-61 ABS COUPLER LOCATION CHART ............8-63 MAINTENANCE OF THE ABS ECU ............8-65 ABS TROUBLESHOOTING OUTLINE............8-65 BASIC INSTRUCTIONS FOR TROUBLESHOOTING ......8-66 BASIC PROCESS FOR TROUBLESHOOTING ........8-67 [A] CHECKING THE ABS WARNING LIGHT ..........8-68 [A-1] ONLY THE ABS WARNING LIGHT FAILS TO COME ON.....8-68 [A-2] ALL INDICATOR LIGHTS FAIL TO COME ON ......8-68 [A-3] THE ABS WARNING LIGHT COMES ON ........8-68 [A-4] ONLY THE ABS ECU FAILS TO COMMUNICATE...

  • Page 326: Ignition System

    IGNITION SYSTEM EAS20072 IGNITION SYSTEM EAS30490 CIRCUIT DIAGRAM...
  • Page 327 IGNITION SYSTEM 1. Crankshaft position sensor 3. Main fuse 1 10.Main switch 12.Battery 18.Sidestand switch 29.ECU (Engine Control Unit) 30.Ignition coil 31.Spark plug 52.Engine ground 53.Frame ground...

  • Page 328: 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 2. Front side covers 3. Fuel tank cover 4. Storage box 5. Footrest board assemblies 6.
  • Page 329 IGNITION SYSTEM NG → 8. Check the main switch. Refer to “CHECKING THE Replace the main switch. SWITCHES” on page 8-95. OK ↓ NG → 9. Check the sidestand switch. Refer to “CHECKING THE Replace the sidestand switch. SWITCHES” on page 8-95. OK ↓...

  • Page 330: Electric Starting System

    ELECTRIC STARTING SYSTEM EAS20073 ELECTRIC STARTING SYSTEM EAS30493 CIRCUIT DIAGRAM...
  • Page 331 ELECTRIC STARTING SYSTEM 3. Main fuse 1 7. Signaling system fuse 10.Main switch 12.Battery 13.Starter relay 14.Starter motor 15.Handlebar switch (right) 16.Start switch 17.Diode 18.Sidestand switch 39.Rear brake light switch 40.Front brake light switch 53.Frame ground A. Wire harness B. Starter motor sub-wire harness...

  • Page 332: 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 start switch “ ” is pushed, the starter motor can only oper- ate if at least one of the following conditions is met: •...

  • Page 333: Troubleshooting

    ELECTRIC STARTING SYSTEM EAS30495 TROUBLESHOOTING The starter motor fails to turn. • Before troubleshooting, remove the following part(s): 1. Battery cover 2. Front side covers 3. Fuel tank cover 4. Storage box 5. Footrest board assemblies 6. Front cowling assembly NG →...
  • Page 334 ELECTRIC STARTING SYSTEM NG → 8. Check the sidestand switch. Refer to “CHECKING THE Replace the sidestand switch. SWITCHES” on page 8-95. OK ↓ NG → 9. Check the start switch. The start switch is faulty. Replace the right Refer to “CHECKING THE handlebar switch.
  • Page 335 ELECTRIC STARTING SYSTEM 8-10...

  • Page 336: Charging System

    CHARGING SYSTEM EAS20074 CHARGING SYSTEM EAS30496 CIRCUIT DIAGRAM 8-11...
  • Page 337 CHARGING SYSTEM 2. AC magneto 3. Main fuse 1 9. Rectifier/regulator 12.Battery 53.Frame ground 8-12...

  • Page 338: Troubleshooting

    CHARGING SYSTEM EAS30497 TROUBLESHOOTING The battery is not being charged. • Before troubleshooting, remove the following part(s): 1. Battery cover 2. Front side covers 3. Footrest board assemblies 4. Front upper cowling assembly NG → 1. Check the fuse. (Main 1) Replace the fuse.
  • Page 339 CHARGING SYSTEM 8-14...

  • Page 340: Lighting System

    LIGHTING SYSTEM EAS20075 LIGHTING SYSTEM EAS30498 CIRCUIT DIAGRAM 8-15...
  • Page 341 LIGHTING SYSTEM 3. Main fuse 1 6. Taillight fuse 10.Main switch 12.Battery 29.ECU (Engine Control Unit) 43.Handlebar switch (left) 44.Dimmer switch 47.Tail/brake light assembly 49.Taillight 52.Engine ground 53.Frame ground 56.Headlight unit 57.Auxiliary light 58.Headlight 59.Meter assembly 60.Multi-function meter 64.Meter light 67.High beam indicator light 8-16...

  • Page 342: Troubleshooting

    LIGHTING SYSTEM EAS30499 TROUBLESHOOTING Any of the following fail to light: headlight, high beam indicator light, taillight, auxiliary lights or meter light. • Before troubleshooting, remove the following part(s): 1. Battery cover 2. Front side covers 3. Footrest board assembly 4.
  • Page 343 LIGHTING SYSTEM 8-18...

  • Page 344: Signaling System

    SIGNALING SYSTEM EAS20076 SIGNALING SYSTEM EAS30500 CIRCUIT DIAGRAM 8-19...
  • Page 345 6. Taillight fuse 7. Signaling system fuse 8. ABS control unit fuse 10.Main switch 12.Battery 19.Fuel sender 21.Yamaha diagnostic tool coupler 22.Coolant temperature sensor 29.ECU (Engine Control Unit) 34.Front wheel sensor 38.ABS ECU 39.Rear brake light switch 40.Front brake light switch 41.Turn signal relay...

  • Page 346: Troubleshooting

    SIGNALING SYSTEM EAS30501 TROUBLESHOOTING • Any of the following fail to light: turn signal lights, brake light, warning lights or indicator lights. • The horn fails to sound. • The fuel meter fails to come on. • The speedometer fails to operate. •...
  • Page 347 SIGNALING SYSTEM NG → 2. Check the entire signaling system wiring. Properly connect or replace the wire har- Refer to “CIRCUIT DIAGRAM” on ness. page 8-19. OK ↓ Replace the horn. The brake light fails to come on. NG → 1.
  • Page 348 SIGNALING SYSTEM NG → 4. Check the entire signaling system wiring. Properly connect or replace the wire har- Refer to “CIRCUIT DIAGRAM” on ness. page 8-19. OK ↓ Replace the meter assembly. The coolant temperature warning light fails to come on. NG →...
  • Page 349 SIGNALING SYSTEM NG → 2. Check the entire wiring. Properly connect or replace the wiring har- Refer to TIP. ness. OK ↓ Replace the ECU, ABS ECU, or meter assembly. Refer to “REPLACING THE ECU (engine control unit)” on page 8-99.

  • Page 350: Fuel Injection System

    FUEL INJECTION SYSTEM EAS20078 FUEL INJECTION SYSTEM EAS30504 CIRCUIT DIAGRAM 8-25...
  • Page 351 6. Taillight fuse 8. ABS control unit fuse 10.Main switch 12.Battery 18.Sidestand switch 20.Fuel pump 21.Yamaha diagnostic tool coupler 22.Coolant temperature sensor 23.Throttle body sensor assembly 24.Intake air pressure sensor 25.Intake air temperature sensor 26.Throttle position sensor 27.ISC (Idle Speed Control) unit 28.Fuel injector...

  • Page 352: Ecu Self-Diagnostic Function

    FUEL INJECTION SYSTEM EAS30505 ECU SELF-DIAGNOSTIC FUNCTION The ECU is equipped with a self-diagnostic function in order to ensure that the fuel injection system is operating normally. If this function detects a malfunction in the system, it immediately operates the en- gine under substitute characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the system.

  • Page 353: 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 90890-03231 Features of the Yamaha diagnostic tool You can use the Yamaha diagnostic tool to identify malfunctions quicker than with conventional meth- ods.
  • Page 354 Disconnect the Yamaha diagnostic tool coupler “1”, and then connect the Yamaha diagnostic tool “2” to the coupler. When the Yamaha diagnostic tool is connected to the vehicle, “Er-1” or “Er-4” will be displayed on the multi-function meter. Operation of the Yamaha diagnostic tool (Malfunction mode) Malfunction results are displayed in the top part of the window area.
  • Page 355 FUEL INJECTION SYSTEM 1. Recovered The item list of the malfunction detected in the past (already recovered) are displayed. 2. Detected The item list of the malfunction currently occurred are displayed. 3. Code The following icons and the fault code numbers for the detected malfunctions are displayed. A.

  • Page 356: Troubleshooting Details

    FUEL INJECTION SYSTEM 6. Condition The current conditions are displayed. (Detected/Recovered) 7. Symptom The symptoms of the detected malfunction are displayed. 8. Diagnosis code The diagnosis codes related to the detected malfunction are displayed. 9. FFD (only for models that can display freeze frame data) The mark “...
  • Page 357 FUEL INJECTION SYSTEM Fault code No. Crankshaft position sensor: no normal signals are received from the Item crankshaft position sensor. Improperly connected → Con- Connection of ECU coupler. Crank the engine. Check the locking condition of nect the coupler securely or re- Fault code number is not dis- played →...
  • Page 358 FUEL INJECTION SYSTEM Fault code No. Item Intake air pressure sensor: open or short circuit detected. Probable cause of malfunc- Confirmation of service com- Item Maintenance job tion and check pletion Improperly connected → Con- Connection of throttle body sen- Turn the main switch to “ON”.
  • Page 359 FUEL INJECTION SYSTEM Fault code No. Item Intake air pressure sensor: open or short circuit detected. Defective intake air pressure Execute the diagnostic mode. Turn the main switch to “ON”. sensor. (Code No. 03) Fault code number is not dis- played →...
  • Page 360 FUEL INJECTION SYSTEM Fault code No. Intake air pressure sensor: system malfunction (clogged hole or de- Item tached). Installed condition of throttle po- Check the mounting section for Start the engine and let it idle for sition sensor assembly. loose or pinched mounting. approximately 5 seconds.
  • Page 361 FUEL INJECTION SYSTEM Fault code No. Item Throttle position sensor: open or short circuit detected. Improperly connected → Con- Connection of throttle body sen- Turn the main switch to “ON”. sor assembly coupler. nect the coupler securely or re- Fault code number is not dis- played →...
  • Page 362 FUEL INJECTION SYSTEM Fault code No. Item Throttle position sensor: stuck throttle position sensor is detected. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. Throttle position sensor signal Tool display • 13–21 (fully closed position) •...
  • Page 363 FUEL INJECTION SYSTEM Fault code No. Sidestand switch: a break or disconnection of the Blue/Yellow lead Item of the ECU is detected. Improperly connected → Con- Connection of sidestand switch Turn the main switch to “ON” coupler. nect the coupler securely or re- and then extend and retract the Check the locking condition of place the wire harness.
  • Page 364 FUEL INJECTION SYSTEM Fault code No. Item Coolant temperature sensor: open or short circuit detected. Improperly connected → Con- Connection of coolant tempera- Turn the main switch to “ON”. ture sensor coupler. nect the coupler securely or re- Fault code number is not dis- played →...
  • Page 365 FUEL INJECTION SYSTEM Fault code No. Item Intake air temperature sensor: open or short circuit detected. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. Tool display Displays the intake air temperature. When engine is cold: Displays temperature closer to air temperature Procedure When engine is hot: Air temperature + approx.
  • Page 366 FUEL INJECTION SYSTEM Fault code No. 24 Fault code No. sensor: no normal signals are received from the O sensor. Item Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. — Tool display — Procedure — Probable cause of malfunc- Confirmation of service com- Item...
  • Page 367 Fully closes the ISC valve, and then opens the valve. This operation Actuation takes approximately 3 seconds. The “CHECK” indicator and “ ” on the Yamaha diagnostic tool screen comes on during the operation. Procedure The ISC unit vibrates when the ISC valve operates. Probable cause of malfunc-...
  • Page 368 Fully closes the ISC valve, and then opens the valve. This operation Actuation takes approximately 3 seconds. The “CHECK” indicator and “ ” on the Yamaha diagnostic tool screen comes on during the operation. Procedure The ISC unit vibrates when the ISC valve operates. Probable cause of malfunc-...
  • Page 369 FUEL INJECTION SYSTEM Fault code No. Component other than ISC (idle speed control) unit is defec- tive (ISC operating sound is heard). Item Defective ISC (idle speed control) unit (ISC operating sound is not heard). ISC operating sound is heard → Locate the malfunction.
  • Page 370 Actuates fuel injector five times at one-second intervals. Actuation The “CHECK” indicator and “ ” 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 371 FUEL INJECTION SYSTEM Fault code No. Item Fuel injector: open or short circuit detected. Open or short circuit → Replace Wire harness continuity. Execute the diagnostic mode. the wire harness. (Code No. 36) Operating sound → Go to item Between fuel injector coupler and ECU coupler.
  • Page 372 FUEL INJECTION SYSTEM Fault code No. Front wheel sensor: no normal signals are received from the front Item wheel sensor. Improperly connected → Con- Connection of ECU coupler. Execute the diagnostic mode. Check the locking condition of nect the coupler securely or re- (Code No.
  • Page 373 FUEL INJECTION SYSTEM Fault code No. EEPROM fault code number: an error is detected while reading or Item writing on EEPROM. Probable cause of malfunc- Confirmation of service com- Item Maintenance job tion and check pletion Locate the malfunction Execute the diagnostic mode. (Code No.
  • Page 374 FUEL INJECTION SYSTEM Fault code No. Faulty ECU memory. (When this malfunction is detected in the ECU, Item the fault code number might not appear on the tool display.) Probable cause of malfunc- Confirmation of service com- Item Maintenance job tion and check pletion Malfunction in ECU.
  • Page 375 Diagnostic code No. Actuates the VVA (variable valve actuator) solenoid five times at three- second intervals. The “CHECK” indicator and “ ” on the Yamaha diag- Action nostic tool screen come on each time the VVA (variable valve actuator) solenoid is actuated.
  • Page 376 Turn the main switch to “ON”. the wire harness. Fault code number is not dis- played → Service is finished. Between ECU coupler and Yamaha diagnostic tool coupler. Fault code number is displayed → Go to item 4. Yellow/Blue–Yellow/Blue Between Yamaha diagnostic tool coupler and meter assem- bly coupler.
  • Page 377 Turn the main switch to “ON”. the wire harness. Fault code number is not dis- played → Service is finished. Between ECU coupler and Yamaha diagnostic tool coupler. Fault code number is displayed → Go to item 4. Yellow/Blue–Yellow/Blue Between Yamaha diagnostic tool coupler and meter assem- bly coupler.
  • Page 378 Turn the main switch to “ON”. the wire harness. Fault code number is not dis- played → Service is finished. Between ECU coupler and Yamaha diagnostic tool coupler. Fault code number is displayed → Go to item 4. Yellow/Blue–Yellow/Blue Between Yamaha diagnostic tool coupler and meter assem- bly coupler.
  • Page 379 Turn the main switch to “ON”. the wire harness. Fault code number is not dis- played → Service is finished. Between ECU coupler and Yamaha diagnostic tool coupler. Fault code number is displayed → Go to item 4. Yellow/Blue–Yellow/Blue Between Yamaha diagnostic tool coupler and meter assem- bly coupler.
  • Page 380 FUEL INJECTION SYSTEM Fault code No. Er-4 (fault code display) ECU (engine control unit) internal malfunction (input signal error): Item non-registered data has been received from the meter. Defective meter assembly. Replace the meter assembly. Turn the main switch to “ON”. Fault code number is not dis- played →...
  • Page 381 FUEL INJECTION SYSTEM 8-56...

  • Page 382: Fuel Pump System

    FUEL PUMP SYSTEM EAS20081 FUEL PUMP SYSTEM EAS30513 CIRCUIT DIAGRAM 8-57...
  • Page 383 FUEL PUMP SYSTEM 3. Main fuse 1 5. Main fuse 2 10.Main switch 12.Battery 20.Fuel pump 29.ECU (Engine Control Unit) 52.Engine ground 53.Frame ground 8-58...

  • Page 384: Troubleshooting

    FUEL PUMP SYSTEM EAS30514 TROUBLESHOOTING If the fuel pump fails to operate. • Before troubleshooting, remove the following part(s): 1. Battery cover 2. Front side covers 3. Footrest board assemblies 4. Fuel tank NG → 1. Check the fuses. (Main 1 and main 2) Replace the fuse(s).
  • Page 385 FUEL PUMP SYSTEM 8-60...

  • Page 386: Abs (Anti-Lock Brake System)

    ABS (ANTI-LOCK BRAKE SYSTEM) EAS20085 ABS (ANTI-LOCK BRAKE SYSTEM) EAS30843 CIRCUIT DIAGRAM 8-61...
  • Page 387 4. ABS solenoid fuse 6. Taillight fuse 7. Signaling system fuse 8. ABS control unit fuse 10.Main switch 11.ABS motor fuse 12.Battery 21.Yamaha diagnostic tool coupler 29.ECU (Engine Control Unit) 34.Front wheel sensor 35.Rear wheel sensor 36.Joint connector 37.ABS test coupler 38.ABS ECU 39.Rear brake light switch...

  • Page 388: Abs Coupler Location Chart

    ABS (ANTI-LOCK BRAKE SYSTEM) EAS30844 ABS COUPLER LOCATION CHART L Br Br/W L/R L/B Br Y Ch Dg Y/B Y/B (Gy) 8-63...
  • Page 389 ABS (ANTI-LOCK BRAKE SYSTEM) 1. ABS ECU coupler 2. Rear wheel sensor coupler 3. ABS test coupler 4. Meter assembly coupler 5. Front wheel sensor coupler 8-64...

  • Page 390: Maintenance Of The Abs Ecu

    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 8-69. For troubleshooting items other than the following items, follow the normal service method.

  • Page 391: Basic Instructions For Troubleshooting

    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 392: Basic Process For Troubleshooting

    The taillight 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 The ABS control unit fuse is blown.

  • Page 393: [A] Checking The Abs Warning Light

    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 394: [A-4] Only The Abs Ecu Fails To Communicate (The Select Unit Screen Does Not Appear.)

    ABS test coupler. (CANL) EAS31165 [B-1] MALFUNCTION ARE CURRENTLY DETECTED When the Yamaha diagnostic tool is connected to the ABS test coupler, the fault codes will be displayed on the computer screen. • A fault code is displayed. [B-2] •...
  • Page 395 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. Operation of the Yamaha diagnostic tool (Fault diagnosis mode) Malfunction results are displayed in the top part of the window area.
  • Page 396 ABS (ANTI-LOCK BRAKE SYSTEM) A. Detected malfunction B. Recovered malfunction 4. ECU The types of the control units are displayed. (e.g., FI, ABS) 5. Item The item names of the detected malfunction are displayed. 6. Condition The current conditions are displayed. (Detected/Recovered) 7.
  • Page 397 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Item Symptom Check point Front wheel sensor (abnor- Front wheel sensor signal is • Foreign material adhered mal pulse period) not received properly. (The around the front wheel sen- pulse period is abnormal while the vehicle is traveling.) •...
  • Page 398 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Item Symptom Check point Rear wheel sensor (missing Rear wheel sensor signal is • Foreign material adhered pulses) not received properly. (Miss- around the rear wheel sen- ing pulses are detected in the signal while the vehicle is •...
  • Page 399 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Item Symptom Check point Front wheel ABS (intermit- • Pulses from the front wheel • Incorrect installation of the tent wheel speed pulses or sensor are received inter- front wheel sensor incorrect depressurization) mittently while the vehicle •...
  • Page 400 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Item Symptom Check point Vehicle system power supply Power voltage supplied to • Defective battery (voltage of ABS ECU power the ABS ECU in the hydrau- • Defective coupler between supply is low) lic unit assembly is too low.
  • Page 401 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Item Front wheel sensor (intermittent pulses or no pulses) Front wheel sensor signal is not received properly. (Pulses are not re- Symptom ceived or are received intermittently while the vehicle is traveling.) Order Item/components and probable cause Check or maintenance job Foreign material adhered around the front Check the surface of the sensor rotor and wheel sensor...
  • Page 402 ABS (ANTI-LOCK BRAKE SYSTEM) • Vehicle possibly ridden on uneven roads. Fault code No. Item Front wheel sensor (abnormal pulse period) Front wheel sensor signal is not received properly. (The pulse period Symptom is abnormal while the vehicle is traveling.) Order Item/components and probable cause Check or maintenance job Foreign material adhered around the front...
  • Page 403 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Item Rear wheel sensor (abnormal pulse period) Rear wheel sensor signal is not received properly. (The pulse period Symptom is abnormal while the vehicle is traveling.) Order Item/components and probable cause Check or maintenance job Defective rear wheel sensor or incorrect Check the wheel sensor for damage and the installed installation of the sensor...
  • Page 404 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 405 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 406 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Item Front wheel sensor (missing pulses) Front wheel sensor signal is not received properly. (Missing pulses Symptom are detected in the signal while the vehicle is traveling.) Order Item/components and probable cause Check or maintenance job Foreign material adhered around the front Check the surface of the sensor rotor and wheel sensor wheel sensor...
  • Page 407 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. 21 Fault code No. Item Hydraulic unit assembly (defective solenoid drive circuit) Solenoid drive circuit in the hydraulic unit assembly is open or short- Symptom circuited. Order Item/components and probable cause Check or maintenance job Defective hydraulic unit assembly Replace the hydraulic unit assembly.
  • Page 408 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Item Hydraulic unit assembly (abnormal ABS solenoid power supply) Power is not supplied to the solenoid circuit in the hydraulic unit as- Symptom sembly. Order Item/components and probable cause Check or maintenance job Defective coupler between the battery •...
  • Page 409 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 Open or short circuit in the wire harness •...
  • Page 410 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 411 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. 43 Fault code No. Item Front wheel sensor (missing pulses) Front wheel sensor signal is not received properly. (Missing pulses Symptom are detected in the signal while the vehicle is traveling.) Order Item/components and probable cause Check or maintenance job Foreign material adhered around the front Check the surface of the sensor rotor and wheel sensor...
  • Page 412 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. 51, 52 Fault code No. • Vehicle system power supply (voltage of ABS ECU power supply is high) (for fault code No. 51) Item • Vehicle system power supply (voltage of wheel sensor power supply is high) (for fault code No.
  • Page 413 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 battery Recharge or replace the battery.
  • Page 414 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 415: [B-3] Deleting The Fault Codes

    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: [C-1] Final Check

    ABS (ANTI-LOCK BRAKE SYSTEM) Connecting the Yamaha diagnostic tool Remove the protective cap “1”, and then connect the Yamaha diagnostic tool to the coupler. EAS31168 [C-1] FINAL CHECK Check all the following items to complete the inspection. If the process is not completed properly, start again from the beginning.
  • Page 417 ABS (ANTI-LOCK BRAKE SYSTEM) 8-92...

  • Page 418: Electrical Components

    ELECTRICAL COMPONENTS EAS20089 ELECTRICAL COMPONENTS 27,28,29,30 8-93...
  • Page 419 ELECTRICAL COMPONENTS 1. Starter relay 2. Battery 3. ECU (Engine Control Unit) 4. Fuse box 1 5. Front brake light switch 6. Rear brake light switch 7. Fuse box 2 8. Main switch 9. Turn signal relay 10. Rectifier/regulator 11. ABS ECU 12.

  • Page 420: Checking The Switches

    ELECTRICAL COMPONENTS EAS30549 CHECKING THE SWITCHES R Br Y L/B Br/W Br/W L/B P L/W B 8-95...
  • Page 421 ELECTRICAL COMPONENTS 1. Rear brake light switch 2. Main switch 3. Front brake light switch 4. Start switch 5. Sidestand switch 6. Turn signal switch 7. Horn switch 8. Dimmer switch 8-96...
  • Page 422 ELECTRICAL COMPONENTS Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. ECA14371 NOTICE Never insert the tester probes into the coupler terminal slots. Always insert the probes from the opposite end “a”...

  • Page 423: Checking The Bulbs And Bulb Sockets

    ELECTRICAL COMPONENTS EAS30550 CHECKING THE BULBS AND BULB Pocket tester SOCKETS 90890-03112 Analog pocket tester YU-03112-C Do not check any of the lights that use LEDs. Check each bulb and bulb socket for damage or wear, proper connections, and also for continuity Before checking for continuity, set the pocket between the terminals.

  • Page 424: Checking The Fuses

    ELECTRICAL COMPONENTS c. Check the bulb socket for continuity. If any of Amperage Fuses Q’ty the readings indicate no continuity, replace rating the bulb socket. ABS control unit 7.5 A ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲...
  • Page 425 ELECTRICAL COMPONENTS • DO NOT SMOKE when charging or han- ECA13640 NOTICE dling batteries. First, disconnect the negative battery lead • KEEP BATTERIES AND ELECTROLYTE “1”, and then positive battery lead “2”. OUT OF REACH OF CHILDREN. • Avoid bodily contact with electrolyte as it can cause severe burns or permanent eye injury.
  • Page 426 ELECTRICAL COMPONENTS • If the battery becomes hot to the touch at C. Relationship between the open-circuit voltage and the charging time at 20 °C (68 °F) any time during the charging process, dis- D. These values vary with the temperature, the connect the battery charger and let the bat- condition of the battery plates, and the tery cool before reconnecting it.

  • Page 427: Checking The Relays

    ELECTRICAL COMPONENTS • Standard charging current is reached 12.8 V or more --- Charging is complete. Battery is good. 12.7 V or less --- Recharging is required. • Standard charging current is not reached Under 12.0 V --- Replace the battery. Replace the battery.

  • Page 428: Checking The Turn Signal Relay

    E L E C T R I C A L C O M P O N E N T S Starter relay b. Turn the main switch to “ON”. c. Measure the turn signal relay input voltage. ▲ ▲▲▲ ▲ ▲▲▲ ▲...

  • Page 429: Checking The Spark Plug Cap

    ELECTRICAL COMPONENTS Continuity Positive tester probe → Blue/Yellow “1” Negative tester probe → Blue/White “2” No continuity Positive tester probe → Blue/White “2” Negative tester probe → Blue/Yellow “1” c. Measure the spark plug cap resistance. ▲ ▲▲▲ ▲ ▲▲▲ ▲...

  • Page 430: Checking The Ignition Spark Gap

    ELECTRICAL COMPONENTS ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect the pocket tester (Ω × 1k) to the ig- nition coil as shown. Pocket tester 90890-03112 Analog pocket tester YU-03112-C •...

  • Page 431: Checking The Starter Motor Operation

    ELECTRICAL COMPONENTS 2. Check: • Stator coil resistance Out of specification → Replace the stator coil. Stator coil resistance 0.500–0.740 Ω ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect the digital circuit tester to the stator coil coupler as shown.

  • Page 432: Checking The Fuel Sender

    ELECTRICAL COMPONENTS • Positive tester probe → positive battery terminal “1” • Negative tester probe → negative battery terminal “2” b. Move the fuel sender float to minimum “3” and maximum “4” level position. c. Start the engine and let it run at approximate- ly 5000 r/min.

  • Page 433: Checking The Coolant Temperature Sensor

    ELECTRICAL COMPONENTS EAS30578 CHECKING THE COOLANT TEMPERATURE SENSOR 1. Remove: • Coolant temperature sensor Refer to “CYLINDER HEAD” on page 5-9. EWA14130 WARNING • Handle the coolant temperature sensor with special care. • Never subject the coolant temperature sen- sor to strong shocks. If the coolant temper- ature sensor is dropped, replace it.

  • Page 434: Checking The Vva Solenoid

    ELECTRICAL COMPONENTS • Positive tester probe Injector terminal “1” • Negative tester probe Injector terminal “2” c. Measure the fuel injector resistance. ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ EAS31612 CHECKING THE VVA SOLENOID 1.

  • Page 435: Troubleshooting

    FAULTY LIGHTING OR SIGNALING SYSTEM ........9-3 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE.... 9-5 SELF-DIAGNOSTIC FUNCTION TABLE ..........9-5 COMMUNICATION ERROR WITH THE YAMAHA DIAGNOSTIC TOOL ......................9-5 DIAGNOSTIC CODE: SENSOR OPERATION TABLE ......9-6 DIAGNOSTIC CODE: ACTUATOR OPERATION TABLE ......9-7...

  • Page 436: Troubleshooting

    TROUBLESHOOTING Electrical system EAS20090 TROUBLESHOOTING 1. Battery • Discharged battery EAS30599 • Faulty battery GENERAL INFORMATION 2. Fuse(s) • Blown, damaged or incorrect fuse The following guide for troubleshooting does not • Improperly installed fuse cover all the possible causes of trouble. It should 3.

  • Page 437: Poor Medium-And-High-Speed Performance

    TROUBLESHOOTING • Faulty battery Poor starting performance 2. Spark plug 1. V-belt • Incorrect spark plug gap • Slipping V-belt • Incorrect spark plug heat range • Oil or grease on the V-belt • Fouled spark plug 2. Primary sliding sheave •...

  • Page 438: Overcooling

    TROUBLESHOOTING Fuel system • Incorrect oil viscosity 1. Throttle body • Incorrect oil level • Damaged or loose throttle body joint EAS30611 2. Air filter UNSTABLE HANDLING • Clogged air filter element 1. Handlebar • Bent or improperly installed handlebar Chassis 2.
  • Page 439 TROUBLESHOOTING Turn signal does not come on • Faulty turn signal switch • Faulty turn signal relay • Burnt-out turn signal light bulb • Incorrect connection • Damaged or faulty wire harness • Improperly grounded circuit • Faulty battery • Blown, damaged or incorrect fuse Turn signal blinks slowly •...

  • Page 440: Self-Diagnostic Function And Diagnostic Code Table

    Waiting for con- ECU (engine control unit) internal malfunction (output signal error): Signals cannot be nection (Yamaha transmitted between the ECU and Yamaha diagnostic tool. diagnostic tool) ECU (engine control unit) internal malfunction (output signal error): no signals are re- Er-2 ceived from the ECU within the specified duration.

  • Page 441: Diagnostic Code: Sensor Operation Table

    SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Fault code No. Item Er-4 (Yamaha di- ECU (engine control unit) internal malfunction (input signal error): no normal signals are agnostic tool) received from the Yamaha diagnostic tool. EAS31120 DIAGNOSTIC CODE: SENSOR OPERATION TABLE Diagnostic Item Tool display Procedure code No.

  • Page 442: Diagnostic Code: Actuator Operation Table

    — • History exists • Displays the total number To erase the history, click of malfunctions, including “Action” on the Yamaha diag- the current malfunction, nostic tool screen. that have occurred since the history was last erased. (For example, if there have been three malfunctions, “03”...
  • Page 443 Check that fuel injector is ac- The “CHECK” indicator and tuated five times by listening for the operating sound. “ ” on the Yamaha diag- nostic tool screen come on each time the fuel injector is actuated. VVA (variable valve actuator)

  • Page 444: 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 13 maintenance jobs for sure sensor fault code number 13.
  • Page 445 EVENT CODE TABLE Item Symptom Possible cause Remarks ISC (idle speed control) Correction value re- High engine idling • If a fault code is indi- (Correction value re- mains at lower limit speed cated, perform the mains at lower limit) while the engine is •...
  • Page 448 Gy/R Gray/Red 18. Sidestand switch Blue/Black 19. Fuel sender Blue/Red 20. Fuel pump Blue/White 21. Yamaha diagnostic tool coupler Blue/Yellow 22. Coolant temperature sensor Orange/Black 23. Throttle body sensor assembly Pink/White 24. Intake air pressure sensor Red/Black 25. Intake air temperature sensor Red/Blue 26.
  • Page 449 GPD150-A 2015 WIRING DIAGRAM L/B Y/L P/W Br/W Gy/R B/W,B G/R B/L Br/W Br/W Gy/R Gy/R Gy/R P/W Br/W L/B R/L G Ch (Gy) (Gy) Br/W Br Br Br/W Br/W Br/W Br/W Br/W L/B P Br/W L/R L/B Ch Dg Y/B Y/B (Gy) 48 49 50 51...
  • Page 450 GPD150-A 2015 WIRING DIAGRAM (Gy) (Gy) (Gy) 48 49 50 51 (Br) (Br)

Table of Contents