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MT-09 2021
Service manual
Yamaha MT-09 2021 Service Manual
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Table of Contents
General Information
Identification
Vehicle Identification Number
Model Label
Glossary
Display
Basic Service Information
Electrical System
Special Tools
Specifications
General Specifications
Engine Specifications
Chassis Specifications
Electrical Specifications
Chassis Tightening Torques
Engine Tightening Torques
Tightening Torques
Cable Routing
Periodic Checks and Adjustments
General Maintenance and Lubrication Chart
Introduction
Periodic Maintenance
Periodic Maintenance Chart for the Emission Control System
Checking the Fuel Line
Checking the Vehicle Using the Yamaha Diagnostic Tool
Adjusting the Valve Clearance
Checking the Spark Plugs
Checking the Engine Idling Speed
Synchronizing the Throttle Bodies
Checking the Cylinder Head Breather Hose
Checking the Exhaust System
Checking the Throttle Body Joints
Adjusting the Exhaust Gas Volume
Checking the Canister
Checking the Purge Cut Valve Solenoid
Replacing the Air Filter Element
Adjusting the Clutch Lever Free Play
Adjusting the Front Disc Brake
Checking the Brake Fluid Level
Checking the Brake Operation
Adjusting the Rear Disc Brake
Checking the Front Brake Pads
Bleeding the Hydraulic Brake System (Abs)
Checking the Front Brake Hoses
Checking the Rear Brake Hose
Checking the Rear Brake Pads
Checking the Tires
Checking the Wheels
Checking the Swingarm Operation
Checking the Wheel Bearings
Drive Chain Slack
Lubricating the Swingarm Pivot
Checking and Adjusting the Steering Head
Lubricating the Drive Chain
Checking the Chassis Fasteners
Lubricating the Brake Lever
Lubricating the Steering Head
ADJUSTING the FRONT FORK LEGS (for MTN890)
Adjusting the Shift Pedal
Checking the Front Fork
Checking the Sidestand
Checking the Sidestand Switch
Lubricating the Clutch Lever
Lubricating the Pedal
Lubricating the Sidestand
ADJUSTING the FRONT FORK LEGS (for MTN890D)
ADJUSTING the REAR SHOCK ABSORBER ASSEMBLY (for MTN890)
Checking the Rear Shock Absorber Assembly
ADJUSTING the REAR SHOCK ABSORBER ASSEMBLY (for MTN890D)
Changing the Engine Oil
Checking the Connecting Arm and Relay Arm
Checking the Engine Oil Level
Measuring the Engine Oil Pressure
Changing the Coolant
Checking the Coolant Level
Checking the Cooling System
Adjusting the Rear Brake Light Switch
Checking and Lubricating the Cables
Checking the Front Brake Light Switch
Adjusting the Headlight Beam
Checking and Charging the Battery
Checking the Fuses
Checking the Throttle Grip
Chassis
General Chassis (1)
Installing the Fuel Tank Side Cover
Removing the Fuel Tank Side Cover
Removing the Headlight
Removing the Seat
Installing the Headlight
Installing the Imu
General Chassis (2)
Installing the Seat
Front Wheel
Checking the Front Wheel
Disassembling the Front Wheel
Removing the Front Wheel
Assembling the Front Wheel
Adjusting the Front Wheel Static Balance
Maintenance of the Front Wheel Sensor and Sensor Rotor
Installing the Front Wheel (Front Brake Discs)
Rear Wheel
Checking and Replacing the Rear Wheel Sprocket
Checking the Rear Wheel
Checking the Rear Wheel Drive Hub
Disassembling the Rear Wheel
Removing the Rear Wheel
Adjusting the Rear Wheel Static Balance
Assembling the Rear Wheel
Maintenance of the Rear Wheel Sensor and Sensor Rotor
Installing the Rear Wheel (Rear Brake Disc)
Front Brake
Checking the Front Brake Discs
Introduction
Replacing the Front Brake Pads
Checking the Front Brake Calipers
Disassembling the Front Brake Calipers
Removing the Front Brake Calipers
Assembling the Front Brake Calipers
Installing the Front Brake Calipers
Assembling the Front Brake Master Cylinder
Checking the Front Brake Master Cylinder
Installing the Front Brake Master Cylinder
Removing the Front Brake Master Cylinder
Rear Brake
Adjusting the Footrest Position
Checking the Rear Brake Disc
Introduction
Replacing the Rear Brake Pads
Checking the Rear Brake Caliper
Disassembling the Rear Brake Caliper
Removing the Rear Brake Caliper
Assembling the Rear Brake Caliper
Installing the Rear Brake Caliper
Assembling the Rear Brake Master Cylinder
Checking the Rear Brake Master Cylinder
Installing the Rear Brake Master Cylinder
Removing the Rear Brake Master Cylinder
Abs (Anti-Lock Brake System)
Checking the Hydraulic Unit Assembly
Removing the Hydraulic Unit Assembly
Checking the Brake Pipes
Installing the Hydraulic Unit Assembly
Hydraulic Unit Operation Tests
Checking the Abs Warning Light
Handlebar
Adjusting the Handlebar Position
Removing the Handlebar
Checking the Handlebar
Installing the Handlebar
Front Fork
Disassembling the Front Fork Legs
Removing the Front Fork Legs
Checking the Front Fork Legs
Assembling the Front Fork Legs
Installing the Front Fork Legs
Steering Head
Checking the Steering Head
Removing the Lower Bracket
Installing the Steering Head
Checking the Rear Shock Absorber Assembly
DISPOSING of a REAR SHOCK ABSORBER (for MTN890)
DISPOSING of a REAR SHOCK ABSORBER (for MTN890D)
Handling the Rear Shock Absorber
Rear Shock Absorber Assembly
Removing the Rear Shock Absorber Assembly
Checking the Connecting Arm and Relay Arm
Installing the Rear Shock Absorber Assembly
Installing the Relay Arm
Swingarm
Checking the Swingarm
Installing the Swingarm
Removing the Swingarm
Chain Drive
Checking the Drive Chain
Removing the Drive Chain
Checking the Drive Sprocket
Checking the Rear Wheel Drive Hub
Checking the Rear Wheel Sprocket
Installing the Drive Chain
Adjusting the Shift Pedal
Engine
Engine Oil Lubrication Chart
Lubrication System Chart and Diagrams
Lubrication Diagrams
Engine Inspection
Measure the Compression Pressure
Engine Removal
Installing the Engine
Removing the Engine
Camshafts
Removing the Camshafts
Checking the Camshafts
Checking the Timing Chain and Camshaft Sprocket
Checking the Timing Chain Guides
Checking the Timing Chain Tensioner
Installing the Camshafts
Cylinder Head
Checking the Cylinder Head
Checking the Timing Chain Guide (Exhaust Side)
Removing the Cylinder Head
Installing the Cylinder Head
Valves and Valve Springs
Checking the Valves and Valve Guides
Removing the Valves
Checking the Valve Seats
Checking the Valve Lifters
Checking the Valve Springs
Installing the Valves
Generator and Starter Clutch
Checking the Starter Clutch
Removing the Generator
Removing the Starter Clutch
Installing the Generator
Installing the Starter Clutch
Electric Starter
Assembling the Starter Motor
Checking the Starter Motor
Installing the Starter Motor
Clutch
Removing the Clutch
Checking the Clutch Plates
Checking the Friction Plates
Checking the Clutch Housing
Checking the Clutch Springs
Checking the Clutch Boss
Checking the Pressure Plate
Checking the Primary Drive Gear
Checking the Primary Driven Gear
Checking the Pull Lever Shaft and Pull Rod
Installing the Clutch
Shift Shaft
Checking the Shift Shaft
Checking the Stopper Lever
Installing the Shift Shaft
Oil Pump
Assembling the Oil Pump
Checking the Oil Pump
Checking the Relief Valve
Checking the Sprocket and Chain
Installing the Oil Pump
Oil Pan
Checking the Oil Strainer
Installing the Oil Pan
Removing the Oil Pan
Crankcase
Assembling the Crankcase
Checking the Crankcase
Disassembling the Crankcase
Installing the Gear Position Sensor
Installing the Oil Pressure Switch
Checking the Cylinder and Piston
Connecting Rods and Pistons
Removing the Connecting Rods and Pistons
Checking the Piston Rings
Checking the Connecting Rods
Checking the Piston Pin
Installing the Connecting Rod and Piston
Checking the Crankshaft
Checking the Oil Nozzles
Crankshaft and Balancer Shaft
Removing the Crankshaft and Balancer Shaft
Checking the Balancer Shaft
Installing the Balancer Assembly
Installing the Crankshaft
Transmission
Checking the Shift Forks
Removing the Transmission
Checking the Shift Drum Assembly
Checking the Transmission
Assembling the Main Axle and Drive Axle
Installing the Transmission
Cooling System
Cooling System Diagrams
Radiator
Checking the Radiator
Installing the Radiator
Oil Cooler
Checking the Oil Cooler
Installing the Oil Cooler
Thermostat
Checking the Thermostat
Installing the Thermostat Assembly
Water Pump
Assembling the Water Pump
Checking the Water Pump
Disassembling the Water Pump
Fuel System
Fuel Tank
Checking the Fuel Pump Body
Checking the Fuel Pump Operation
Removing the Fuel Pump
Removing the Fuel Tank
Checking the Purge Cut Valve Solenoid
Installing the Fuel Pump
Installing the Fuel Tank
Checking and Cleaning the Throttle Bodies
Checking the Injectors
Checking the Injectors (before Removing)
Removing the Fuel Hose (Fuel Rail Side)
Removing the Injectors
Installing the Injectors
Replacing the Throttle Bodies
Checking the Fuel Pressure
Checking the Injector Pressure
Adjusting the Throttle Position Sensor
Installing the Fuel Hose (Fuel Rail Side)
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2021
SERVICE MANUAL
MT-09
MT-09SP
MTN890
MTN890D
B7N-28197-E0
Table of
Contents
Previous
Page
Next
Page
1
2
3
4
5
Advertisement
Chapters
Table of Contents
7
Specifications
27
Periodic Checks and Adjustments
95
Chassis
131
Engine
225
Cooling System
323
Fuel System
339
Electrical System
353
Self Diagnostic
423
Table of Contents
Troubleshooting
TROUBLESHOOTING
361
TROUBLESHOOTING
370
TROUBLESHOOTING
376
TROUBLESHOOTING
382
TROUBLESHOOTING
388
TROUBLESHOOTING
398
TROUBLESHOOTING
404
BASIC PROCESS FOR TROUBLESHOOTING
446
TROUBLESHOOTING
456
BASIC INSTRUCTIONS FOR TROUBLESHOOTING
461
BASIC PROCESS FOR TROUBLESHOOTING
462
MAINTENANCE OF THE ABS ECU
472
BASIC INSTRUCTIONS FOR TROUBLESHOOTING
473
30_EVENT
515
70_EVENT
517
C0520
518
P0030
522
P00D1, P2195
526
P0105
530
P0106
532
P0107, P0108
534
P0110
538
P0111
540
P0112, P0113
543
P0115
547
P0116
548
P0117, P0118
551
P0122, P0123, P0222, P0223, P2135
555
P0132
560
TROUBLESHOOTING
565
P0134
566
P0201
568
P0202
571
P0203
574
FAIL-SAFE SYSTEM
578
P0335
581
P0351
585
P0352
589
P0353
593
P0458
597
P0480
601
P0500, P1500
604
P0560, P0563
617
P0564
618
P056C
624
P0601
631
P0606
632
P062F
633
P0638
635
P0657
639
P0914
643
P0915
645
P0916, P0917
647
P1004
651
P1600
653
P1601
657
P1602
661
P1606, P1607
665
P1608
669
P1609
671
P1806, P1807
673
P2122, P2123, P2127, P2128, P2138
677
P2158
681
U0125
686
U0155 or Err
690
51_IMMOBILIZER
694
52_IMMOBILIZER
695
53_IMMOBILIZER
696
54_IMMOBILIZER
699
55_IMMOBILIZER
701
56_IMMOBILIZER
702
11_ABS
705
12_ABS
706
13, 26_ABS
707
14, 27_ABS
708
15_ABS
709
16_ABS
711
21_ABS
713
31_ABS
714
33_ABS
716
34_ABS
718
41_ABS
719
42_ABS
720
43, 45_ABS
721
44, 46_ABS
722
51_ABS
723
53_ABS
724
55_ABS
726
56_ABS
727
57_ABS
728
62_ABS
732
68_ABS
733
89_ABS
734
90_ABS
737
TROUBLESHOOTING
740
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