Yamaha MT-09 2021 Service Manual

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2021

SERVICE MANUAL

MT-09

MT-09SP

MTN890

MTN890D

B7N-28197-E0

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Summary of Contents for Yamaha MT-09 2021

Page 1 2021 SERVICE MANUAL MT-09 MT-09SP MTN890 MTN890D B7N-28197-E0...
Page 3 EAS20003 IMPORTANT This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one man- ual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
Page 4 EAS20004 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive ex- planations 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
TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE COOLING SYSTEM FUEL SYSTEM ELECTRICAL SYSTEM SELF DIAGNOSTIC...
Page 9: General Information
GENERAL INFORMATION IDENTIFICATION .................... 1-1 VEHICLE IDENTIFICATION NUMBER .............1-1 MODEL LABEL..................1-1 FEATURES...................... 1-2 GLOSSARY....................1-2 DISPLAY ....................1-2 BASIC SERVICE INFORMATION..............1-9 ELECTRICAL SYSTEM................1-9 SPECIAL TOOLS ..................1-10...
Page 10: Identification
IDENTIFICATION EAS20007 IDENTIFICATION EAS30002 VEHICLE IDENTIFICATION NUMBER The vehicle identification number “1” is stamped into the right side of the steering head pipe. EAS30003 MODEL LABEL The model label “1” is affixed to the frame under the seat. This information will be needed to order spare parts.
Page 11: Glossary
FEATURES EAS20008 FEATURES This model uses a thin-film-transistor liquid-crys- EAS31706 tal display (TFT LCD) for good contrast and GLOSSARY readability in various lighting conditions. Howev- ABS - Anti-lock Brake System er, due to the nature of this technology, it is nor- ABS ECU - Anti-lock Brake System Electronic mal for a small number of pixels to be inactive.
Page 12 FEATURES • Fuel meter Transmission gear display • FUELCON: amount of fuel consumed This shows which gear the transmission is in. • TRIPTIME: running time This model has 6 gears and a neutral position. Operate the vehicle information display as fol- The neutral position is indicated by the neutral lows: indicator light “...
Page 13 FEATURES The QS functions can be turned on or off in the Lap timer setting MENU. This stopwatch function can be activated through the setting MENU. Once activated, the vehicle information display The upshift and downshift functions are inde- is replaced with: pendent and can be activated separately.
Page 14 Additionally, ABS may Switch lap time not function properly. Use extra care when brak- mode on/off and ad- ing and have a Yamaha dealer check the vehicle “Display Setting” just the tachometer immediately. color Adjust TCS/SCS/LIF Auxiliary system warning “...
Page 15 FEATURES “Display Setting” SCS can be set to OFF, 1, 2, and 3. OFF turns the slide control system off, setting Display Setting level 1 provides the least amount of system in- tervention, and setting level 3 provides the Lap Time greatest amount of system intervention.
Page 16 FEATURES “Maintenance” QS Setting Maintenance 1 0 0 0 INTERVAL 1 1 0 0 0 INTERVAL 2 1 000 km/h km/h The quick shift system indicators are divided into This module allows you to record the distance and QS sections. traveled between engine oil changes (use the and QS are not linked and can be inde-...
Page 17 FEATURES “Brightness” Brightness km/h This module allows you to adjust the general brightness level of the display screen. Select the desired brightness level by rotating the wheel switch, and then short push the wheel switch to fix the setting and return to the top MENU screen.
Page 18: Basic Service Information
BASIC SERVICE INFORMATION EAS20010 BASIC SERVICE INFORMATION EAS30014 ELECTRICAL SYSTEM Electrical parts handling ECA22611 NOTICE • Do not perform angle adjustment of the IMU and battery box by pinching the washer and related parts. • When installing the IMU, apply a thin coat of silicone grease onto the washer where con- tacting the IMU grommet.
Page 19: Special Tools
• For U.S.A. and Canada, use part number starting with “YM-”, “YU-”, or “ACC-”. • For others, use part number starting with “90890-”. Reference Tool name/Tool No. Illustration pages Yamaha diagnostic tool USB 3-4, 3-11, 4-54, 90890-03267 4-55, 7-11, 9-3, 9-46, 9-47 Yamaha diagnostic tool (A/I)
Page 20 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Carburetor angle driver 2 90890-03173 Steering nut wrench 3-20, 4-76 90890-01403 Exhaust flange nut wrench YU-A9472 Oil filter wrench 3-29 90890-01426 Oil filter wrench YU-38411 Oil pressure gauge joint 18 mm 3-30 90890-04176 YU-04176 ø18...
Page 21 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Rod puller 4-70, 4-71 90890-01437 Universal damping rod bleeding tool set YM-A8703 YM-A8703 Rod puller attachment (M10 long) 4-70, 4-71 90890-01578 90890-01578 Universal damping rod bleeding tool set YM-A8703 YM-A8703 Ring nut wrench 4-76 90890-01268 Spanner wrench...
Page 22 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Pivot shaft wrench 5-14, 5-14, 5-15 90890-01518 Frame spanner socket YM-01518 Pivot shaft wrench adapter 5-14, 5-14, 5-15 90890-01476 Camshaft wrench 5-19, 5-22 90890-04162 Camshaft wrench YM-04162 Valve spring compressor 5-31, 5-35 90890-04200 Valve spring compressor YM-04019...
Page 23 Reference Tool name/Tool No. Illustration pages Flywheel puller 5-38 90890-01362 Heavy duty puller YU-33270-B Yamaha bond No. 1215 5-40, 5-65 90890-85505 Three bond No. 1215® Digital circuit tester (CD732) 5-43, 8-55, 90890-03243 8-56, 8-58, Model 88 Multimeter with tachometer 8-59, 8-59,...
Page 24 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Radiator cap tester 6-5, 6-5 90890-01325 Mityvac cooling system tester kit YU-24460-A YU-24460-A Radiator cap tester adapter 6-5, 6-5 90890-01352 Pressure tester adapter YU-33984 YU-33984 Mechanical seal installer 6-14 90890-04078 Water pump seal installer YM-33221-A Middle driven shaft bearing driver 6-14...
Page 25 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Ignition checker 8-59 90890-06754 Oppama pet–4000 spark checker YM-34487 1-16...
Page 26 SPECIAL TOOLS 1-17...
Page 27: Specifications
SPECIFICATIONS GENERAL SPECIFICATIONS ................ 2-1 ENGINE SPECIFICATIONS ................2-2 CHASSIS SPECIFICATIONS ................2-6 ELECTRICAL SPECIFICATIONS ..............2-10 TIGHTENING TORQUES ................2-12 ENGINE TIGHTENING TORQUES............2-12 CHASSIS TIGHTENING TORQUES............2-12 CABLE ROUTING ..................2-15...
Page 28: General Specifications
GENERAL SPECIFICATIONS EAS20013 GENERAL SPECIFICATIONS Model Model B7N1 (MTN890) BAM1 (MTN890D) Dimensions Overall length 2090 mm (82.3 in) Overall width 795 mm (31.3 in) Overall height 1190 mm (46.9 in) Wheelbase 1430 mm (56.3 in) Ground clearance 140 mm (5.51 in) Minimum turning radius 3.4 m (11.16 ft) Weight...
Page 29: Engine Specifications
ENGINE SPECIFICATIONS EAS20014 ENGINE SPECIFICATIONS Engine Combustion cycle 4-stroke Cooling system Liquid cooled Valve train DOHC Displacement 890 cm³ Cylinder arrangement Inline Number of cylinders 3-cylinder Bore × stroke 78.0 × 62.1 mm (3.07 × 2.44 in) Compression ratio 11.5 : 1 Compression pressure 1365–1758 kPa/600 r/min (13.7–17.6 kgf/cm²/ 600 r/min, 194.3–250.1 psi/600 r/min)
Page 30 ENGINE SPECIFICATIONS Spark plug(s) Manufacturer/model NGK/LMAR9A-9 Spark plug gap 0.8–0.9 mm (0.031–0.035 in) Cylinder head Warpage limit 0.10 mm (0.0039 in) Camshaft Camshaft cap inside diameter 24.500–24.521 mm (0.9646–0.9654 in) Camshaft journal diameter 24.459–24.472 mm (0.9630–0.9635 in) Camshaft-journal-to-camshaft-cap clearance limit 0.080 mm (0.0032 in) Camshaft lobe dimensions Lobe height limit (Intake)
Page 31 ENGINE SPECIFICATIONS Piston ring Top ring End gap limit 0.50 mm (0.0197 in) Side clearance limit 0.115 mm (0.0045 in) 2nd ring End gap limit 1.15 mm (0.0453 in) Side clearance limit 0.115 mm (0.0045 in) Connecting rod Oil clearance 0.027–0.051 mm (0.0011–0.0020 in) Bearing color code Code 1...
Page 32 ENGINE SPECIFICATIONS Clutch plate 1 thickness 2.18–2.42 mm (0.086–0.095 in) Plate quantity 1 pcs Warpage limit 0.10 mm (0.004 in) Clutch plate 2 thickness 1.90–2.10 mm (0.075–0.083 in) Plate quantity 7 pcs Warpage limit 0.10 mm (0.004 in) Clutch spring free length limit 42.53 mm (1.67 in) Drivetrain Primary reduction ratio...
Page 33: Chassis Specifications
CHASSIS SPECIFICATIONS EAS20015 CHASSIS SPECIFICATIONS Chassis 25.0 ° Caster angle Trail 108 mm (4.3 in) Front wheel Wheel type Cast wheel Rim size 17M/C x MT3.50 Radial wheel runout limit 1.0 mm (0.04 in) Lateral wheel runout limit 0.5 mm (0.02 in) Wheel axle bending limit 0.40 mm (0.02 in) Rear wheel...
Page 34 Fork spring free length limit 268.9 mm (10.59 in) Inner tube bending limit 0.2 mm (0.01 in) Recommended oil Yamaha Suspension Oil 01 Quantity (left) 468.0 cm³ (15.82 US oz, 16.51 Imp.oz) (MTN890) 473.0 cm³ (15.99 US oz, 16.68 Imp.oz)
Page 35 CHASSIS SPECIFICATIONS Fast compression damping Unit for adjustment Turn (MTN890D) Adjustment value from the start position (Soft) 5 1/2 (MTN890D) Adjustment value from the start position (STD) 3 1/4 (MTN890D) Adjustment value from the start position (Hard) 0 (MTN890D) Slow compression damping Unit for adjustment Click (MTN890D) Adjustment value from the start position...
Page 36 CHASSIS SPECIFICATIONS Drive chain Size Chain type Sealed type Number of links Drive chain slack (Sidestand) 36.0–41.0 mm (1.42–1.61 in) Drive chain slack (Maintenance stand) 36.0–41.0 mm (1.42–1.61 in) Drive chain slack limit (Sidestand) 46.0 mm (1.81 in) 15-link length limit 239.3 mm (9.42 in)
Page 37: Electrical Specifications
ELECTRICAL SPECIFICATIONS EAS20016 ELECTRICAL SPECIFICATIONS Voltage System voltage 12 V Ignition system 3.0–7.0 °/1300 r/min Ignition timing (B.T.D.C.) Engine control unit Model TBDF3W (MTN890) TBDF5R (MTN890D) Ignition coil 1.19–1.61 Ω Primary coil resistance Secondary coil resistance 8.50–11.50 kΩ Charging system Charging system AC magneto Standard output...
Page 38 ELECTRICAL SPECIFICATIONS Starter motor Brush overall length limit 6.5 mm (0.26 in) Mica undercut (depth) 0.70 mm (0.03 in) Fuel sender unit 9.0–11.0 Ω Sender unit resistance (full) 213.0–219.0 Ω Sender unit resistance (empty) Fuel injection sensor 228–342 Ω Crankshaft position sensor resistance 5400–6600 Ω...
Page 39: Tightening Torques
TIGHTENING TORQUES EAS20017 TIGHTENING TORQUES EAS30016 ENGINE TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Exhaust pipe nut 20 N·m (2.0 kgf·m, 15 lb·ft) Spark plug 13 N·m (1.3 kgf·m, 9.6 lb·ft) Cylinder head cover bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft) Generator rotor bolt 75 N·m (7.5 kgf·m, 55 lb·ft) Generator cover bolt...
Page 40 TIGHTENING TORQUES Lower ring nut 1. Tighten the ring nut to approximately 52 N·m (5.2 kgf·m, 38 lb·ft) with a torque wrench, then loosen the lower ring nut completely. 2. Tighten the lower ring nut to 14 N·m (1.4 kgf·m, 10 lb·ft). 2-13...
Page 41 TIGHTENING TORQUES 2-14...
Page 42: Cable Routing
CABLE ROUTING EAS20021 CABLE ROUTING Handlebar (front view) (for MTN890) 16 P 11 N K 18 J 17 11 E 26 R 27 S 2-15...
Page 43 CABLE ROUTING L. Insert the handlebar switch lead (right) into 1. Meter assembly the hole of the meter assembly bracket. 2. Handlebar M. Route the handlebar switch lead (left) 3. Handlebar switch (left) (to horn) on the rear side of the clutch cable. 4.
Page 44 CABLE ROUTING Handlebar (front view) (for MTN890D) M 22 11 D 12 E 14 F 2-17...
Page 45 CABLE ROUTING H. Face the terminal of the horn inside. 1. Meter assembly 2. Handlebar Route the handlebar switch lead (right) on the front side of the wire harness (to front brake 3. Handlebar switch (left) light switch). 4. Clutch switch J.
Page 46 CABLE ROUTING Steering head (left and right view) 2-19...
Page 47 CABLE ROUTING 1. Coupler cover 2. Handlebar switch lead (left) 3. Handlebar switch lead (left) (to horn) 4. Clamp 5. Meter assembly bracket 6. Upper bracket 7. Clutch cable 8. Brake hose 9. Wire harness (to meter) A. Insert the clamp into the hole of the coupler cover.
Page 48 CABLE ROUTING Frame (right side view) 24 27 38 T 35 Q 13 S 2-21...
Page 49 CABLE ROUTING G. Right side of the vehicle 1. Battery box 2. Rectifier/regulator H. Left side of the vehicle 3. Rectifier/regulator cover Set the neutral switch coupler installation direction within the range as shown in the fig- 4. Wire harness (to rectifier/regulator) ure.
Page 50 CABLE ROUTING Frame (front left side view) 14 C 2-23...
Page 51 CABLE ROUTING Insert the clamp into the hole in the cable 1. Intake air temperature sensor coupler guide. 2. Intake air temperature sensor J. Fix the ECU with the claw of air filter case 3. Air filter case assembly assembly properly. 4.
Page 52 CABLE ROUTING Frame (rear left side view) 18 M 10 C 10 L 20 N 2-25...
Page 53 CABLE ROUTING S. Route the wire harness (to gear position sen- 1. Shift sensor lead sor) on the left side of the rear shock 2. Wire harness absorber hose and starter motor lead. 3. Clamp T. Left outside of the vehicle 4.
Page 54 CABLE ROUTING Canister (left side view) 2-27...
Page 55 CABLE ROUTING P. Route the fuel tank drain hose on the rear 1. Canister purge hose (purge cut valve sole- noid to canister) side of the stator coil lead, sidestand switch lead and shift sensor lead. Route the fuel 2. Starter motor lead tank drain hose on the left side of the canister 3.
Page 56 CABLE ROUTING Main switch (rear view) (for MTN890) C 10 2-29...
Page 57 CABLE ROUTING 1. Bracket 2. Handlebar switch coupler 2 (left) 3. Handlebar switch coupler 1 (left) 4. Radiator fan motor coupler 5. Immobilizer unit coupler 6. Brake hose 7. Radiator fan motor lead 8. Wire harness (to front turn signal light (right) and oil pressure switch) 9.
Page 58 CABLE ROUTING Main switch (rear view) (for MTN890D) 2-31...
Page 59 CABLE ROUTING 1. Bracket 2. Handlebar switch coupler 2 (left) 3. Handlebar switch coupler 1 (left) (blue) 4. Handlebar switch coupler 3 (left) 5. Radiator fan motor coupler 6. Immobilizer unit coupler 7. Brake hose 8. Radiator fan motor lead 9.
Page 60 CABLE ROUTING Main switch (left side view) 2-33...
Page 61 CABLE ROUTING 1. Wire harness 2. Front wheel sensor coupler 3. Front wheel sensor lead 4. Wire harness (to O sensor) 5. Bracket 6. Frame A. Insert the clamp into the hole of the bracket. B. Insert the clamp into the rib of the frame. C.
Page 62 CABLE ROUTING Frame (top view) 2-35...
Page 63 CABLE ROUTING E. Pass the wire harness (to radiator fan motor 1. Throttle body relay) into the coupler cover and push it 2. Throttle servo motor coupler between the wire harness (to ABS ECU) and 3. Fuel tank breather hose wire harness (main line).
Page 64 CABLE ROUTING Rear fender (top view) K 20 2-37...
Page 65 CABLE ROUTING P. For MTN890 1. Positive battery terminal 2. Fuse box Q. Make a slack to the license plate light lead in front of the seat bracket. 3. Box 4. License plate light coupler 5. Tail/brake light coupler 6. Rear turn signal light (left) (black) 7.
Page 66 CABLE ROUTING ABS ECU (top view) 2-39...
Page 67 CABLE ROUTING 1. Crankshaft position sensor coupler 2. Rear brake light switch lead 3. Rear wheel sensor lead 4. Rear wheel sensor coupler 5. Wire harness (to joint coupler) 6. Wire harness (to ABS ECU) 7. Wire harness (to radiator fan motor relay) 8.
Page 68 CABLE ROUTING IMU (top view) 2-41...
Page 69 CABLE ROUTING 1. IMU (Inertial Measurement Unit) 2. Positive battery lead 3. Starter relay 4. Wire harness (to starter relay) 5. Bracket 6. Starter motor lead 7. Battery box 8. IMU coupler 9. Wire harness 10. Negative battery lead A. Do not contact the starter motor lead with the bracket.
Page 70 CABLE ROUTING Front brake hose (left side view) 2-43...
Page 71 CABLE ROUTING 1. Front brake caliper assembly (left) 2. Brake hose (front brake caliper (left) to front brake caliper (right)) 3. Front wheel sensor lead 4. Brake hose (hydraulic unit to front brake cali- per (left)) 5. Brake hose (front brake master cylinder to hydraulic unit) 6.
Page 72 CABLE ROUTING Front brake hose (right side view) 2-45...
Page 73 CABLE ROUTING 1. Brake hose (hydraulic unit to front brake cali- per (left)) 2. Brake hose (front brake master cylinder to hydraulic unit) 3. Meter assembly bracket 4. Front fork 5. Front brake caliper assembly (right) 6. Front fender 7. Clamp 8.
Page 74 CABLE ROUTING Rear brake hose (right side view) 10 J 10 J 10 J 2-47...
Page 75 CABLE ROUTING 1. Rear wheel sensor 2. Rear brake hose (hydraulic unit to rear brake caliper) 3. Clamp 4. Rear brake hose (rear brake master cylinder to hydraulic unit) 5. Rear fender 6. Frame 7. Brake fluid reservoir hose 8. Rear brake light switch lead 9.
Page 76 CABLE ROUTING ABS ECU (Electronic Control Unit) (top and left side view) 2-49...
Page 77 CABLE ROUTING 1. Front brake hose (front brake master cylinder to hydraulic unit) 2. Front brake hose (hydraulic unit to front brake caliper (left)) 3. Brake hose joint 4. Hydraulic unit brake pipe (rear brake master cylinder to hydraulic unit) 5.
Page 78 CABLE ROUTING Fuel tank (left side view) 2-51...
Page 79 CABLE ROUTING 1. Fuel tank 2. Frame 3. Fuel pump 4. Fuel tank breather hose 5. Fuel tank drain hose 6. Fuel hose 7. White paint mark 8. Projection 9. Yellow paint mark A. To engine B. Insert the fuel tank drain hose up to the sec- tion where the fuel tank pipe increases in diameter.
Page 80 CABLE ROUTING Canister 2-53...
Page 81 CABLE ROUTING 1. Frame 2. Fuel tank breather hose (fuel tank to canister) 3. Canister 4. Canister breather hose 5. Fuel tank drain hose 6. Canister purge hose (purge cut valve sole- noid to canister) A. Front side of the vehicle B.
Page 82 CABLE ROUTING Air filter case and throttle bodies (left side view) 2-55...
Page 83 CABLE ROUTING 1. Throttle body 2. Yellow paint mark 3. White paint mark 4. Cylinder head breather hose 5. Canister purge hose (purge cut valve sole- noid to hose joint) 6. Hose clamp A. Face the bolt head to the position as shown in the figure.
Page 84 CABLE ROUTING Radiator (front side view) C B A 2-57...
Page 85 CABLE ROUTING 1. Front turn signal light lead (left) 2. Radiator 3. Radiator outlet hose 4. Thermostat assembly 5. Front turn signal light lead (right) 6. Radiator cap 7. Coolant reservoir hose 8. Water jacket joint 9. Radiator inlet hose A.
Page 86 CABLE ROUTING Radiator (right side view) 2-59...
Page 87 CABLE ROUTING 1. Radiator 2. Radiator hose (cylinder head to radiator) 3. Radiator fan motor lead 4. Radiator fan cover A. Direction of the hose tip does not matter. B. Pass the coolant reservoir hose through the front side panel (right) guide. C.
Page 88 CABLE ROUTING Radiator (right side view) 2-61...
Page 89 CABLE ROUTING 1. Radiator hose (cylinder head to radiator) A. Insert the radiator hose (cylinder head to radiator) to the root of the radiator properly. B. 0–2 mm (0–0.08 in) C. Front side of the vehicle D. Right side of the vehicle E.
Page 90 CABLE ROUTING Oil cooler and thermostat (front side view) 2-63...
Page 91 CABLE ROUTING 1. Water jacket joint 2. Water pump inlet hose 3. Thermostat assembly 4. Oil cooler 5. Oil cooler outlet hose 6. Oil cooler inlet hose 7. Radiator inlet hose A. Install the clip with its end facing the front. B.
Page 92 CABLE ROUTING Water pump (left side view) 2-65...
Page 93 CABLE ROUTING 1. Water pump inlet hose 2. Water pump assembly 3. Radiator outlet hose 4. Radiator A. Align the white paint mark on the water pump inlet hose with the rib on the water pump and insert until the hose stops. B.
Page 94 CABLE ROUTING 2-67...
Page 95: Periodic Checks And Adjustments
INTRODUCTION ..................3-1 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM ....................3-1 GENERAL MAINTENANCE AND LUBRICATION CHART .......3-1 CHECKING THE VEHICLE USING THE YAMAHA DIAGNOSTIC TOOL ......................3-4 CHECKING THE FUEL LINE ..............3-4 CHECKING THE SPARK PLUGS ............. 3-5 ADJUSTING THE VALVE CLEARANCE ..........3-5 CHECKING THE ENGINE IDLING SPEED ..........3-8...
Page 96 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY ....3-25 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY (for MTN890) ..................3-25 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY (for MTN890D)..................3-26 CHECKING THE CONNECTING ARM AND RELAY ARM.....3-28 CHECKING THE ENGINE OIL LEVEL............3-28 CHANGING THE ENGINE OIL ...............3-28 MEASURING THE ENGINE OIL PRESSURE ........
Page 97: Periodic Maintenance
All service technicians should be familiar with this entire chapter. • Items marked with an asterisk should be performed by your Yamaha dealer because these items re- quire special tools, data, and technical skills.
Page 98 PERIODIC MAINTENANCE ODOMETER READING CHECK OR MAINTENANCE ANNUAL ITEM 1000 km 10000 km 20000 km 30000 km 40000 km CHECK (600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi) √ √ √ √ √ • Check for cracks or damage. 6 * Brake hoses •...
Page 99 PERIODIC MAINTENANCE ODOMETER READING CHECK OR MAINTENANCE ANNUAL ITEM 1000 km 10000 km 20000 km 30000 km 40000 km CHECK (600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi) Moving parts and √ √ √ √ √ 28 * •...
Page 100: Checking The Vehicle Using The Yamaha Diagnostic Tool
ECA14940 NOTICE cludes YDT sub harness (6P) (90890-03266). Make sure the fuel tank breather hose is rout- • If you already have Yamaha diagnostic tool (A/ ed correctly. I) (90890-03262), YDT sub harness (6P) (90890-03266) is separately required. 3. Check: Before removing the fuel hoses, place a few •...
Page 101: Checking The Spark Plugs
PERIODIC MAINTENANCE EAS30620 CHECKING THE SPARK PLUGS The following procedure applies to all of the spark plugs. 1. Remove: • Rider seat Refer to “GENERAL CHASSIS (1)” on page 4-1. • Fuel tank center cover Refer to “GENERAL CHASSIS (1)” on G088879 page 4-1.
Page 102 PERIODIC MAINTENANCE • Front side panel Refer to “GENERAL CHASSIS (1)” on TDC on the compression stroke can be found page 4-1. when the camshaft lobes are turned away from • Radiator each other. Refer to “RADIATOR” on page 6-3. c.
Page 103 PERIODIC MAINTENANCE Example: Cylinder #2 240° If the valve pad is marked “158”, the pad Cylinder #3 480° thickness is 1.58 mm (0.062 in). 5. Remove: • Camshaft • Refer to “CAMSHAFTS” on page 5-16. • When removing the timing chain and cam- shafts, fasten the timing chain with a wire to re- trieve it if it falls into the crankcase.
Page 104: Checking The Engine Idling Speed
PERIODIC MAINTENANCE Engine idling speed • Lubricate the valve pad with molybdenum di- 1200–1400 r/min sulfide oil. • Lubricate the valve lifter (Top side) with molyb- 3. Check: denum disulfide oil. • ISC (idle speed control) learning value • Lubricate the valve lifter (Outer side) with en- “00”...
Page 105 PERIODIC MAINTENANCE 3. Remove: Adjusting the throttle body synchronization • Service hose cap “1” 1. Adjust: • Throttle body synchronization a. Start the engine, warm it up for several min- utes, and then let it run at the specified en- gine idling speed.
Page 106: Checking The Throttle Body Joints
PERIODIC MAINTENANCE 3. Install: • Service hose cap 4. Install: • Air filter case Refer to “GENERAL CHASSIS (2)” on page 4-10. • Fuel tank Refer to “FUEL TANK” on page 7-1. • Fuel tank center cover Refer to “GENERAL CHASSIS (1)” on 3.
Page 107: Checking The Canister
• Yamaha diagnostic tool (A/I) (90890-03264) in- Refer to “GENERAL CHASSIS (1)” on cludes YDT sub harness (6P) (90890-03266). page 4-1. • If you already have Yamaha diagnostic tool • Fuel tank center cover (A/I) (90890-03262), YDT sub harness (6P) Refer to “GENERAL CHASSIS (1)” on (90890-03266) is separately required.
Page 108: Adjusting The Clutch Lever Free Play
PERIODIC MAINTENANCE 5. Install: • Fuel tank Refer to “FUEL TANK” on page 7-1. • Fuel tank center cover Refer to “GENERAL CHASSIS (1)” on page 4-1. • Rider seat Refer to “GENERAL CHASSIS (1)” on page 4-1. 3. Check: EAS30629 ADJUSTING THE CLUTCH LEVER FREE •...
Page 109: Checking The Brake Operation
PERIODIC MAINTENANCE Engine side EWA13090 WARNING a. Loosen the locknut “1”. • Use only the designated brake fluid. Other b. Turn the adjusting nut “2” until the specified brake fluids may cause the rubber seals to clutch lever free play is obtained. deteriorate, causing leakage and poor c.
Page 110: Checking The Front Brake Pads
PERIODIC MAINTENANCE EAS30631 ADJUSTING THE REAR DISC BRAKE 1. Adjust: • Brake pedal position a. Loosen the locknut “1”. b. Turn the adjusting bolt “2” until the specified brake pedal position is obtained. EWA18830 WARNING After adjusting the brake pedal position, G088890 check that the end of the adjusting bolt “a”...
Page 111: Checking The Rear Brake Pads
PERIODIC MAINTENANCE EAS30634 EAS30893 CHECKING THE REAR BRAKE PADS BLEEDING THE HYDRAULIC BRAKE The following procedure applies to all of the SYSTEM (ABS) brake pads. EWA14000 WARNING 1. Operate the brake. Always bleed the brake system when the 2. Check: brake related parts are removed.
Page 112: Checking The Wheels
PERIODIC MAINTENANCE ECA17061 NOTICE Make sure that the main switch is turned to “OFF” before checking the operation of the hydraulic unit. k. After operating the ABS, repeat steps (e) to (i), and then fill the brake fluid reservoir to the proper level with the specified brake flu- l.
Page 113 Yamaha is used on this vehicle. • Operation of an overloaded vehicle could cause tire damage, an accident or an injury. Front tire NEVER OVERLOAD THE VEHICLE.
Page 114: Checking The Wheel Bearings
PERIODIC MAINTENANCE EAS30641 2. Check: CHECKING THE WHEEL BEARINGS • Drive chain slack The following procedure applies to all of the Out of specification → Adjust. wheel bearing. 1. Check: • Measure the distance “a” between the rib end • Wheel bearing on the drive chain guide “1”...
Page 115: Lubricating The Drive Chain
PERIODIC MAINTENANCE Adjusting the drive chain slack EAS30803 LUBRICATING THE DRIVE CHAIN EWA13120 The drive chain consists of many interacting WARNING parts. If the drive chain is not maintained proper- Securely support the vehicle so that there is ly, it will wear out quickly. Therefore, the drive no danger of it falling over.
Page 116: Lubricating The Steering Head
PERIODIC MAINTENANCE d. Check the steering head for looseness or binding by turning the front fork all the way in both directions. If any binding is felt, re- move the lower bracket and check the up- per and lower bearings. Refer to “STEERING HEAD”...
Page 117: Lubricating The Clutch Lever
PERIODIC MAINTENANCE EAS30805 4. Check: LUBRICATING THE CLUTCH LEVER • Front fork operation Lubricate the pivoting point and metal-to-metal Push down hard on the handlebar several moving parts of the lever. times and check if the front fork rebounds smoothly. Recommended lubricant Rough movement →...
Page 118 PERIODIC MAINTENANCE Rebound damping The spring preload setting is determined by Adjustment value from the start measuring the distance “c” shown in the illustra- position (Soft) tion. The shorter distance “c” is, the higher the 11 (MTN890) spring preload; the longer distance “c” is, the Adjustment value from the start lower the spring preload.
Page 119: Adjusting The Front Fork Legs (For Mtn890D)
PERIODIC MAINTENANCE ECA13590 Compression damping NOTICE Adjustment value from the start Never go beyond the maximum or minimum position (Soft) adjustment positions. 11 (MTN890) 1. Adjust: Adjustment value from the start • Spring preload position (STD) 6 (MTN890) a. Turn the adjusting bolt “1” in direction “a” or Adjustment value from the start “b”.
Page 120 PERIODIC MAINTENANCE Rebound damping Compression damping ECA13590 ECA13590 NOTICE NOTICE Never go beyond the maximum or minimum Never go beyond the maximum or minimum adjustment positions. adjustment positions. 1. Adjust: 1. Adjust: • Rebound damping • Compression damping a. Turn the adjusting screw “1” in direction “a” a.
Page 121: Checking The Rear Shock Absorber Assembly
PERIODIC MAINTENANCE 2. Adjust: EAS30655 ADJUSTING THE REAR SHOCK ABSORBER • Compression damping (slow compression ASSEMBLY (for MTN890) damping) EWA13120 a. Turn the adjusting bolt “1” in direction “a” or WARNING “b”. Securely support the vehicle so that there is no danger of it falling over.
Page 122: Adjusting The Rear Shock Absorber Assembly (For Mtn890D)
PERIODIC MAINTENANCE Rebound damping EAS31609 ADJUSTING THE REAR SHOCK ABSORBER ECA13590 ASSEMBLY (for MTN890D) NOTICE EWA13120 Never go beyond the maximum or minimum WARNING adjustment positions. Securely support the vehicle so that there is no danger of it falling over. 1.
Page 123 PERIODIC MAINTENANCE Spring preload Adjustment value (Soft) 154.0 mm (6.06 in) (MTN890D) Adjustment value (STD) 154.0 mm (6.06 in) (MTN890D) Adjustment value (Hard) 146.0 mm (5.75 in) (MTN890D) Rebound damping ECA13590 Compression damping NOTICE ECA13590 Never go beyond the maximum or minimum NOTICE adjustment positions.
Page 124: Checking The Connecting Arm And Relay Arm
PERIODIC MAINTENANCE ECA13361 NOTICE • Engine oil also lubricates the clutch and the wrong oil types or additives could cause clutch slippage. Therefore, do not add any chemical additives or use engine oils with a grade of “CD” or higher and do not use oils labeled “ENERGY CONSERVING II”.
Page 125: Measuring The Engine Oil Pressure
PERIODIC MAINTENANCE 4. Drain: • Engine oil Engine oil quantity (completely from the crankcase) Quantity (disassembled) 3.50 L (3.70 US qt, 3.08 Imp.qt) 5. If the oil filter cartridge is also to be replaced, Oil change perform the following procedure. 2.80 L (2.96 US qt, 2.46 Imp.qt) a.
Page 126 PERIODIC MAINTENANCE EWA12980 ECA13410 WARNING NOTICE The engine, muffler and engine oil are ex- When the engine is cold, the engine oil will tremely hot. have a higher viscosity, causing the engine oil pressure to increase. Therefore, be sure to measure the engine oil pressure after warming up the engine.
Page 127: Checking The Coolant Level
PERIODIC MAINTENANCE EAS30811 • Oil cooler outlet hose “9” CHECKING THE COOLANT LEVEL • Water jacket joint “10” 1. Stand the vehicle on a level surface. • Oil cooler inlet hose “11” • Oil cooler “12” • Place the vehicle on a maintenance stand. Cracks/damage →...
Page 128 PERIODIC MAINTENANCE 6. Drain: • Coolant (from the engine and radiator) 7. Install: • Water pump drain bolt • Copper washer Water pump drain bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft) 2. Remove: 8. Install: • Coolant reservoir bolt • Collar •...
Page 129: Checking The Front Brake Light Switch
PERIODIC MAINTENANCE ECA21291 EAS30659 ADJUSTING THE REAR BRAKE LIGHT NOTICE SWITCH • Adding water instead of coolant dilutes the antifreeze concentration of the coolant. If water is used instead of coolant; check, The rear brake light switch is operated by move- and if necessary, correct the antifreeze ment of the brake pedal.
Page 130: Checking The Throttle Grip
PERIODIC MAINTENANCE Hold the cable end upright and pour a few drops of lubricant into the cable sheath or use a suit- able lubricating device. EAS30815 CHECKING THE THROTTLE GRIP 1. Check: • Throttle grip movement Rough movement → Lubricate or replace the defective part(s).
Page 131: Chassis
CHASSIS GENERAL CHASSIS (1) ................. 4-1 REMOVING THE SEAT ................4-7 REMOVING THE HEADLIGHT FRONT COVER ........4-7 REMOVING THE FUEL TANK SIDE COVER...........4-7 INSTALLING THE FUEL TANK SIDE COVER ......... 4-7 INSTALLING THE HEADLIGHT FRONT COVER........4-8 INSTALLING THE IMU................4-8 INSTALLING THE SEAT ................4-9 GENERAL CHASSIS (2) ................
Page 132 REAR BRAKE ....................4-37 ADJUSTING THE FOOTREST POSITION ..........4-43 INTRODUCTION ..................4-43 CHECKING THE REAR BRAKE DISC............4-43 REPLACING THE REAR BRAKE PADS..........4-44 REMOVING THE REAR BRAKE CALIPER ..........4-45 DISASSEMBLING THE REAR BRAKE CALIPER ........4-45 CHECKING THE REAR BRAKE CALIPER..........4-45 ASSEMBLING THE REAR BRAKE CALIPER ........
Page 133 REAR SHOCK ABSORBER ASSEMBLY ............4-78 HANDLING THE REAR SHOCK ABSORBER ........4-80 DISPOSING OF A REAR SHOCK ABSORBER (for MTN890) ....4-80 DISPOSING OF A REAR SHOCK ABSORBER (for MTN890D) ....4-80 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY....4-80 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY ....4-80 CHECKING THE CONNECTING ARM AND RELAY ARM.....4-81 INSTALLING THE RELAY ARM..............4-81 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY ....
Page 134 GENERAL CHASSIS (1) EAS20026 GENERAL CHASSIS (1) Removing the seat and battery m (0.7 kgf m, 5.2 lb • • • 2.2 N m (0.22 kgf m, 1.6 lb • • • Order Job/Parts to remove Q’ty Remarks Rider seat Battery holding bracket Negative battery lead Disconnect.
Page 135: General Chassis (1)
GENERAL CHASSIS (1) Removing the rear cover m (0.7 kgf m, 5.2 lb 2.0 N m (0.20 kgf m, 1.5 lb m (0.7 kgf m, 5.2 lb • • • • • • • • • m (0.7 kgf m, 5.2 lb •...
Page 136 GENERAL CHASSIS (1) Removing the headlight assembly, auxiliary light and meter assembly 4.3 N m (0.43 kgf m, 3.2 lb m (0.7 kgf m, 5.2 lb • • • • • • 1.5 N m (0.15 kgf m, 1.1 lb •...
Page 137 GENERAL CHASSIS (1) Removing the headlight assembly, auxiliary light and meter assembly 4.3 N m (0.43 kgf m, 3.2 lb m (0.7 kgf m, 5.2 lb • • • • • • 1.5 N m (0.15 kgf m, 1.1 lb •...
Page 138 GENERAL CHASSIS (1) Removing the front side panel 1.5 N m (0.15 kgf m, 1.1 lb • • • m (0.7 kgf m, 5.2 lb • • • m (0.7 kgf m, 5.2 lb • • • 1.5 N m (0.15 kgf m, 1.1 lb •...
Page 139 GENERAL CHASSIS (1) Removing the air scoop and fuel tank center cover 1.0 N m (0.10 kgf m, 0.73 lb • • • 1.0 N m (0.10 kgf m, 0.73 lb • • • m (0.7 kgf m, 5.2 lb •...
Page 140: Removing The Seat
GENERAL CHASSIS (1) EAS32229 REMOVING THE SEAT 1. Remove: a. Open the seat lock cover “1”, insert the key into the seat lock “2”, and then turn the key counterclockwise “3”. EAS32778 INSTALLING THE FUEL TANK SIDE COVER The following procedure applies to both of the fuel tank side cover.
Page 141: Installing The Headlight
GENERAL CHASSIS (1) EAS33545 1. Install: INSTALLING THE HEADLIGHT FRONT • IMU (Inertial Measurement Unit) “1” COVER a. Connect the IMU coupler “2” to the IMU. 1. Install: b. Install the grommets, collars, IMU “1”, • Headlight front cover “1” washers, IMU nuts and IMU bolts, and then tighten the bolts to specification.
Page 142: Installing The Seat
GENERAL CHASSIS (1) EAS31629 INSTALLING THE SEAT 1. Install: • Seat a. Insert the projections “1” into the seat hold- ers “2” as shown. b. Push the rear of the seat down to lock it in place. Make sure that the seat is properly secured be- fore riding.
Page 143 GENERAL CHASSIS (2) EAS20155 GENERAL CHASSIS (2) Removing the air filter case m (0.7 kgf m, 5.2 lb 1.6 N m (0.16 kgf m, 1.2 lb • • • • • • (10) 2.8 N m (0.28 kgf m, 2.1 lb •...
Page 144: Front Wheel
FRONT WHEEL EAS20028 FRONT WHEEL Removing the front wheel and brake discs 72 N ・ m (7.2 kgf ・ m, 53 lb ・ ft) 35 N ・ m (3.5 kgf ・ m, 26 lb ・ ft) 23 N ・ m (2.3 kgf ・ m, 17 lb ・ ft) 18 N ・...
Page 145 FRONT WHEEL Disassembling the front wheel 8 N ・ m (0.8 kgf ・ m, 5.9 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Front wheel sensor rotor Oil seal Wheel bearing Spacer 4-12...
Page 146: Removing The Front Wheel
FRONT WHEEL EAS31148 1. Remove: REMOVING THE FRONT WHEEL • Oil seal ECA20981 • Wheel bearing NOTICE a. Clean the surface of the front wheel hub. • Keep any type of magnets (including mag- b. Remove the oil seals “1” with a flat-head netic pick-up tools, magnetic screwdrivers, screwdriver.
Page 147: Assembling The Front Wheel
FRONT WHEEL Place a suitable washer “1” between the socket “2” and the bearing so that both the inner race “3” and outer race “4” are pressed at the same time, and then press the bearing until the inner race makes contact with the spacer “5”. G088897 4.
Page 148: Maintenance Of The Front Wheel Sensor And Sensor Rotor
FRONT WHEEL Wheel sensor rotor runout limit Wheel sensor rotor runout limit 0.25 mm (0.01 in) 0.25 mm (0.01 in) a. Hold the dial gauge at a right angle against EAS31151 MAINTENANCE OF THE FRONT WHEEL the wheel sensor rotor surface. SENSOR AND SENSOR ROTOR b.
Page 149: Installing The Front Wheel (Front Brake Discs)
FRONT WHEEL EAS31327 INSTALLING THE FRONT WHEEL (FRONT BRAKE DISCS) 1. Install: • Front brake disc Front brake disc bolt 18 N·m (1.8 kgf·m, 13 lb·ft) LOCTITE® ECA19150 6. Install: NOTICE • Front wheel sensor Replace the brake disc bolts with new ones. Front wheel sensor bolt 7 N·m (0.7 kgf·m, 5.2 lb·ft) Tighten the brake disc bolts in stages and in a...
Page 150 FRONT WHEEL Measure the distance between the front wheel sensor rotor and front wheel sensor in several places in one rotation of the front wheel. Do not turn the front wheel while the thickness gauge is installed. This may damage the front wheel sen- sor rotor and the front wheel sensor.
Page 151: Rear Wheel
REAR WHEEL EAS20029 REAR WHEEL Removing the rear wheel 105 N ・ m (10.5 kgf ・ m, 77 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 16 N ・ m (1.6 kgf ・ m, 12 lb ・ ft) 16 N ・...
Page 152 REAR WHEEL Removing the brake disc and rear wheel sprocket 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) 8 N ・ m (0.8 kgf ・ m, 5.9 lb ・ ft) 80 N ・ m (8.0 kgf ・ m, 59 lb ・ ft) Order Job/Parts to remove Q’ty...
Page 153 REAR WHEEL Disassembling the rear wheel Order Job/Parts to remove Q’ty Remarks Oil seal Wheel bearing Spacer Wheel bearing 4-20...
Page 154: Removing The Rear Wheel
REAR WHEEL EAS30910 REMOVING THE REAR WHEEL Push the rear wheel forward and remove the ECA21030 NOTICE drive chain from the rear wheel sprocket. • Keep any type of magnets (including mag- netic pick-up tools, magnetic screwdrivers, EAS31154 DISASSEMBLING THE REAR WHEEL etc.) away from the rear wheel sensor or ECA21340 rear wheel sensor rotor;...
Page 155: Assembling The Rear Wheel
REAR WHEEL Bent teeth → Replace the drive sprocket, the EAS31156 MAINTENANCE OF THE REAR WHEEL rear wheel sprocket and the drive chain as a SENSOR AND SENSOR ROTOR set. ECA21060 NOTICE • Handle the ABS components with care since they have been accurately adjusted. Keep them away from dirt and do not sub- ject them to shocks.
Page 156: Installing The Rear Wheel (Rear Brake Disc)
REAR WHEEL EAS31157 INSTALLING THE REAR WHEEL (REAR BRAKE DISC) 1. Install: • Rear brake disc Rear brake disc bolt 30 N·m (3.0 kgf·m, 22 lb·ft) LOCTITE® ECA19150 NOTICE Replace the brake disc bolts with new ones. Tighten the brake disc bolts in stages and in a crisscross pattern.
Page 157 REAR WHEEL 9. Measure: • Distance “a” When tightening the wheel axle nut, there (between the wheel sensor rotor “1” and rear should be no clearance “a” between the adjust- wheel sensor “2”) ing block “1” and adjusting bolt “2”. Out of specification →...
Page 158: Front Brake
FRONT BRAKE EAS20030 FRONT BRAKE Removing the front brake pads 5 N ・ m (0.5 kgf ・ m, 3.7 lb ・ ft) 35 N ・ m (3.5 kgf ・ m, 26 lb ・ ft) Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers.
Page 159 FRONT BRAKE Removing the front brake master cylinder 3.5 N m (0.35 kgf m, 2.6 lb • • • m (0.7 kgf m, 5.2 lb • • • 16 N m (1.6 kgf m, 12 lb • • • 1.2 N m (0.12 kgf m, 0.88 lb •...
Page 160 FRONT BRAKE Removing the front brake master cylinder 3.5 N m (0.35 kgf m, 2.6 lb • • • m (0.7 kgf m, 5.2 lb • • • 16 N m (1.6 kgf m, 12 lb • • • 1.2 N m (0.12 kgf m, 0.88 lb •...
Page 161 FRONT BRAKE Disassembling the front brake master cylinder 5 N ・ m (0.5 kgf ・ m, 3.7 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Brake master cylinder kit Bleed screw Brake master cylinder body 4-28...
Page 162 FRONT BRAKE Removing the front brake calipers 35 N m (3.5 kgf m, 26 lb • • • 3.8 N m (0.38 kgf m, 2.8 lb • • • 30 N m (3.0 kgf m, 22 lb • • • Order Job/Parts to remove Q’ty...
Page 163 FRONT BRAKE Disassembling the front brake calipers 5 N ・ m (0.5 kgf ・ m, 3.7 lb ・ ft) Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers. Brake pad clip Brake pad pin Brake pad spring Brake pad Brake caliper piston...
Page 164: Introduction
FRONT BRAKE EAS30168 INTRODUCTION EWA14101 WARNING Disc brake components rarely require disas- sembly. Therefore, always follow these pre- ventive measures: • Never disassemble brake components un- less absolutely necessary. • If any connection on the hydraulic brake G088908 system is disconnected, the entire brake 3.
Page 165 FRONT BRAKE 1. Remove: a. Connect a clear plastic hose “1” tightly to • Brake pad clip “1” the bleed screw “2”. Put the other end of the • Brake pad pin “2” hose into an open container. • Brake pad spring “3” b.
Page 166: Removing The Front Brake Calipers
FRONT BRAKE 8. Check: c. Remove the brake caliper piston dust seals • Brake lever operation and brake caliper piston seals. Soft or spongy feeling → Bleed the brake sys- d. Repeat the previous steps to force out the tem. right side pistons from the brake caliper.
Page 167: Assembling The Front Brake Calipers
FRONT BRAKE EAS30174 ASSEMBLING THE FRONT BRAKE CALIPERS EWA16560 WARNING • Before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. • Never use solvents on internal brake com- ponents as they will cause the brake caliper piston dust seals and brake caliper piston seals to swell and distort.
Page 168: Removing The Front Brake Master Cylinder
FRONT BRAKE EWA13090 WARNING To collect any remaining brake fluid, place a • Use only the designated brake fluid. Other container under the master cylinder and the end brake fluids may cause the rubber seals to of the brake hose. deteriorate, causing leakage and poor brake performance.
Page 169 FRONT BRAKE 3. Fill: • Brake master cylinder reservoir • Install the front brake master cylinder holder (with the specified amount of the specified with the “UP” mark “a” facing up. brake fluid) • Align the end of the front brake master cylinder holder with the punch mark “b”...
Page 170: Rear Brake
REAR BRAKE EAS20031 REAR BRAKE Removing the rear brake pads m (0.5 kgf m, 3.7 lb • • • 27 N m (2.7 kgf m, 20 lb • • • 22 N m (2.2 kgf m, 16 lb • • •...
Page 171 REAR BRAKE Removing the rear brake master cylinder 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) 28 N ・ m (2.8 kgf ・ m, 21 lb ・ ft) 5 N ・ m (0.5 kgf ・ m, 3.7 lb ・ ft) 23 N ・...
Page 172 REAR BRAKE Removing the rear brake master cylinder 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) 28 N ・ m (2.8 kgf ・ m, 21 lb ・ ft) 5 N ・ m (0.5 kgf ・ m, 3.7 lb ・ ft) 23 N ・...
Page 173 REAR BRAKE Disassembling the rear brake master cylinder 18 N ・ m (1.8 kgf ・ m, 13 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Brake master cylinder yoke Brake master cylinder kit Hose joint Bushing Brake master cylinder body 4-40...
Page 174 REAR BRAKE Removing the rear brake caliper 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) 22 N m (2.2 kgf m, 16 lb • • • 27 N m (2.7 kgf m, 20 lb • • •...
Page 175 REAR BRAKE Disassembling the rear brake caliper 5 N ・ m (0.5 kgf ・ m, 3.7 lb ・ ft) 17 N ・ m (1.7 kgf ・ m, 13 lb ・ ft) 2.5 N ・ m (0.25 kgf ・ m, 1.8 lb ・ ft) Order Job/Parts to remove Q’ty...
Page 176: Adjusting The Footrest Position
REAR BRAKE EAS33521 EAS30183 ADJUSTING THE FOOTREST POSITION INTRODUCTION 1. Check: EWA14101 WARNING • Footrest position Disc brake components rarely require disas- sembly. Therefore, always follow these pre- The rider footrests can be adjusted to one of two ventive measures: positions.
Page 177: Replacing The Rear Brake Pads
REAR BRAKE 4. Replace: • Brake disc Refer to “REAR WHEEL” on page 4-18. Rear brake disc bolt 30 N·m (3.0 kgf·m, 22 lb·ft) LOCTITE® EAS30185 REPLACING THE REAR BRAKE PADS c. Tighten the bleed screw. When replacing the brake pads, it is not neces- sary to disconnect the brake hose or disassem- Brake caliper bleed screw ble the brake caliper.
Page 178: Removing The Rear Brake Caliper
REAR BRAKE 4. Install: EWA13550 WARNING • Rear brake caliper • Cover the brake caliper piston with a rag. • Brake pad retaining bolt Be careful not to get injured when the pis- • Screw plug ton is expelled from the brake caliper. •...
Page 179: Assembling The Rear Brake Caliper
REAR BRAKE 2. Check: • Rear brake caliper bracket • Rear brake caliper bracket retainer Cracks/damage → Replace the rear brake caliper bracket assembly. Refer to “REAR WHEEL” on page 4-18. EAS30189 ASSEMBLING THE REAR BRAKE CALIPER EWA17080 WARNING 2. Remove: •...
Page 180: Removing The Rear Brake Master Cylinder
REAR BRAKE EWA13090 EAS30194 CHECKING THE REAR BRAKE MASTER WARNING CYLINDER • Use only the designated brake fluid. Other 1. Check: brake fluids may cause the rubber seals to • Brake master cylinder deteriorate, causing leakage and poor Damage/scratches/wear → Replace. brake performance.
Page 181 REAR BRAKE EWA13531 4. Check: WARNING • Brake fluid level Proper brake hose routing is essential to in- Below the minimum level mark → Add the sure safe vehicle operation. specified brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID ECA14160 LEVEL”...
Page 182: Abs (Anti-Lock Brake System)
ABS (ANTI-LOCK BRAKE SYSTEM) EAS20032 ABS (ANTI-LOCK BRAKE SYSTEM) Removing the hydraulic unit assembly 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 16 N ・ m (1.6 kgf ・ m, 12 lb ・ ft) 16 N ・...
Page 183 ABS (ANTI-LOCK BRAKE SYSTEM) Removing the hydraulic unit assembly 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 16 N ・ m (1.6 kgf ・ m, 12 lb ・ ft) 16 N ・...
Page 184: Removing The Hydraulic Unit Assembly
ABS (ANTI-LOCK BRAKE SYSTEM) EAS30197 REMOVING THE HYDRAULIC UNIT • Do not operate the brake lever and brake pedal ASSEMBLY while removing the brake hoses. ECA21091 • Do not bend the brake pipe when loosening the NOTICE brake pipe flare nuts. Unless necessary, avoid removing and in- stalling the brake hoses of the hydraulic unit ECA19800...
Page 185: Checking The Brake Pipes
ABS (ANTI-LOCK BRAKE SYSTEM) EAS30935 CHECKING THE BRAKE PIPES Hydraulic unit brake pipe flare The following procedure applies to all of the brake pipes. 16 N·m (1.6 kgf·m, 12 lb·ft) 1. Check: • Brake pipe end (flare nut) ECA19820 Damage → Replace the hydraulic unit as- NOTICE If the brake pipe flare nut does not turn easi- sembly, brake pipes, and related parts as a...
Page 186: Hydraulic Unit Operation Tests
ABS (ANTI-LOCK BRAKE SYSTEM) 10.Delete the DTC. (Refer to “SELF-DIAGNOS- TIC FUNCTION AND DIAGNOSTIC CODE TABLE” on page 9-48.) 11.Perform a trial run. (Refer to “CHECKING THE ABS WARNING LIGHT” on page 4-56.) EAS30930 HYDRAULIC UNIT OPERATION TESTS The reaction-force pulsating action generated in the brake lever and brake pedal when the ABS is activated can be tested when the vehicle is 7.
Page 187 • Yamaha diagnostic tool (A/I) (90890-03264) in- G088911 cludes YDT sub harness (6P) (90890-03266). • If you already have Yamaha diagnostic tool (A/ “ON” and “OFF” on the tool screen indicate I) (90890-03262), YDT sub harness (6P) when the brakes are being applied and released (90890-03266) is separately required.
Page 188 • Yamaha diagnostic tool (A/I) (90890-03264) in- cludes YDT sub harness (6P) (90890-03266). • If you already have Yamaha diagnostic tool (A/I) (90890-03262), YDT sub harness (6P) (90890-03266) is separately required. Refer to “YDT” on page 9-3.
Page 189: Checking The Abs Warning Light
ABS (ANTI-LOCK BRAKE SYSTEM) G088914 11.After the pulsating action has stopped in the brake pedal, it is generated in the brake lever and continues for a few seconds. • The reaction-force pulsating action consists of quick pulses. • “ON” and “OFF” on the tool screen indicate when the brakes are being applied and re- leased respectively.
Page 190: Handlebar
HANDLEBAR EAS20033 HANDLEBAR Removing the handlebar 3.8 N ・ m (0.38 kgf ・ m, 2.8 lb ・ ft) 17 N ・ m (1.7 kgf ・ m, 13 lb ・ ft) 16 N ・ m (1.6 kgf ・ m, 12 lb ・ ft) 22 N ・...
Page 191 HANDLEBAR Removing the handlebar 3.8 N ・ m (0.38 kgf ・ m, 2.8 lb ・ ft) 17 N ・ m (1.7 kgf ・ m, 13 lb ・ ft) 16 N ・ m (1.6 kgf ・ m, 12 lb ・ ft) 22 N ・...
Page 192: Adjusting The Handlebar Position
HANDLEBAR EAS31396 ADJUSTING THE HANDLEBAR POSITION Upper handlebar holder bolt 1. Check: 22 N·m (2.2 kgf·m, 16 lb·ft) • Handlebar position ECA18300 NOTICE The handlebar position can be adjusted in two First, tighten the bolts on the front side of the positions to suit the rider’s preference.
Page 193: Checking The Handlebar
HANDLEBAR G088916 3. Tighten: EAS30204 • Lower handlebar holder nut CHECKING THE HANDLEBAR 1. Check: Lower handlebar holder nut • Handlebar 40 N·m (4.0 kgf·m, 30 lb·ft) Bends/cracks/damage → Replace. EWA13690 4. Install: WARNING • Handlebar switch (right) Do not attempt to straighten a bent handle- •...
Page 194 HANDLEBAR c. Install the handlebar switch (right, rear side) “4”. Align the projection “c” on the handlebar switch (right, rear side) with the hole “d” in the handle- bar “3”. 7. Install: • Handlebar grip • Grip end (left) “1” Grip end bolt 3.8 N·m (0.38 kgf·m, 2.8 lb·ft) d.
Page 195 HANDLEBAR Align the projection “a” on the handlebar switch (left) with the hole “b” in the handlebar. A. For MTN890 B. For MTN890D 9. Adjust: • Clutch lever free play Refer to “ADJUSTING THE CLUTCH LEVER FREE PLAY” on page 3-12. Clutch lever free play 10.0–15.0 mm (0.39–0.59 in) (MTN890)
Page 196: Front Fork
FRONT FORK EAS20034 FRONT FORK Removing the front fork legs 23 N ・ m (2.3 kgf ・ m, 17 lb ・ ft) 26 N ・ m (2.6 kgf ・ m, 19 lb ・ ft) 23 N ・ m (2.3 kgf ・ m, 17 lb ・ ft) 10 N ・...
Page 197 FRONT FORK Disassembling the front fork leg 23 N m (2.3 kgf m, 17 lb • • • 15 N m (1.5 kgf m, 11 lb • • • 23 N m (2.3 kgf m, 17 lb • • • Order Job/Parts to remove Q’ty...
Page 198 FRONT FORK Disassembling the front fork leg 23 N m (2.3 kgf m, 17 lb • • • 15 N m (1.5 kgf m, 11 lb • • • 23 N m (2.3 kgf m, 17 lb • • • Order Job/Parts to remove Q’ty...
Page 199: Removing The Front Fork Legs
FRONT FORK EAS30206 EAS30207 REMOVING THE FRONT FORK LEGS DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the The following procedure applies to both of the front fork legs. front fork legs. 1. Remove: • Cap bolt “1” For MTN890: (from the damper rod assembly) Each front fork leg is equipped with a spring pre-...
Page 200: Checking The Front Fork Legs
FRONT FORK While holding the damper rod with the damper rod holder “1”, loosen the damper rod assembly bolt. Damper rod holder (ø27) 90890-01582 Damper rod holder YM-01582 G088919 3. Remove: • Dust seal “1” • Oil seal clip “2” (with a flat-head screwdriver) ECA19100 NOTICE...
Page 201: Assembling The Front Fork Legs
FRONT FORK 3. Check: • Damper rod • When assembling the front fork leg, be sure to Damage/wear → Replace. replace the following parts: Obstruction → Blow out all of the oil passag- – Inner tube bushing es with compressed air. –...
Page 202 • Inner tube’s outer surface Fork seal driver 90890-01442 Adjustable fork seal driver Recommended oil (36–46 mm) Yamaha Suspension Oil 01 YM-01442 4. Install: • Dust seal “1” • Oil seal clip “2” • Oil seal “3” • Washer “4”...
Page 203 FRONT FORK 9. Install: • Dust seal “1” Recommended oil Yamaha Suspension Oil 01 (with the fork seal driver “2”) Quantity (left) 468.0 cm³ (15.82 US oz, 16.51 Fork seal driver Imp.oz) (MTN890) 90890-01442 473.0 cm³ (15.99 US oz, 16.68 Adjustable fork seal driver (36–...
Page 204 FRONT FORK h. Pull up the rod puller and install the rod Level (left) holder “2” between the locknut “3” and the 107 mm (4.2 in) (MTN890) washer “4”. 110 mm (4.3 in) (MTN890D) Level (right) Rod puller 107 mm (4.2 in) (MTN890) 90890-01437 110 mm (4.3 in) (MTN890D) Universal damping rod bleeding...
Page 205: Installing The Front Fork Legs
FRONT FORK EAS30210 INSTALLING THE FRONT FORK LEGS Distance “c” The following procedure applies to both of the 13 mm (0.51 in) front fork legs. 1. Install: • Front fork leg Temporarily tighten the upper and lower bracket pinch bolts. Installed length (from the top of the outer tube) “a”...
Page 206 FRONT FORK For MTN890D: When installing the front fork legs, make sure that the letters on the cap bolts are positioned within the angle range shown in the illustration. 5° 5° 5° 5° 3. Check: • Cable routing Make sure the brake hoses, clutch cable, and handlebar switch leads are routed properly.
Page 207: Steering Head
STEERING HEAD EAS20035 STEERING HEAD Removing the lower bracket 110 N m (11 kgf m, 81 lb • • • 52 N ・ m (5.2 kgf ・ m, 38 lb ・ ft) *2nd 14 N ・ m (1.4 kgf ・ m, 10 lb ・ ft) m (0.7 kgf m, 5.2 lb •...
Page 208 STEERING HEAD Removing the lower bracket 110 N m (11 kgf m, 81 lb • • • 52 N ・ m (5.2 kgf ・ m, 38 lb ・ ft) *2nd 14 N ・ m (1.4 kgf ・ m, 10 lb ・ ft) m (0.7 kgf m, 5.2 lb •...
Page 209: Removing The Lower Bracket
STEERING HEAD EAS30213 2. Check: REMOVING THE LOWER BRACKET • Bearing 1. Stand the vehicle on a level surface. • Bearing race EWA13120 Damage/pitting → Replace the bearings and WARNING bearing races as a set. Securely support the vehicle so that there is 3.
Page 210: Installing The Steering Head
STEERING HEAD EAS30216 INSTALLING THE STEERING HEAD 1. Lubricate: • Upper bearing • Lower bearing Recommended lubricant Lithium-soap-based grease 2. Install: • Lower ring nut “1” • Rubber washer “2” • Upper ring nut “3” • Lock washer “4” Refer to “CHECKING AND ADJUSTING THE STEERING HEAD”...
Page 211 REAR SHOCK ABSORBER ASSEMBLY EAS20036 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly (for MTN890) 44 N m (4.4 kgf m, 32 lb • • • 44 N m (4.4 kgf m, 32 lb • • • 44 N m (4.4 kgf m, 32 lb •...
Page 212 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly (for MTN890D) 44 N m (4.4 kgf m, 32 lb • • • m (0.7 kgf m, 5.2 lb • • • 44 N m (4.4 kgf m, 32 lb •...
Page 213: Rear Shock Absorber Assembly
REAR SHOCK ABSORBER ASSEMBLY EAS30826 EWA13760 HANDLING THE REAR SHOCK ABSORBER WARNING EWA13740 Wear eye protection to prevent eye damage WARNING from released gas or metal chips. This rear shock absorber contains highly compressed nitrogen gas. Before handling the rear shock absorber, read and make sure you understand the following information.
Page 214: Checking The Connecting Arm And Relay Arm
REAR SHOCK ABSORBER ASSEMBLY EAS30221 CHECKING THE CONNECTING ARM AND RELAY ARM 1. Check: • Connecting arm • Relay arm Damage/wear → Replace. 2. Check: • Bearing Damage/pitting → Replace. 3. Check: • Collar Damage/scratches → Replace. EAS30222 INSTALLING THE RELAY ARM 1.
Page 215 REAR SHOCK ABSORBER ASSEMBLY 2. Tighten: • Gas cylinder bracket bolt (for MTN890D) • Bracket bolt (for MTN890D) • Rear shock absorber assembly upper nut • Rear shock absorber assembly lower nut Gas cylinder bracket bolt (for MTN890D) 7 N·m (0.7 kgf·m, 5.2 lb·ft) LOCTITE®...
Page 216: Swingarm
SWINGARM EAS20037 SWINGARM Removing the swingarm m (0.7 kgf m, 5.2 lb • • • m (0.7 kgf m, 5.2 lb • • • m (0.7 kgf m, 5.2 lb • • • 105 N m (10.5 kgf m, 77 lb •...
Page 217: Removing The Swingarm
SWINGARM EAS30226 EWA13770 REMOVING THE SWINGARM WARNING 1. Stand the vehicle on a level surface. Do not attempt to straighten a bent pivot EWA13120 shaft. WARNING Securely support the vehicle so that there is 3. Wash: no danger of it falling over. •...
Page 218 SWINGARM When installing the oil seals to the swingarm, face the character stamp of the oil seals outside. A. Left side B. Right side 3. Install: • Swingarm • Pivot shaft Relay arm nut 44 N·m (4.4 kgf·m, 32 lb·ft) Pivot shaft nut 105 N·m (10.5 kgf·m, 77 lb·ft) 4.
Page 219: Chain Drive
CHAIN DRIVE EAS20038 CHAIN DRIVE Removing the drive chain 14 N m (1.4 kgf m, 10 lb • • • 160 N m (16 kgf m, 118 lb • • • m (0.7 kgf m, 5.2 lb • • • m (0.8 kgf m, 5.9 lb •...
Page 220: Removing The Drive Chain
CHAIN DRIVE EAS30229 a. Measure the length “b” between the inner REMOVING THE DRIVE CHAIN sides of the pins and the length “c” between 1. Stand the vehicle on a level surface. the outer sides of the pins on a 15-link sec- EWA13120 tion of the drive chain as shown in the illus- WARNING...
Page 221: Checking The Drive Sprocket
CHAIN DRIVE 3. Clean: • Drive chain a. Wipe the drive chain with a clean cloth. b. Put the drive chain in kerosene and remove any remaining dirt. c. Remove the drive chain from the kerosene and completely dry it. ECA19090 NOTICE G088943...
Page 222: Installing The Drive Chain
CHAIN DRIVE EAS30234 INSTALLING THE DRIVE CHAIN 1. Install: • Drive chain ECA17410 NOTICE Be sure to put on safety goggles when work- ing. Install the drive chain joint with the drive chain cut & rivet tool. 2. Lubricate: • Drive chain Drive chain cut &...
Page 223: Adjusting The Shift Pedal
CHAIN DRIVE 4. Install: a. 24 mm (0.94 in) • Shift arm “1” b. 24.4 mm (0.96 in) 6. Adjust: Before installing, make sure to align the mark “a” • Installed shift rod length of the shift shaft with the punch mark “b” of the Refer to “ADJUSTING THE SHIFT PEDAL”...
Page 224 CHAIN DRIVE 2. Adjust: • Installed shift rod length a. Loosen both locknuts “1”. b. Turn the shift rod “2” until the specified in- stalled shift rod length is obtained. c. Tighten both locknuts. Be sure to place the shift rod joints in parallel. The allowable twist of the shift rod joints is ±5°.
Page 225: Engine
ENGINE LUBRICATION SYSTEM CHART AND DIAGRAMS........5-1 ENGINE OIL LUBRICATION CHART ............5-1 LUBRICATION DIAGRAMS ..............5-2 ENGINE INSPECTION ..................5-7 MEASURE THE COMPRESSION PRESSURE........5-7 ENGINE REMOVAL ..................5-9 REMOVING THE ENGINE ..............5-14 INSTALLING THE ENGINE..............5-14 CAMSHAFTS....................5-16 REMOVING THE CAMSHAFTS..............5-19 CHECKING THE CAMSHAFTS ..............5-20 CHECKING THE TIMING CHAIN AND CAMSHAFT SPROCKET ..5-21 CHECKING THE TIMING CHAIN GUIDES..........
Page 226 CLUTCH ......................5-45 REMOVING THE CLUTCH ..............5-49 CHECKING THE FRICTION PLATES.............5-50 CHECKING THE CLUTCH PLATES ............5-50 CHECKING THE CLUTCH SPRINGS.............5-51 CHECKING THE CLUTCH HOUSING ............5-51 CHECKING THE CLUTCH BOSS............5-52 CHECKING THE PRESSURE PLATE ............5-52 CHECKING THE PRIMARY DRIVE GEAR..........5-52 CHECKING THE PRIMARY DRIVEN GEAR ..........5-52 CHECKING THE PULL LEVER SHAFT AND PULL ROD ......5-52 INSTALLING THE CLUTCH..............
Page 227 CRANKSHAFT AND BALANCER SHAFT ...........5-80 REMOVING THE CRANKSHAFT AND BALANCER SHAFT....5-81 CHECKING THE OIL NOZZLES ............. 5-81 CHECKING THE CRANKSHAFT ............5-81 CHECKING THE BALANCER SHAFT ............5-83 INSTALLING THE CRANKSHAFT ............5-85 INSTALLING THE BALANCER ASSEMBLY...........5-85 TRANSMISSION.................... 5-86 REMOVING THE TRANSMISSION ............5-91 CHECKING THE SHIFT FORKS.............
Page 228: Lubrication System Chart And Diagrams
LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20298 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS32362 ENGINE OIL LUBRICATION CHART 1. Oil strainer 15. Intake camshaft 2. Oil pump 16. Exhaust camshaft 3. Relief valve 4. Oil cooler 5. Oil filter cartridge 6. Main gallery 7.
Page 229: Lubrication Diagrams
LUBRICATION SYSTEM CHART AND DIAGRAMS EAS32363 LUBRICATION DIAGRAMS 1. Oil filter cartridge union bolt 2. Oil filter cartridge 3. Oil delivery pipe 4. Drive axle 5. Main axle...
Page 230 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Timing chain tensioner 2. Intake camshaft 3. Exhaust camshaft 4. Balancer shaft 5. Crankshaft 6. Oil cooler 7. Oil strainer 8. Oil drain bolt 9. Oil pump driven sprocket 10. Oil delivery pipe...
Page 231 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil cooler 2. Oil filter cartridge 3. Oil pressure switch 4. Oil strainer 5. Oil pump...
Page 232 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Balancer shaft 2. Crankshaft 3. Oil delivery pipe 4. Main axle 5. Drive axle 6. Oil gallery bolt...
Page 233 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Cylinder head 2. Intake camshaft 3. Exhaust camshaft 4. Oil passage to the cylinder head 5. Oil passage to the clutch chamber 6. Oil return passage from the cylinder head 7. Crankshaft 8. Main gallery...
Page 234: Engine Inspection
ENGINE INSPECTION EAS20041 ENGINE INSPECTION EAS30249 MEASURE THE COMPRESSION PRESSURE The following procedure applies to all of the cyl- inders. Insufficient compression pressure will result in a loss of performance. 5. Measure: 1. Measure: • Compression pressure • Valve clearance Out of specification →...
Page 235 ENGINE INSPECTION Compression pressure (with oil applied into the cylinder) Reading Diagnosis Higher than without Piston ring(s) wear or damage → Repair. Same as without oil Piston, valves, cylin- der head gasket pos- sibly defective → Repair. 6. Install: • Spark plug Spark plug 13 N·m (1.3 kgf·m, 9.6 lb·ft) 7.
Page 236: Engine Removal
18 lb 20 N m (2.0 kgf m, 15 lb • • • • • • * YAMAHA GREASE “G” Order Job/Parts to remove Q’ty Remarks Radiator bracket Refer to “RADIATOR” on page 6-3. sensor coupler Disconnect. Muffler assembly...
Page 237 ENGINE REMOVAL Disconnecting the leads and hoses m (0.7 kgf m, 5.2 lb • • • m (0.7 kgf m, 5.2 lb • • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS (1)” on Rider seat page 4-1. Refer to “GENERAL CHASSIS (1)”...
Page 238 ENGINE REMOVAL Disconnecting the leads and hoses m (0.7 kgf m, 5.2 lb • • • m (0.7 kgf m, 5.2 lb • • • Order Job/Parts to remove Q’ty Remarks Footrest assembly (right) Refer to “REAR BRAKE” on page 4-37. Shift rod/Drive sprocket Refer to “CHAIN DRIVE”...
Page 239 ENGINE REMOVAL Removing the engine 25 N m (2.5 kgf m, 18 lb 25 N m (2.5 kgf m, 18 lb • • • • • • 45 N m (4.5 kgf m, 33 lb • • • 105 N m (10.5 kgf m, 77 lb 60 N...
Page 240 ENGINE REMOVAL Removing the engine 25 N m (2.5 kgf m, 18 lb 25 N m (2.5 kgf m, 18 lb • • • • • • 45 N m (4.5 kgf m, 33 lb • • • 105 N m (10.5 kgf m, 77 lb •...
Page 241: Removing The Engine
ENGINE REMOVAL EAS30250 5. Install: REMOVING THE ENGINE • Engine mounting bolt (left front lower side) “7” 1. Loosen: (temporarily tighten) • Engine mounting adjust bolt (rear) 6. Install: • Collar “8” Loosen the engine mounting adjust bolts with • Collar “9” the pivot shaft wrench “1”...
Page 242 ENGINE REMOVAL 16.Tighten: Engine mounting bolt (left front • Engine bracket bolt (left) “17” lower side) • Engine mounting bolt (left front upper side) 60 N·m (6.0 kgf·m, 44 lb·ft) “18” Engine mounting bolt (right front • Engine bracket bolt (right) “20” lower side) •...
Page 243: Camshafts
CAMSHAFTS EAS20043 CAMSHAFTS Removing the cylinder head cover 10 N m (1.0 kgf m, 7.4 lb • • • 10 N m (1.0 kgf m, 7.4 lb • • • 13 N m (1.3 kgf m, 9.6 lb • • •...
Page 244 CAMSHAFTS Removing the camshafts 10 N m (1.0 kgf m, 7.4 lb • • • 10 N m (1.0 kgf m, 7.4 lb • • • 10 N m (1.0 kgf m, 7.4 lb • • • 10 N m (1.0 kgf m, 7.4 lb •...
Page 245 CAMSHAFTS Removing the camshafts 10 N m (1.0 kgf m, 7.4 lb • • • 10 N m (1.0 kgf m, 7.4 lb • • • 10 N m (1.0 kgf m, 7.4 lb • • • 10 N m (1.0 kgf m, 7.4 lb •...
Page 246: Removing The Camshafts
CAMSHAFTS EAS30256 4. Remove: REMOVING THE CAMSHAFTS • Camshaft cap 1. Remove: • Intake camshaft cap • Timing mark accessing bolt “1” • Exhaust camshaft cap • Crankshaft end cover “2” ECA13720 NOTICE To prevent damage to the cylinder head, camshafts or camshaft caps, loosen the camshaft cap bolts in stages and in a criss- cross pattern, working from the outside in.
Page 247: Checking The Camshafts
CAMSHAFTS 4. Measure: • Camshaft-journal-to-camshaft-cap clearance Out of specification → Measure the camshaft journal diameter. Camshaft-journal-to-camshaft- cap clearance limit 0.080 mm (0.0032 in) a. Install the camshaft into the cylinder head (without the camshaft caps). EAS30257 b. Position strip of Plastigauge® “1” onto the CHECKING THE CAMSHAFTS camshaft journal as shown.
Page 248: Checking The Timing Chain And Camshaft Sprocket
CAMSHAFTS a. Using the valve spring compressor “1”, push and insert timing chain tensioner rod “2” into the timing chain tensioner housing. Push the timing chain tensioner rod in direction “a”, and turn the timing chain tensioner body “3” in direction “b” until the circlip fits into the groove. G088949 EAS30258 CHECKING THE TIMING CHAIN AND...
Page 249: Installing The Camshafts
CAMSHAFTS • Install the camshaft projection “a” at the posi- tion shown in the illustration. • Tighten the camshaft sprocket bolt with the camshaft wrench “3”. Camshaft wrench 90890-04162 Camshaft wrench YM-04162 EAS30269 INSTALLING THE CAMSHAFTS 1. Remove: • Timing mark accessing bolt “1” •...
Page 250 CAMSHAFTS • Make sure each camshaft cap is installed in its Tighten the camshaft cap bolts in stage and in a original place. Refer to the identification marks crisscross pattern, working from the inner caps as follows: out. “IL”: Intake left side camshaft cap mark ECA17430 “EL”: Exhaust left side camshaft cap mark NOTICE...
Page 251 CAMSHAFTS 12.Check: • Mark “a” Make sure the mark “a” on the generator rotor is aligned with the generator rotor cover mark “b”. • Camshaft punch mark “c” Make sure the camshaft punch mark “c” on the camshaft is aligned with the camshaft cap alignment mark “d”.
Page 252 CAMSHAFTS Install the ignition coils “1” in the direction shown in the illustration. 15.Install: • Timing chain guide (top side) • Cylinder head cover gasket “1” • Cylinder head cover Cylinder head cover bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft) •...
Page 253: Cylinder Head
CYLINDER HEAD EAS20044 CYLINDER HEAD Removing the cylinder head 20 N ・ m (2.0 kgf ・ m, 15 lb ・ ft) 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 15 N ・...
Page 254: Removing The Cylinder Head
CYLINDER HEAD EAS30276 REMOVING THE CYLINDER HEAD Warpage limit 1. Remove: 0.10 mm (0.0039 in) • Intake camshaft • Exhaust camshaft Refer to “REMOVING THE CAMSHAFTS” on page 5-19. 2. Remove: • Cylinder head bolt (M6) (×4) • Cylinder head bolt (M9) (×8) •...
Page 255: Installing The Cylinder Head
CYLINDER HEAD EAS30282 INSTALLING THE CYLINDER HEAD 1. Install: • Timing chain guide (exhaust side) “1” • Cylinder head gasket “2” • Dowel pin “3” 4. Install: • Exhaust camshaft • Intake camshaft Refer to “INSTALLING THE CAMSHAFTS” on page 5-22. 2.
Page 256 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 5-26. Intake valve lifter Intake valve pad Intake valve cotter Intake valve spring retainer Intake valve spring Intake valve Intake valve stem seal...
Page 257: Valves And Valve Springs
VALVES AND VALVE SPRINGS Removing the valves and valve springs Order Job/Parts to remove Q’ty Remarks Exhaust valve Exhaust valve stem seal Exhaust valve spring seat Exhaust valve guide 5-30...
Page 258: Removing The Valves
VALVES AND VALVE SPRINGS EAS30283 REMOVING THE VALVES Valve spring compressor The following procedure applies to all of the 90890-04200 valves and related components. Valve spring compressor YM-04019 Before removing the internal parts of the cylinder Valve spring compressor attach- ment (ø23) head (e.g., valves, valve springs, valve seats), 90890-04179...
Page 259 VALVES AND VALVE SPRINGS G088960 G088963 a. Valve guide position c. After installing the valve guide, bore the valve guide with the valve guide reamer “3” to obtain the proper valve-stem-to-valve- guide clearance. G088961 2. Replace: • Valve guide To ease valve guide removal and installation, and to maintain the correct fit, heat the cylinder G088964 head to 100 °C (212 °F) in an oven.
Page 260: Checking The Valve Seats
VALVES AND VALVE SPRINGS 5. Measure: a. Apply blue layout fluid “b” onto the valve • Valve stem runout face. Out of specification → Replace the valve. • When installing a new valve, always replace the valve guide. • If the valve is removed or replaced, always re- place the valve stem seal.
Page 261: Checking The Valve Springs
VALVES AND VALVE SPRINGS d. Turn the valve until the valve face and valve EAS30286 CHECKING THE VALVE SPRINGS seat are evenly polished, then clean off all The following procedure applies to all of the of the lapping compound. valve springs. 1.
Page 262 VALVES AND VALVE SPRINGS Recommended lubricant Molybdenum disulfide oil 3. Install: • Valve spring seat “1” • Valve stem seal “2” • Valve “3” • Valve spring “4” • Valve spring retainer “5” G088959 5. To secure the valve cotters onto the valve (into the cylinder head) stem, lightly tap the valve tip with a soft-face hammer.
Page 263: Generator And Starter Clutch
12 N ・ m (1.2 kgf ・ m, 8.9 lb ・ ft) 11 N ・ m (1.1 kgf ・ m, 8.1 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) * YAMAHA bond No. 1215 (Three bond No. 1215®) Order Job/Parts to remove Q’ty...
Page 264 12 N ・ m (1.2 kgf ・ m, 8.9 lb ・ ft) 11 N ・ m (1.1 kgf ・ m, 8.1 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) * YAMAHA bond No. 1215 (Three bond No. 1215®) Order Job/Parts to remove Q’ty...
Page 265: Removing The Generator
GENERATOR AND STARTER CLUTCH EAS30867 REMOVING THE GENERATOR 1. Remove: • Generator rotor bolt “1” • Washer While holding the generator rotor “2” with the sheave holder “3”, loosen the generator rotor bolt. Sheave holder EAS30868 REMOVING THE STARTER CLUTCH 90890-01903 1.
Page 266: Installing The Starter Clutch
GENERATOR AND STARTER CLUTCH 4. Check: • Starter clutch operation a. Install the starter clutch gear “1” onto the generator rotor “2” and hold the generator rotor. b. When turning the starter clutch gear clock- wise “A”, the starter clutch and the starter clutch gear should engage, otherwise the starter clutch is faulty and must be re- placed.
Page 267 To route the stator coil lead, refer to “CABLE ROUTING” on page 2-15. 3. Apply: • Sealant (onto the stator coil assembly lead grommet) Yamaha bond No. 1215 90890-85505 Three bond No. 1215® G088980 4. Install: • Generator cover gasket •...
Page 268: Electric Starter
ELECTRIC STARTER EAS20052 ELECTRIC STARTER Removing the starter motor 12 N m (1.2 kgf m, 8.9 lb • • • m (0.7 kgf m, 5.2 lb • • • Order Job/Parts to remove Q’ty Remarks Purge cut valve solenoid Refer to “FUEL TANK” on page 7-1. Throttle bodies Refer to “THROTTLE BODIES”...
Page 269 ELECTRIC STARTER Disassembling the starter motor 11 N m (1.1 k gf m, 8.1 lb • • • m (0.5 k gf m, 3.7 lb • • • Order Job/Parts to remove Q’ty Remarks O-ring Starter motor front cover Starter motor yoke Armature assembly Gasket Brush holder set...
Page 270: Checking The Starter Motor
ELECTRIC STARTER EAS30325 4. Measure: CHECKING THE STARTER MOTOR • Brush length “a” 1. Check: Out of specification → Replace the brush • Commutator holder set. Dirt → Clean with 600 grit sandpaper. 2. Measure: Brush overall length limit • Mica undercut “a” 6.5 mm (0.26 in) Out of specification →...
Page 271: Installing The Starter Motor
ELECTRIC STARTER 2. Install: • Starter motor rear cover “1” • Starter motor yoke “2” • Starter motor front cover “3” Align the match marks “a” on the starter motor yoke with the match marks “b” on the front and rear cover.
Page 272: Clutch
CLUTCH EAS20055 CLUTCH Removing the clutch cover m (0.7 kgf m, 5.2 lb • • • 12 N m (1.2 kgf m, 8.9 lb • • • 1.5 N m (0.15 kgf m, 1.1 lb • • • 12 N m (1.2 kgf m, 8.9 lb •...
Page 273 CLUTCH Removing the pull lever shaft Order Job/Parts to remove Q’ty Remarks Circlip Pull lever Pull lever spring Circlip Pull lever shaft Oil seal Bearing Bearing 5-46...
Page 274 CLUTCH Removing the clutch 125 N m (12.5 k gf m, 92 lb • • • 10 N m (1.0 k gf m, 7.4 lb • • • Order Job/Parts to remove Q’ty Remarks Oil pump driven sprocket Refer to “OIL PUMP” on page 5-57. Pressure plate 1 Clutch spring Pressure plate 2...
Page 275 CLUTCH Removing the clutch 125 N m (12.5 k gf m, 92 lb • • • 10 N m (1.0 k gf m, 7.4 lb • • • Order Job/Parts to remove Q’ty Remarks Clutch boss Thrust plate Clutch housing Oil pump drive chain Bearing Spacer...
Page 276: Removing The Clutch
CLUTCH EAS30346 4. Remove: REMOVING THE CLUTCH • Friction plate 2 “1” 1. Remove: • Cover “1” • Clutch cover “2” • Gasket Loosen each bolt 1/4 of a turn at a time, in stag- es and in a crisscross pattern. After all of the bolts are fully loosened, remove them.
Page 277: Checking The Friction Plates
CLUTCH G088993 8. Remove: A. Friction plate 1 • Clutch boss nut B. Friction plate 2 • Conical spring washer • Washer EAS30349 CHECKING THE CLUTCH PLATES • Clutch boss The following procedure applies to all of the • Thrust plate clutch plates.
Page 278: Checking The Clutch Springs
CLUTCH • Perform the thickness measurement without applying the oil. • This step should be performed only if the fric- tion plates and clutch plates were replaced. • To measure the total width of the friction plates and clutch plates, combine 9 friction plates and 8 clutch plates as shown.
Page 279: Checking The Clutch Boss
CLUTCH 2. Check: EAS30356 CHECKING THE PRIMARY DRIVE GEAR • Oil pump drive sprocket “1” 1. Check: Cracks/damage/wear → Replace the oil • Primary drive gear pump drive chain and clutch housing as a set. Damage/wear → Replace the crankshaft and clutch housing as a set.
Page 280 CLUTCH Clutch boss nut • First, install a friction plate and then alternate 125 N·m (12.5 kgf·m, 92 lb·ft) between a clutch plate and a friction plate. • Install the last friction plate “1” offset from the other friction plates “2”, making sure to align a •...
Page 281 CLUTCH 5. Install: 7. Connect: • Dowel pin • Clutch cable “1” • Clutch cover gasket • Clutch cover • For the clutch cable “1”, turn the nut “2” in fully • Cover and then adjust the length “a” by using the nut “3”...
Page 282: Shift Shaft
SHIFT SHAFT EAS20057 SHIFT SHAFT Removing the shift shaft and stopper lever 22 N m (2.2 kgf m, 16 lb • • • Order Job/Parts to remove Q’ty Remarks Clutch assembly Refer to “CLUTCH” on page 5-45. Shift arm Refer to “CHAIN DRIVE” on page 4-86. Circlip Washer Shift shaft...
Page 283: Checking The Shift Shaft
SHIFT SHAFT EAS30377 CHECKING THE SHIFT SHAFT Lubricate the oil seal lips with lithium-soap- 1. Check: based grease. • Shift shaft Bends/damage/wear → Replace. • Shift shaft spring • Collar Damage/wear → Replace. EAS30378 CHECKING THE STOPPER LEVER 1. Check: •...
Page 284: Oil Pump
OIL PUMP EAS20054 OIL PUMP Removing the oil pump 10 N m (1.0 kgf m, 7.4 lb • • • 15 N m (1.5 kgf m, 11 lb • • • 10 N m (1.0 kgf m, 7.4 lb • •...
Page 285 OIL PUMP Disassembling the oil pump 3.8 N m (0.38 kgf m, 2.8 lb • • • Order Job/Parts to remove Q’ty Remarks Oil pump cover Oil pump shaft Oil pump inner rotor Oil pump outer rotor Washer Spring Relief valve Dowel pin 5-58...
Page 286: Checking The Sprocket And Chain
OIL PUMP EAS30336 EAS30338 CHECKING THE SPROCKET AND CHAIN CHECKING THE RELIEF VALVE 1. Check: 1. Check: • Oil pump drive sprocket • Relief valve “1” Refer to “CHECKING THE CLUTCH HOUS- • Spring “2” Damage/wear → Replace the oil pump as- ING”...
Page 287: Installing The Oil Pump
OIL PUMP 3. Check: • Oil pump operation Refer to “CHECKING THE OIL PUMP” on page 5-59. EAS30343 INSTALLING THE OIL PUMP 1. Install: • Oil pump “1” • Oil pump bolt “2” Oil pump bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft) •...
Page 288: Oil Pan
OIL PAN EAS20177 OIL PAN Removing the oil pan 43 N m (4.3 kgf m, 32 lb • • • 13 N m (1.3 kgf m, 9.6 lb 10 N m (1.0 kgf m, 7.4 lb 10 N m (1.0 kgf m, 7.4 lb •...
Page 289: Removing The Oil Pan
OIL PAN EAS31068 REMOVING THE OIL PAN 1. Remove: • Oil pan • Oil pan gasket Loosen each bolt 1/4 of a turn at a time, in stag- es and in a crisscross pattern. After all of the bolts are fully loosened, remove them. EAS31069 CHECKING THE OIL STRAINER 1.
Page 290: Crankcase
• • • • * Following the tightening order, loosen the bolt one by one, and then retighten it to the specific torque and the specified angle. ** YAMAHA Bond No. 1215B® Order Job/Parts to remove Q’ty Remarks Engine Refer to “ENGINE REMOVAL” on page 5-9.
Page 291 • • • * Following the tightening order, loosen the bolt one by one, and then retighten it to the specific torque and the specified angle. ** YAMAHA Bond No. 1215B® Order Job/Parts to remove Q’ty Remarks Oil filter cartridge...
Page 292: Disassembling The Crankcase
Recommended lubricant Engine oil 2. Apply: • Sealant (onto the crankcase mating surfaces) Yamaha bond No. 1215 90890-85505 Three bond No. 1215® • Do not allow any sealant to come into contact with the oil gallery or crankshaft journal bear- ings, or balancer shaft journal bearings.
Page 293 CRANKCASE 3. Install: • Dowel pin 4. Set the shift drum assembly and transmission 19 20 gears in the neutral position. 23 24 5. Install: • Lower crankcase “1” (onto the upper crankcase “2”) ECA13980 NOTICE Before tightening the crankcase bolts, make sure the transmission gears shift correctly when the shift drum assembly is turned by hand.
Page 294: Installing The Oil Pressure Switch
CRANKCASE EAS31071 INSTALLING THE OIL PRESSURE SWITCH 1. Install: • Oil pressure switch “1” • Oil pressure switch lead “2” Oil pressure switch 13 N·m (1.3 kgf·m, 9.6 lb·ft) Oil pressure switch lead bolt 1.8 N·m (0.18 kgf·m, 1.3 lb·ft) •...
Page 295 CRANKCASE Gear position sensor bolt 4.0 N·m (0.40 kgf·m, 3.0 lb·ft) LOCTITE® • Lubricate the O-ring with lithium-soap-based grease. • Fit the end “a” of the shift drum assembly into the opening “b” in the gear position sensor “1”. 5-68...
Page 296 CONNECTING RODS AND PISTONS EAS20132 CONNECTING RODS AND PISTONS Removing the connecting rods and pistons 20 N m (2.0 k gf m, 15 lb • • • Specified angle 180˚ Order Job/Parts to remove Q’ty Remarks Lower crankcase Refer to “CRANKCASE” on page 5-63. Connecting rod cap Big end lower bearing Piston pin clip...
Page 297: Connecting Rods And Pistons
CONNECTING RODS AND PISTONS EAS30745 REMOVING THE CONNECTING RODS AND When removing a piston ring, open the end gap PISTONS with your fingers and lift the other side of the ring The following procedure applies to all of the con- over the piston crown.
Page 298: Checking The Piston Rings
CONNECTING RODS AND PISTONS c. Measure piston skirt diameter “b” with the micrometer. Piston Diameter 77.975–77.990 mm (3.0699– 3.0705 in) G089002 2. Install: • Piston ring (into the cylinder) Use the piston crown to level the piston ring near bottom of cylinder, where cylinder wear is low- est.
Page 299: Checking The Piston Pin
CONNECTING RODS AND PISTONS EAS30749 The following procedure applies to all of the con- CHECKING THE PISTON PIN necting rods. The following procedure applies to all of the pis- ECA13930 ton pins. NOTICE 1. Check: Do not interchange the big end bearings and •...
Page 300 CONNECTING RODS AND PISTONS Install by carrying out the following procedures in order to assemble in the most suitable condition. e. Tighten the connecting rod bolt while checking that the sections shown “a” and “b” are flush with each other by touching the surface.
Page 301 CONNECTING RODS AND PISTONS • Do not move the connecting rod or crankshaft until the clearance measurement has been completed. • Make sure that the projection “a” on the con- necting rod cap faces the same direction as the “Y” mark “b” on the connecting rod. •...
Page 302: Installing The Connecting Rod And Piston
CONNECTING RODS AND PISTONS • The numbers “A” stamped into the crankshaft web and the numbers “1” on the connecting rods are used to determine the replacement big end bearings sizes. • “P ”–“P ” refer to the bearings shown in the crankshaft illustration.
Page 303 CONNECTING RODS AND PISTONS d. Tighten the connecting rod bolt while checking that the sections shown “a” and “b” are flush with each other by touching the surface. Connecting rod bolt 30 N·m (3.0 kgf·m, 22 lb·ft) To install the big end bearing, care should be taken not to install it at an angle and the position should not be out of alignment.
Page 304 CONNECTING RODS AND PISTONS 4. Install: • Piston “1” 90˚ (onto the respective connecting rod “2”) • Piston pin “3” • Piston pin clip “4” 90˚ • Apply engine oil onto the piston pin. • Make sure that the “Y” mark “a” on the connect- ing rod faces left when the punch mark “b”...
Page 305 CONNECTING RODS AND PISTONS 9. Install: c. Tighten the connecting rod bolts further to • Connecting rod cap reach the specified angle 180°. • Connecting rod bolt Connecting rod bolt (final) • Make sure the “Y” marks “a” on the connecting Specified angle 180°...
Page 306 CONNECTING RODS AND PISTONS 5-79...
Page 307 CRANKSHAFT AND BALANCER SHAFT EAS20178 CRANKSHAFT AND BALANCER SHAFT Removing the crankshaft and balancer shaft Order Job/Parts to remove Q’ty Remarks Lower crankcase Refer to “CRANKCASE” on page 5-63. Refer to “REMOVING THE CONNECTING Connecting rod RODS AND PISTONS” on page 5-70. Balancer shaft Balancer shaft journal lower bearing Balancer shaft journal upper bearing...
Page 308: Crankshaft And Balancer Shaft
CRANKSHAFT AND BALANCER SHAFT EAS31171 2. Check: REMOVING THE CRANKSHAFT AND • Crankshaft journal surfaces BALANCER SHAFT • Crankshaft pin surfaces 1. Remove: • Bearing surfaces • Balancer shaft “1” Scratches/wear → Replace the crankshaft. • Balancer shaft journal bearing 3.
Page 309 CRANKSHAFT AND BALANCER SHAFT • The numbers “A” stamped into the crankshaft web and the numbers “B” stamped into the lower crankcase are used to determine the re- placement crankshaft journal bearing sizes. • “J ”–“J ” refer to the bearings shown in the crankshaft and lower crankcase illustration.
Page 310: Checking The Balancer Shaft
CRANKSHAFT AND BALANCER SHAFT a. Clean the balancer shaft journal bearings, balancer shaft journals, and bearing por- tions of the crankcase. b. Place the upper crankcase upside down on a bench. c. Install the balancer shaft journal upper bearings “1” and the balancer shaft into the upper crankcase.
Page 311 CRANKSHAFT AND BALANCER SHAFT Bearing color code Code 1 Blue Code 2 Black Code 3 Brown Code 4 Green G089019 Code 5 f. Tighten the bolts to specification in the tight- Yellow ening sequence cast on the crankcase. Re- fer to “CRANKCASE” on page 5-63. g.
Page 312: Installing The Crankshaft
CRANKSHAFT AND BALANCER SHAFT EAS31077 INSTALLING THE CRANKSHAFT Install by aligning the crankshaft match mark “a” 1. Install: and the balancer shaft match mark “b”. • Crankshaft journal upper bearing (into the upper crankcase) • Crankshaft journal lower bearing (into the lower crankcase) •...
Page 313: Transmission
TRANSMISSION EAS20062 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks 12 N m (1.2 kgf m, 8.9 lb • • • 14 N m (1.4 kgf m, 10 lb • • • 10 N m (1.0 kgf m, 7.4 lb •...
Page 314 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks 12 N m (1.2 kgf m, 8.9 lb • • • 14 N m (1.4 kgf m, 10 lb • • • 10 N m (1.0 kgf m, 7.4 lb •...
Page 315 TRANSMISSION Disassembling the main axle assembly Order Job/Parts to remove Q’ty Remarks 2nd pinion gear Toothed lock washer Toothed lock washer retainer 6th pinion gear Collar Washer Circlip 3rd pinion gear Circlip Washer 5th pinion gear Collar Bearing housing Bearing Main axle 5-88...
Page 316 TRANSMISSION Disassembling the drive axle assembly Order Job/Parts to remove Q’ty Remarks 1st wheel gear Collar 5th wheel gear Circlip Washer 3rd wheel gear Collar Toothed lock washer Toothed lock washer retainer 4th wheel gear Collar Washer Circlip 6th wheel gear Circlip 5-89...
Page 317 TRANSMISSION Disassembling the drive axle assembly Order Job/Parts to remove Q’ty Remarks Washer 2nd wheel gear Collar Collar Bearing Circlip Drive axle 5-90...
Page 318: Removing The Transmission
TRANSMISSION EAS30430 REMOVING THE TRANSMISSION 1. Remove: • Drive axle assembly “1” • Shift drum retainer “2” • Shift fork guide bar 2 • Spring • Shift fork-L • Shift fork-R • Shift fork guide bar 1 • Spring • Shift drum assembly EAS30431 CHECKING THE SHIFT FORKS •...
Page 319: Checking The Shift Drum Assembly
TRANSMISSION EAS30432 CHECKING THE SHIFT DRUM ASSEMBLY 1. Check: • Shift drum groove Damage/scratches/wear → Replace the shift drum assembly. • Shift drum segment “1” Damage/wear → Replace the shift drum as- sembly. • Shift drum bearing “2” Damage/pitting → Replace the shift drum as- 3.
Page 320: Assembling The Main Axle And Drive Axle
TRANSMISSION EAS30435 ASSEMBLING THE MAIN AXLE AND DRIVE • With the toothed lock washer retainer in the AXLE groove “a” in the axle, align the projection on 1. Install: the retainer with an axle spline, and then install • Toothed washer “1” the toothed lock washer.
Page 321 TRANSMISSION 4. Install: • Shift fork-R “1” • Shift fork-L “2” • Spring • Shift fork guide bar 2 • Shift drum retainer “3” • Bearing “4” • Circlip “5” • Oil seal • Drive axle assembly “6” 2. Install: •...
Page 322 TRANSMISSION 5. Check: • Transmission Rough movement → Repair. Oil each gear, shaft, and bearing thoroughly. 5-95...
Page 323: Cooling System
COOLING SYSTEM COOLING SYSTEM DIAGRAMS ..............6-1 RADIATOR ...................... 6-3 CHECKING THE RADIATOR..............6-5 INSTALLING THE RADIATOR..............6-5 OIL COOLER....................6-7 CHECKING THE OIL COOLER ..............6-8 INSTALLING THE OIL COOLER .............. 6-8 THERMOSTAT ....................6-9 CHECKING THE THERMOSTAT............6-10 INSTALLING THE THERMOSTAT ASSEMBLY ........6-10 WATER PUMP....................6-11 DISASSEMBLING THE WATER PUMP..........
Page 324: Cooling System Diagrams
COOLING SYSTEM DIAGRAMS EAS20299 COOLING SYSTEM DIAGRAMS 1. Water pump 2. Thermostat 3. Radiator...
Page 325 COOLING SYSTEM DIAGRAMS 1. Water jacket 2. Thermostat 3. Water pump 4. Oil cooler 5. Coolant reservoir...
Page 326 RADIATOR EAS20063 RADIATOR Removing the radiator 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 8 N ・ m (0.8 kgf ・ m, 5.9 lb ・ ft) 0.5 N ・...
Page 327: Radiator
RADIATOR Removing the radiator 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 8 N ・ m (0.8 kgf ・ m, 5.9 lb ・ ft) 0.5 N ・...
Page 328: Checking The Radiator
RADIATOR EAS30439 CHECKING THE RADIATOR 1. Check: • Radiator fin Obstruction → Clean. Apply compressed air to the rear of the radia- tor. Damage → Repair or replace. Straighten any flattened fins with a thin, flat-head G089029 b. Apply specified pressure to the radiator cap screwdriver.
Page 329 RADIATOR G089031 b. Apply the specified pressure. Cooling system leak test pres- sure 137.3 kPa (1.37 kgf/cm², 19.9 psi) ECA24270 NOTICE • Do not apply such a high pressure as ex- ceeds the test pressure. • Make sure that a checkup after the cylinder head gasket is replaced is made after 3 min- utes of warm-up.
Page 330: Oil Cooler
OIL COOLER EAS20064 OIL COOLER Removing the oil cooler 2.0 N m (0.20 kgf m, 1.5 lb • • • 10 N m (1.0 kgf m, 7.4 lb • • • Order Job/Parts to remove Q’ty Remarks Coolant reservoir Refer to “RADIATOR” on page 6-3. Drain.
Page 331: Checking The Oil Cooler
OIL COOLER EAS30441 5. Measure: CHECKING THE OIL COOLER • Radiator cap valve opening pressure 1. Check: Below the specified pressure → Replace the • Oil cooler radiator cap. Cracks/damage → Replace. Refer to “CHECKING THE RADIATOR” on 2. Check: page 6-5.
Page 332: Thermostat
THERMOSTAT EAS20065 THERMOSTAT Removing the thermostat assembly 10 N m (1.0 kgf m, 7.4 lb • • • Order Job/Parts to remove Q’ty Remarks Drain. Coolant Refer to “CHANGING THE COOLANT” on page 3-31. Radiator Refer to “RADIATOR” on page 6-3. Muffler assembly Refer to “ENGINE REMOVAL”...
Page 333: Checking The Thermostat
THERMOSTAT EAS30443 4. Measure: CHECKING THE THERMOSTAT • Radiator cap valve opening pressure 1. Check: Below the specified pressure → Replace the • Thermostat radiator cap. When the water temperature in the specified Refer to “CHECKING THE RADIATOR” on value, the thermostat does not fully open. → page 6-5.
Page 334: Water Pump
WATER PUMP EAS20066 WATER PUMP Removing the water pump 12 N m (1.2 kgf m, 8.9 lb • • • Order Job/Parts to remove Q’ty Remarks Drain. Coolant Refer to “CHANGING THE COOLANT” on page 3-31. Water pump inlet hose Disconnect.
Page 335 WATER PUMP Disassembling the water pump 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Water pump housing cover O-ring Circlip Water pump driven gear Washer Impeller shaft Mechanical seal Bearing Oil seal 6-12...
Page 336: Disassembling The Water Pump
WATER PUMP EAS30446 EAS30447 DISASSEMBLING THE WATER PUMP CHECKING THE WATER PUMP 1. Remove: 1. Check: • Mechanical seal (housing side) “1” • Water pump housing cover “1” • Impeller shaft “2” Cracks/damage/wear → Replace. Remove the mechanical seal (housing side) •...
Page 337 WATER PUMP ECA20330 NOTICE Never lubricate the mechanical seal (hous- ing side) surface with oil or grease. Use the special tools and a press to press the mechanical seal (housing side) straight in until it touches the water pump housing. G089035 Mechanical seal installer 90890-04078...
Page 338 WATER PUMP 6-15...
Page 339: Fuel System
FUEL SYSTEM FUEL TANK..................... 7-1 REMOVING THE FUEL TANK ..............7-3 REMOVING THE FUEL PUMP ..............7-3 CHECKING THE FUEL PUMP BODY............7-3 CHECKING THE FUEL PUMP OPERATION..........7-3 CHECKING THE PURGE CUT VALVE SOLENOID .........7-4 INSTALLING THE FUEL PUMP..............7-4 INSTALLING THE FUEL TANK..............7-4 THROTTLE BODIES ..................7-5 CHECKING THE INJECTORS (BEFORE REMOVING) ......
Page 340: Fuel Tank
FUEL TANK EAS20067 FUEL TANK Removing the fuel tank m (0.6 kgf m, 4.4 lb • • • m (0.7 kgf m, 5.2 lb • • • m (0.7 kgf m, 5.2 lb • • • m (0.7 kgf m, 5.2 lb •...
Page 341 FUEL TANK Removing the canister Order Job/Parts to remove Q’ty Remarks Fuel tank Refer to “FUEL TANK” on page 7-1. Fuel tank breather hose (fuel tank to canister) Canister purge hose (purge cut valve solenoid to canister) Canister breather hose Canister Purge cut valve solenoid coupler Disconnect.
Page 342: Removing The Fuel Tank
FUEL TANK EAS30450 REMOVING THE FUEL TANK 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. 2. Remove: • Rider seat • Fuel tank side cover • Fuel tank center cover Refer to “GENERAL CHASSIS (1)” on page 4-1.
Page 343: Checking The Purge Cut Valve Solenoid
FUEL TANK EAS33542 EAS30457 CHECKING THE PURGE CUT VALVE INSTALLING THE FUEL TANK SOLENOID 1. Connect: 1. Check: • Fuel hose (fuel tank side) • Canister purge hose ECA17500 NOTICE Loose connection → Connect properly. Cracks/damage/wear → Replace. When installing the fuel hose, make sure that it is securely connected, and that the fuel 2.
Page 344 THROTTLE BODIES EAS20070 THROTTLE BODIES Removing the throttle bodies 8 (3) 10 N m (1.0 kgf m, 7.4 lb • • • m (0.30 kgf m, 2.2 lb • • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS (2)” on Air filter case page 4-10.
Page 345 THROTTLE BODIES Removing the injectors 3.5 N m (0.35 kgf m, 2.6 lb • • • 3.5 N m (0.35 kgf m, 2.6 lb • • • 3.5 N m (0.35 kgf m, 2.6 lb • • • Order Job/Parts to remove Q’ty Remarks Fuel rail...
Page 346: Checking The Injectors (Before Removing)
THROTTLE BODIES EAS30475 EAS30476 CHECKING THE INJECTORS (BEFORE REMOVING THE INJECTORS REMOVING) EWA17330 WARNING 1. Check: • Check the injectors in a well-ventilated area • Injector free of combustible materials. Make sure Use the diagnostic code numbers “36”–“38”. that there is no smoking or use of electric Refer to “DIAGNOSTIC CODE: ACTUATOR tools in the vicinity of the injectors.
Page 347 • Do not turn the bypass air screws “a”; oth- erwise, the throttle body synchronization will be affected. Recommended cleaning solvent Yamaha Oil & Brake Cleaner d. Apply the recommended cleaning solvent to the throttle valves and the inside of the throttle bodies to remove any carbon de- posits.
Page 348: Replacing The Throttle Bodies
THROTTLE BODIES ECA17590 EAS31160 REPLACING THE THROTTLE BODIES NOTICE 1. Remove the throttle bodies from the vehicle. • Do not use a tool, such as a wire brush, to 2. Install a new throttle bodies to the vehicle. remove the carbon deposits; otherwise, the 3.
Page 349: Checking The Injector Pressure
THROTTLE BODIES 4. Check the injector pressure after the injectors f. Close the valve on the fuel injector pressure are installed. adapter. Refer to “CHECKING THE INJECTOR g. Check that the specified air pressure is held PRESSURE” on page 7-10. at least one minute.
Page 350: Installing The Fuel Hose (Fuel Rail Side)
• Yamaha diagnostic tool (A/I) (90890-03264) in- cludes YDT sub harness (6P) (90890-03266). • If you already have Yamaha diagnostic tool (A/ I) (90890-03262), YDT sub harness (6P) (90890-03266) is separately required. e. Diagnostic code number “01” is selected.
Page 351 THROTTLE BODIES f. Adjust the position of the throttle position sensor angle so that 11–21 can appear in the YDT screen. g. After adjusting the throttle position sensor angle, tighten the throttle position sensor screws. Throttle position sensor screw 3.5 N·m (0.35 kgf·m, 2.6 lb·ft) 7-12...
Page 352 THROTTLE BODIES 7-13...
Page 353: Electrical System
ELECTRICAL SYSTEM IGNITION SYSTEM ..................8-1 CIRCUIT DIAGRAM .................. 8-1 ENGINE STOPPING DUE TO SIDESTAND OPERATION.......8-5 TROUBLESHOOTING ................8-6 ELECTRIC STARTING SYSTEM ..............8-9 CIRCUIT DIAGRAM .................. 8-9 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION ......8-13 TROUBLESHOOTING ................8-15 CHARGING SYSTEM..................8-17 CIRCUIT DIAGRAM ................8-17 TROUBLESHOOTING ................8-21 LIGHTING SYSTEM ..................8-23 CIRCUIT DIAGRAM ................
Page 354 CHECKING THE HORN................8-62 CHECKING THE FUEL SENDER ............8-62 CHECKING THE FUEL LEVEL WARNING LIGHT .........8-62 CHECKING THE RADIATOR FAN MOTOR ...........8-63 CHECKING THE COOLANT TEMPERATURE SENSOR.......8-63 CHECKING THE THROTTLE SERVO MOTOR ........8-63 CHECKING THE INTAKE AIR TEMPERATURE SENSOR ....8-64 CHECKING THE FUEL INJECTORS............8-64 CHECKING THE PURGE CUT VALVE SOLENOID .......8-65 CHECKING THE WHEEL SWITCH ............
Page 356: Ignition System
IGNITION SYSTEM EAS20072 IGNITION SYSTEM EAS30490 CIRCUIT DIAGRAM MTN890...
Page 357 IGNITION SYSTEM 3. Fuse box 4. Main fuse 5. Main switch 9. Backup fuse 2 11. Ignition fuse 2 12. Ignition fuse 1 21. Battery 22. Engine ground 26. Handlebar switch (right) 29. Stop/run/start switch 31. Relay unit 32. Starting circuit cut-off relay 34.
Page 358 IGNITION SYSTEM MTN890D...
Page 359 IGNITION SYSTEM 3. Fuse box 4. Main fuse 5. Main switch 9. Backup fuse 2 11. Ignition fuse 2 12. Ignition fuse 1 23. Battery 24. Engine ground 31. Handlebar switch (right) 33. Stop/run/start switch 35. Relay unit 36. Starting circuit cut-off relay 38.
Page 360: Engine Stopping Due To Sidestand Operation
IGNITION SYSTEM EAS30491 ENGINE STOPPING DUE TO SIDESTAND OPERATION When the engine is running and the transmission is in gear, the engine will stop if the sidestand is moved down. This is because the electric current from the ECU does not flow to the ignition coils or fuel injectors when the neutral switch or sidestand switch is open.
Page 361: Troubleshooting
IGNITION SYSTEM EAS30492 TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Fuel tank side cover 3. Fuel tank center cover 4. Fuel tank 5. Air filter case 1.
Page 362 IGNITION SYSTEM 8. Check the stop/run/start switch. Refer to “CHECKING THE NG→ Replace the handlebar switch (right). SWITCHES” on page 8-53. OK↓ 9. Check the neutral switch. Refer to “CHECKING THE NG→ Replace the neutral switch. SWITCHES” on page 8-53. OK↓...
Page 363 IGNITION SYSTEM...
Page 364: Electric Starting System
ELECTRIC STARTING SYSTEM EAS20073 ELECTRIC STARTING SYSTEM EAS30493 CIRCUIT DIAGRAM MTN890...
Page 365 ELECTRIC STARTING SYSTEM 3. Fuse box 4. Main fuse 5. Main switch 9. Backup fuse 2 11. Ignition fuse 2 12. Ignition fuse 1 21. Battery 22. Engine ground 23. Starter relay 24. Starter motor 26. Handlebar switch (right) 29. Stop/run/start switch 31.
Page 366 ELECTRIC STARTING SYSTEM MTN890D 8-11...
Page 367 ELECTRIC STARTING SYSTEM 3. Fuse box 4. Main fuse 5. Main switch 9. Backup fuse 2 11. Ignition fuse 2 12. Ignition fuse 1 23. Battery 24. Engine ground 25. Starter relay 26. Starter motor 28. Clutch switch 31. Handlebar switch (right) 33.
Page 368: Starting Circuit Cut-Off System Operation
ELECTRIC STARTING SYSTEM EAS30494 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the main switch is turned to “ON” and the “ ” side of the stop/run/start switch is pushed, the starter motor can only operate if at least one of the following conditions is met: •...
Page 369 ELECTRIC STARTING SYSTEM 8-14...
Page 370: Troubleshooting
ELECTRIC STARTING SYSTEM EAS30495 TROUBLESHOOTING The starter motor fails to turn. • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Fuel tank side cover 3. Fuel tank center cover 4. Fuel tank 5. Air filter case 6. Canister 1.
Page 371 ELECTRIC STARTING SYSTEM 8. Check the main switch. Refer to “CHECKING THE NG→ Replace the main switch/immobilizer unit. SWITCHES” on page 8-53. OK↓ 9. Check the neutral switch. Refer to “CHECKING THE NG→ Replace the neutral switch. SWITCHES” on page 8-53. OK↓...
Page 372: Charging System
CHARGING SYSTEM EAS20074 CHARGING SYSTEM EAS30496 CIRCUIT DIAGRAM MTN890 8-17...
Page 373 CHARGING SYSTEM 1. AC magneto 2. Rectifier/regulator 3. Fuse box 4. Main fuse 21. Battery 22. Engine ground 8-18...
Page 374 CHARGING SYSTEM MTN890D 8-19...
Page 375 CHARGING SYSTEM 1. AC magneto 2. Rectifier/regulator 3. Fuse box 4. Main fuse 23. Battery 24. Engine ground 8-20...
Page 376: Troubleshooting
CHARGING SYSTEM EAS30497 TROUBLESHOOTING The battery is not being charged. • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Fuel tank side cover 3. Fuel tank center cover 4. Fuel tank 5. Air filter case 1. Check the fuse. (Main) NG→...
Page 377 CHARGING SYSTEM 8-22...
Page 378: Lighting System
LIGHTING SYSTEM EAS20075 LIGHTING SYSTEM EAS30498 CIRCUIT DIAGRAM MTN890 8-23...
Page 379 LIGHTING SYSTEM 3. Fuse box 4. Main fuse 5. Main switch 9. Backup fuse 2 10. Signaling system fuse 11. Ignition fuse 2 13. Headlight fuse 18. Backup fuse 1 21. Battery 22. Engine ground 45. ECU (Engine Control Unit) 64.
Page 380 LIGHTING SYSTEM MTN890D 8-25...
Page 381 LIGHTING SYSTEM 3. Fuse box 4. Main fuse 5. Main switch 9. Backup fuse 2 10. Signaling system fuse 11. Ignition fuse 2 13. Headlight fuse 20. Backup fuse 1 23. Battery 24. Engine ground 49. ECU (Engine Control Unit) 68.
Page 382: Troubleshooting
LIGHTING SYSTEM EAS30499 TROUBLESHOOTING Any of the following fail to light: headlight, auxiliary light, high beam indicator light, taillight, license light or meter light. • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Fuel tank side cover 3. Fuel tank center cover 4.
Page 383 LIGHTING SYSTEM Replace the ECU, meter assembly, headlight assembly, tail/brake light, li- cense plate light or auxiliary light. Refer to “REPLACING THE ECU (En- gine Control Unit)” on page 8-56. 8-28...
Page 384: Signaling System
SIGNALING SYSTEM EAS20076 SIGNALING SYSTEM EAS30500 CIRCUIT DIAGRAM MTN890 8-29...
Page 385 SIGNALING SYSTEM 3. Fuse box 4. Main fuse 5. Main switch 9. Backup fuse 2 10. Signaling system fuse 11. Ignition fuse 2 12. Ignition fuse 1 14. ABS ECU fuse 18. Backup fuse 1 21. Battery 22. Engine ground 26.
Page 386 SIGNALING SYSTEM MTN890D 8-31...
Page 387 SIGNALING SYSTEM 3. Fuse box 4. Main fuse 5. Main switch 9. Backup fuse 2 10. Signaling system fuse 11. Ignition fuse 2 12. Ignition fuse 1 14. ABS ECU fuse 16. Brake light fuse 20. Backup fuse 1 23. Battery 24.
Page 388: Troubleshooting
SIGNALING SYSTEM EAS30501 TROUBLESHOOTING • Any of the following fail to light: turn signal light, brake light or an indicator light. • The horn fails to sound. • The fuel meter fails to come on. • The speedometer fails to operate. •...
Page 389 SIGNALING SYSTEM Checking the signaling system The horn fails to sound. 1. Check the horn switch. Refer to “CHECKING THE NG→ Replace the handlebar switch (left). SWITCHES” on page 8-53. OK↓ 2. Check the horn. Refer to “CHECKING THE HORN” NG→...
Page 390 SIGNALING SYSTEM OK↓ 3. Check the entire signaling sys- tem’s wiring. Properly connect or repair the signaling NG→ Refer to “CIRCUIT DIAGRAM” on system’s wiring. page 8-29. OK↓ Replace the meter assembly or turn signal light. The neutral indicator light fails to come on. 1.
Page 391 SIGNALING SYSTEM The oil pressure and coolant temperature warning light remains on after the engine is started. 1. Check the entire signaling sys- tem’s wiring. Properly connect or replace the wiring har- NG→ Refer to “CIRCUIT DIAGRAM” on ness. page 8-29. OK↓...
Page 392 SIGNALING SYSTEM QSS (Quick Shift System) does not operate. 1. Check that the MIL does not come NG→ Repair the faulty parts. OK↓ 2. Check that the QSS is working un- Check the QSS operating conditions ex- der normal QSS operating condi- NG→...
Page 393 SIGNALING SYSTEM Replace the ECU. Refer to “REPLACING THE ECU (En- gine Control Unit)” on page 8-56. The speedometer fails to operate. 1. Check the rear wheel sensor. Refer to “MAINTENANCE OF THE NG→ Replace the rear wheel sensor. REAR WHEEL SENSOR AND SENSOR ROTOR”...
Page 394: Cooling System
COOLING SYSTEM EAS20077 COOLING SYSTEM EAS30502 CIRCUIT DIAGRAM MTN890 8-39...
Page 395 COOLING SYSTEM 3. Fuse box 4. Main fuse 5. Main switch 6. Radiator fan motor relay 9. Backup fuse 2 12. Ignition fuse 1 19. Radiator fan motor fuse 21. Battery 22. Engine ground 43. Coolant temperature sensor 45. ECU (Engine Control Unit) 89.
Page 396 COOLING SYSTEM MTN890D 8-41...
Page 397 COOLING SYSTEM 3. Fuse box 4. Main fuse 5. Main switch 6. Radiator fan motor relay 9. Backup fuse 2 12. Ignition fuse 1 21. Radiator fan motor fuse 23. Battery 24. Engine ground 47. Coolant temperature sensor 49. ECU (Engine Control Unit) 95.
Page 398: Troubleshooting
COOLING SYSTEM EAS30503 TROUBLESHOOTING • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Fuel tank side cover 3. Fuel tank center cover 4. Fuel tank 5. Air filter case 1. Check the fuses. (Main, ignition 1, backup 2, and ra- diator fan motor) NG→...
Page 399 COOLING SYSTEM Replace the ECU. Refer to “REPLACING THE ECU (En- gine Control Unit)” on page 8-56. 8-44...
Page 400: Fuel Pump System
FUEL PUMP SYSTEM EAS20081 FUEL PUMP SYSTEM EAS30513 CIRCUIT DIAGRAM MTN890 8-45...
Page 401 FUEL PUMP SYSTEM 3. Fuse box 4. Main fuse 5. Main switch 7. Fuel injection system fuse 9. Backup fuse 2 12. Ignition fuse 1 21. Battery 22. Engine ground 26. Handlebar switch (right) 29. Stop/run/start switch 31. Relay unit 33.
Page 402 FUEL PUMP SYSTEM MTN890D 8-47...
Page 403 FUEL PUMP SYSTEM 3. Fuse box 4. Main fuse 5. Main switch 7. Fuel injection system fuse 9. Backup fuse 2 12. Ignition fuse 1 23. Battery 24. Engine ground 31. Handlebar switch (right) 33. Stop/run/start switch 35. Relay unit 37.
Page 404: Troubleshooting
FUEL PUMP SYSTEM EAS30514 TROUBLESHOOTING If the fuel pump fails to operate. • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Fuel tank side cover 3. Fuel tank center cover 4. Fuel tank 1. Check the fuses. (Main, ignition 1, backup 2, and fuel injection system) NG→...
Page 405 FUEL PUMP SYSTEM Replace the ECU. Refer to “REPLACING THE ECU (En- gine Control Unit)” on page 8-56. 8-50...
Page 406: Electrical Components
ELECTRICAL COMPONENTS EAS20089 ELECTRICAL COMPONENTS 1. ECU (Engine Control Unit) 18. Intake air temperature sensor 2. Fuel pump 19. Clutch switch 3. Relay unit 4. Radiator fan motor relay 5. Fuse box 6. Brake light relay (for MTN890D) 7. Starter relay 8.
Page 407 ELECTRICAL COMPONENTS 1. ABS ECU (Electronic Control Unit) 2. Throttle servo motor 3. Intake air pressure sensor 2 4. Intake air pressure sensor 1 5. Throttle position sensor 6. Injector 7. Accelerator position sensor 8. Front brake light switch 9. Main switch/Immobilizer unit 10.
Page 408: Checking The Switches
ELECTRICAL COMPONENTS EAS30549 CHECKING THE SWITCHES 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. Refer to “CHECKING THE SWITCHES” in “BASIC INFORMATION” (separate volume). MTN890 G/B W/G B FREE...
Page 409 ELECTRICAL COMPONENTS MTN890D Y/W O/W PUSH FREE G/L Y/W Br/L FREE Br/L PASS L/R B/W W/R G/B Y/W Br/L W/Y W/L L Y Y/B START W/G B FREE PUSH G/B B W/R DOWN L Br/L W/L L/R W/Y 1. Cruise control power switch 2.
Page 410 ELECTRICAL COMPONENTS EAS30551 Amper- CHECKING THE FUSES Fuses Q’ty age rating The following procedure applies to all of the fus- Main 50 A ECA13680 Headlight 7.5 A NOTICE Signaling system 7.5 A To avoid a short circuit, always set the main switch to “OFF”...
Page 411: Replacing The Ecu (Engine Control Unit)
ELECTRICAL COMPONENTS ECA27250 ECA13700 NOTICE NOTICE • Be careful not to lose or damage the fuse First, disconnect the negative battery lead, box cover. If the fuse box cover is lost or and then the positive battery lead. damaged, replace it with a new one. 3.
Page 412 ELECTRICAL COMPONENTS 2. Connect the digital circuit tester (Ω) and bat- Relay unit (fuel pump relay) tery (12 V) to the relay terminal as shown. Check the relay operation. Out of specification → Replace. Starter relay Sb B Sb/W 1. Positive battery terminal 2.
Page 413: Checking The Relay Unit (Diode)
ELECTRICAL COMPONENTS Brake light relay (for MTN890D) Continuity Positive tester probe sky blue “1” Negative tester probe black “2” No continuity Positive tester probe Y Lg/B black “2” Negative tester probe sky blue “1” Continuity Positive tester probe 1. Positive battery terminal sky blue “1”...
Page 414: Checking The Ignition Coils
ELECTRICAL COMPONENTS c. Check the relay unit (diode) for continuity. d. Check the relay unit (diode) for no continui- Digital circuit tester (CD732) 90890-03243 Model 88 Multimeter with ta- EAS30558 chometer CHECKING THE IGNITION COILS YU-A1927 The following procedure applies to all of the igni- tion coils.
Page 415: Checking The Crankshaft Position Sensor
ELECTRICAL COMPONENTS G089048 b. Measure the crankshaft position sensor re- 2. Ignition coil sistance. c. Turn the main switch to “ON”. d. Measure the ignition spark gap “a”. EAS30562 CHECKING THE STARTER MOTOR e. Crank the engine by pushing the “ ” side of OPERATION the stop/run/start switch and gradually in- 1.
Page 416: Checking The Stator Coil
ELECTRICAL COMPONENTS EAS30566 EAS30680 CHECKING THE STATOR COIL CHECKING THE RECTIFIER/REGULATOR 1. Disconnect: 1. Check: • Stator coil coupler • Rectifier/regulator input voltage Out of specification → Correct the stator coil (from the wire harness) 2. Check: condition. • Stator coil resistance Refer to “CHECKING THE STATOR COIL”...
Page 417: Checking The Horn
ELECTRICAL COMPONENTS Regulated voltage (DC) Digital circuit tester (CD732) 14.3–14.7 V 90890-03243 Model 88 Multimeter with ta- chometer a. Connect the digital circuit tester (DC V) to YU-A1927 the battery as shown. • Positive tester probe → Digital circuit tester (CD732) Fuel sender terminal “1”...
Page 418: Checking The Radiator Fan Motor
ELECTRICAL COMPONENTS Coolant temperature sensor re- sistance 2513–2777 Ω at 20 °C (2513– 2777 Ω at 68 °F) Coolant temperature sensor re- sistance 210–221 Ω at 100 °C (210–221 Ω at 212 °F) a. Connect the digital circuit tester (Ω) to the EAS30577 coolant temperature sensor as shown.
Page 419: Checking The Intake Air Temperature Sensor
ELECTRICAL COMPONENTS 2. Check: • Throttle valve operation Intake air temperature sensor re- Throttle valves do not fully close → Replace sistance 5400–6600 Ω at 0 °C the throttle bodies. (5400–6600 Ω at 32 °F) a. Connect two C-size batteries to the throttle Intake air temperature sensor re- servo motor terminals “1”...
Page 420: Checking The Purge Cut Valve Solenoid
ELECTRICAL COMPONENTS • Positive tester probe → Resistance Purge cut valve solenoid terminal “1” 12.0 Ω • Negative tester probe → Purge cut valve solenoid terminal “2” a. Disconnect the fuel injector coupler from the fuel injector. b. Connect the digital circuit tester (Ω) to the fuel injector coupler as shown.
Page 421 ELECTRICAL COMPONENTS Digital circuit tester (CD732) 90890-03243 Model 88 Multimeter with ta- chometer YU-A1927 • Positive tester probe white/black “4” • Negative tester probe black/white “3” e. When turning the wheel switch in direction “a”, check that the output voltage is within the specified values.
Page 422 ELECTRICAL COMPONENTS 8-67...
Page 423: Self Diagnostic
SELF DIAGNOSTIC SELF-DIAGNOSTIC FUNCTION..............9-1 GLOSSARY....................9-1 OUTLINE ....................9-1 CHECKING THE WARNING LIGHT ............9-2 YDT ......................9-3 PARTS CONNECTED TO THE ECU ............9-4 PARTS CONNECTED TO THE ABS ECU..........9-4 PRECAUTIONS FOR ROAD TEST ............9-4 COPE WITH THE MIL FLASHING ............9-4 SYSTEM DIAGRAM ..................9-5 ECU CIRCUIT DIAGRAM................9-5 ECU COUPLER LAYOUT .................
Page 424 ABS (Anti-lock Brake System) ..............9-36 CIRCUIT DIAGRAM ................9-36 ABS COMPONENTS CHART ..............9-40 ABS COUPLER LOCATION CHART ............9-41 MAINTENANCE OF THE ABS ECU ............9-42 ABS TROUBLESHOOTING OUTLINE............9-42 BASIC INSTRUCTIONS FOR TROUBLESHOOTING ......9-43 [A] CHECKING THE ABS WARNING LIGHT..........9-45 [A-1] ONLY THE ABS WARNING LIGHT FAILS TO COME ON.....
Page 425 P0105......................9-100 TROUBLESHOOTING ................9-100 P0106......................9-102 TROUBLESHOOTING ................9-102 P0107, P0108 ....................9-104 TROUBLESHOOTING ................9-104 P0110......................9-108 TROUBLESHOOTING ................9-108 P0111......................9-110 TROUBLESHOOTING ................9-110 P0112, P0113 ....................9-113 TROUBLESHOOTING ................9-113 P0115......................9-117 TROUBLESHOOTING ................9-117 P0116......................9-118 TROUBLESHOOTING ................9-118 P0117, P0118 ....................9-121 TROUBLESHOOTING ................9-121 P0122, P0123, P0222, P0223, P2135 ............9-125 TROUBLESHOOTING ................9-125 P0132......................9-130 TROUBLESHOOTING ................9-130 P0133......................9-134...
Page 426 P0202......................9-141 TROUBLESHOOTING ................9-141 P0203......................9-144 TROUBLESHOOTING ................9-144 P0300, P0301, P0302, P0303 ..............9-147 OUTLINE ....................9-147 FAIL-SAFE SYSTEM................9-148 TROUBLESHOOTING ................9-148 P0335......................9-151 TROUBLESHOOTING ................9-151 P0351......................9-155 TROUBLESHOOTING ................9-155 P0352......................9-159 TROUBLESHOOTING ................9-159 P0353......................9-163 TROUBLESHOOTING ................9-163 P0458......................9-167 TROUBLESHOOTING ................9-167 P0480......................
Page 427 P0606......................9-202 TROUBLESHOOTING ................9-202 P062F ......................9-203 TROUBLESHOOTING ................9-203 P0638......................9-205 TROUBLESHOOTING ................9-205 P0657......................9-209 TROUBLESHOOTING ................9-209 P0914......................9-213 TROUBLESHOOTING ................9-213 P0915......................9-215 TROUBLESHOOTING ................9-215 P0916, P0917 ....................9-217 TROUBLESHOOTING ................9-217 P1004......................9-221 TROUBLESHOOTING ................9-221 P1600......................9-223 TROUBLESHOOTING ................9-223 P1601......................9-227 TROUBLESHOOTING ................9-227 P1602......................9-231 TROUBLESHOOTING ................9-231 P1606, P1607 ....................9-235 TROUBLESHOOTING ................9-235 P1608......................9-239 TROUBLESHOOTING ................9-239 P1609......................9-241...
Page 428 P1806, P1807 ....................9-243 TROUBLESHOOTING ................9-243 P2122, P2123, P2127, P2128, P2138 ............9-247 TROUBLESHOOTING ................9-247 P2158......................9-251 TROUBLESHOOTING ................9-251 U0125 ......................9-256 TROUBLESHOOTING ................9-256 U0155 or Err....................9-260 TROUBLESHOOTING ................9-260 51_IMMOBILIZER ..................9-264 TROUBLESHOOTING ................9-264 52_IMMOBILIZER ..................9-265 TROUBLESHOOTING ................9-265 53_IMMOBILIZER ..................9-266 TROUBLESHOOTING ................9-266 54_IMMOBILIZER ..................
Page 429 14, 27_ABS ....................9-278 TROUBLESHOOTING ................9-278 15_ABS .......................9-279 TROUBLESHOOTING ................9-279 16_ABS .......................9-281 TROUBLESHOOTING ................9-281 21_ABS .......................9-283 TROUBLESHOOTING ................9-283 31_ABS .......................9-284 TROUBLESHOOTING ................9-284 33_ABS .......................9-286 TROUBLESHOOTING ................9-286 34_ABS .......................9-288 TROUBLESHOOTING ................9-288 41_ABS .......................9-289 TROUBLESHOOTING ................9-289 42_ABS .......................9-290 TROUBLESHOOTING ................9-290 43, 45_ABS ....................9-291 TROUBLESHOOTING ................9-291 44, 46_ABS ....................9-292 TROUBLESHOOTING ................9-292...
Page 430 56_ABS .......................9-297 TROUBLESHOOTING ................9-297 57_ABS .......................9-298 TROUBLESHOOTING ................9-298 62_ABS .......................9-302 TROUBLESHOOTING ................9-302 68_ABS .......................9-303 TROUBLESHOOTING ................9-303 89_ABS .......................9-304 TROUBLESHOOTING ................9-304 90_ABS .......................9-307 TROUBLESHOOTING ................9-307 91_ABS .......................9-310 TROUBLESHOOTING ................9-310...
Page 431: Self-Diagnostic Function
Generic diagnostic tool that complies with OBD standards. (Generic scan tool) (Yamaha diagnostic Diagnostic tool developed especially for Yamaha vehicles. tool) EAS32858 OUTLINE The control unit is equipped with a self-diagnostic function in order to ensure that the system is operat- ing normally.
Page 432: Checking The Warning Light
SELF-DIAGNOSTIC FUNCTION EAS32859 CHECKING THE WARNING LIGHT The warning light comes on after the main switch has been set to “ON”. Refer to the following table for lighting up time. If the warning light still comes on, refer to a check item of a troubleshooting of each system, check and repair it.
Page 433: Ydt
90890-03264 • Yamaha diagnostic tool (A/I) (90890-03264) includes YDT sub harness (6P) (90890-03266). • If you already have Yamaha diagnostic tool (A/I) (90890-03262), YDT sub harness (6P) (90890- 03266) is separately required. • A GST can also be used to identify malfunctions.
Page 434: Parts Connected To The Ecu
SELF-DIAGNOSTIC FUNCTION EAS32864 PARTS CONNECTED TO THE ECU The following parts are connected to the ECU. When checking for a power short circuit, the couplers must be disconnected from all of the following parts beforehand. • Crankshaft position sensor • Fuel pump •...
Page 435: System Diagram
SYSTEM DIAGRAM EAS20387 SYSTEM DIAGRAM EAS32920 ECU CIRCUIT DIAGRAM 41. Injector #1 8. Fuel pump relay 42. Injector #2 14. Engine stop 20. Fuel switch pump 43. Injector #3 6. Ignition 9. Starter 22. Neutral fuse 2 relay indicator light 11.
Page 436 SYSTEM DIAGRAM 49. Grip 50. Grip warmer (left) warmer (right) 32. Throttle 51. Purge cut position sensor valve solenoid 52. Radiator fan motor 55. Headlight control unit 33. Accelerator position sensor 56. Meter assembly 57. CAN communication 34. ABS ECU (Electronic Control Unit) circuit...
Page 437 SYSTEM DIAGRAM 52. Radiator fan motor 1. ECU (Engine Control Unit) 2. Battery 53. Dimmer switch 3. Main fuse 54. Pass switch 4. Electronic throttle valve fuse 55. Headlight control unit 5. Backup fuse 2 56. Meter assembly 6. Ignition fuse 2 57.
Page 438: Ecu Coupler Layout
SYSTEM DIAGRAM EAS33369 ECU COUPLER LAYOUT 1 2 3 4 5 6 7 8 9 35 36 37 38 39 40 41 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 10 11 12 13 14 15 16 17 42 43 44 45 46 47 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 18 19 20 21 22 23 24 25...
Page 439 SYSTEM DIAGRAM Wire harness Wire harness Connected parts Connected parts color color — — — — Accelerator position — — sensor Starting circuit cut- — — off relay, Clutch switch — — — — Accelerator position sensor Cruise control set- Br/L (*1) ting switch (RES+)
Page 440 SYSTEM DIAGRAM Wire harness Connected parts color Gear position sen- — — ABS ECU (Electron- ic Control Unit) — — ABS ECU (Electron- ic Control Unit) — — *1. For MTN890D 9-10...
Page 441 SYSTEM DIAGRAM 9-11...
Page 442: Fuel Injection System
FUEL INJECTION SYSTEM EAS20440 FUEL INJECTION SYSTEM EAS32871 CIRCUIT DIAGRAM MTN890 9-12...
Page 443 FUEL INJECTION SYSTEM 89. Radiator fan motor 1. AC magneto 2. Rectifier/regulator 91. Handlebar switch (left) 3. Fuse box 92. Clutch switch 4. Main fuse 5. Main switch 6. Radiator fan motor relay 7. Fuel injection system fuse 8. Electronic throttle valve fuse 9.
Page 444 FUEL INJECTION SYSTEM MTN890D 9-14...
Page 445 FUEL INJECTION SYSTEM 69. Multi-function meter 1. AC magneto 2. Rectifier/regulator 76. MIL (Malfunction indicator light) 3. Fuse box 95. Radiator fan motor 4. Main fuse 5. Main switch 6. Radiator fan motor relay 7. Fuel injection system fuse 8. Electronic throttle valve fuse 9.
Page 446: Basic Process For Troubleshooting
FUEL INJECTION SYSTEM EAS32917 BASIC PROCESS FOR TROUBLESHOOTING This section describes the basic process about fuel injection system troubleshooting. But because a work procedure varies depending to symptom and DTC, check and repair it according to applicable troubleshooting. When turning the main switch to Does the MIL (LED) work Check the MIL (LED).
Page 447: [A] The Mil Comes On/Flashes And Engine Operation Is Not Normal
FUEL INJECTION SYSTEM EAS33147 [A] THE MIL COMES ON/FLASHES AND ENGINE OPERATION IS NOT NORMAL 1. Check the DTC of “malfunction” using the YDT. 2. Delete the DTC using the YDT. (Only for *1) 3. Check and repair the malfunction according to applicable DTC troubleshooting. 4.
Page 448: Immobilizer System
IMMOBILIZER SYSTEM EAS20442 IMMOBILIZER SYSTEM EAS32885 CIRCUIT DIAGRAM MTN890 9-18...
Page 449 IMMOBILIZER SYSTEM 3. Fuse box 4. Main fuse 5. Main switch 9. Backup fuse 2 11. Ignition fuse 2 12. Ignition fuse 1 18. Backup fuse 1 21. Battery 22. Engine ground 25. Immobilizer unit 45. ECU (Engine Control Unit) 63.
Page 450 IMMOBILIZER SYSTEM MTN890D 9-20...
Page 451 IMMOBILIZER SYSTEM 3. Fuse box 4. Main fuse 5. Main switch 9. Backup fuse 2 11. Ignition fuse 2 12. Ignition fuse 1 20. Backup fuse 1 23. Battery 24. Engine ground 27. Immobilizer unit 49. ECU (Engine Control Unit) 67.
Page 452: System Outline
IMMOBILIZER SYSTEM EAS32886 SYSTEM OUTLINE This vehicle is equipped with an immobilizer system to help prevent theft by re-registering codes in the standard keys. This system consists of the following: • A code re-registering key (with a red bow) • Two standard keys (with a black bow) that can be re-registered with new codes •...
Page 453: Part Replacement And Key Code Registration Requirements
IMMOBILIZER SYSTEM EAS32887 PART REPLACEMENT AND KEY CODE REGISTRATION REQUIREMENTS In the course of use, you may encounter the following cases where replacement of parts and registra- tion of code re-registering/standard keys are required. Each standard key is registered during production, therefore re-registering at purchase is not neces- sary.
Page 454 IMMOBILIZER SYSTEM Standby mode a. Main switch “ON” e. Standby mode on b. Main switch “OFF” Standby mode off c. LED on d. LED off Standard key registration: Standard key registration is required when a standard key is lost and needs to be replaced, or when the code re-registering key is re-registered after the immobilizer unit or ECU are replaced.
Page 455 IMMOBILIZER SYSTEM Standard key registration a. Main switch “ON” h. Second standard key b. Main switch “OFF” Registration mode c. LED on A. Registration of the second standard key is d. LED off complete. e. Less than 5.0 s B. Immobilizer system indicator light stops flash- Code re-registering key ing when the registration of the second stan- dard key is complete.
Page 456: Troubleshooting
IMMOBILIZER SYSTEM EAS32888 TROUBLESHOOTING When the main switch is turned to “ON”, the immobilizer system indicator light does not come on nor flashes. 1. Check the fuses. (Main, ignition 1, ignition 2, backup 1, and backup 2) NG→ Replace the fuse(s). Refer to “CHECKING THE FUS- ES”...
Page 457: How To Check Dtc
IMMOBILIZER SYSTEM EAS32889 HOW TO CHECK DTC When a system malfunction occurs, the DTC is indicated in the meter display and the immobilizer sys- tem indicator light flashes at the same time. The pattern of flashing also shows the DTC. Immobilizer system indicator light DTC indication Digit of 10: Cycles of 1 sec.
Page 458: Cruise Control System (For Mtn890D)
CRUISE CONTROL SYSTEM (for MTN890D) EAS20441 CRUISE CONTROL SYSTEM (for MTN890D) EAS32875 CIRCUIT DIAGRAM 9-28...
Page 459 CRUISE CONTROL SYSTEM (for MTN890D) 3. Fuse box 4. Main fuse 5. Main switch 9. Backup fuse 2 10. Signaling system fuse 11. Ignition fuse 2 12. Ignition fuse 1 16. Brake light fuse 17. Cruise control fuse 20. Backup fuse 1 23.
Page 460: Cruise Control Circuit Operation
CRUISE CONTROL SYSTEM (for MTN890D) EAS32876 CRUISE CONTROL CIRCUIT OPERATION 7. Ignition 8. Cruise control 9. Cruise control fuse 1 system fuse power switch 10.Cruise control setting switch 11.Front brake 12.Rear brake light switch light switch 16.ECU (Engine 5. Signaling 6.
Page 461: Basic Instructions For Troubleshooting
CRUISE CONTROL SYSTEM (for MTN890D) EAS32877 BASIC INSTRUCTIONS FOR TROUBLESHOOTING 1. Check the DTC of “malfunction” using the YDT. 2. Check and repair the malfunction according to applicable DTC troubleshooting. 3. Turn the main switch from “OFF” to “ON”, and then check the DTC of “malfunction” is not displayed. •...
Page 462: Basic Process For Troubleshooting
CRUISE CONTROL SYSTEM (for MTN890D) EAS32878 BASIC PROCESS FOR TROUBLESHOOTING When turning the main switch to Check the MIL (LED). “ON”, does the MIL come on? The MIL goes off after 2 seconds? Fails to come on Push the cruise control The cruise control power switch is •...
Page 463: [A] Checking The Cruise Control System Indicator Light
CRUISE CONTROL SYSTEM (for MTN890D) EAS32879 [A] CHECKING THE CRUISE CONTROL SYSTEM INDICATOR LIGHT Turn the main switch, and then push the cruise control power switch. 1. The cruise control system indicator light does not come on. • Check the control power switch for continuity. Refer to “CHECKING THE SWITCHES” on page 8- 53.
Page 464: [C-1] Erasing The Dtc
CRUISE CONTROL SYSTEM (for MTN890D) EAS32883 [C-1] ERASING THE DTC 1. Delete the DTC using the malfunction of the YDT, and check that the MIL goes off. EAS32884 [C-2] FINAL CHECK EWA17441 WARNING When maintenance or checks have been performed on components related to the cruise control system, be sure to perform a final check before delivering the vehicle to the customer.
Page 465 CRUISE CONTROL SYSTEM (for MTN890D) 9-35...
Page 466: Abs (Anti-Lock Brake System)
ABS (Anti-lock Brake System) EAS20443 ABS (Anti-lock Brake System) EAS32890 CIRCUIT DIAGRAM MTN890 9-36...
Page 467 ABS (Anti-lock Brake System) 3. Fuse box 4. Main fuse 5. Main switch 9. Backup fuse 2 10. Signaling system fuse 11. Ignition fuse 2 12. Ignition fuse 1 14. ABS ECU fuse 16. ABS solenoid fuse 17. ABS motor fuse 18.
Page 468 ABS (Anti-lock Brake System) MTN890D 9-38...
Page 469 ABS (Anti-lock Brake System) 3. Fuse box 4. Main fuse 5. Main switch 9. Backup fuse 2 10. Signaling system fuse 11. Ignition fuse 2 12. Ignition fuse 1 14. ABS ECU fuse 16. Brake light fuse 17. Cruise control fuse 18.
Page 470: Abs Components Chart
ABS (Anti-lock Brake System) EAS32891 ABS COMPONENTS CHART 1. Meter assembly 2. Hydraulic unit assembly (ABS ECU) 3. Fuse box (ABS motor fuse, ABS ECU fuse, ABS solenoid fuse) 4. YDT coupler 5. Rear wheel sensor 6. Rear wheel sensor rotor 7.
Page 471: Abs Coupler Location Chart
ABS (Anti-lock Brake System) EAS32892 ABS COUPLER LOCATION CHART R/GY/B R/G R/G R/W B/W Lg L/W L/B G/W Y W/G W/R G/B W W/G W/B Sb/W G/L W/Y W/L Br/L B G/O Br/W Br/B G Br (Gy) W/G G Y L R/B Br L/W G/O W/Y L B W Y L/B 1.
Page 472: Maintenance Of The Abs Ecu
ABS (Anti-lock Brake System) EAS32893 MAINTENANCE OF THE ABS ECU Checking the ABS ECU 1. Check: • Terminals “1” of the hydraulic unit assembly (ABS ECU) Cracks/damages → Replace the hydraulic unit assembly, brake hoses, and brake pipes that are connected to the assembly as a set.
Page 473: Basic Instructions For Troubleshooting
ABS (Anti-lock Brake System) Self-diagnosis with the ABS ECU The ABS ECU performs a static check of the entire system when the main switch is turned to “ON”. It also checks for malfunctions while the vehicle is ridden. Since all malfunctions are recorded after they are detected, it is possible to check the recorded malfunction data by utilizing the YDT when the ABS ECU has entered the self-diagnosis mode.
Page 474 ABS (Anti-lock Brake System) Fails to Turn the main switch to “ON”, • The ABS warning light (LED) is [A-1] Does only the ABS come on and check the ABS warning Return to [A]. defective. warning light fail to light. come on? •...
Page 475: [A] Checking The Abs Warning Light
ABS (Anti-lock Brake System) EAS32897 [A] CHECKING THE ABS WARNING LIGHT Turn the main switch to “ON”. (Do not start the engine.) 1. The ABS warning light does not come on. • Only the ABS warning light fails to come on. [A-1] •...
Page 476: [A-5] Abs Ecu And Fi Ecu Fail To Communicate
90890-03264 • Yamaha diagnostic tool (A/I) (90890-03264) includes YDT sub harness (6P) (90890-03266). • If you already have Yamaha diagnostic tool (A/I) (90890-03262), YDT sub harness (6P) (90890- 03266) is separately required. Details about the displayed DTCs are shown in the following chart. Refer to this chart and check the ve- hicle.
Page 477: [B-3] Deleting The Dtc
Yamaha diagnostic tool (A/I) 90890-03264 • Yamaha diagnostic tool (A/I) (90890-03264) includes YDT sub harness (6P) (90890-03266). • If you already have Yamaha diagnostic tool (A/I) (90890-03262), YDT sub harness (6P) (90890- 03266) is separately required. EAS32905 [C-1] FINAL CHECK...
Page 478: Self-Diagnostic Function And Diagnostic Code Table
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE EAS20551 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE EAS33149 DTC TABLE Fail-safe system Diagnos- Symptom Starting the Driving the tic code engine vehicle Front wheel sensor (intermittent pulses “11_ABS” — — — or no pulses) Rear wheel sensor (intermittent pulses or “12_ABS”...
Page 479 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Fail-safe system Diagnos- Symptom Starting the Driving the tic code engine vehicle “54_IMMO- Codes transmitted between the ECU and — — — BILIZER” the immobilizer unit do not match. Hydraulic unit assembly (defective ABS “55_ABS”...
Page 480 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Fail-safe system Diagnos- Symptom Starting the Driving the tic code engine vehicle [P0112] Intake air temperature sensor: “P0112, ground short circuit detected. Able Able P0113” [P0113] Intake air temperature sensor: open or power short circuit detected. “P0115”...
Page 481 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Fail-safe system Diagnos- Symptom Starting the Driving the tic code engine vehicle Able Able Cylinder-#1 ignition coil: open or short (depending (depending “P0351” circuit detected in the primary lead of the on the num- on the num- cylinder-#1 ignition coil.
Page 482 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Fail-safe system Diagnos- Symptom Starting the Driving the tic code engine vehicle Fuel system voltage: incorrect voltage “P0657” supplied to the fuel injector and fuel Able Able 09, 50 pump. “P0914” Gear position sensor: signal stuck Able Able —...
Page 483: Self-Diagnostic Function Table (For Fuel Injection System)
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE EAS33028 SELF-DIAGNOSTIC FUNCTION TABLE (FOR FUEL INJECTION SYSTEM) For details of the DTC, refer to “BASIC PROCESS FOR TROUBLESHOOTING” on page 9-16. Probable cause of Fail-safe system Item Vehicle symptom malfunction operation 30_EVEN Overturn detected. •...
Page 484 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Probable cause of Fail-safe system Item Vehicle symptom malfunction operation P00D1 sensor: heater • Improperly in- Increased exhaust feedback is not stalled O sensor. emissions. performance deteri- carried out. oration • Defective coupler learning is not between O sen- carried out.
Page 485 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Probable cause of Fail-safe system Item Vehicle symptom malfunction operation P0106 Intake air pressure • Intake air pressure Engine idling speed Intake air pressure sensor 1: clogging sensor 1 hose is is high. is fixed to 101.3 of hose or sensor not installed.
Page 486 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Probable cause of Fail-safe system Item Vehicle symptom malfunction operation P0110 Intake air tempera- • Improperly in- Engine is difficult to The intake air tem- ture sensor: signal stalled intake air start. perature is fixed to stuck temperature sen- Increased exhaust...
Page 487 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Probable cause of Fail-safe system Item Vehicle symptom malfunction operation P0112 [P0112] Intake air [P0112] Low voltage Engine is difficult to The intake air tem- P0113 temperature sensor: of the intake air tem- start. perature is fixed to ground short circuit perature sensor cir-...
Page 488 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Probable cause of Fail-safe system Item Vehicle symptom malfunction operation P0116 Coolant tempera- • Defective coupler Engine is difficult to The radiator fan mo- ture sensor: signal between coolant start. tor relay is on only out of range temperature sen- Increased exhaust...
Page 489 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Probable cause of Fail-safe system Item Vehicle symptom malfunction operation P0122 [P0122] Throttle po- [P0122, P0222] Low Engine idling speed Change in the throt- P0123 sition sensor: voltage of the throt- is high. tle opening is 0 P0222 ground short circuit tle position sensor...
Page 490 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Probable cause of Fail-safe system Item Vehicle symptom malfunction operation P0133 sensor: re- • Defective O sen- Increased exhaust emissions. sponse delay sor. • Malfunction in fuel — system. • Malfunction in ex- haust system. P0134 sensor: signal •...
Page 491 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Probable cause of Fail-safe system Item Vehicle symptom malfunction operation P0302 Misfire in cylinder #2 • Ignition system Engine is difficult to malfunction/abnor- start. Loss of engine pow- • Fuel system mal- function/abnormal Engine idling speed —...
Page 492 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Probable cause of Fail-safe system Item Vehicle symptom malfunction operation P0351 [P0351] Cylinder-#1 feedback is not • Defective coupler Engine stops. P0352 ignition coil: open or between ignition Loss of engine pow- carried out. P0353 short circuit detect- coil and ECU.
Page 493 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Probable cause of Fail-safe system Item Vehicle symptom malfunction operation P0500 [P0500] Rear wheel • Open or short cir- Vehicle speed is not Vehicle speed dis- P1500 sensor: no normal cuit in wire har- displayed on the played on the meter signals are received...
Page 494 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Probable cause of Fail-safe system Item Vehicle symptom malfunction operation P0564 Cruise control set- • Open or short cir- Cruise control sys- Cruise control sys- ting switch “RES+”: cuit in wire har- tem cannot be oper- tem cannot be oper- open or short circuit ness.
Page 495 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Probable cause of Fail-safe system Item Vehicle symptom malfunction operation P062F EEPROM DTC: an • CO adjustment Increased exhaust CO adjustment val- error is detected value is not prop- emissions. ue for the faulty cyl- while reading or erly written.
Page 496 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Probable cause of Fail-safe system Item Vehicle symptom malfunction operation P0915 Gear position sen- • Defective coupler Improper display for Maintains the gear sor: signal out of between gear po- position. position value at the range sition sensor and Engine response is...
Page 497 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Probable cause of Fail-safe system Item Vehicle symptom malfunction operation P1004 Intake air pressure • Intake pressure Engine is difficult to Intake air pressure sensor 1 and intake sensor 1 hose or start. is fixed to 101.3 air pressure sensor intake pressure Engine idling speed...
Page 498 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Probable cause of Fail-safe system Item Vehicle symptom malfunction operation P1602 Malfunction in ECU • Open or short cir- feedback learn- Engine idling speed internal circuit (mal- cuit in wire har- is unstable. ing is not carried function of ECU ness between Engine idling speed...
Page 499 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Probable cause of Fail-safe system Item Vehicle symptom malfunction operation P1806 [P1806] Shift sen- • Defective coupler Unable to carry out QSS is not carried P1807 sor: open or ground between shift sen- QSS. out.
Page 500 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Probable cause of Fail-safe system Item Vehicle symptom malfunction operation P2158 Front wheel sensor: • Open or short cir- Traction control Traction control no normal signals cuit in wire har- does not work. does not work. are received from ness between Traction control sys-...
Page 501: Self-Diagnostic Function Table (For Immobilizer System)
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE EAS33029 SELF-DIAGNOSTIC FUNCTION TABLE (FOR IMMOBILIZER SYSTEM) For details of the DTC, refer to “HOW TO CHECK DTC” on page 9-27. Item Immobilizer unit: Code cannot be transmitted between the key and the immobilizer unit. Immobilizer unit: Codes between the key and immobilizer unit do not match.
Page 502 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Item Symptom Check point Front wheel sensor (ab- Front wheel sensor signal • Foreign material ad- normal pulse period) is not received properly. hered around the front (The pulse period is ab- wheel sensor normal while the vehicle is •...
Page 503 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Item Symptom Check point Hydraulic unit assembly Power is not supplied to • Blown ABS solenoid fuse (defective ABS solenoid the solenoid circuit in the • Defective coupler be- power circuit) hydraulic unit assembly. tween the battery and the hydraulic unit assembly •...
Page 504 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Item Symptom Check point Front wheel sensor (miss- Front wheel sensor signal • Foreign material ad- ing pulses) is not received properly. hered around the front (Missing pulses are de- wheel sensor tected in the signal while •...
Page 505 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Item Symptom Check point Vehicle CAN communica- Short-circuit in CAN com- • Short-circuit in CAN tion line or power source of munication line or the volt- communication line vehicle system age that supplies the •...
Page 506: Communication Error With The Meter
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE * The DTC number varies according to the vehicle conditions. EAS33030 COMMUNICATION ERROR WITH THE METER Probable cause of Fail-safe system Item Vehicle symptom malfunction operation U0155 [U0155 (FI)] Multi- Communication be- Defective meter dis- MAP changeover: (YDT) function meter: sig-...
Page 507 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Diagnostic Item Tool display Procedure code No. Rear wheel vehicle speed Rear wheel speed pulse Check that the number in- pulses 0–999 creases when the rear wheel is rotated. The num- ber is cumulative and does not reset each time the wheel is stopped.
Page 508 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Diagnostic Item Tool display Procedure code No. Bank angle display Displays the bank angle in Check that 0–5° is dis- increments of 5° played when the vehicle is • 0–5° (vehicle is vertical) vertical and that the dis- •...
Page 509 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Diagnostic Item Tool display Procedure code No. ISC (Idle Speed Control) To erase the ISC (Idle learning condition display ISC (Idle Speed Control) Speed Control) learning ISC (Idle Speed Control) learning data has been data, push the “Operation”...
Page 510: Diagnostic Code: Actuator Operation Table
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Diagnostic Item Tool display Procedure code No. feedback learning data To erase the O feedback feedback learning data erasure learning data, push the has been erased. “Operation” button 3 times in 5 seconds. feedback learning data has not been erased.
Page 511 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Diagnostic Item Actuation Procedure code No. Injector #2 Actuates the injector #2 Disconnect the fuel pump five times at one-second coupler before doing this intervals. procedure. The “check” indicator on Check that injector #2 is the YDT screen come on actuated five times by lis- each time the fuel injector...
Page 512: Event Code Table
EVENT CODE TABLE EAS20707 EVENT CODE TABLE The event code numbers listed below cannot be displayed on the meter. To display the event code numbers, use the YDT. Item Symptom Possible causes Note Intake air pres- Brief abnormality Same as for DTC num- Perform the inspection sure sensor detected in the in-...
Page 513 EVENT CODE TABLE Item Symptom Possible causes Note sensor During O feed- • Open or short circuit • If a DTC is occurring, in the wire harness respond to that first. (Stuck at the back, the adjust- between the sensor * Rarely, Code 241 oc- lower limit for ment is maintained...
Page 514 EVENT CODE TABLE Item Symptom Possible causes Note Cruise control Automatic turning The cruise control sys- The automatic turning off off of the cruise con- tem will automatically of the cruise control sys- trol system detected turn off under the fol- tem does not indicate a lowing conditions: malfunction in the sys-...
Page 515: 30_Event
30_EVENT EAS20552 30_EVENT EAS33033 TROUBLESHOOTING Item Overturn detected. Fail-safe system • Unable to start engine • Unable to drive vehicle Procedure 1. The vehicle has overturned. • Raise the overturned vehicle vertically and check again. • Turn the main switch to “ON”, then to “OFF”, and then back to “ON”. Is the MIL on? →...
Page 516 30_EVENT Is the MIL on? → Go to step 4. → Service is completed. 4. Malfunction in ECU. • Replace the ECU, and complete the service. Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-56. 9-86...
Page 517: 70_Event
70_EVENT EAS20554 70_EVENT EAS33034 TROUBLESHOOTING Item Engine forcibly stops when the vehicle is left idling for a long period. Procedure If another error code is displayed at the same time, check the other error code first and repair it. 1. Allow to idle for a long period. •...
Page 518: C0520
C0520 EAS20560 C0520 EAS33319 TROUBLESHOOTING Item ECU: no normal signals or malfunction signals are received from the IMU. Fail-safe system • Able/Unable to start engine • Able/Unable to drive vehicle Procedure 1. Connection of IMU coupler. • Check the locking condition of the coupler. •...
Page 519 C0520 Between ignition fuse 1 “4” coupler and IMU red/white–red/white coupler “3” blue/white–blue/white Between IMU coupler “3” and joint coupler “2” blue/black–blue/black blue/white–blue/white Between IMU coupler “3” and joint coupler “2” blue/black–blue/black Between IMU coupler “3” and ground black/white–ground Lg/L Gy/G Br/W L/W W...
Page 520 C0520 Lines short circuit check “B” blue/black–any other coupler terminal ECU coupler “1” blue/white–any other coupler terminal blue/black–any other coupler terminal IMU coupler “3” blue/white–any other coupler terminal red/white–any other coupler terminal blue/black–any other coupler terminal Joint coupler “2” blue/white–any other coupler terminal Lg/L Gy/G Br/W...
Page 521 C0520 Is check result OK? → Go to step 5. a. Fix the IMU installation condition. b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode of the YDT. Is it in the “Recovered” condition? →...
Page 522: P0030
P0030 EAS20397 P0030 EAS33134 TROUBLESHOOTING Item sensor heater: defective heater controller detected. Fail-safe system • Able to start engine • Able to drive vehicle Procedure If more than one DTC is detected at the same time, perform troubleshooting of DTC listed below first. •...
Page 523 P0030 Is the coupler condition normal? → Go to step 3. a. Connect the coupler securely or replace the wire harness. b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode of the YDT. Is it in the “Recovered”...
Page 524 P0030 Is it in the “Recovered” condition? → Go to step 6, and complete the service. → Start the engine, and then check the condition of the DTC. Is it in the “Recovered” condition? → Go to step 6, and complete the service. →...
Page 525 P0030 Is it in the “Recovered” condition? → Go to step 6, and complete the service. → Go to step 4. For this check, also set the stop/run/start switch to “ON”. 4. Defective O sensor. • Replace the O sensor. Refer to “ENGINE REMOVAL”...
Page 526: P00D1, P2195
P00D1, P2195 EAS20660 P00D1, P2195 EAS33115 TROUBLESHOOTING Item • [P00D1] O sensor: heater performance deterioration • [P2195] O sensor: open circuit detected. Fail-safe system • Able to start engine • Able to drive vehicle Procedure If more than one DTC is detected at the same time, perform troubleshooting of DTC listed below first. •...
Page 527 P00D1, P2195 3. Connection of ECU coupler. • Check the locking condition of the coupler. • Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the pins). Is the coupler condition normal? → Go to step 4. a.
Page 528 P00D1, P2195 Is it in the “Recovered” condition? → Go to step 8, and complete the service. → Go to “Short circuit check”. • Short circuit check Disconnect the ECU related connectors before checking. Refer to “PARTS CONNECTED TO THE ECU” on page 9-4. Ground short circuit check “A”...
Page 529 P00D1, P2195 Is it in the “Recovered” condition? → Go to step 8, and complete the service. → Go to step 5. 5. Check fuel pressure. • Check the fuel pressure. Refer to “CHECKING THE FUEL PRESSURE” on page 7-10. Is check result OK? →...
Page 530: P0105
P0105 EAS20420 P0105 EAS32838 TROUBLESHOOTING Item Intake air pressure sensor: signal out of range Fail-safe system • Able to start engine • Able to drive vehicle Procedure If more than one DTC is detected at the same time, perform troubleshooting of DTC listed below first. •...
Page 531 P0105 Is it in the “Recovered” condition? → Go to step 5, and complete the service. → Go to step 4. 4. Malfunction in ECU. • Replace the ECU, and complete the service. Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-56. 5.
Page 532: P0106
P0106 EAS20421 P0106 EAS32840 TROUBLESHOOTING Item Intake air pressure sensor 1: clogging of hose or sensor disconnection Fail-safe system • Able to start engine • Able to drive vehicle Procedure If more than one DTC is detected at the same time, perform troubleshooting of DTC listed below first. •...
Page 533 P0106 a. Replace the intake air pressure sensor 1. Refer to “THROTTLE BODIES” on page 7-5. b. Start the engine and let it idle for approximately 5 seconds with the throttle fully closed, and then check the condition of the DTC using the malfunction mode of the YDT. c.
Page 534: P0107, P0108
P0107, P0108 EAS20567 P0107, P0108 EAS33047 TROUBLESHOOTING Item • [P0107] Intake air pressure sensor 1: ground short circuit detected. • [P0108] Intake air pressure sensor 1: open or power short circuit detected. Fail-safe system • Able to start engine • Able to drive vehicle Procedure 1.
Page 535 P0107, P0108 Between ECU coupler “3” and joint coupler cap [P0108] black/blue–black/blue “2” Between ECU coupler “3” and intake air pres- [P0108] blue–blue sure sensor 1 coupler “1” [P0107, P0108] pink/white–pink/white Between intake air pressure sensor 1 coupler [P0108] black–black “1”...
Page 536 P0107, P0108 Ground short circuit check “A” Between intake air pressure sensor 1 coupler blue–ground “1” and ground pink/white–ground Lines short circuit check “B” [P0108] blue–any other coupler terminal [P0108] black/blue–any other coupler terminal ECU coupler “3” [P0107, P0108] pink/white–any other coupler terminal [P0108] blue–any other coupler terminal [P0108] black–any other coupler terminal...
Page 537 P0107, P0108 4. Installed condition of intake air pressure sensor 1. • Check for looseness or pinching. Is check result OK? → Go to step 5. a. Reinstall or replace the sensor. b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode of the YDT.
Page 538: P0110
P0110 EAS20426 P0110 EAS32845 TROUBLESHOOTING Item Intake air temperature sensor: signal stuck Fail-safe system • Able to start engine • Able to drive vehicle Procedure • Perform this procedure when the engine is cold. • If more than one DTC is detected at the same time, perform troubleshooting of DTC listed below first. •...
Page 539 P0110 → Go to step 3. 3. Malfunction in ECU. • Replace the ECU, and complete the service. Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-56. 4. Delete the DTC and check that the MIL goes off. •...
Page 540: P0111
P0111 EAS20425 P0111 EAS32844 TROUBLESHOOTING Item Intake air temperature sensor: signal out of range Fail-safe system • Able to start engine • Able to drive vehicle Procedure • Perform this procedure when the engine is cold. • If more than one DTC is detected at the same time, perform troubleshooting of DTC listed below first. •...
Page 541 P0111 3. Installed condition of intake air temperature sensor. • Check for looseness or pinching. Refer to “GENERAL CHASSIS (2)” on page 4-10. Is check result OK? → Go to step 4. a. Reinstall the sensor. b. Execute the diagnostic mode. (Code 05) •...
Page 542 P0111 6. Malfunction in ECU. • Replace the ECU, and complete the service. Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-56. 7. Delete the DTC and check that the MIL goes off. • Confirm that the DTC has a condition of “Recovered” using the YDT, and then delete the DTC. 9-112...
Page 543: P0112, P0113
P0112, P0113 EAS20568 P0112, P0113 EAS33048 TROUBLESHOOTING Item • [P0112] Intake air temperature sensor: ground short circuit detected. • [P0113] Intake air temperature sensor: open or power short circuit detected. Fail-safe system • Able to start engine • Able to drive vehicle Procedure Perform this procedure when the engine is cold.
Page 544 P0112, P0113 3. Wire harness continuity. • Disconnect the intake air temperature sensor coupler “1” and ECU coupler “3”. • Remove the joint coupler cap “2”. • Open circuit check Between ECU coupler “3” and intake air tem- [P0113] brown/white–brown/white perature sensor coupler “1”...
Page 545 P0112, P0113 Ground short circuit check “A” Between intake air temperature sensor coupler [P0112, P0113] brown/white–ground “1” and ground Lines short circuit check “B” [P0112, P0113] brown/white–any other coupler intake air temperature sensor coupler “1” terminal [P0113] black–any other coupler terminal [P0113] black/blue–any other coupler terminal Joint coupler “2”...
Page 546 P0112, P0113 4. Installed condition of intake air temperature sensor. • Check for looseness or pinching. Refer to “GENERAL CHASSIS (2)” on page 4-10. Is check result OK? → Go to step 5. a. Reinstall the sensor. b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode of the YDT.
Page 547: P0115
P0115 EAS20424 P0115 EAS32843 TROUBLESHOOTING Item Coolant temperature sensor: signal stuck Fail-safe system • Able to start engine • Able to drive vehicle Procedure • Perform this procedure when the engine is cold. • If more than one DTC is detected at the same time, perform troubleshooting of DTC listed below first. •...
Page 548: P0116
P0116 EAS20423 P0116 EAS32842 TROUBLESHOOTING Item Coolant temperature sensor: signal out of range Fail-safe system • Able to start engine • Able to drive vehicle Procedure • Perform this procedure when the engine is cold. • If more than one DTC is detected at the same time, perform troubleshooting of DTC listed below first. •...
Page 549 P0116 3. Installed condition of coolant temperature sensor. • Check for looseness or pinching. Refer to “CYLINDER HEAD” on page 5-26. Is check result OK? → Go to step 4. a. Reinstall the sensor. b. Execute the diagnostic mode. (Code 06) •...
Page 550 P0116 Is check result OK? → Go to step 7, and complete the service. → Go to step 6. 6. Malfunction in ECU. • Replace the ECU, and complete the service. Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-56. 7.
Page 551: P0117, P0118
P0117, P0118 EAS20569 P0117, P0118 EAS33049 TROUBLESHOOTING Item • [P0117] Coolant temperature sensor: ground short circuit detected. • [P0118] Coolant temperature sensor: open or power short circuit detected. Fail-safe system • Able to start engine • Able to drive vehicle Procedure Perform this procedure when the engine is cold.
Page 552 P0117, P0118 3. Wire harness continuity. • Disconnect the coolant temperature sensor coupler “1” and ECU coupler “3”. • Remove the joint coupler cap “2”. • Open circuit check Between coolant temperature sensor coupler [P0117, P0118] green/white–green/white “1” and ECU coupler “3” Between coolant temperature sensor coupler [P0118] black–black “1”...
Page 553 P0117, P0118 Ground short circuit check “A” Between coolant temperature sensor coupler [P0117, P0118] green/white–ground “1” and ground Lines short circuit check “B” [P0117, P0118] green/white–any other coupler Coolant temperature sensor coupler “1” terminal [P0118] black–any other coupler terminal [P0118] black/blue–any other coupler terminal Joint coupler “2”...
Page 554 P0117, P0118 Is check result OK? → Go to step 5. a. Reinstall the sensor. b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode of the YDT. Is it in the “Recovered” condition? →...
Page 555: P0122, P0123, P0222, P0223, P2135
P0122, P0123, P0222, P0223, P2135 EAS20570 P0122, P0123, P0222, P0223, P2135 EAS33050 TROUBLESHOOTING Item • [P0122] Throttle position sensor: ground short circuit detected. • [P0123] Throttle position sensor: open or power short circuit detected. • [P0222] Throttle position sensor: open or ground short circuit detected. •...
Page 556 P0122, P0123, P0222, P0223, P2135 Is it in the “Recovered” condition? → Go to step 8, and complete the service. → Go to step 3. 3. Wire harness continuity. • Disconnect the throttle position sensor coupler “1” and ECU coupler “2”. •...
Page 557 P0122, P0123, P0222, P0223, P2135 Disconnect the ECU related connectors before checking. Refer to “PARTS CONNECTED TO THE ECU” on page 9-4. Ground short circuit check “A” [P0122, P0123, P0222, P0223, P2135] white– ground Between throttle position sensor coupler “1” and [P0122, P0222] blue–ground ground [P0122, P0123, P0222, P0223, P2135] black–...
Page 558 P0122, P0123, P0222, P0223, P2135 Is it in the “Recovered” condition? → Go to step 8, and complete the service. → Go to step 4. 4. Installed condition of throttle position sensor. • Check for looseness or pinching. Refer to “ADJUSTING THE THROTTLE POSITION SENSOR” on page 7-11. Is check result OK? →...
Page 559 P0122, P0123, P0222, P0223, P2135 Is check result OK? → Go to step 7. a. Replace the throttle position sensor. Refer to “ADJUSTING THE THROTTLE POSITION SENSOR” on page 7-11. b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode of the YDT.
Page 560: P0132
P0132 EAS20571 P0132 EAS33051 TROUBLESHOOTING Item sensor: short circuit detected (power short circuit). Fail-safe system • Able to start engine • Able to drive vehicle Procedure 1. Installed condition of O sensor. • Check for looseness or pinching. Refer to “ENGINE REMOVAL” on page 5-9. Is check result OK? →...
Page 561 P0132 Is the coupler condition normal? → Go to step 4. a. Connect the coupler securely or replace the wire harness. b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode of the YDT. Is it in the “Recovered”...
Page 562 P0132 Is it in the “Recovered” condition? → Go to step 7, and complete the service. → Go to “Short circuit check”. • Short circuit check Disconnect the ECU related connectors before checking. Refer to “PARTS CONNECTED TO THE ECU” on page 9-4. Ground short circuit check “A”...
Page 563 P0132 Is it in the “Recovered” condition? → Go to step 7, and complete the service. → Go to step 5. 5. Defective O sensor. a. Replace the O sensor. Refer to “ENGINE REMOVAL” on page 5-9. b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode of the YDT.
Page 564: P0133
P0133 EAS20767 P0133 • O sensor: deterioration detected EAS33291 OUTLINE Explanation of detection method The O sensor detects the oxygen concentration in the exhaust gas, converts it into an electrical signal, and sends it to the ECU. The ECU determines whether there is any deterioration by comparing the out- put value from the O sensor with a predetermined threshold value such as response time.
Page 565: Troubleshooting
P0133 EAS32813 TROUBLESHOOTING If more than one DTC is detected at the same time, perform troubleshooting of DTC listed below first. • DTC except P0133 1. Connect the YDT to check and delete the DTC stored in the ECU. 2. Perform the reproduction test under the following conditions, then go to step 3. Reproduction test conditions A.
Page 566: P0134
P0134 EAS20414 P0134 EAS32834 TROUBLESHOOTING Item sensor: signal stuck Fail-safe system • Able to start engine • Able to drive vehicle Procedure If more than one DTC is detected at the same time, perform troubleshooting of DTC listed below first. 1.
Page 567 P0134 Is it in the “Recovered” condition? → Go to step 6, and complete the service. → Go to step 3. 3. Check fuel pressure. • Check the fuel pressure. Refer to “CHECKING THE FUEL PRESSURE” on page 7-10. Is check result OK? →...
Page 568: P0201
P0201 EAS20574 P0201 EAS33054 TROUBLESHOOTING Item Injector #1: malfunction in injector #1. Fail-safe system • Able to start engine (depending on the number of faulty cylinders) • Able to drive vehicle (depending on the number of faulty cylinders) Procedure 1. Connection of injector #1 coupler. •...
Page 569 P0201 Is the coupler condition normal? → Go to step 4. a. Connect the coupler securely or replace the wire harness. b. Execute the diagnostic mode. (Code 36) Is it hear operating sound? → Go to step 6. → Go to step 4. 4.
Page 570 P0201 Disconnect the ECU related connectors before checking. Refer to “PARTS CONNECTED TO THE ECU” on page 9-4. Ground short circuit check “A” red/black–ground Between injector #1 coupler “1” and ground red/blue–ground Lines short circuit check “B” red/black–any other coupler terminal Injector #1 coupler “1”...
Page 571: P0202
P0202 EAS20575 P0202 EAS33055 TROUBLESHOOTING Item Injector #2: malfunction in injector #2. Fail-safe system • Able to start engine (depending on the number of faulty cylinders) • Able to drive vehicle (depending on the number of faulty cylinders) Procedure 1. Connection of injector #2 coupler. •...
Page 572 P0202 Is the coupler condition normal? → Go to step 4. a. Connect the coupler securely or replace the wire harness. b. Execute the diagnostic mode. (Code 37) Is it hear operating sound? → Go to step 6. → Go to step 4. 4.
Page 573 P0202 Disconnect the ECU related connectors before checking. Refer to “PARTS CONNECTED TO THE ECU” on page 9-4. Ground short circuit check “A” green/black–ground Between injector #2 coupler “1” and ground red/blue–ground Lines short circuit check “B” green/black–any other coupler terminal Injector #2 coupler “1”...
Page 574: P0203
P0203 EAS20576 P0203 EAS33056 TROUBLESHOOTING Item Injector #3: malfunction in injector #3. Fail-safe system • Able to start engine (depending on the number of faulty cylinders) • Able to drive vehicle (depending on the number of faulty cylinders) Procedure 1. Connection of injector #3 coupler. •...
Page 575 P0203 Is the coupler condition normal? → Go to step 4. a. Connect the coupler securely or replace the wire harness. b. Execute the diagnostic mode. (Code 38) Is it hear operating sound? → Go to step 6. → Go to step 4. 4.
Page 576 P0203 Disconnect the ECU related connectors before checking. Refer to “PARTS CONNECTED TO THE ECU” on page 9-4. Ground short circuit check “A” blue/black–ground Between injector #3 coupler “1” and ground red/blue–ground Lines short circuit check “B” blue/black–any other coupler terminal Injector #3 coupler “1”...
Page 577: Outline
P0300, P0301, P0302, P0303 EAS20773 P0300, P0301, P0302, P0303 • [P0300] Misfire in multiple cylinders • [P0301] Misfire in cylinder #1 • [P0302] Misfire in cylinder #2 • [P0303] Misfire in cylinder #3 EAS33318 OUTLINE Explanation of detection method The ECU monitors the consistency of the crankshaft rotation by crankshaft position sensor, and if the angular velocity fluctuates irregularly, the ECU determines that there is a misfire.
Page 578: Fail-Safe System
P0300, P0301, P0302, P0303 Storing DTC Once an abnormality has been detected, a pending DTC is stored in the memory of the ECU. Then, if the abnormality is detected in the next two driving cycles, the MIL comes on and the DTC and FFD are stored.
Page 579 P0300, P0301, P0302, P0303 Reproduction test condition A. Speed [km/h] E. Steady driving time B. Time [min] F. Stop the engine C. Vehicle speed of FFD D. Start the engine Conversion table of steady driving time Engine speed (r/min) Time (sec.) 2000 3000 4000...
Page 580 P0300, P0301, P0302, P0303 4. Check the ignition system Is the inspection result OK? → Go to step 5. →Repair or replace the defective part, then go to step 6. 5. Check the following parts. If defective, replace the parts and go to step 6. •...
Page 581: P0335
P0335 EAS20578 P0335 EAS33058 TROUBLESHOOTING Item Crankshaft position sensor: no normal signals are received from the crankshaft position sensor. Fail-safe system • Unable to start engine • Unable to drive vehicle Procedure 1. Connection of crankshaft position sensor coupler. • Check the locking condition of the coupler. •...
Page 582 P0335 Between crankshaft position sensor coupler “1” gray–gray and ECU coupler “3” Between crankshaft position sensor coupler “1” black–black and joint coupler “2” Between joint coupler “2” and ECU coupler “3” black/blue–black/blue Gy B Lg/L Br/L Gy/G Br/W Gy/G Br/W Lg/B L/B W L/B L/B L/B B L/B L/B L/B L/B...
Page 583 P0335 Gy B Gy B Gy/G Br/W L/W W B L/B L/B Y/B Y/B B B/L B B B B B L/R L/R L/R Lg/L Br/L Gy/G Br/W Lg/B *. MTN890 **. MTN890D Is resistance ∞ Ω? → Go to step 4. a.
Page 584 P0335 5. Defective crankshaft position sensor. • Check the crankshaft position sensor. Refer to “CHECKING THE CRANKSHAFT POSITION SENSOR” on page 8-60. Is check result OK? → Go to step 6. a. Replace the crankshaft position sensor. b. Crank the engine, and then check the condition of the DTC using the malfunction mode of the YDT.
Page 585: P0351
P0351 EAS20580 P0351 EAS33060 TROUBLESHOOTING Item Cylinder-#1 ignition coil: open or short circuit detected in the primary lead of the cylinder-#1 ignition coil. Fail-safe system • Able to start engine (depending on the number of faulty cylinders) • Able to drive vehicle (depending on the number of faulty cylinders) Procedure 1.
Page 586 P0351 Gy/R Lg/R O R/W Is resistance 0 Ω? → Go to “Short circuit check”. a. Replace the wire harness. b. Start the engine and let it idle for approximately 5 seconds. c. Check the condition of the DTC using the malfunction mode of the YDT. Is it in the “Recovered”...
Page 587 P0351 Is resistance ∞ Ω? → Go to step 4. a. Replace the wire harness. b. Start the engine and let it idle for approximately 5 seconds. c. Check the condition of the DTC using the malfunction mode of the YDT. Is it in the “Recovered”...
Page 588 P0351 6. Malfunction in ECU. • Execute the diagnostic mode. (Code 30) • Confirm that spark plug does not sparking. • Replace the ECU, and complete the service. Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-56. 7. Delete the DTC and check that the MIL goes off. •...
Page 589: P0352
P0352 EAS20581 P0352 EAS33061 TROUBLESHOOTING Item Cylinder-#2 ignition coil: open or short circuit detected in the primary lead of the cylinder-#2 ignition coil. Fail-safe system • Able to start engine (depending on the number of faulty cylinders) • Able to drive vehicle (depending on the number of faulty cylinders) Procedure 1.
Page 590 P0352 Gy/R Lg/R Gy/R R/W Is resistance 0 Ω? → Go to “Short circuit check”. a. Replace the wire harness. b. Start the engine and let it idle for approximately 5 seconds. c. Check the condition of the DTC using the malfunction mode of the YDT. Is it in the “Recovered”...
Page 591 P0352 Is resistance ∞ Ω? → Go to step 4. a. Replace the wire harness. b. Start the engine and let it idle for approximately 5 seconds. c. Check the condition of the DTC using the malfunction mode of the YDT. Is it in the “Recovered”...
Page 592 P0352 6. Malfunction in ECU. • Execute the diagnostic mode. (Code 31) • Confirm that spark plug does not sparking. • Replace the ECU, and complete the service. Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-56. 7. Delete the DTC and check that the MIL goes off. •...
Page 593: P0353
P0353 EAS20582 P0353 EAS33062 TROUBLESHOOTING Item Cylinder-#3 ignition coil: open or short circuit detected in the primary lead of the cylinder-#3 ignition coil. Fail-safe system • Able to start engine (depending on the number of faulty cylinders) • Able to drive vehicle (depending on the number of faulty cylinders) Procedure 1.
Page 594 P0353 Gy/R Lg/R O/G R/W Is resistance 0 Ω? → Go to “Short circuit check”. a. Replace the wire harness. b. Start the engine and let it idle for approximately 5 seconds. c. Check the condition of the DTC using the malfunction mode of the YDT. Is it in the “Recovered”...
Page 595 P0353 Is resistance ∞ Ω? → Go to step 4. a. Replace the wire harness. b. Start the engine and let it idle for approximately 5 seconds. c. Check the condition of the DTC using the malfunction mode of the YDT. Is it in the “Recovered”...
Page 596 P0353 6. Malfunction in ECU. • Execute the diagnostic mode. (Code 32) • Confirm that spark plug does not sparking. • Replace the ECU, and complete the service. Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-56. 7. Delete the DTC and check that the MIL goes off. •...
Page 597: P0458
P0458 EAS20785 P0458 EAS33528 TROUBLESHOOTING Item Purge cut valve solenoid: open circuit detected. Fail-safe system • Able to start engine • Able to drive vehicle Procedure 1. Connection of purge cut valve solenoid coupler. • Check the locking condition of the coupler. •...
Page 598 P0458 Between ignition fuse 1 holder “1” and purge cut red–red/white valve solenoid coupler “2” Between purge cut valve solenoid coupler “2” yellow/red–yellow/red and ECU coupler “3” Between main switch coupler “4” and ignition brown/blue–brown/blue fuse 1 holder “1” Gy/R Lg/R Br/L Is resistance 0 Ω?
Page 599 P0458 Br/L Br/L Gy/R Lg/R Is resistance ∞ Ω? →Go to step 4. a. Replace the wire harness. b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode of the YDT. Is it in the “Recovered”...
Page 600 P0458 Is it hear operationg sound? → Go to step 7, and complete the service. → Check the purge cut valve solenoid. Refer to “CHECKING THE PURGE CUT VALVE SOLENOID” on page 8-65. Is check result OK? → Go to step 6. a.
Page 601: P0480
P0480 EAS20585 P0480 EAS33065 TROUBLESHOOTING Item Radiator fan motor relay: open or short circuit detected. Fail-safe system • Able to start engine • Able to drive vehicle Procedure 1. Connection of radiator fan motor relay coupler. • Check the locking condition of the coupler. •...
Page 602 P0480 Between radiator fan motor relay “1” and igni- red–red tion fuse 1 holder “3” Between radiator fan motor relay “1” and ECU green/yellow–green/yellow coupler “2” Gy/R Lg/R Is resistance 0 Ω? → Go to “Short circuit check”. a. Replace the wire harness. b.
Page 603 P0480 Gy/R Lg/R Is resistance ∞ Ω? → Go to step 4. a. Replace the wire harness. b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode of the YDT. Is it in the “Recovered” condition? →...
Page 604: P0500, P1500
P0500, P1500 EAS20774 P0500, P1500 EAS33303 TROUBLESHOOTING Item • Rear wheel sensor: no normal signals are received from the rear wheel sensor. • Neutral switch: open or short circuit is detected. • Clutch switch: open or short circuit is detected. Fail-safe system •...
Page 605 P0500, P1500 Is check result OK? → Go to step 21. → Go to step 15. Perform the procedure from step 15 to step 21. 2. Connection of rear wheel sensor coupler. • Check the locking condition of the coupler. •...
Page 606 P0500, P1500 Is the coupler condition normal? → Go to step 5. a. Connect the coupler securely or replace the wire harness. b. Execute the diagnostic mode. (Code 07) c. Rotate the rear wheel by hand and check that the indicated value increases. Is that value increased? →...
Page 607 P0500, P1500 • Short circuit check Disconnect the ECU related connectors before checking. Refer to “PARTS CONNECTED TO THE ECU” on page 9-4. Ground short circuit check “A” black–ground Between ABS ECU coupler “2” and ground white–ground white/yellow–ground Lines short circuit check “B” black–any other coupler terminal Rear wheel sensor coupler “1”...
Page 608 P0500, P1500 Is that value increased? → Go to step 21. → Go to step 6. 6. Malfunction in ECU. • Replace the ECU. Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-56. • Execute the diagnostic mode. (Code 07) •...
Page 609 P0500, P1500 When the transmission is in neutral When the transmission is in gear with the clutch lever released Is it correct indication? → Go to step 21. → Go to step 10. 10.Wire harness continuity. • Disconnect the relay unit coupler “1”, ECU coupler “2” and neutral switch coupler “3”. •...
Page 610 P0500, P1500 Is it correct indication? → Go to step 21. → Go to “Short circuit check”. • Short circuit check Disconnect the ECU related connectors before checking. Refer to “PARTS CONNECTED TO THE ECU” on page 9-4. Ground short circuit check “A” black–ground Between relay unit coupler “1”...
Page 611 P0500, P1500 Is it correct indication? → Go to step 21. → Go to step 11. 11.Defective relay unit. • Check the relay unit. Refer to “CHECKING THE RELAY UNIT (DIODE)” on page 8-58. Is check result OK? → Go to step 12. a.
Page 612 P0500, P1500 Is check result OK? → Go to step 14. → Replace the shift drum and go to step 21. Refer to “TRANSMISSION” on page 5-86. 14.Malfunction in ECU. • Replace the ECU, and complete the service. Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-56. 15.Clutch lever adjustment.
Page 613 P0500, P1500 17.Connection of ECU coupler. • Check the locking condition of the coupler. • Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the pins). Is the coupler condition normal? → Go to step 18. a.
Page 614 P0500, P1500 L/W R W L/W R L/B L B Sb/W Lg/L Gy/G Br/W Lg/L Br/L Gy/G Br/W Lg/B Y/B B/Y Y/W L/Y *. MTN890 **. MTN890D Is resistance 0 Ω? → Go to “Short circuit check”. a. Replace the wire harness. b.
Page 615 P0500, P1500 Ground short circuit check “A” black–ground Between relay unit coupler “1” and ground blue–ground Lines short circuit check “B” black–any other coupler terminal Relay unit coupler “1” blue–any other coupler terminal ECU coupler “2” black/yellow–any other coupler terminal black/yellow–any other coupler terminal Clutch switch coupler “3”...
Page 616 P0500, P1500 19.Defective clutch switch. • Check the clutch switch. Refer to “CHECKING THE SWITCHES” on page 8-53. Is check result OK? → Go to step 20. a. Replace the clutch switch. Refer to “HANDLEBAR” on page 4-57. b. Execute the diagnostic mode. (Code 21) When the clutch lever is released with the transmission in gear and when the sidestand is retracted When the clutch lever is squeezed with the transmission in gear and when...
Page 617: P0560, P0563
P0560, P0563 EAS20434 P0560, P0563 EAS33304 TROUBLESHOOTING Item • [P0560] Charging voltage is abnormal. • [P0563] Vehicle system power voltage out of range Fail-safe system • Able to start engine • Able to drive vehicle Procedure If more than one DTC is detected at the same time, perform troubleshooting of DTC listed below first. •...
Page 618: P0564
P0564 EAS20594 P0564 EAS33074 TROUBLESHOOTING Item • Cruise control setting switch “RES+”: open or short circuit is detected. • Cruise control setting switch “SET–”: open or short circuit is detected. Fail-safe system • Able to start engine • Able to drive vehicle Procedure 1.
Page 619 P0564 Perform the procedure from step 6 to step 10. 3. Check the fuse. • Check the ignition fuse 1 and cruise control fuse. Is check result OK? →Go to step 4. a. Replace the fuse. b. Turn the main switch to “ON”. c.
Page 620 P0564 Is resistance 0 Ω? →Go to “Short circuit check”. a. Replace the wire harness. b. Turn the main switch to “ON”. c. Push and release the “RES+” side of the cruise control setting switch, and then check the condi- tion of the DTC using the malfunction mode of the YDT.
Page 621 P0564 Is it in the “Recovered” condition? →Go to step 10, and complete the service. →Go to step 5. 5. Defective cruise control setting switch. • Replace the handlebar switch (left). • Turn the main switch to “ON”. • Push the “RES+” side and “SET–” side of the cruise control setting switch, and then check the con- dition of the DTC using the malfunction mode of the YDT.
Page 622 P0564 Lg/L Br/L Gy/G Br/W Lg/B Br/L Br/L Is resistance 0 Ω? →Go to “Short circuit check”. a. Replace the wire harness. b. Turn the main switch to “ON”. c. Push and “SET–” side of the cruise control setting switch, and then check the condition of the DTC using the malfunction mode of the YDT.
Page 623 P0564 Br/L Br/L Br/L Lg/L Br/L Gy/G Br/W Lg/B Br/L Is resistance ∞ Ω? →Go to step 8. a. Replace the wire harness. b. Turn the main switch to “ON”. c. Push and “SET–” side of the cruise control setting switch, and then check the condition of the DTC using the malfunction mode of the YDT.
Page 624: P056C
P056C EAS20595 P056C EAS33075 TROUBLESHOOTING Item • Front brake light switch: open or short circuit is detected. • Rear brake light switch: open or short circuit is detected. Fail-safe system • Able to start engine • Able to drive vehicle Procedure 1.
Page 625 P056C Is it in the “Recovered” condition? →Go to step 11, and complete the service. →Go to step 3. 3. Check the fuse. (signaling system fuse and brake light fuse) Is check result OK? →Go to step 4. a. Replace the fuse. b.
Page 626 P056C Is resistance 0 Ω? →Go to “Short circuit check”. a. Replace the wire harness. b. Turn the main switch to “ON”. c. Operate the front brake lever, and then check the condition of the DTC using the malfunction mode of the YDT. Is it in the “Recovered”...
Page 627 P056C Is resistance ∞ Ω? →Go to step 5. a. Replace the wire harness. b. Turn the main switch to “ON”. c. Operate the front brake lever, and then check the condition of the DTC using the malfunction mode of the YDT. Is it in the “Recovered”...
Page 628 P056C 7. Check the fuse. (signaling system fuse and brake light fuse) Is check result OK? →Go to step 8. a. Replace the fuse. b. Turn the main switch to “ON”. c. Operate the rear brake pedal, and then check the condition of the DTC using the malfunction mode of the YDT.
Page 629 P056C Is resistance 0 Ω? →Go to “Short circuit check”. a. Replace the wire harness. b. Turn the main switch to “ON”. c. Operate the rear brake pedal, and then check the condition of the DTC using the malfunction mode of the YDT. Is it in the “Recovered”...
Page 630 P056C Is resistance ∞ Ω? →Go to step 9. a. Replace the wire harness. b. Turn the main switch to “ON”. c. Operate the rear brake pedal, and then check the condition of the DTC using the malfunction mode of the YDT. Is it in the “Recovered”...
Page 631: P0601
P0601 EAS20676 P0601 EAS33305 TROUBLESHOOTING Item Internal malfunction in ECU. (When this malfunction is detected in the ECU, the DTC might not appear on the tool display.) Fail-safe system • Unable to start engine • Unable to drive vehicle Procedure 1.
Page 632: P0606
P0606 EAS20677 P0606 EAS33306 TROUBLESHOOTING Item Internal malfunction in ECU. (When this malfunction is detected in the ECU, the DTC might not appear on the tool display.) Fail-safe system • Able/Unable to start engine • Able/Unable to drive vehicle Procedure 1.
Page 633: P062F
P062F EAS20598 P062F EAS33078 TROUBLESHOOTING Item EEPROM DTC: an error is detected while reading or writing on EEPROM. Fail-safe system • Able/Unable to start engine • Able/Unable to drive vehicle Procedure 1. Locate the malfunction. • Execute the diagnostic mode (Code 60) Go to step 6.
Page 634 P062F 4. “03” is indicated in diagnostic mode (code D60). EEPROM data error for adjustment of CO concen- tration of cylinder #3. • Change the CO concentration of cylinder #3, and rewrite in EEPROM. Refer to “ADJUSTING THE EXHAUST GAS VOLUME” on page 3-11. •...
Page 635: P0638
P0638 EAS20599 P0638 EAS33079 TROUBLESHOOTING Item YCC-T drive system: malfunction detected. Fail-safe system • Able/Unable to start engine • Able/Unable to drive vehicle Procedure 1. Connection of throttle servo motor coupler. • Check the locking condition of the coupler. • Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the pins).
Page 636 P0638 3. Check the electronic throttle valve fuse. Is check result OK? → Go to step 4. a. Replace the electronic throttle valve fuse. b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode of the YDT.
Page 637 P0638 Disconnect the ECU related connectors before checking. Refer to “PARTS CONNECTED TO THE ECU” on page 9-4. Ground short circuit check “A” yellow/red–ground Between ECU coupler “2” and ground light green/red–ground red/blue–ground Lines short circuit check “B” yellow/red–any other coupler terminal Throttle servo motor coupler “1”...
Page 638 P0638 Is check result OK? → Go to step 6. a. Replace the throttle bodies. Refer to “REPLACING THE THROTTLE BODIES” on page 7-9. b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode of the YDT.
Page 639: P0657
P0657 EAS20601 P0657 EAS33081 TROUBLESHOOTING Item Fuel system voltage: incorrect voltage supplied to the fuel injector and fuel pump. Fail-safe system • Able to start engine • Able to drive vehicle Procedure If more than one DTC is detected at the same time, perform troubleshooting of DTC listed below first. •...
Page 640 P0657 3. Connection of ECU coupler. • Check the locking condition of the coupler. • Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the pins). Is the coupler condition normal? → Go to step 4. a.
Page 641 P0657 Is resistance 0 Ω? → Go to “Short circuit check”. a. Replace the wire harness. b. Start the engine and let it idle for approximately 5 seconds. c. Check the condition of the DTC using the malfunction mode of the YDT. Is it in the “Recovered”...
Page 642 P0657 Is resistance ∞ Ω? → Go to step 5. a. Replace the wire harness. b. Start the engine and let it idle for approximately 5 seconds. c. Check the condition of the DTC using the malfunction mode of the YDT. Is it in the “Recovered”...
Page 643: P0914
P0914 EAS20417 P0914 EAS32837 TROUBLESHOOTING Item Gear position sensor: signal stuck Fail-safe system • Able to start engine • Able to drive vehicle Procedure • If more than one DTC is detected at the same time, perform troubleshooting of DTC listed below first. •...
Page 644 P0914 Is the resistance change? → Go to step 3. a. Replace the gear position sensor. Refer to “CRANKCASE” on page 5-63. b. Make sure that the position of each gear is correctly displayed on the meter. Is check result OK? →...
Page 645: P0915
P0915 EAS20416 P0915 EAS32836 TROUBLESHOOTING Item Gear position sensor: signal out of range Fail-safe system • Able to start engine • Able to drive vehicle Procedure If more than one DTC is detected at the same time, perform troubleshooting of DTC listed below first. •...
Page 646 P0915 3. Connection of ECU coupler. • Check the locking condition of the coupler. • Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the pins). Is the coupler condition normal? → Go to step 4. a.
Page 647: P0916, P0917
P0916, P0917 EAS20611 P0916, P0917 EAS33091 TROUBLESHOOTING Item • [P0916] Gear position sensor: open or ground short circuit detected. • [P0917] Gear position sensor: power short circuit detected. Fail-safe system • Able to start engine • Able to drive vehicle Procedure 1.
Page 648 P0916, P0917 black/blue–black/blue Between gear position sensor coupler “1” and green/white–green/ white ECU coupler “2” blue–blue Lg/L L G/W B/L Gy/G Br/W Br/L Gy/G Br/W Lg/B *. MTN890 **. MTN890D Is resistance 0 Ω? → Go to “Short circuit check”. a.
Page 649 P0916, P0917 L G/W B/L L G/W B/L Gy/G Br/W Lg/L Br/L Gy/G Br/W Lg/B *. MTN890 **. MTN890D Is resistance ∞ Ω? → Go to step 4. a. Replace the wire harness. b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode of the YDT.
Page 650 P0916, P0917 5. Defective gear position sensor. • Make sure that the position of each gear is correctly displayed on the meter. Is check result OK? → Go to step 6. a. Replace the gear position sensor. Refer to “CRANKCASE” on page 5-63. b.
Page 651: P1004
P1004 EAS20786 P1004 EAS33529 TROUBLESHOOTING Item Intake air pressure sensor 1 and intake air pressure sensor 2: output voltage deviation error. Fail-safe system • Able to start engine • Able to drive vehicle Procedure If more than one DTC is detected at the same time, perform troubleshooting of DTC listed below first. •...
Page 652 P1004 Approx. 101 kPa (757.6 mmHg, 29.8 inHg), ap- At sea level prox. 3.64 V Approx. 90 kPa (675.1 mmHg, 26.6 inHg), ap- 1000 m (3300 ft) above sea level prox. 3.30 V Approx. 80 kPa (600.0 mmHg, 23.6 inHg), ap- 2000 m (6700 ft) above sea level prox.
Page 653: P1600
P1600 EAS20613 P1600 EAS33093 TROUBLESHOOTING Item Lean angle sensor: open or short circuit detected. Fail-safe system • Unable to start engine • Unable to drive vehicle Procedure If more than one DTC is detected at the same time, perform troubleshooting of DTC listed below first. •...
Page 654 P1600 3. Wire harness continuity. • Disconnect the ECU coupler “1”, IMU coupler “3” and ignition fuse 2 “4”. • Remove the joint coupler cap “2”. • Open circuit check blue/white–blue/white Between ECU coupler “1” and joint coupler “2” blue/black–blue/black blue/white–blue/white Between joint coupler “2”...
Page 655 P1600 Ground short circuit check “A” blue/white–ground Between ECU coupler “1” and ground blue/black–ground blue/white–ground Between IMU coupler “3” and ground blue/black–ground red/white–ground Lines short circuit check “B” blue/white–any other coupler terminal ECU coupler “1” black/black–any other coupler terminal blue/white–any other coupler terminal Joint coupler “2”...
Page 656 P1600 4. Installed condition of IMU. • Check the installed direction and condition of the sensor. Refer to “GENERAL CHASSIS (1)” on page 4-1. • Check the grommet for cracks. Is check result OK? → Go to step 5. a. Fix the IMU installation condition. b.
Page 657: P1601
P1601 EAS20614 P1601 EAS33094 TROUBLESHOOTING Item Sidestand switch: open or short circuit of the blue/yellow lead of the ECU is detected. Fail-safe system • Unable to start engine • Unable to drive vehicle Procedure 1. Connection of sidestand switch coupler. •...
Page 658 P1601 Is the coupler condition normal? → Go to step 4. a. Connect the coupler securely or replace the wire harness. b. Turn the main switch to “ON”, and then extend and retract the sidestand. c. Check the condition of the DTC using the malfunction mode of the YDT. Is it in the “Recovered”...
Page 659 P1601 Is it in the “Recovered” condition? → Go to step 7, and complete the service. → Go to “Short circuit check”. • Short circuit check Disconnect the ECU related connectors before checking. Refer to “PARTS CONNECTED TO THE ECU” on page 9-4. Ground short circuit check “A”...
Page 660 P1601 5. Defective sidestand switch. • Execute the diagnostic mode. (Code 20) • Shift the transmission into gear. Sidestand retracted Sidestand extended Is check result OK? → Go to step 6. a. Replace the sidestand switch. b. Turn the main switch to “ON”, and then extend and retract the sidestand. c.
Page 661: P1602
P1602 EAS20615 P1602 EAS33095 TROUBLESHOOTING Item Malfunction in ECU internal circuit (malfunction of ECU power cut-off function). Fail-safe system • Able/Unable to start engine • Able/Unable to drive vehicle Procedure 1. Installed condition of battery leads. • Check the installed condition of the battery and battery leads (loose bolts). Is check result OK? →...
Page 662 P1602 Is the coupler condition normal? → Go to step 4. a. Connect the coupler securely or replace the wire harness. b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode of the YDT. Is it in the “Recovered”...
Page 663 P1602 Gy/R Lg/R Br/L Br/Y Is resistance 0 Ω? → Go to “Short circuit check”. a. Replace the wire harness. b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode of the YDT. Is it in the “Recovered”...
Page 664 P1602 Gy/R Gy/R Br/Y Lg/R Lg/R Br/Y Br/L Br/L Is resistance ∞ Ω? → Go to step 6. a. Replace the wire harness. b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode of the YDT.
Page 665: P1606, P1607
P1606, P1607 EAS20787 P1606, P1607 EAS33530 TROUBLESHOOTING Item • [P1606] Intake air pressure sensor 2: ground short circuit detected. • [P1607] Intake air pressure sensor 2: open or power short circuit detected. Fail-safe system • Able to start engine • Able to drive vehicle Procedure 1.
Page 666 P1606, P1607 Between ECU coupler “3” and joint coupler “2” [P1607] black/blue–black/blue Between ECU coupler “3” and intake air pres- [P1607] blue–blue sure sensor 2 coupler “1” [P1606, P1607] pink–pink Between intake air pressure sensor 2 coupler [P1607] black–black “1” and joint coupler “2” Lg/L Gy/G Br/W...
Page 667 P1606, P1607 Ground short circuit check “A” Between intake air pressure sensor 2 coupler [P1607] blue–ground “1” and ground [P1606, P1607] pink–ground Lines short circuit check “B” [P1607] blue–any other coupler terminal ECU coupler “3” [P1607] black/blue–any other coupler terminal [P1606, P1607] pink–any other coupler terminal [P1607] blue–any other coupler terminal Intake air pressure sensor 2 coupler “1”...
Page 668 P1606, P1607 Is check result OK? → Go to step 5. a. Reinstall or replace the sensor. b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode of the YDT. Is it in the “Recovered” condition? →...
Page 669: P1608
P1608 EAS20788 P1608 EAS33531 TROUBLESHOOTING Item Intake air pressure sensor 2: signal out of range Fail-safe system • Able to start engine • Able to drive vehicle Procedure If more than one DTC is detected at the same time, perform troubleshooting of DTC listed below first. •...
Page 670 P1608 Is it in the “Recovered” condition? → Go to step 5, and complete the service. → Go to step 4. 4. Malfunction in ECU. • Replace the ECU, and complete the service. Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-56. 5.
Page 671: P1609
P1609 EAS20789 P1609 EAS33532 TROUBLESHOOTING Item Intake air pressure sensor 2: clogging of hose or sensor disconnection Fail-safe system • Able to start engine • Able to drive vehicle Procedure If more than one DTC is detected at the same time, perform troubleshooting of DTC listed below first. •...
Page 672 P1609 Is check result OK? → Go to step 3, and complete the service. a. Replace the intake air pressure sensor. Refer to “THROTTLE BODIES” on page 7-5 b. Start the engine and let it idle for approximately 5 seconds with the throttle fully closed, and then check the condition of the DTC using the malfunction mode of the YDT.
Page 673: P1806, P1807
P1806, P1807 EAS20623 P1806, P1807 EAS33103 TROUBLESHOOTING Item • [P1806] Shift sensor: open or ground short circuit detected. • [P1807] Shift sensor: power short circuit detected. Fail-safe system • Able to start engine • Able to drive vehicle Procedure 1. Connection of shift sensor coupler. •...
Page 674 P1806, P1807 Between shift sensor coupler “1” and ECU cou- blue–blue pler “2” violet–violet Between shift sensor coupler “1” and joint cou- black–black pler “3” Between joint coupler “3” and ECU coupler “2” black/blue–black/blue Lg/L Lg/L Gy/G Br/W Br/L Gy/G Br/W B V L Lg/B...
Page 675 P1806, P1807 Ground short circuit check “A” violet–ground Between shift sensor coupler “1” and ground blue–ground Lines short circuit check “B” black–any other coupler terminal Shift sensor coupler “1” violet–any other coupler terminal blue–any other coupler terminal black/blue–any other coupler terminal ECU coupler “2”...
Page 676 P1806, P1807 Is check result OK? → Go to step 5. a. Reinstall or replace the sensor. Refer to “CHAIN DRIVE” on page 4-86. b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode of the YDT.
Page 677: P2122, P2123, P2127, P2128, P2138
P2122, P2123, P2127, P2128, P2138 EAS20632 P2122, P2123, P2127, P2128, P2138 EAS33112 TROUBLESHOOTING Item • [P2122] Accelerator position sensor: open or ground short circuit detected. • [P2123] Accelerator position sensor: power short circuit detected. • [P2127] Accelerator position sensor: open or ground short circuit detected. •...
Page 678 P2122, P2123, P2127, P2128, P2138 Is it in the “Recovered” condition? → Go to step 6, and complete the service. → Go to step 3. 3. Wire harness continuity. • Disconnect the accelerator position sensor coupler “1” and ECU coupler “2”. •...
Page 679 P2122, P2123, P2127, P2128, P2138 Ground short circuit check “A” [P2122, P2123, P2127, P2128, P2138] brown– ground Between accelerator position sensor coupler “1” [P2122, P2127] white/red–ground and ground [P2122, P2127] yellow/red–ground [P2122, P2123, P2127, P2128, P2138] yellow– ground Lines short circuit check “B” [P2122, P2123, P2127, P2128, P2138] brown–...
Page 680 P2122, P2123, P2127, P2128, P2138 Is resistance ∞ Ω? → Go to step 4. a. Replace the wire harness. b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode of the YDT. Is it in the “Recovered”...
Page 681: P2158
P2158 EAS20633 P2158 EAS33113 TROUBLESHOOTING Item Front wheel sensor: no normal signals are received from the front wheel sensor. Fail-safe system • Able to start engine • Able to drive vehicle Procedure 1. Locate the malfunction. • Check the ABS warning light. Is the ABS warning light on? →...
Page 682 P2158 Is the coupler condition normal? → Go to step 5. a. Connect the coupler securely or replace the wire harness. b. Execute the diagnostic mode. (Code 16) c. Rotate the front wheel by hand and check that the indicated value increases. Is that value increased? →...
Page 683 P2158 Lg/L Gy/G Br/W W/G G Y L R/B Br L/W G/O W/Y L B W Y L/B Lg/L Br/L Gy/G Br/W Lg/B *. MTN890 **. MTN890D Is resistance 0 Ω? → Go to “Short circuit check”. a. Replace the wire harness. b.
Page 684 P2158 Lg/L Gy/G Br/W W/G G Y L R/B Br L/W W/G G Y L R/B Br L/W Lg/L G/O W/Y L B W Y L/B Br/L Gy/G Br/W G/O W/Y L B W Y L/B Lg/B *. MTN890 **. MTN890D Is resistance ∞...
Page 685 P2158 • Replace the ECU. Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-56. • Execute the diagnostic mode. (Code 16) • Rotate the front wheel by hand and check that the indicated value increases. Is that value increased? →...
Page 686: U0125
U0125 EAS20775 U0125 EAS33127 TROUBLESHOOTING Item Signals cannot be transmitted between the ECU and the IMU. Fail-safe system • Unable to start engine • Able/Unable to drive vehicle Procedure If more than one DTC is detected at the same time, perform troubleshooting of DTC listed below first. •...
Page 687 U0125 3. Wire harness continuity. • Disconnect the ECU coupler “1”, IMU coupler “3” and ignition fuse 2 “4”. • Remove the joint coupler cap “2”. • Open circuit check blue/white–blue/white Between ECU coupler “1” and joint coupler “2” blue/black–blue/black blue/white–blue/white Between joint coupler “2”...
Page 688 U0125 Ground short circuit check “A” blue/white–ground Between ECU coupler “1” and ground blue/black–ground blue/white–ground Between IMU coupler “3” and ground blue/black–ground red/white–ground Lines short circuit check “B” blue/white–any other coupler terminal ECU coupler “1” blue/black–any other coupler terminal blue/white–any other coupler terminal Joint coupler “2”...
Page 689 U0125 4. Malfunction in IMU. • Replace the IMU. Refer to “GENERAL CHASSIS (1)” on page 4-1. • Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode of the YDT. Is it in the “Recovered” condition? →...
Page 690: U0155 Or Err
U0155 or Err EAS20649 U0155 or Err EAS33129 TROUBLESHOOTING Item Multi-function meter: signals cannot be transmitted between the ECU and the multi-function meter. Fail-safe system • Able to start engine • Able to drive vehicle Procedure “Err” is displayed on the clock display of the multi-function meter, but the MIL does not come on. 1.
Page 691 U0155 or Err 3. Wire harness continuity. • Disconnect the meter assembly coupler “1” and ECU coupler “4”. • Remove the joint coupler cap “2” and joint coupler cap “3”. • Open circuit check Between meter assembly coupler “1” and joint blue/black–blue/black coupler “2”...
Page 692 U0155 or Err Ground short circuit check “A” Between meter assembly coupler “1” and blue/white–ground ground blue/black–ground blue/white–ground Between ECU coupler “4” and ground blue/black–ground Lines short circuit check “B” blue/white–any other coupler terminal Meter assembly coupler “1” blue/black–any other coupler terminal blue/white–any other coupler terminal ECU coupler “4”...
Page 693 U0155 or Err Is it in the “Recovered” condition? → Go to step 6, and complete the service. → Go to step 5. 5. Malfunction in ECU. • Replace the ECU, and complete the service. Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-56. 6.
Page 694: 51_Immobilizer
51_IMMOBILIZER EAS20680 51_IMMOBILIZER EAS33309 TROUBLESHOOTING Item Code cannot be transmitted between the key and the immobilizer unit. Cause • Radio wave interference caused by objects around the keys and antennas. • Immobilizer unit malfunction. • Key malfunction. Procedure When a system malfunction occurs, the immobilizer system indicator light will flash. The DTC can be identified by the flashing pattern.
Page 695: 52_Immobilizer
52_IMMOBILIZER EAS20679 52_IMMOBILIZER EAS33308 TROUBLESHOOTING Item Codes between the key and immobilizer unit do not match. Cause • Signal received from other transponder (failed to recognize code after ten consecutive attempts). • Signal received from unregistered standard key. • Immobilizer unit malfunction •...
Page 696: 53_Immobilizer
53_IMMOBILIZER EAS20681 53_IMMOBILIZER EAS33310 TROUBLESHOOTING Item Codes cannot be transmitted between the ECU and the immobilizer unit. Cause • Disconnected lead/cable. • Open or short circuit in wire harness between immobilizer unit and ECU. • Immobilizer unit malfunction. • ECU malfunction. Procedure When a system malfunction occurs, the immobilizer system indicator light will flash.
Page 697 53_IMMOBILIZER Gy/G Br/W Y/L Lg Lg/L Br/L Gy/G Br/W Lg/B *. MTN890 **. MTN890D Is resistance 0 Ω? → Go to “Short circuit check”. → Replace the wire harness. • Short circuit check Disconnect the ECU related connectors before checking. Refer to “HANDLEBAR”...
Page 698 53_IMMOBILIZER Gy/G Br/W Y/L Lg Y/L Lg Lg/L Br/L Gy/G Br/W Lg/B *. MTN890 **. MTN890D Is resistance ∞ Ω? → Go to step 4. → Replace the wire harness. 4. Turn the main switch to “ON”. Is DTC displayed? →...
Page 699: 54_Immobilizer
54_IMMOBILIZER EAS20682 54_IMMOBILIZER EAS33311 TROUBLESHOOTING Item Codes transmitted between the ECU and the immobilizer unit do not match. Cause • Disconnected lead/cable. • Immobilizer unit malfunction. • ECU failure. (The ECU or immobilizer unit was replaced with a used unit from another vehicle.) •...
Page 700 54_IMMOBILIZER 5. Replace the main switch/immobilizer unit, ECU and all key, and complete the service. Refer to “HANDLEBAR” on page 4-57 and “REPLACING THE ECU (Engine Control Unit)” on page 8-56. 9-270...
Page 701: 55_Immobilizer
55_IMMOBILIZER EAS20683 55_IMMOBILIZER EAS33312 TROUBLESHOOTING Item Key code registration malfunction. Cause • Same standard key was attempted to be registered two consecutive times. Procedure When a system malfunction occurs, the immobilizer system indicator light will flash. The DTC can be identified by the flashing pattern.
Page 702: 56_Immobilizer
56_IMMOBILIZER EAS20684 56_IMMOBILIZER EAS33313 TROUBLESHOOTING Item Codes cannot be transmitted between the ECU and the immobilizer unit. Cause • Disconnected lead/cable. • Open or short circuit in wire harness between immobilizer unit and ECU. • Immobilizer unit malfunction. • ECU malfunction. Procedure When a system malfunction occurs, the immobilizer system indicator light will flash.
Page 703 56_IMMOBILIZER Gy/G Br/W Y/L Lg Lg/L Br/L Gy/G Br/W Lg/B *. MTN890 **. MTN890D Is resistance 0 Ω? → Go to “Short circuit check”. →Replace the wire harness. • Short circuit check Disconnect the ECU related connectors before checking. Refer to “HANDLEBAR” on page 4-57. Ground short circuit check “A”...
Page 704 56_IMMOBILIZER Gy/G Br/W Y/L Lg Y/L Lg Lg/L Br/L Gy/G Br/W Lg/B *. MTN890 **. MTN890D Is resistance ∞ Ω? → Go to step 4. → Replace the wire harness. 4. Turn the main switch to “ON”. Is DTC displayed? →...
Page 705: 11_Abs
11_ABS EAS20685 11_ABS EAS33314 TROUBLESHOOTING Item Front wheel sensor (intermittent pulses or no pulses) Procedure If the rear wheel continues to turn for more than 20 seconds after the front wheel has stopped, this will be recorded. 1. Foreign material adhered around the front wheel sensor •...
Page 706: 12_Abs
12_ABS EAS20686 12_ABS EAS33315 TROUBLESHOOTING Item Rear wheel sensor (intermittent pulses or no pulses) Procedure 1. Foreign material adhered around the rear wheel sensor • Check the surface of the sensor rotor and wheel sensor for foreign material, such as metal particles. Is check result OK? →...
Page 707: 13, 26_Abs
13, 26_ABS EAS20687 13, 26_ABS EAS33316 TROUBLESHOOTING Item Front wheel sensor (abnormal pulse period) Procedure • If the front brake ABS operates continuously for 20 seconds or more, DTC No. 26 will be recorded. If the front brake ABS operates continuously for 36 seconds or more, DTC No. 13 will be recorded. •...
Page 708: 14, 27_Abs
14, 27_ABS EAS20688 14, 27_ABS EAS33317 TROUBLESHOOTING Item Rear wheel sensor (abnormal pulse period) Procedure • If the rear brake ABS operates continuously for 20 seconds or more, DTC No. 27 will be recorded. If the rear brake ABS operates continuously for 36 seconds or more, DTC No. 14 will be recorded. •...
Page 709: 15_Abs
15_ABS EAS20662 15_ABS EAS33040 TROUBLESHOOTING Item Front wheel sensor (open or short circuit) Procedure 1. Defective coupler between the front wheel sensor and the hydraulic unit assembly • Check the coupler for any pins that may be pulled out. • Check the locking condition of the coupler. Turn the main switch to “OFF”...
Page 710 15_ABS Lines short circuit check “B” yellow–any other coupler terminal ABS ECU coupler “1” brown–any other coupler terminal W/G G Y L R/B Br L/W W/G G Y L R/B Br L/W G/O W/Y L B W Y L/B G/O W/Y L B W Y L/B Is resistance ∞...
Page 711: 16_Abs
16_ABS EAS20663 16_ABS EAS33285 TROUBLESHOOTING Item Rear wheel sensor (open or short circuit) Procedure 1. Defective coupler between the rear wheel sensor and the hydraulic unit assembly • Check the coupler for any pins that may be pulled out. • Check the locking condition of the coupler. Turn the main switch to “OFF”...
Page 712 16_ABS Ground short circuit check “A” white–ground Between ABS ECU coupler “1” and ground black–ground Lines short circuit check “B” white–any other coupler terminal ABS ECU coupler “1” black–any other coupler terminal W/G G Y L R/B Br L/W W/G G Y L R/B Br L/W G/O W/Y L B W Y L/B G/O W/Y L B W Y L/B Is resistance ∞...
Page 713: 21_Abs
21_ABS EAS20690 21_ABS EAS33320 TROUBLESHOOTING Item Hydraulic unit assembly (defective solenoid drive circuit) Procedure 1. Defective hydraulic unit assembly • Replace the hydraulic unit assembly. Refer to “ABS (ANTI-LOCK BRAKE SYSTEM)” on page 4-49. 9-283...
Page 714: 31_Abs
31_ABS EAS20691 31_ABS EAS33321 TROUBLESHOOTING Hydraulic unit assembly (defective ABS solenoid power circuit) Procedure 1. Blown ABS solenoid fuse • Check the ABS solenoid fuse. Refer to “CHECKING THE FUSES” on page 8-55. Is check result OK? → Go to step 2. →...
Page 715 31_ABS Disconnect the ABS ECU related connectors before checking. Refer to “PARTS CONNECTED TO THE ABS ECU” on page 9-4. Ground short circuit check “A” Between ABS ECU coupler “2” and ground blue/white–ground Lines short circuit check “B” ABS ECU coupler “2” blue/white–any other coupler terminal W/G G Y L R/B Br L/W W/G G Y L R/B Br L/W...
Page 716: 33_Abs
33_ABS EAS20692 33_ABS EAS33322 TROUBLESHOOTING Item Hydraulic unit assembly (abnormal ABS motor power supply) Procedure 1. Blown ABS motor fuse • Check the ABS motor fuse. Refer to “CHECKING THE FUSES” on page 8-55. Is check result OK? → Go to step 2. →...
Page 717 33_ABS • Short circuit check Disconnect the ABS ECU related connectors before checking. Refer to “PARTS CONNECTED TO THE ABS ECU” on page 9-4. Ground short circuit check “A” Between ABS ECU coupler “2” and ground red–ground Lines short circuit check “B” ABS ECU coupler “2”...
Page 718: 34_Abs
34_ABS EAS20693 34_ABS EAS33323 TROUBLESHOOTING Item Hydraulic unit assembly (short circuit in ABS motor power supply circuit) Procedure 1. Defective hydraulic unit assembly • Replace the hydraulic unit assembly. Refer to “ABS (ANTI-LOCK BRAKE SYSTEM)” on page 4-49. 9-288...
Page 719: 41_Abs
41_ABS EAS20694 41_ABS EAS33331 TROUBLESHOOTING Item Front wheel ABS (intermittent wheel speed pulses or incorrect depressurization) Procedure 1. Incorrect installation of the front wheel sensor • Check the components for looseness, distortion, and bends. Refer to “MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR” on page 4- Is check result OK? →...
Page 720: 42_Abs
42_ABS EAS20695 42_ABS EAS33324 TROUBLESHOOTING Item Rear wheel ABS (intermittent wheel speed pulses or incorrect depressurization) Procedure 1. Incorrect installation of the rear wheel sensor • Check the components for looseness, distortion, and bends. Refer to “MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR” on page 4- Is check result OK? →...
Page 721: 43, 45_Abs
43, 45_ABS EAS20696 43, 45_ABS EAS33330 TROUBLESHOOTING Item Front wheel sensor (missing pulses) Procedure After the DTC 45 is recorded, DTC 43 will be recorded if a certain speed and time are exceeded. 1. Foreign material adhered around the front wheel sensor •...
Page 722: 44, 46_Abs
44, 46_ABS EAS20697 44, 46_ABS EAS33325 TROUBLESHOOTING Item Rear wheel sensor (missing pulses) Procedure After the DTC 46 is recorded, DTC 44 will be recorded if a certain speed and time are exceeded. 1. Foreign material adhered around the rear wheel sensor •...
Page 723: 51_Abs
51_ABS EAS20698 51_ABS EAS33326 TROUBLESHOOTING Item Vehicle system power supply (voltage of ABS ECU power supply is high) Procedure 1. Defective battery • Recharge or replace the battery, and check again. Refer to “CHECKING AND CHARGING THE BATTERY” on page 8-56. 2.
Page 724: 53_Abs
53_ABS EAS20699 53_ABS EAS33327 TROUBLESHOOTING Item Vehicle system power supply (voltage of ABS ECU power supply is low) Procedure 1. Defective battery • Recharge or replace the battery, and check again. Refer to “CHECKING AND CHARGING THE BATTERY” on page 8-56. 2.
Page 725 53_ABS Ground short circuit check “A” Between ABS ECU coupler “2” and ground red/black–ground Lines short circuit check “B” ABS ECU coupler “2” red/black–any other coupler terminal W/G G Y L R/B Br L/W W/G G Y L R/B Br L/W G/O W/Y L B W Y L/B G/O W/Y L B W Y L/B Is resistance ∞...
Page 726: 55_Abs
55_ABS EAS20700 55_ABS EAS33328 TROUBLESHOOTING Item Hydraulic unit assembly (defective ABS ECU) Procedure 1. Defective hydraulic unit assembly • Replace the hydraulic unit assembly. Refer to “ABS (ANTI-LOCK BRAKE SYSTEM)” on page 4-49. 9-296...
Page 727: 56_Abs
56_ABS EAS20701 56_ABS EAS33329 TROUBLESHOOTING Item Hydraulic unit assembly (abnormal internal circuit) Procedure 1. Defective hydraulic unit assembly • Replace the hydraulic unit assembly. Refer to “ABS (ANTI-LOCK BRAKE SYSTEM)” on page 4-49. 9-297...
Page 728: 57_Abs
57_ABS EAS20666 57_ABS EAS33292 TROUBLESHOOTING Item Vehicle CAN communication line or power source of vehicle system Procedure 1. Wire harness continuity. • Disconnect the ECU coupler “1” and ABS ECU coupler “5”. • Remove the joint coupler cap “2”, joint coupler cap “3” and joint coupler cap “4”. •...
Page 729 57_ABS Ground short circuit check “A” blue/white–ground Between ECU coupler “1” and ground blue/black–ground blue/white–ground Between ABS ECU coupler “5” and ground blue/black–ground Lines short circuit check “B” blue/white–any other coupler terminal ECU coupler “1” blue/black–any other coupler terminal yellow/black–any other coupler terminal Joint coupler “2”...
Page 730 57_ABS Turn the main switch to “OFF” before disconnecting or connecting a coupler. Is check result OK? → Go to step 4. → If there is a malfunction, repair it and connect the coupler securely. 4. Wire harness continuity • Disconnect the ABS ECU fuse “1”, ABS solenoid fuse “2” and ABS ECU coupler “3”. •...
Page 731 57_ABS W/G G Y L R/B Br L/W W/G G Y L R/B Br L/W G/O W/Y L B W Y L/B G/O W/Y L B W Y L/B Is resistance ∞ Ω? → Go to step 5. → Replace the wire harness. 5.
Page 732: 62_Abs
62_ABS EAS20702 62_ABS EAS33333 TROUBLESHOOTING Item Power supply voltage failure in pressure sensor Procedure 1. Defective hydraulic unit assembly • Replace the hydraulic unit assembly. Refer to “ABS (ANTI-LOCK BRAKE SYSTEM)” on page 4-49. 9-302...
Page 733: 68_Abs
68_ABS EAS20705 68_ABS EAS33336 TROUBLESHOOTING Item Defective hydraulic unit assembly (defective front pressure sensor) Procedure 1. Defective front brake line • Check the front brake line. Is check result OK? → Go to step 2. → If there is bending or blocking, replace the front brake line. 2.
Page 734: 89_Abs
89_ABS EAS20669 89_ABS EAS33299 TROUBLESHOOTING Item CAN communication (between meter assembly and hydraulic unit assembly) Procedure 1. Defective coupler between the meter assembly and the hydraulic unit assembly • Check the coupler for any pins that may be pulled out. •...
Page 735 89_ABS Is resistance 0 Ω? → Go to “Short circuit check”. → Replace the wire harness. • Short circuit check Disconnect the ABS ECU related connectors before checking. Refer to “PARTS CONNECTED TO THE ABS ECU” on page 9-4. Ground short circuit check “A” Between meter assembly coupler “1”...
Page 736 89_ABS 4. Defective hydraulic unit assembly • Replace the hydraulic unit assembly. 9-306...
Page 737: 90_Abs
90_ABS EAS20670 90_ABS EAS33300 TROUBLESHOOTING Item CAN communication (between ECU and hydraulic unit assembly) Procedure 1. Defective coupler between the ECU and the hydraulic unit assembly • Check the coupler for any pins that may be pulled out. • Check the locking condition of the coupler. Turn the main switch to “OFF”...
Page 738 90_ABS Is resistance 0 Ω? → Go to “Short circuit check”. → Replace the wire harness. • Short circuit check Disconnect the ECU and ABS ECU related connectors before checking. Refer to “PARTS CONNECTED TO THE ECU” on page 9-4 and “PARTS CONNECTED TO THE ABS ECU”...
Page 739 90_ABS Is resistance ∞ Ω? → Go to step 3. → Replace the wire harness. 3. Defective ECU • Replace the ECU, and check again. 4. Defective hydraulic unit assembly • Replace the hydraulic unit assembly. 9-309...
Page 740: 91_Abs
91_ABS EAS20671 91_ABS EAS33301 TROUBLESHOOTING Item CAN communication (between IMU and hydraulic unit assembly) Procedure 1. Defective coupler between the IMU and the hydraulic unit assembly • Check the coupler for any pins that may be pulled out. • Check the locking condition of the coupler. Turn the main switch to “OFF”...
Page 741 91_ABS Is resistance 0 Ω? → Go to “Short circuit check”. → Replace the wire harness. • Short circuit check Disconnect the ABS ECU related connectors before checking. Refer to “PARTS CONNECTED TO THE ABS ECU” on page 9-4. Ground short circuit check “A” blue/white–ground Between IMU coupler “1”...
Page 742 91_ABS 4. Defective hydraulic unit assembly • Replace the hydraulic unit assembly. 9-312...
Page 743 57. ABS ECU (Electronic Control EAS20091 WIRING DIAGRAM Unit) 58. Front wheel sensor MTN890 2021 59. Rear wheel sensor 1. AC magneto 60. IMU (Inertial Measurement 2. Rectifier/regulator Unit) 3. Fuse box 61. Purge cut valve solenoid 4. Main fuse 62.
Page 744 MTN890D 2021 60. Throttle servo motor 61. ABS ECU (Electronic Control 1. AC magneto Unit) 2. Rectifier/regulator 62. Front wheel sensor 3. Fuse box 63. Rear wheel sensor 4. Main fuse 64. IMU (Inertial Measurement 5. Main switch Unit) 6. Radiator fan motor relay 65.
Page 745 EAS30613 COLOR CODE Black Brown Dark gray Green Gray Blue Light green Orange Pink Sky blue Violet White Yellow Black/Blue Black/White Black/Yellow Br/B Brown/Black Br/L Brown/Blue Br/W Brown/White Br/Y Brown/Yellow Green/Black Green/Blue Green/Orange Green/White Green/Yellow Gy/G Gray/Green Gy/R Gray/Red Blue/Black Blue/Red Blue/White Blue/Yellow...
Page 749 MTN890 2021 MTN890 2021 MTN890 2021 MTN890 2021 MTN890 2021 SCHÉMA DE CÂBLAGE SCHEMA ELETTRICO WIRING DIAGRAM SCHALTPLAN DIAGRAMA ELÉCTRICO W W W Y/L Lg R/W Lg W W W (Dgy) R Y/L O R/W Sb/W Gy/R R/W Br/Y Gy/R Gy/R Gy/R Lg/R...
Page 750 MTN890 2021 MTN890 2021 MTN890 2021 MTN890 2021 MTN890 2021 SCHÉMA DE CÂBLAGE SCHEMA ELETTRICO WIRING DIAGRAM SCHALTPLAN DIAGRAMA ELÉCTRICO (Dgy) (Gy) (Gy) START (Gy) (Gy) (Gy) (Gy) FREE DOWN 84 85 (Gy) (Gy) (Gy)
Page 751 MTN890D 2021 MTN890D 2021 MTN890D 2021 MTN890D 2021 MTN890D 2021 SCHÉMA DE CÂBLAGE SCHEMA ELETTRICO WIRING DIAGRAM SCHALTPLAN DIAGRAMA ELÉCTRICO W W W Y/L Lg R/W Lg W W W (Dgy) R Y/L O R/W Sb/W Gy/R R/W Br/Y Gy/R Gy/R Gy/R Lg/R...
Page 752 MTN890D 2021 MTN890D 2021 MTN890D 2021 MTN890D 2021 MTN890D 2021 SCHÉMA DE CÂBLAGE SCHEMA ELETTRICO WIRING DIAGRAM SCHALTPLAN DIAGRAMA ELÉCTRICO (Dgy) (Gy) (Gy) START (Gy) (Gy) (Dgy) (Gy) (Gy) (Gy) FREE PASS FREE PUSH DOWN PUSH FREE (Gy) (Gy) 90 91 (Gy) (Gy) (Gy)

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Mt-09sp 2021

Yamaha MT-09 2021 Service Manual

Table of Contents

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Periodic Checks and Adjustments

Chassis

Engine

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