Yamaha XSR 900 2022 Service Manual
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Yamaha XSR 900 2022 Service Manual

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Table of Contents

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2022
SERVICE MANUAL
XSR 900
MTM890
BEA-28197-E0

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Summary of Contents for Yamaha XSR 900 2022

  • Page 1 2022 SERVICE MANUAL XSR 900 MTM890 BEA-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..............1-11 ELECTRICAL SYSTEM................1-11 SPECIAL TOOLS ..................1-12...

  • 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. 1 1 1 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 The two vehicle information displays can be indi- Fuel reserve tripmeter: vidually set to show the following items: • ODO: odometer • F-TRIP: fuel reserve tripmeter • TRIP1: tripmeter • TRIP2: tripmeter • F.AVE: average fuel economy • F.CRNT: instantaneous fuel economy •...
  • Page 13 FEATURES The coolant temperature is displayed from 40 °C Instantaneous fuel economy: (104 °F) to 124 °C (255 °F) in 1 °C (1 °F) incre- ments. • If the vehicle coolant temperature is below 40 °C (104 °F) the coolant temperature display will read “Lo”...
  • Page 14 FEATURES To reset information display items 1. Rotate the wheel switch to select one of the • When “TCS-MODE” has been set to “OFF”, two vehicle information displays. the traction control system, SCS and LIF sys- 2. Press the wheel switch inward to highlight the tems are all turned off together.
  • Page 15 Additionally, ABS may not function through the setting MENU. properly. Use extra care when braking and have Once activated, the vehicle information display a Yamaha dealer check the vehicle immediately. is replaced with: Auxiliary system warning “ ” This icon appears if a problem is detected in a non-engine-related system.
  • Page 16 FEATURES Settings MENU • Certain settings menu screens have an up- MENU ward pointing triangle mark item. Select the tri- angle mark to save settings changes and exit Exit the current screen. Display Setting • Should vehicle motion be detected, the screen Manual TCS Setting will automatically exit the settings MENU and Vehicle Setting...
  • Page 17 FEATURES Traction control system This model uses a variable traction control sys- tem. For each setting level, the further the vehi- BC Setting cle is leaned over, the greater the amount of traction control (system intervention) is applied. There are 3 setting levels available for the “TCS- MODE M”.
  • Page 18 FEATURES “Shift Indicator” “Unit” Unit Shift Indicator km or mile km/L or L/100km L/100km °C or °F IND Mode °C IND Start 8000 r/min IND Stop 10000 r/min km/h km/h This module allows a custom shift indicator to be This module allows you to switch the display be- set.
  • Page 19 FEATURES “Clock” Clock km/h This module allows you to set the clock. When the clock module is selected, the hours will be highlighted. Set the hours by rotating the wheel switch. Press the wheel switch inward to confirm and highlight the minutes.

  • Page 20: 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 21: 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, 4-57, 90890-03267 4-58, 7-12, 9-3, 9-41, 9-41 Yamaha diagnostic tool (A/I)
  • Page 22 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Carburetor angle driver 2 3-10 90890-03173 Steering nut wrench 3-20, 4-79 90890-01403 Exhaust flange nut wrench YU-A9472 Oil filter wrench 3-25 90890-01426 Oil filter wrench YU-38411 Oil pressure gauge joint 18 mm 3-26 90890-04176 YU-04176...
  • Page 23 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Rod puller 4-73, 4-74 90890-01437 Universal damping rod bleeding tool set YM-A8703 YM-A8703 Rod puller attachment (M10 long) 4-73, 4-74 90890-01578 90890-01578 Universal damping rod bleeding tool set YM-A8703 YM-A8703 Ring nut wrench 4-79 90890-01268 Spanner wrench...
  • Page 24 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 5-20, 5-23 90890-04162 Camshaft wrench YM-04162 Valve spring compressor 5-32, 5-36 90890-04200 Valve spring compressor YM-04019...
  • Page 25 Reference Tool name/Tool No. Illustration pages Flywheel puller 5-39 90890-01362 Heavy duty puller YU-33270-B Yamaha bond No. 1215 5-41, 5-66 90890-85505 Three bond No. 1215® Digital circuit tester (CD732) 5-44, 8-40, 90890-03243 8-42, 8-43, Model 88 Multimeter with tachometer 8-44, 8-44,...
  • Page 26 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Piston installing tool 5-79 90890-04161 Piston installing tool YM-04161 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...
  • Page 27 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Fuel pressure adapter 7-12 90890-03176 Fuel pressure adapter YM-03176 Ignition checker 8-45 90890-06754 Oppama pet–4000 spark checker YM-34487 1-18...
  • Page 28 SPECIAL TOOLS 1-19...

  • Page 29: Specifications

    SPECIFICATIONS GENERAL SPECIFICATIONS ................ 2-1 ENGINE SPECIFICATIONS ................2-2 CHASSIS SPECIFICATIONS ................2-6 ELECTRICAL SPECIFICATIONS ..............2-9 TIGHTENING TORQUES ................2-11 ENGINE TIGHTENING TORQUES............2-11 CHASSIS TIGHTENING TORQUES............2-11 CABLE ROUTING ..................2-13...

  • Page 30: General Specifications

    GENERAL SPECIFICATIONS EAS20013 GENERAL SPECIFICATIONS Model Model BEA1 Dimensions Overall length 2155 mm (84.8 in) Overall width 860 mm (33.9 in) Overall height 1155 mm (45.5 in) Wheelbase 1495 mm (58.9 in) Ground clearance 140 mm (5.51 in) Minimum turning radius 3.5 m (11.48 ft) Weight Curb weight...

  • Page 31: 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 32 ENGINE SPECIFICATIONS Water pump Impeller shaft tilt limit 0.15 mm (0.006 in) 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...
  • Page 33 ENGINE SPECIFICATIONS Piston Diameter 77.975–77.990 mm (3.0699–3.0705 in) Measuring point (from piston skirt bottom) 9.0 mm (0.35 in) Piston-to-cylinder clearance 0.010–0.035 mm (0.0004–0.0014 in) Piston pin bore inside diameter limit 17.043 mm (0.6710 in) Piston pin outside diameter limit 16.970 mm (0.6681 in) Piston ring Top ring End gap limit...
  • Page 34 ENGINE SPECIFICATIONS Plate quantity 6 pcs Wear limit 2.82 mm (0.111 in) Friction plate 2 thickness 2.92–3.08 mm (0.115–0.121 in) Plate quantity 3 pcs Wear limit 2.82 mm (0.111 in) 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)

  • Page 35: 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 36 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) 466.0 cm³ (15.76 US oz, 16.44 Imp.oz) Quantity (right) 470.0 cm³ (15.89 US oz, 16.58 Imp.oz) Level (left) 107 mm (4.2 in)
  • Page 37 CHASSIS SPECIFICATIONS Rear suspension Shock absorber Gas-hydraulic damper Spring preload Unit for adjustment Cam position Adjustment value (Soft) Adjustment value (STD) Adjustment value (Hard) Rebound damping Unit for adjustment Turn Adjustment value from the start position (Soft) 2+1/2 Adjustment value from the start position (STD) Adjustment value from the start position (Hard)

  • Page 38: 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 TBDF6Z 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 14.0 V, 29.6 A at 5000 r/min 0.152–0.228 Ω...
  • Page 39 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 9.0–12.0 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 40: 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 41 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). 2-12...

  • Page 42: Cable Routing

    CABLE ROUTING EAS20021 CABLE ROUTING Handlebar (front view) 13,G 14,J 13,E 12,D 16,N 17,O 21,T 20,S 19,R 18,Q 2-13...
  • Page 43 CABLE ROUTING N. Insert the projection on the clutch switch cou- 1. Clutch cable pler into the hole in the coupler holder. 2. Clutch switch lead O. Insert the auxiliary DC jack coupler 3. Handlebar switch lead (left) (OPTION) into the rib of the coupler holder. 4.
  • Page 44 CABLE ROUTING Handlebar (side view) 2-15...
  • Page 45 CABLE ROUTING 1. Handlebar switch lead (right) 2. Front brake light switch lead 3. Brake hose 4. Connector cover 5. Clutch cable 6. Horn lead 7. Handlebar switch lead (left) 8. Clutch switch lead 9. Upper bracket 10. Headlight bracket 2 11.
  • Page 46 CABLE ROUTING Main switch (left side view) 2-17...
  • Page 47 CABLE ROUTING 1. Front wheel sensor coupler 2. Wire harness 3. Front wheel sensor lead 4. Bracket 5. Frame A. Insert the clamp into the hole of the bracket. B. Insert the clamp into the rib of the frame. C. Insert the clamp with touched the protrusion on the frame.
  • Page 48 CABLE ROUTING Frame and engine (right side view) 14,F 19,L 10,D 10,Q 20,U 2-19...
  • Page 49 CABLE ROUTING N. Route the wire harness and front turn signal 1. Canister light lead (right) through the hole in the front 2. Canister purge hose (purge cut valve sole- side panel (right). noid to canister) O. Install the clamp align to the protector part of 3.
  • Page 50 CABLE ROUTING Frame 1 (front left side view) 18,O 27,Q 28,P 20,M 11,I 12,I 2-21...
  • Page 51 CABLE ROUTING N. Route the handlebar switch lead (left) on the 1. Radiator outlet hose rear side of the wire harness. (to intake air 2. O sensor lead temperature sensor) 3. Radiator cover (left) O. Insert the projection on the handlebar switch 4.
  • Page 52 CABLE ROUTING Frame 2 (rear left side view) 11,H 11,H 2-23...
  • Page 53 CABLE ROUTING 1. Wire harness (to gear position sensor) 2. Starter motor lead 3. Gear position sensor coupler 4. Gear position sensor 5. Shift sensor 6. Sidestand switch 7. Sidestand switch lead 8. Fuel tank drain hose 9. Stator coil assembly lead 10.
  • Page 54 CABLE ROUTING Frame 3 (rear left side view) 2-25...
  • Page 55 CABLE ROUTING 1. Wire harness 2. Wire harness (to purge cut valve solenoid) 3. Fuel tank drain hose 4. Shift sensor lead 5. Canister breather hose 6. Sidestand switch lead 7. Plastic locking tie 8. Stator coil lead 9. Clutch cable 10.
  • Page 56 CABLE ROUTING Top view 1 13,B 16,C 23,H 21,G 20,F 19,E 18,D 30,L 31,M 23,N 2-27...
  • Page 57 CABLE ROUTING H. Route the rear brake light switch lead 1. Injector #1 coupler between the wire harness and joint coupler. 2. Intake air pressure sensor 2 coupler (between clamp and rear brake light switch 3. Ignition coil #1 coupler coupler) 4.
  • Page 58 CABLE ROUTING Top view 2 19,I 19,G 19,K 15,F 13,E 15,M 21,L 2-29...
  • Page 59 CABLE ROUTING 1. Crankshaft position sensor lead 2. Crankshaft position sensor coupler 3. Rear brake light switch lead 4. Wire harness (to rectifier/regulator) 5. Rear wheel sensor lead 6. Rear wheel sensor coupler 7. Wire harness (to joint coupler) 8. Wire harness (to ABS) 9.
  • Page 60 CABLE ROUTING Top view 3 17,O 22,M 23,N 21,L 14,K 24,P 13,P 12,J 11,J 10,J 12,Q 10,Q 11,Q 2-31...
  • Page 61 CABLE ROUTING M. Pass the starter motor lead under the positive 1. ABS ECU (Electronic Control Unit) battery lead (to starter relay). 2. Battery box N. Bend the positive battery lead as shown in 3. Fuse box the illustration and fit it between the fuse box 4.
  • Page 62 CABLE ROUTING Front brake hose (right side view) 10,D 2-33...
  • Page 63 CABLE ROUTING 1. Brake hose (hydraulic unit to front brake cali- per (left)) 2. Brake hose (front brake master cylinder to hydraulic unit) 3. Front fork 4. Front brake caliper assembly (right) 5. Clamp 6. Front fender 7. Bracket 8. Frame 9.
  • Page 64 CABLE ROUTING Front brake hose (left side view) 2-35...
  • Page 65 CABLE ROUTING 1. Brake hose (front brake master cylinder to hydraulic unit) 2. Brake hose (hydraulic unit to front brake cali- per (left)) 3. Front wheel sensor lead 4. Brake hose (front brake caliper (left) to front brake caliper (right)) 5.
  • Page 66 CABLE ROUTING Rear brake hose (right side view) 2-37...
  • Page 67 CABLE ROUTING R. Fasten the grommet of the rear wheel sensor 1. Brake fluid reservoir hose lead with the clamp. Route the rear wheel 2. Rear brake light switch lead sensor lead on the outside of the rear brake 3. Rear brake hose (rear brake master cylinder hose (hydraulic unit to rear brake caliper).
  • Page 68 CABLE ROUTING ABS ECU (Electronic Control Unit) (top and left side view) 2-39...
  • Page 69 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 70 CABLE ROUTING Air filter case and throttle bodies (left side view) 2-41...
  • Page 71 CABLE ROUTING 1. Throttle body 2. Cylinder head breather hose 3. Canister purge hose (purge cut valve sole- noid to hose joint) A. 5–7 mm (0.20–0.28 in) (3 places) B. Insert the cylinder head breather hose until it reaches the rounded end of the pipe. Install the cylinder head breather hose with the yel- low paint mark facing the left.
  • Page 72 CABLE ROUTING Fuel tank (left side view) 2-43...
  • Page 73 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 74 CABLE ROUTING Canister 2-45...
  • Page 75 CABLE ROUTING 1. Frame 2. Fuel tank breather hose (fuel tank to canister) 3. Canister 4. Canister purge hose (purge cut valve sole- noid to canister) 5. Canister breather hose 6. Fuel tank drain hose 7. Canister purge hose (purge cut valve sole- noid to hose joint) 8.
  • Page 76 CABLE ROUTING Radiator (front side view) 2-47...
  • Page 77 CABLE ROUTING 1. Radiator 2. Radiator outlet hose 3. Thermostat assembly 4. Radiator hose (cylinder head to radiator) 5. Radiator cap 6. Coolant reservoir hose 7. Water jacket joint 8. Radiator inlet hose A. Face the tip of the clip toward the yellow paint mark on the radiator outlet hose.
  • Page 78 CABLE ROUTING Radiator (right side view) 2-49...
  • Page 79 CABLE ROUTING 1. Radiator fan cover 2. Radiator fan motor lead 3. Radiator hose (cylinder head to radiator) 4. Radiator A. Route the radiator hose (cylinder head to radiator) through the notch of the radiator fan cover. B. Route the radiator fan motor lead through the notch of the radiator fan cover.
  • Page 80 CABLE ROUTING Water pump (left side view) 2-51...
  • Page 81 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 82 CABLE ROUTING Oil cooler and thermostat (front side view) 2-53...
  • Page 83 CABLE ROUTING 1. Thermostat assembly 2. Water pump inlet hose 3. Oil cooler 4. Oil cooler outlet hose 5. Oil cooler inlet hose 6. Radiator inlet hose 7. Water jacket joint A. Install the hose clamp with its end facing the front.
  • Page 84 CABLE ROUTING 2-55...

  • Page 85: 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 86 CHECKING THE CONNECTING ARM AND RELAY ARM.....3-24 CHECKING THE ENGINE OIL LEVEL............3-24 CHANGING THE ENGINE OIL ...............3-25 MEASURING THE ENGINE OIL PRESSURE ........3-26 CHECKING THE COOLANT LEVEL............3-27 CHECKING THE COOLING SYSTEM ............3-28 CHANGING THE COOLANT..............3-28 CHECKING THE FRONT BRAKE LIGHT SWITCH ........3-30 ADJUSTING THE REAR BRAKE LIGHT SWITCH .........3-30 CHECKING AND LUBRICATING THE CABLES ........

  • Page 87: 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 88 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 89 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 • Lubricate. √ √ √ √ √ 28 * cables •...

  • Page 90: Checking The Vehicle Using The Yamaha Diagnostic Tool

    • Yamaha diagnostic tool (A/I) (90890-03264) in- cludes YDT sub harness (6P) (90890-03266). ECA14940 NOTICE • If you already have Yamaha diagnostic tool (A/ Make sure the fuel tank breather hose is rout- I) (90890-03262), YDT sub harness (6P) ed correctly.

  • Page 91: Checking The Spark Plugs

    PERIODIC MAINTENANCE EAS30620 6. Measure: CHECKING THE SPARK PLUGS • Spark plug gap “a” The following procedure applies to all of the (with a wire thickness gauge) spark plugs. Out of specification → Regap. 1. Remove: • Rider seat Spark plug gap •...
  • Page 92 PERIODIC MAINTENANCE 1. Remove: a. Turn the crankshaft counterclockwise. • Rider seat b. When piston #1 is at TDC on the compres- • Side cover sion stroke, align the TDC mark “a” on the Refer to “GENERAL CHASSIS (1)” on generator rotor with the generator rotor cov- page 4-1.
  • Page 93 PERIODIC MAINTENANCE Example: Specified valve clearance = 0.11–0.20 mm (0.004–0.008 in) Measured valve clearance = 0.25 mm (0.010 in) 0.25 mm (0.010 in) - 0.20 mm (0.008 in) = 0.05 mm (0.002 in) c. Check the thickness of the current valve pad.

  • Page 94: Checking The Engine Idling Speed

    PERIODIC MAINTENANCE EAS31017 Valve pad range Nos. 150–240 CHECKING THE ENGINE IDLING SPEED Valve pad thickness 1.50–2.40 mm (0.0590–0.0944 in) Prior to checking the engine idling speed, the Available valve pads 25 thicknesses in throttle body synchronization should be adjusted 0.05 mm (0.002 in) in- properly, the air filter element should be clean, crements...
  • Page 95 PERIODIC MAINTENANCE 2. Remove: a. Start the engine, warm it up for several min- • Rider seat utes, and then let it run at the specified en- • Side cover gine idling speed. Refer to “GENERAL CHASSIS (1)” on page 4-1. Engine idling speed 1200–1400 r/min •...

  • Page 96: Checking The Throttle Body Joints

    PERIODIC MAINTENANCE EAS30623 CHECKING THE CYLINDER HEAD Carburetor angle driver 2 BREATHER HOSE 90890-03173 1. Remove: • Rider seat • Side cover Refer to “GENERAL CHASSIS (1)” on page 4-1. • Fuel tank cover Refer to “GENERAL CHASSIS (4)” on page 4-10.

  • Page 97: Checking The Exhaust System

    • Yamaha diagnostic tool (A/I) (90890-03264) in- • Fuel tank cover cludes YDT sub harness (6P) (90890-03266). Refer to “GENERAL CHASSIS (4)” on • If you already have Yamaha diagnostic tool (A/ page 4-10. I) (90890-03262), YDT sub harness (6P) • Fuel tank (90890-03266) is separately required.

  • Page 98: Replacing The Air Filter Element

    PERIODIC MAINTENANCE EAS30628 ECA20710 REPLACING THE AIR FILTER ELEMENT NOTICE 1. Remove: Never operate the engine without the air filter • Rider seat element installed. Unfiltered air will cause • Side cover rapid wear of engine parts and may damage Refer to “GENERAL CHASSIS (1)”...

  • Page 99: Checking The Brake Operation

    PERIODIC MAINTENANCE 2. Adjust: EAS30632 CHECKING THE BRAKE FLUID LEVEL • Clutch lever free play 1. Stand the vehicle on a level surface. Handlebar side a. Turn the adjusting bolt “1” until the specified • Place the vehicle on a maintenance stand. clutch lever free play is obtained.

  • Page 100: Adjusting The Front Disc Brake

    PERIODIC MAINTENANCE EAS30630 EAS30633 ADJUSTING THE FRONT DISC BRAKE CHECKING THE FRONT BRAKE PADS 1. Adjust: The following procedure applies to all of the • Front brake lever position brake pads. (distance “a” from the throttle grip to the brake 1.

  • Page 101: Checking The Rear Brake Pads

    PERIODIC MAINTENANCE EAS30636 CHECKING THE REAR BRAKE HOSE 1. Check: • Brake hose Cracks/damage/wear → Replace. 2. Check: • Brake hose holder Loose Connection → Tighten the holder bolt. 3. Hold the vehicle upright and apply the rear brake several times. 4.

  • Page 102: Checking The Wheels

    PERIODIC MAINTENANCE 1. Bleed: h. Tighten the bleed screw and then release • ABS the brake lever or brake pedal. i. Repeat steps (e) to (h) until all of the air a. Fill the brake fluid reservoir to the proper bubbles have disappeared from the brake level with the specified brake fluid.

  • Page 103: Checking The Tires

    WARNING en if a tire combination other than one • The tire pressure should only be checked approved by Yamaha is used on this vehicle. and regulated when the tire temperature equals the ambient air temperature. • The tire pressure and the suspension must...

  • Page 104: Checking The Wheel Bearings

    PERIODIC MAINTENANCE EAS30641 1. Shift the transmission into the neutral posi- CHECKING THE WHEEL BEARINGS tion. The following procedure applies to all of the 2. Check: wheel bearing. • Drive chain slack 1. Check: Out of specification → Adjust. • Wheel bearing Refer to “CHECKING THE FRONT WHEEL”...

  • Page 105: 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 106: Lubricating The Steering Head

    PERIODIC MAINTENANCE 4. Adjust: d. Check the steering head for looseness or • Steering head binding by turning the front fork all the way in both directions. If any binding is felt, re- a. Remove the lock washer “1”, the upper ring move the lower bracket and check the up- nut “2”, and the rubber washer “3”.

  • Page 107: 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 108 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 spring preload; the longer distance “c” is, the Adjustment value from the start lower the spring preload.

  • Page 109: Checking The Rear Shock Absorber Assembly

    PERIODIC MAINTENANCE a. Turn the adjusting screw “1” in direction “a” EAS30655 ADJUSTING THE REAR SHOCK ABSORBER or “b”. ASSEMBLY EWA13120 Direction “a” WARNING Compression damping is increased Securely support the vehicle so that there is (suspension is harder). no danger of it falling over. Direction “b”...

  • Page 110: Checking The Connecting Arm And Relay Arm

    PERIODIC MAINTENANCE Rebound damping ECA13590 NOTICE Never go beyond the maximum or minimum adjustment positions. 1. Remove: • Cover “1” EAS30809 CHECKING THE CONNECTING ARM AND RELAY ARM Refer to “CHECKING THE CONNECTING ARM AND RELAY ARM” on page 4-82. EAS30656 CHECKING THE ENGINE OIL LEVEL 2.

  • Page 111: Changing The Engine Oil

    PERIODIC MAINTENANCE ECA13361 4. Drain: NOTICE • Engine oil • Engine oil also lubricates the clutch and the (completely from the crankcase) wrong oil types or additives could cause 5. If the oil filter cartridge is also to be replaced, clutch slippage.

  • Page 112: Measuring The Engine Oil Pressure

    PERIODIC MAINTENANCE 7. Fill: 3. Remove: • Crankcase • Oil pressure switch joint bolt “1” (with the specified amount of the recom- • Oil pressure switch joint (with the oil pressure mended engine oil) switch) “2” EWA12980 WARNING Engine oil quantity The engine, muffler and engine oil are ex- Quantity (disassembled) tremely hot.

  • Page 113: Checking The Coolant Level

    PERIODIC MAINTENANCE 6. Start the engine, warm it up for several min- EAS30811 utes. CHECKING THE COOLANT LEVEL ECA13410 1. Stand the vehicle on a level surface. NOTICE When the engine is cold, the engine oil will • Place the vehicle on a maintenance stand. have a higher viscosity, causing the engine •...

  • Page 114: Checking The Cooling System

    PERIODIC MAINTENANCE EAS30812 EWA13030 CHECKING THE COOLING SYSTEM WARNING 1. Check: A hot radiator is under pressure. Therefore, • Radiator “1” do not remove the radiator cap when the en- • Water pump inlet hose “2” gine is hot. Scalding hot fluid and steam may •...
  • Page 115 PERIODIC MAINTENANCE 4. Drain: 9. Fill: • Coolant • Cooling system (from the coolant reservoir) (with the specified amount of the recom- 5. Remove: mended coolant) • Water pump drain bolt “1” • Copper washer “2” Recommended antifreeze High-quality ethylene glycol anti- freeze containing corrosion inhibitors for aluminum engines Mixing ratio...

  • Page 116: Checking The Front Brake Light Switch

    PERIODIC MAINTENANCE 11.Fill: 3. Adjust: • Coolant reservoir • Rear brake light operation timing (with the recommended coolant to the maxi- a. Hold the main body “1” of the rear brake mum level mark “a”) light switch so that it does not rotate and turn the adjusting nut “2”...

  • Page 117: Checking The Throttle Grip

    PERIODIC MAINTENANCE EAS30815 2. Adjust: CHECKING THE THROTTLE GRIP • Headlight beam (horizontally) 1. Check: • Throttle grip movement To adjust the headlight beam (horizontally), turn Rough movement → Lubricate or replace the the adjusting screw. defective part(s). a. Turn the adjusting screw “1”. Recommended lubricant Suitable cable lubricant With the engine stopped, turn the throttle grip...
  • Page 118 PERIODIC MAINTENANCE 3-32...

  • Page 119: Chassis

    CHASSIS GENERAL CHASSIS (1) ................. 4-1 REMOVING THE SEAT ................4-4 REMOVING THE SIDE COVER..............4-4 INSTALLING THE IMU................4-4 INSTALLING THE SIDE COVER .............. 4-5 INSTALLING THE SEAT ................4-5 GENERAL CHASSIS (2) ................. 4-6 GENERAL CHASSIS (3) ................. 4-8 REMOVING THE RADIATOR COVER .............4-9 INSTALLING THE RADIATOR COVER ............
  • Page 120 FRONT BRAKE ..................... 4-27 INTRODUCTION ..................4-33 CHECKING THE FRONT BRAKE DISCS..........4-33 REPLACING THE FRONT BRAKE PADS ..........4-33 REMOVING THE FRONT BRAKE CALIPERS ........4-35 DISASSEMBLING THE FRONT BRAKE CALIPERS......4-35 CHECKING THE FRONT BRAKE CALIPERS ........4-35 ASSEMBLING THE FRONT BRAKE CALIPERS........4-36 INSTALLING THE FRONT BRAKE CALIPERS ........
  • Page 121 STEERING HEAD..................4-77 REMOVING THE LOWER BRACKET.............4-79 CHECKING THE STEERING HEAD ............4-79 INSTALLING THE STEERING HEAD .............4-80 REAR SHOCK ABSORBER ASSEMBLY ............4-81 HANDLING THE REAR SHOCK ABSORBER ........4-82 DISPOSING OF A REAR SHOCK ABSORBER ........4-82 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY....4-82 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY ....
  • Page 122 GENERAL CHASSIS (1) EAS20026 GENERAL CHASSIS (1) Removing the seat and side covers Order Job/Parts to remove Q’ty Remarks Rider seat Side cover (left) Side cover grille (left) Side cover (right) Side cover grille (right)

  • Page 123: General Chassis (1)

    GENERAL CHASSIS (1) Removing the battery m (0.9 kgf m, 6.6 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 124 GENERAL CHASSIS (1) Removing the tail/brake light and mudguard assembly m (0.6 kgf m, 4.4 lb • • • m (0.7 kgf m, 5.2 lb • • • m (0.7 kgf m, 5.2 lb • • • 10 N m (1.0 kgf m, 7.4 lb •...

  • Page 125: Removing The Seat

    GENERAL CHASSIS (1) EAS32229 EAS31636 REMOVING THE SEAT INSTALLING THE IMU 1. Remove: ECA22611 NOTICE a. Open the seat lock cover “1”, insert the key • Do not perform angle adjustment of the IMU into the seat lock “2”, and then turn the key and battery box by pinching the washer counterclockwise “3”.

  • Page 126: Installing The Side Cover

    GENERAL CHASSIS (1) EAS30125 INSTALLING THE SEAT (4) (4) 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 127: General Chassis (2)

    GENERAL CHASSIS (2) EAS20155 GENERAL CHASSIS (2) Removing the headlight assembly and meter assembly 1.8 N m (0.18 kgf m, 1.3 lb • • • 10 N m (1.0 kgf m, 7.4 lb • • • m (0.7 kgf m, 5.2 lb •...
  • Page 128 GENERAL CHASSIS (2) Removing the headlight bracket 2 m (0.7 kgf m, 5.2 lb m (0.7 kgf m, 5.2 lb • • • • • • (2) (2) 1.5 N m (0.15 kgf m, 1.1 lb • • • Order Job/Parts to remove Q’ty Remarks...
  • Page 129 GENERAL CHASSIS (3) EAS20156 GENERAL CHASSIS (3) Removing the radiator cover and front turn signal light (left/right) 3.8 N m (0.38 kgf m, 2.8 lb • • • m (0.7 kgf m, 5.2 lb • • • 3.8 N m (0.38 kgf m, 2.8 lb •...

  • Page 130: Removing The Radiator Cover

    GENERAL CHASSIS (3) EAS33427 REMOVING THE RADIATOR COVER The following procedure applies to both of the radiator cover. 1. Remove: • Radiator cover “1” a. Remove the radiator cover bolts. b. Remove the radiator cover. EAS32348 INSTALLING THE RADIATOR COVER The following procedure applies to both of the radiator cover.

  • Page 131: General Chassis (4)

    GENERAL CHASSIS (4) EAS20157 GENERAL CHASSIS (4) Removing the fuel tank cover 2.5 N m (0.25 kgf m, 1.8 lb • • • 2.5 N m (0.25 kgf m, 1.8 lb • • • 2.5 N m (0.25 kgf m, 1.8 lb •...
  • Page 132 GENERAL CHASSIS (5) EAS20158 GENERAL CHASSIS (5) 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 133: Front Wheel

    FRONT WHEEL EAS20028 FRONT WHEEL Removing the front wheel and brake discs 35 N m (3.5 kgf m, 26 lb • • • 72 N m (7.2 kgf m, 53 lb • • • 23 N m (2.3 kgf m, 17 lb •...
  • Page 134 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 4-13...

  • Page 135: 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 136: 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 137: 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 138: 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 139 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 140: Rear Wheel

    REAR WHEEL EAS20029 REAR WHEEL Removing the rear wheel 105 N m (10.5 kgf m, 77 lb m (0.7 kgf m, 5.2 lb • • • • • • 16 N m (1.6 kgf m, 12 lb 16 N m (1.6 kgf m, 12 lb •...
  • Page 141 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 142 REAR WHEEL Disassembling the rear wheel Order Job/Parts to remove Q’ty Remarks Oil seal Wheel bearing Spacer Wheel bearing 4-21...

  • Page 143: 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 144: Checking And Replacing The Rear Wheel Sprocket

    REAR WHEEL EAS30161 EAS30163 CHECKING AND REPLACING THE REAR ASSEMBLING THE REAR WHEEL WHEEL SPROCKET ECA21340 NOTICE 1. Check: • Do not drop the wheel sensor rotor or sub- • Rear wheel sprocket More than 1/4 tooth “a” wear → Replace the ject it to shocks.

  • Page 145: Maintenance Of The Rear Wheel Sensor And Sensor Rotor

    REAR WHEEL EAS31156 EAS31157 MAINTENANCE OF THE REAR WHEEL INSTALLING THE REAR WHEEL (REAR SENSOR AND SENSOR ROTOR BRAKE DISC) ECA21060 1. Install: NOTICE • Rear brake disc • Handle the ABS components with care since they have been accurately adjusted. Rear brake disc bolt Keep them away from dirt and do not sub- 30 N·m (3.0 kgf·m, 22 lb·ft)
  • Page 146 REAR WHEEL When tightening the wheel axle nut, there should be no clearance “a” between the adjust- ing block “1” and adjusting bolt “2”. A. Left side B. Right side 5. Install: • Rear brake caliper • Rear brake caliper bolt A.
  • Page 147 REAR WHEEL 9. Measure: • Distance “a” (between the wheel sensor rotor “1” and rear wheel sensor “2”) Out of specification → Check the wheel bear- ing for looseness, and the rear wheel sensor and sensor rotor installation conditions (warpage caused by overtorque, wrong in- stallation direction, rotor decentering, LOC- TITE®...

  • Page 148: Front Brake

    FRONT BRAKE EAS20030 FRONT BRAKE Removing the front brake pads m (0.5 kgf m, 3.7 lb • • • 35 N m (3.5 kgf m, 26 lb • • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers.
  • Page 149 FRONT BRAKE Removing the front brake master cylinder 2.5 N m (0.25 kgf m, 1.8 lb • • • 1.0 N m (0.10 kgf m, 0.73 lb 1.2 N m (0.12 kgf m, 0.88 lb • • • • • •...
  • Page 150 FRONT BRAKE Removing the front brake master cylinder 2.5 N m (0.25 kgf m, 1.8 lb • • • 1.0 N m (0.10 kgf m, 0.73 lb 1.2 N m (0.12 kgf m, 0.88 lb • • • • • •...
  • Page 151 FRONT BRAKE Disassembling the front brake master cylinder m (0.6 kgf m, 4.4 lb • • • Order Job/Parts to remove Q’ty Remarks Brake master cylinder kit Bleed screw Brake master cylinder body 4-30...
  • Page 152 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 153 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 154: 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 155 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 156: 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 157: 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 158: Removing The Front Brake Master Cylinder

    FRONT BRAKE EWA13090 EAS30725 CHECKING THE FRONT 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 159 FRONT BRAKE • Install the front brake master cylinder holder • When installing the brake hose onto the master with the pin “a” facing up. cylinder, make sure the brake pipe “a” touches • Align the end of the front brake master cylinder the projection “b”...
  • Page 160 FRONT BRAKE 5. Check: • Brake fluid level Below the minimum level mark → Add the specified brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL” on page 3-13. 6. Check: • Brake lever operation Soft or spongy feeling → Bleed the brake sys- tem.

  • Page 161: 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 162 REAR BRAKE Removing the rear brake master cylinder m (0.5 kgf m, 3.7 lb • • • 28 N m (2.8 kgf m, 21 lb • • • 23 N m (2.3 kgf m, 17 lb • • • 3.8 N m (0.38 kgf m, 2.8 lb •...
  • Page 163 REAR BRAKE Removing the rear brake master cylinder m (0.5 kgf m, 3.7 lb • • • 28 N m (2.8 kgf m, 21 lb • • • 23 N m (2.3 kgf m, 17 lb • • • 3.8 N m (0.38 kgf m, 2.8 lb •...
  • Page 164 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 4-43...
  • Page 165 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 166 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 167: 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 168: Replacing The Rear Brake Pads

    REAR BRAKE 4. Replace: • Brake disc Refer to “REAR WHEEL” on page 4-19. 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 169: 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 170: 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 4-19. EAS30189 ASSEMBLING THE REAR BRAKE CALIPER EWA17080 WARNING 2. Remove: •...

  • Page 171: 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 172 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 173: Abs (Anti-Lock Brake System)

    ABS (ANTI-LOCK BRAKE SYSTEM) EAS20032 ABS (ANTI-LOCK BRAKE SYSTEM) Removing the hydraulic unit assembly 30 N m (3.0 kgf m, 22 lb m (0.7 kgf m, 5.2 lb • • • • • • 16 N m (1.6 kgf m, 12 lb •...
  • Page 174 ABS (ANTI-LOCK BRAKE SYSTEM) Removing the hydraulic unit assembly 30 N m (3.0 kgf m, 22 lb m (0.7 kgf m, 5.2 lb • • • • • • 16 N m (1.6 kgf m, 12 lb • • • 16 N m (1.6 kgf m, 12 lb...

  • Page 175: Removing The Hydraulic Unit Assembly

    ABS (ANTI-LOCK BRAKE SYSTEM) EAS30197 2. Remove: REMOVING THE HYDRAULIC UNIT • Brake hose ASSEMBLY ECA21091 • Do not operate the brake lever and brake pedal NOTICE while removing the brake hoses. Unless necessary, avoid removing and in- • Do not bend the brake pipe when loosening the stalling the brake hoses of the hydraulic unit brake pipe flare nuts.

  • Page 176: Checking The Brake Pipes

    ABS (ANTI-LOCK BRAKE SYSTEM) EAS30935 4. Tighten: CHECKING THE BRAKE PIPES • Hydraulic unit brake pipe flare nut The following procedure applies to all of the brake pipes. Hydraulic unit brake pipe flare 1. Check: • Brake pipe end (flare nut) 16 N·m (1.6 kgf·m, 12 lb·ft) Damage →...

  • Page 177: 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 9-43.) 11.Perform a trial run. (Refer to “CHECKING THE ABS WARNING LIGHT” on page 4-59.) 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 178 • Yamaha diagnostic tool (A/I) (90890-03264) in- cludes YDT sub harness (6P) (90890-03266). G088911 • If you already have Yamaha diagnostic tool (A/ I) (90890-03262), YDT sub harness (6P) “ON” and “OFF” on the tool screen indicate (90890-03266) is separately required.
  • Page 179 • Be sure to continue operating the brake lever cludes YDT sub harness (6P) (90890-03266). and brake pedal even after the pulsating action • If you already have Yamaha diagnostic tool (A/ has stopped. I) (90890-03262), YDT sub harness (6P) •...

  • Page 180: Checking The Abs Warning Light

    ABS (ANTI-LOCK BRAKE SYSTEM) 10.After the pulsating action has stopped in the 16.Check for brake fluid leakage around the hy- brake lever, it is generated in the brake pedal draulic unit. Brake fluid leakage → Replace the hydraulic “1” and continues for a few seconds. unit, brake pipes, and related parts as a set.

  • Page 181: Handlebar

    HANDLEBAR EAS20033 HANDLEBAR Removing the handlebar 38 N m (3.8 kgf m, 28 lb 38 N m (3.8 kgf m, 28 lb • • • • • • 1.8 N m (0.18 kgf m, 1.3 lb • • • 11 N m (1.1 kgf m, 8.1 lb •...
  • Page 182 HANDLEBAR Removing the handlebar 38 N m (3.8 kgf m, 28 lb 38 N m (3.8 kgf m, 28 lb • • • • • • 1.8 N m (0.18 kgf m, 1.3 lb • • • 11 N m (1.1 kgf m, 8.1 lb •...

  • Page 183: Adjusting The Handlebar Position

    HANDLEBAR EAS31396 ECA18300 ADJUSTING THE HANDLEBAR POSITION NOTICE 1. Check: First, tighten the bolts on the front side of the • Handlebar position handlebar holder, and then on the rear side. The handlebar position can be adjusted in two • Align the punch mark “a” on the handlebar with positions to suit the rider’s preference.

  • Page 184: Checking The Handlebar

    HANDLEBAR EAS30204 3. Tighten: CHECKING THE HANDLEBAR • Lower handlebar holder nut 1. Check: • Handlebar Lower handlebar holder nut Bends/cracks/damage → Replace. 40 N·m (4.0 kgf·m, 30 lb·ft) EWA13690 WARNING 4. Install: Do not attempt to straighten a bent handle- •...
  • Page 185 HANDLEBAR 7. Install: • Handlebar grip • Rearview mirror (left) Rearview mirror bolt (left) 38 N·m (3.8 kgf·m, 28 lb·ft) a. Apply a thin coat of rubber adhesive onto the end of the handlebar (left). b. Slide the handlebar grip over the end of the d.
  • Page 186 HANDLEBAR d. Install the rearview mirror (left) “1”. When installing the rearview mirror, align the mark “b” on the rearview mirror with the between lines mark “c” on the handlebar, as shown in the figure. 8. Install: • Handlebar switch holder •...

  • Page 187: Front Fork

    FRONT FORK EAS20034 FRONT FORK Removing the front fork legs 23 N m (2.3 kgf m, 17 lb • • • 10 N m (1.0 kgf m, 7.4 lb • • • 26 N m (2.6 kgf m, 19 lb •...
  • Page 188 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 189 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 190: 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” Each front fork leg is equipped with a spring pre- (from the damper rod assembly) load adjusting bolt, the fork leg (right) is...

  • Page 191: Checking The Front Fork Legs

    FRONT FORK 5. Remove: • Damper rod assembly bolt • Damper rod assembly While holding the damper rod with the damper rod holder “1”, loosen the damper rod assembly bolt. G088919 Damper rod holder (ø27) 3. Remove: 90890-01582 • Dust seal “1” Damper rod holder YM-01582 •...

  • Page 192: 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 193 • Inner tube’s outer surface Fork seal driver 90890-01442 Adjustable fork seal driver (36– Recommended oil 46 mm) Yamaha Suspension Oil 01 YM-01442 4. Install: • Dust seal “1” • Oil seal clip “2” • Oil seal “3” • Washer “4”...
  • Page 194 (with the fork seal driver “2”) (with the specified amount of the recom- mended fork oil) Fork seal driver 90890-01442 Recommended oil Adjustable fork seal driver (36– Yamaha Suspension Oil 01 46 mm) Quantity (left) YM-01442 466.0 cm³ (15.76 US oz, 16.44 Imp.oz) Quantity (right) 470.0 cm³...
  • Page 195 FRONT FORK Level (left) Rod puller 107 mm (4.2 in) 90890-01437 Level (right) Universal damping rod bleeding 107 mm (4.2 in) tool set YM-A8703 Rod puller attachment (M10 long) 90890-01578 Universal damping rod bleeding tool set YM-A8703 Fork spring compressor 90890-01441 Fork spring compressor YM-01441...

  • Page 196: Installing The Front Fork Legs

    FRONT FORK k. Set the cap bolt distance “c” to specifica- EAS30210 INSTALLING THE FRONT FORK LEGS tion. The following procedure applies to both of the front fork legs. Distance “c” 1. Install: 13 mm (0.51 in) • Front fork leg Temporarily tighten the upper and lower bracket pinch bolts.
  • Page 197 FRONT FORK 3. Check: • Cable routing Make sure the brake hoses, clutch cable, and handlebar switch leads are routed properly. Refer to “CABLE ROUTING” on page 2-13. 4. Adjust: • Spring preload • Rebound damping • Compression damping Refer to “ADJUSTING THE FRONT FORK LEGS”...
  • Page 198 STEERING HEAD EAS20035 STEERING HEAD Removing the lower bracket 52 N m (5.2 kgf m, 38 lb • • • *2nd 14 N m (1.4 kgf m, 10 lb • • • 110 N m (11 kgf m, 81 lb •...
  • Page 199 STEERING HEAD Removing the lower bracket 52 N m (5.2 kgf m, 38 lb • • • *2nd 14 N m (1.4 kgf m, 10 lb • • • 110 N m (11 kgf m, 81 lb • • • 15 N m (1.5 kgf m, 11 lb...

  • Page 200: Steering Head

    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 201: 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 202: Rear Shock Absorber Assembly

    REAR SHOCK ABSORBER ASSEMBLY EAS20036 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly 44 N m (4.4 kgf m, 32 lb • • • 45 N m (4.5 kgf m, 33 lb • • • 44 N m (4.4 kgf m, 32 lb •...

  • Page 203: Handling The Rear Shock Absorber

    REAR SHOCK ABSORBER ASSEMBLY EAS30826 EAS30219 HANDLING THE REAR SHOCK ABSORBER REMOVING THE REAR SHOCK ABSORBER ASSEMBLY EWA13740 WARNING 1. Stand the vehicle on a level surface. This rear shock absorber contains highly EWA13120 WARNING compressed nitrogen gas. Before handling the rear shock absorber, read and make sure Securely support the vehicle so that there is you understand the following information.

  • Page 204: Installing The Relay Arm

    REAR SHOCK ABSORBER ASSEMBLY EAS30222 3. Tighten: INSTALLING THE RELAY ARM • Connecting arm upper nut 1. Lubricate: • Relay arm nut • Collar • Oil seal Connecting arm upper nut 44 N·m (4.4 kgf·m, 32 lb·ft) Recommended lubricant Relay arm nut Lithium-soap-based grease 44 N·m (4.4 kgf·m, 32 lb·ft) 2.

  • Page 205: Swingarm

    SWINGARM EAS20037 SWINGARM Removing the swingarm m (0.7 kgf m, 5.2 lb • • • m (0.7 kgf m, 5.2 lb • • • 115 N m (11.5 kgf m, 85 lb • • • Order Job/Parts to remove Q’ty Remarks Rear brake caliper Refer to “REAR BRAKE”...
  • Page 206 SWINGARM Removing the swingarm m (0.7 kgf m, 5.2 lb • • • m (0.7 kgf m, 5.2 lb • • • 115 N m (11.5 kgf m, 85 lb • • • Order Job/Parts to remove Q’ty Remarks Cable holder Dust cover Collar Bearing...

  • Page 207: Removing The Swingarm

    SWINGARM EAS30226 EAS30227 REMOVING THE SWINGARM CHECKING THE SWINGARM 1. Stand the vehicle on a level surface. 1. Check: EWA13120 • Swingarm WARNING Bends/cracks/damage → Replace. Securely support the vehicle so that there is 2. Check: no danger of it falling over. •...

  • Page 208: Installing The Swingarm

    SWINGARM EAS30228 3. Install: INSTALLING THE SWINGARM • Swingarm 1. Lubricate: • Pivot shaft • Dust cover • Pivot shaft Relay arm bolt • Bearing 45 N·m (4.5 kgf·m, 33 lb·ft) • Oil seal 4. Install: • Collar • Pivot shaft nut Recommended lubricant a.

  • Page 209: Chain Drive

    CHAIN DRIVE EAS20038 CHAIN DRIVE Removing the drive chain 160 N m (16 kgf m, 118 lb • • • 14 N m (1.4 kgf m, 10 lb • • • 10 N m (1.0 kgf m, 7.4 lb • •...

  • Page 210: Removing The Drive Chain

    CHAIN DRIVE EAS30229 a. Measure the length “a” between the inner REMOVING THE DRIVE CHAIN sides of the pins and the length “b” 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 211: 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 212: Checking The Rear Wheel Drive Hub

    CHAIN DRIVE EAS30233 c. After riveting, make sure the space “c”, CHECKING THE REAR WHEEL DRIVE HUB which is inside of the connecting link “3” and Refer to “CHECKING THE REAR WHEEL inside of the connecting plate “1”, is 14.35– DRIVE HUB”...
  • Page 213 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 214: Adjusting The Shift Pedal

    CHAIN DRIVE EAS31729 ADJUSTING THE SHIFT PEDAL The shift pedal position is determined by the in- stalled shift rod length. 1. Measure: • Installed shift rod length “a” Incorrect → Adjust. Installed shift rod length 236.0–238.0 mm (9.29–9.37 in) 2. Adjust: •...

  • Page 215: 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..............5-20 CHECKING THE CAMSHAFTS ..............5-21 CHECKING THE TIMING CHAIN AND CAMSHAFT SPROCKET ..5-22 CHECKING THE TIMING CHAIN GUIDES..........
  • Page 216 CLUTCH ......................5-46 REMOVING THE CLUTCH ..............5-50 CHECKING THE FRICTION PLATES.............5-51 CHECKING THE CLUTCH PLATES ............5-51 CHECKING THE CLUTCH SPRINGS.............5-52 CHECKING THE CLUTCH HOUSING ............5-52 CHECKING THE CLUTCH BOSS............5-53 CHECKING THE PRESSURE PLATE ............5-53 CHECKING THE PRIMARY DRIVE GEAR..........5-53 CHECKING THE PRIMARY DRIVEN GEAR ..........5-53 CHECKING THE PULL LEVER SHAFT AND PULL ROD ......5-53 INSTALLING THE CLUTCH..............
  • Page 217 CRANKSHAFT AND BALANCER SHAFT ...........5-81 REMOVING THE CRANKSHAFT AND BALANCER SHAFT....5-82 CHECKING THE OIL NOZZLES ............. 5-82 CHECKING THE CRANKSHAFT ............5-82 CHECKING THE BALANCER SHAFT ............5-84 INSTALLING THE CRANKSHAFT ............5-86 INSTALLING THE BALANCER ASSEMBLY...........5-86 TRANSMISSION.................... 5-87 REMOVING THE TRANSMISSION ............5-92 CHECKING THE SHIFT FORKS.............

  • Page 218: 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 219: 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 220 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 221 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil cooler 2. Oil filter cartridge 3. Oil pressure switch 4. Oil strainer 5. Oil pump...
  • Page 222 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 223 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 224: Engine Inspection

    ENGINE INSPECTION EAS20041 4. Install: ENGINE INSPECTION • Compression gauge “1” • Extension “2” EAS30249 MEASURE THE COMPRESSION PRESSURE Compression gauge The following procedure applies to all of the cyl- 90890-03081 inders. Engine compression tester YU-33223 Insufficient compression pressure will result in a Compression gauge extension loss of performance.
  • Page 225 ENGINE INSPECTION c. If the compression pressure is above the maximum specification, check the cylinder head, valve surfaces and piston crown for carbon deposits. Carbon deposits → Eliminate. d. If the compression pressure is below the minimum specification, pour a teaspoonful of engine oil into the spark plug bore and measure again.

  • Page 226: 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 227 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 228 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 4-40. Shift rod/Drive sprocket Refer to “CHAIN DRIVE”...
  • Page 229 ENGINE REMOVAL Removing the engine 25 N m (2.5 kgf m, 18 lb 45 N m (4.5 kgf m, 33 lb • • • • • • 45 N m (4.5 kgf m, 33 lb • • • 25 N m (2.5 kgf m, 18 lb •...
  • Page 230 ENGINE REMOVAL Removing the engine 25 N m (2.5 kgf m, 18 lb 45 N m (4.5 kgf m, 33 lb • • • • • • 45 N m (4.5 kgf m, 33 lb • • • 25 N m (2.5 kgf m, 18 lb •...

  • Page 231: Removing The Engine

    ENGINE REMOVAL EAS30250 4. Install: REMOVING THE ENGINE • Engine mounting bolt (rear lower side) “5” 1. Loosen: • Engine mounting bolt (rear upper side) “6” • Engine mounting adjust bolt (rear) 5. Install: • Engine mounting bolt (left front lower side) “7” Loosen the engine mounting adjust bolts with (temporarily tighten) the pivot shaft wrench “1”...
  • Page 232 ENGINE REMOVAL 10.Tighten: 15.Install: • Engine mounting bolt (left front lower side) “7” • Engine bracket (right) “19” • Engine mounting bolt (right front lower side) • Engine bracket bolt (right) “20” “10” (temporarily tighten) • Engine mounting bolt (right front upper side) Engine mounting bolt (left front “21”...

  • Page 233: 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 234 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 • • • * Three Bond No. 1541C® Order Job/Parts to remove Q’ty...
  • Page 235 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 236 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 237: 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 238: 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 239: Checking The Timing Chain And Camshaft Sprocket

    CAMSHAFTS EAS30266 CHECKING THE TIMING CHAIN TENSIONER 1. Check: • Timing chain tensioner Cracks/damage/rough movement → Re- place. a. Using the valve spring compressor “1”, push and insert timing chain tensioner rod “2” into the timing chain tensioner housing. G088949 Push the timing chain tensioner rod in direction EAS30258 CHECKING THE TIMING CHAIN AND...

  • Page 240: Installing The Camshafts

    CAMSHAFTS e. Make sure that the timing chain tensioner rod comes out “d” of the timing chain ten- • Install the camshaft projection “a” at the posi- sioner housing smoothly. If there is rough tion shown in the illustration. movement, replace the timing chain ten- •...
  • Page 241 CAMSHAFTS 5. Install: 7. Tighten: • Camshaft cap • Camshaft cap bolt “1” • Intake camshaft cap • Exhaust camshaft cap Camshaft cap bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft) • Make sure each camshaft cap is installed in its original place.
  • Page 242 CAMSHAFTS 9. Install: d. Turn the crankshaft clockwise several times to release the timing chain tensioner rod. • Timing chain tensioner gasket • Timing chain tensioner 10.Turn: a. Using the valve spring compressor “1”, • Crankshaft push and insert timing chain tensioner rod (several turns counterclockwise) “2”...
  • Page 243 CAMSHAFTS 16.Install: • Spark plug • Ignition coil “1” Spark plug 13 N·m (1.3 kgf·m, 9.6 lb·ft) Install the ignition coils “1” in the direction shown in the illustration. 15.Install: • Timing chain guide (top side) • Cylinder head cover gasket “1” •...

  • Page 244: 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 245: Removing The Cylinder Head

    CYLINDER HEAD EAS30276 3. Measure: REMOVING THE CYLINDER HEAD • Cylinder head warpage 1. Remove: Out of specification → Resurface the cylinder • Intake camshaft head. • Exhaust camshaft Refer to “REMOVING THE CAMSHAFTS” Warpage limit on page 5-20. 0.10 mm (0.0039 in) 2.

  • Page 246: 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 5-23. 2.

  • Page 247: Valves And Valve Springs

    VALVES AND VALVE SPRINGS EAS20045 VALVES AND VALVE SPRINGS Removing the valves and valve springs Order Job/Parts to remove Q’ty Remarks Cylinder head Refer to “CYLINDER HEAD” on page 5-27. Intake valve lifter Intake valve pad Intake valve cotter Intake valve spring retainer Intake valve spring Intake valve Intake valve stem seal...
  • Page 248 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 5-31...

  • Page 249: 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 250 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 251: 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 252: 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 253 VALVES AND VALVE SPRINGS 2. Lubricate: • Valve stem • Valve stem seal (with the recommended lubricant) Recommended lubricant Molybdenum disulfide oil 3. Install: • Valve spring seat “1” G088959 5. To secure the valve cotters onto the valve • Valve stem seal “2” stem, lightly tap the valve tip with a soft-face •...

  • Page 254: Generator And Starter Clutch

    • • 10 N m (1.0 kgf m, 7.4 lb • • • * YAMAHA bond No. 1215 (Three bond No. 1215®) Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS (1)” on Rider seat page 4-1. Refer to “GENERAL CHASSIS (1)” on Side cover page 4-1.
  • Page 255 • • 10 N m (1.0 kgf m, 7.4 lb • • • * YAMAHA bond No. 1215 (Three bond No. 1215®) Order Job/Parts to remove Q’ty Remarks Dowel pin Stator coil lead holder Stator coil assembly (stator coil/crankshaft posi-...

  • Page 256: 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 257: 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 258 To route the stator coil lead, refer to “CABLE ROUTING” on page 2-13. 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 259: 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 260 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 261: 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 262: 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 263: 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 264 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 5-47...
  • Page 265 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 5-58. Pressure plate 1 Clutch spring Pressure plate 2...
  • Page 266 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 267: 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 268: 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 269: 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 270: 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 271 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 272 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 273: 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 5-46. Shift arm Refer to “CHAIN DRIVE” on page 4-88. Circlip Washer Shift shaft...

  • Page 274: Checking The Shift Shaft

    SHIFT SHAFT EAS30377 2. Install: CHECKING THE SHIFT SHAFT • Bearing 1. Check: • Oil seal • Shift shaft • Washer “1” Bends/damage/wear → Replace. • Circlip “2” • Shift shaft spring • Collar Damage/wear → Replace. Lubricate the oil seal lips with lithium-soap- based grease.

  • Page 275: 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 276 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 5-59...

  • Page 277: 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 278: Installing The Oil Pump

    OIL PUMP 3. Check: • Oil pump operation Refer to “CHECKING THE OIL PUMP” on page 5-60. 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) LOCTITE®...

  • Page 279: 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 280: 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 281: 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 282 • • • * 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 283: 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 284 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 285: 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 286: Installing The Gear Position Sensor

    CRANKCASE EAS31658 INSTALLING THE GEAR POSITION SENSOR ECA22630 NOTICE To prevent damage to the gear position sen- sor, keep magnets (including any pickup tool with a magnet, magnetized screwdrivers, etc.) away from the gear position sensor. 1. Install: • O-ring •...

  • Page 287: Connecting Rods And Pistons

    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 5-64. Connecting rod cap Big end lower bearing Piston pin clip...

  • Page 288: Removing The Connecting Rods And Pistons

    CONNECTING RODS AND PISTONS EAS30745 3. Remove: REMOVING THE CONNECTING RODS AND • Top ring PISTONS • 2nd ring The following procedure applies to all of the con- • Oil ring necting rods and pistons. 1. Remove: When removing a piston ring, open the end gap •...

  • Page 289: Checking The Piston Rings

    CONNECTING RODS AND PISTONS b. If out of specification, replace the cylinder, and replace the piston and piston rings as a Top ring set. Side clearance limit 0.115 mm (0.0045 in) c. Measure piston skirt diameter “b” with the 2nd ring micrometer.

  • Page 290: 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 291 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 292 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 293: Installing The Connecting Rod And Piston

    CONNECTING RODS AND PISTONS 2. Select: • Big end bearing (P –P • 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 ”...
  • Page 294 CONNECTING RODS AND PISTONS a. Replace the connecting rod bolts with new ones. b. Clean the connecting rod bolts and lubri- cate the bolt threads and seats with molyb- denum disulfide oil. c. After installing the big end bearing, assem- ble the connecting rod and connecting rod cap without installing them onto the crank- shaft.
  • Page 295 CONNECTING RODS AND PISTONS 3. Install: • Oil ring expander “1” • Lower oil ring rail “2” • Upper oil ring rail “3” • 2nd ring “4” • Top ring “5” (into the piston) Be sure to install the piston rings so that the G089013 manufacturer’s marks or numbers “a”...
  • Page 296 CONNECTING RODS AND PISTONS 7. Lubricate: • Crankshaft pin • Connecting rod big end bearing inner surface (with the recommended lubricant) Recommended lubricant Engine oil 8. Install: • Piston assembly “1” (into the cylinder “2” and onto the crankshaft 10.Tighten: pin) •...
  • Page 297 CONNECTING RODS AND PISTONS EWA16610 WARNING If the bolt is tightened more than the speci- fied angle, do not loosen the bolt and then re- tighten it. Instead, replace the bolt with a new one and perform the procedure again. ECA20890 NOTICE Do not use a torque wrench to tighten the...
  • Page 298 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 5-64. Refer to “REMOVING THE CONNECTING Connecting rod RODS AND PISTONS” on page 5-71. Balancer shaft Balancer shaft journal lower bearing Balancer shaft journal upper bearing...

  • Page 299: 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 300 CRANKSHAFT AND BALANCER SHAFT 4. Select: • Crankshaft journal bearing (J –J • 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. •...

  • Page 301: 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 302 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 5-64. g.

  • Page 303: Installing The Crankshaft

    CRANKSHAFT AND BALANCER SHAFT EAS31077 2. Install: INSTALLING THE CRANKSHAFT • Balancer shaft 1. Install: • Crankshaft journal upper bearing Install by aligning the crankshaft match mark “a” (into the upper crankcase) and the balancer shaft match mark “b”. • Crankshaft journal lower bearing (into the lower crankcase) •...

  • Page 304: 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 305 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 306 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 5-89...
  • Page 307 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 5-90...
  • Page 308 TRANSMISSION Disassembling the drive axle assembly Order Job/Parts to remove Q’ty Remarks Washer 2nd wheel gear Collar Collar Bearing Circlip Drive axle 5-91...

  • Page 309: 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 310: 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 311: Assembling The Main Axle And Drive Axle

    TRANSMISSION EAS30435 2. Install: ASSEMBLING THE MAIN AXLE AND DRIVE • Toothed lock washer retainer “1” AXLE • Toothed lock washer “2” 1. Install: • Toothed washer “1” • With the toothed lock washer retainer in the • Circlip “2” groove “a”...

  • Page 312: Installing The Transmission

    TRANSMISSION EAS30438 3. Install: INSTALLING THE TRANSMISSION • Shift fork-C “1” 1. Install: • Shift drum assembly “2” • Bearing “1” • Spring • Bearing cover plate “2” • Shift fork guide bar 1 “3” • Oil nozzle “3” • Oil delivery pipe “4” •...
  • Page 313 TRANSMISSION • Install shift fork-R into the groove “a” in the 5th wheel gear and shift fork-L into the groove “b” in the 6th wheel gear on the drive axle. • Face the seal side of bearing “4” to the outside. •...
  • Page 314 TRANSMISSION 5-97...

  • Page 315: 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 316: Cooling System Diagrams

    COOLING SYSTEM DIAGRAMS EAS20299 COOLING SYSTEM DIAGRAMS 1. Water pump 2. Thermostat 3. Radiator...
  • Page 317 COOLING SYSTEM DIAGRAMS 1. Water jacket joint 2. Thermostat 3. Water pump 4. Oil cooler 5. Coolant reservoir...
  • Page 318 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 319: 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 320: 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 321 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 322: 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 323: Checking The Oil Cooler

    OIL COOLER EAS30441 4. Check: CHECKING THE OIL COOLER • Cooling system 1. Check: Leaks → Repair or replace any faulty part. • Oil cooler Refer to “INSTALLING THE RADIATOR” on Cracks/damage → Replace. page 6-5. 2. Check: 5. Measure: •...

  • Page 324: Thermostat

    THERMOSTAT EAS20065 THERMOSTAT Removing the thermostat assembly 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 Drain. Coolant Refer to “CHANGING THE COOLANT” on page 3-28.

  • Page 325: Checking The Thermostat

    THERMOSTAT EAS30443 EAS30445 CHECKING THE THERMOSTAT INSTALLING THE THERMOSTAT 1. Check: ASSEMBLY • Thermostat 1. Install: When the water temperature in the specified • Thermostat value, the thermostat does not fully open. → 2. Fill: Replace. • Cooling system (with the specified amount of the recom- mended coolant) Valve full open temperature 95.0 °C (203.00 °F)

  • Page 326: Water Pump

    WATER PUMP EAS20066 WATER PUMP Removing the water pump 2.0 N m (0.20 kgf m, 1.5 lb • • • 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 3-28.
  • Page 327 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 328: 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 • Impeller shaft Cracks/damage/wear → Replace. Remove the mechanical seal (housing side) • Water pump housing from the inside of the water pump housing “2”.
  • Page 329 WATER PUMP Mechanical seal installer 90890-04078 Water pump seal installer YM-33221-A Middle driven shaft bearing driv- 90890-04058 Middle drive bearing installer 40 & 50 mm YM-04058 2. Water pump housing 3. Mechanical seal installer 4. Middle driven shaft bearing driver A.
  • Page 330 WATER PUMP 6-15...

  • Page 331: Fuel System

    FUEL SYSTEM FUEL TANK..................... 7-1 REMOVING THE FUEL TANK ..............7-4 REMOVING THE FUEL PUMP ..............7-4 CHECKING THE FUEL PUMP BODY............7-4 CHECKING THE FUEL PUMP OPERATION..........7-4 CHECKING THE PURGE CUT VALVE SOLENOID .........7-5 INSTALLING THE FUEL PUMP..............7-5 INSTALLING THE FUEL TANK..............7-5 THROTTLE BODIES ..................7-6 CHECKING THE INJECTORS (BEFORE REMOVING) ......

  • Page 332: 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 333 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 334 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 335: 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 • Side cover Refer to “GENERAL CHASSIS (1)” on page 4-1. • Fuel tank cover Refer to “GENERAL CHASSIS (4)”...

  • Page 336: 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 337 THROTTLE BODIES EAS20070 THROTTLE BODIES Removing the throttle bodies 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 (5)” on Air filter case page 4-11.
  • Page 338 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 339: Checking The Injectors (Before Removing)

    THROTTLE BODIES EAS30475 CHECKING THE INJECTORS (BEFORE REMOVING) 1. Check: • Injector Use the diagnostic code numbers “36”–“38”. Refer to “DIAGNOSTIC CODE: ACTUATOR OPERATION TABLE” on page 9-82. EAS31158 REMOVING THE FUEL HOSE (FUEL RAIL SIDE) 1. Remove: • Rider seat •...

  • Page 340: Checking And Cleaning The Throttle Bodies

    G089040 Recommended cleaning solvent d. Apply the recommended cleaning solvent Yamaha Oil & Brake Cleaner to the throttle valves and the inside of the throttle bodies to remove any carbon de- posits.

  • Page 341: Replacing The Throttle Bodies

    THROTTLE BODIES 5. Adjust: • Throttle bodies synchronizing • Do not allow any cleaning solvent to enter the Out of specification → Replace the throttle opening for the injectors. bodies. • Do not apply any cleaning solvent to the por- Refer to “SYNCHRONIZING THE THROT- tions of the throttle valve shafts between the TLE BODIES”...

  • Page 342: Checking The Injector Pressure

    THROTTLE BODIES ECA17600 NOTICE Fuel rail bolt Never exceed the specified air pressure or 3.5 N·m (0.35 kgf·m, 2.6 lb·ft) damage could occur. 4. Check the injector pressure after the injectors f. Close the valve on the fuel injector pressure are installed.

  • Page 343: Installing The Fuel Hose (Fuel Rail Side)

    • Yamaha diagnostic tool (A/I) (90890-03264) in- • It is prohibited to wear the cotton work gloves cludes YDT sub harness (6P) (90890-03266). or equivalent coverings. • If you already have Yamaha diagnostic tool (A/ I) (90890-03262), YDT sub harness (6P) (90890-03266) is separately required. 7-12...
  • Page 344 THROTTLE BODIES e. Diagnostic code number “01” is selected. 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.

  • Page 345: Electrical System

    ELECTRICAL SYSTEM IGNITION SYSTEM ..................8-1 CIRCUIT DIAGRAM .................. 8-1 ENGINE STOPPING DUE TO SIDESTAND OPERATION.......8-3 TROUBLESHOOTING ................8-4 ELECTRIC STARTING SYSTEM ..............8-7 CIRCUIT DIAGRAM .................. 8-7 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION ......8-9 TROUBLESHOOTING ................8-10 CHARGING SYSTEM..................8-13 CIRCUIT DIAGRAM ................8-13 TROUBLESHOOTING ................8-15 LIGHTING SYSTEM ..................8-17 CIRCUIT DIAGRAM ................
  • Page 346 CHECKING THE FUEL LEVEL WARNING LIGHT .........8-47 CHECKING THE RADIATOR FAN MOTOR ...........8-47 CHECKING THE COOLANT TEMPERATURE SENSOR.......8-47 CHECKING THE THROTTLE SERVO MOTOR ........8-48 CHECKING THE INTAKE AIR TEMPERATURE SENSOR ....8-49 CHECKING THE FUEL INJECTORS............8-49 CHECKING THE PURGE CUT VALVE SOLENOID .......8-50 CHECKING THE WHEEL SWITCH ............

  • Page 348: Ignition System

    IGNITION SYSTEM EAS20072 IGNITION SYSTEM EAS30490 CIRCUIT DIAGRAM...
  • Page 349 IGNITION SYSTEM 3. Fuse box 4. Main fuse 5. Main switch 9. Backup fuse 2 11. Ignition fuse 2 12. Ignition fuse 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 350: 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 351: 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 cover 3. Fuel tank 4. Air filter case 1. Check the fuses. (Main, backup 2, ignition, and igni- tion 2) NG→...
  • Page 352 IGNITION SYSTEM 8. Check the stop/run/start switch. Refer to “CHECKING THE NG→ Replace the handlebar switch (right). SWITCHES” on page 8-39. OK↓ 9. Check the neutral switch. Refer to “CHECKING THE NG→ Replace the neutral switch. SWITCHES” on page 8-39. OK↓...
  • Page 353 IGNITION SYSTEM...

  • Page 354: Electric Starting System

    ELECTRIC STARTING SYSTEM EAS20073 ELECTRIC STARTING SYSTEM EAS30493 CIRCUIT DIAGRAM...
  • Page 355 ELECTRIC STARTING SYSTEM 3. Fuse box 4. Main fuse 5. Main switch 9. Backup fuse 2 11. Ignition fuse 2 12. Ignition fuse 23. Battery 24. Engine ground 25. Starter relay 26. Starter motor 28. Clutch switch 31. Handlebar switch (right) 33.

  • Page 356: 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 357: 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 cover 3. Fuel tank 4. Air filter case 5. Canister 1. Check the fuses. (Main, backup 2, ignition, and igni- tion 2) NG→...
  • Page 358 ELECTRIC STARTING SYSTEM 8. Check the main switch. Refer to “CHECKING THE NG→ Replace the main switch/immobilizer unit. SWITCHES” on page 8-39. OK↓ 9. Check the neutral switch. Refer to “CHECKING THE NG→ Replace the neutral switch. SWITCHES” on page 8-39. OK↓...
  • Page 359 ELECTRIC STARTING SYSTEM 8-12...

  • Page 360: Charging System

    CHARGING SYSTEM EAS20074 CHARGING SYSTEM EAS30496 CIRCUIT DIAGRAM 8-13...
  • Page 361 CHARGING SYSTEM 1. AC magneto 2. Rectifier/regulator 3. Fuse box 4. Main fuse 23. Battery 24. Engine ground 8-14...

  • Page 362: Troubleshooting

    CHARGING SYSTEM EAS30497 TROUBLESHOOTING The battery is not being charged. • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Fuel tank cover 3. Fuel tank 4. Air filter case 1. Check the fuse. (Main) NG→ Replace the fuse. Refer to “CHECKING THE FUS- ES”...
  • Page 363 CHARGING SYSTEM 8-16...

  • Page 364: Lighting System

    LIGHTING SYSTEM EAS20075 LIGHTING SYSTEM EAS30498 CIRCUIT DIAGRAM 8-17...
  • Page 365 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 23. Battery 24. Engine ground 49. ECU (Engine Control Unit) 68. Meter assembly 69.

  • Page 366: 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 cover 3. Fuel tank 4.
  • Page 367 LIGHTING SYSTEM Replace the ECU, meter assembly, headlight assembly, tail/brake light or license plate light. Refer to “REPLACING THE ECU (En- gine Control Unit)” on page 8-41. 8-20...

  • Page 368: Signaling System

    SIGNALING SYSTEM EAS20076 SIGNALING SYSTEM EAS30500 CIRCUIT DIAGRAM 8-21...
  • Page 369 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 14. ABS ECU fuse 16. Brake light fuse 20. Backup fuse 23. Battery 24. Engine ground 29.

  • Page 370: 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 371 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 8-39. OK↓ 2. Check the horn. Refer to “CHECKING THE HORN” NG→...
  • Page 372 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 8-21. OK↓ Replace the meter assembly or turn signal light. The neutral indicator light fails to come on. 1.
  • Page 373 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 8-21. OK↓...
  • Page 374 SIGNALING SYSTEM Quick shift system does not operate. 1. Check that the Auxiliary system NG→ Repair the faulty parts. warning does not come on. OK↓ Check the quick shift system operating 2. Check that the quick shift system is conditions explained in the owner’s manu- working under normal quick shift NG→...
  • Page 375 SIGNALING SYSTEM OK↓ Replace the ECU. Refer to “REPLACING THE ECU (En- gine Control Unit)” on page 8-41. 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 376: Cooling System

    COOLING SYSTEM EAS20077 COOLING SYSTEM EAS30502 CIRCUIT DIAGRAM 8-29...
  • Page 377 COOLING SYSTEM 3. Fuse box 4. Main fuse 5. Main switch 6. Radiator fan motor relay 9. Backup fuse 2 12. Ignition fuse 21. Radiator fan motor fuse 23. Battery 24. Engine ground 47. Coolant temperature sensor 49. ECU (Engine Control Unit) 95.

  • Page 378: Troubleshooting

    COOLING SYSTEM EAS30503 TROUBLESHOOTING • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Fuel tank cover 3. Fuel tank 4. Air filter case 1. Check the fuses. (Main, ignition, backup 2, and radi- ator fan motor) NG→ Replace the fuse(s). Refer to “CHECKING THE FUS- ES”...
  • Page 379 COOLING SYSTEM Replace the ECU. Refer to “REPLACING THE ECU (En- gine Control Unit)” on page 8-41. 8-32...

  • Page 380: Fuel Pump System

    FUEL PUMP SYSTEM EAS20081 FUEL PUMP SYSTEM EAS30513 CIRCUIT DIAGRAM 8-33...
  • Page 381 FUEL PUMP SYSTEM 3. Fuse box 4. Main fuse 5. Main switch 7. Fuel injection system fuse 9. Backup fuse 2 12. Ignition fuse 23. Battery 24. Engine ground 31. Handlebar switch (right) 33. Stop/run/start switch 35. Relay unit 37. Fuel pump relay 40.

  • Page 382: 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 cover 3. Fuel tank 1. Check the fuses. (Main, ignition, backup 2, and fuel injection system) NG→...
  • Page 383 FUEL PUMP SYSTEM Replace the ECU. Refer to “REPLACING THE ECU (En- gine Control Unit)” on page 8-41. 8-36...

  • Page 384: Electrical Components

    ELECTRICAL COMPONENTS EAS20089 ELECTRICAL COMPONENTS 1. ECU (Engine Control Unit) 2. Fuel pump 3. Relay unit 4. Radiator fan motor relay 5. Fuse box 6. Brake light relay 7. Starter relay 8. Gear position sensor 9. Shift sensor 10. Sidestand switch 11.
  • Page 385 ELECTRICAL COMPONENTS 1. Hydraulic unit assembly (ABS ECU) 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 386: 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). Y/W O/W PUSH FREE...
  • Page 387 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 388: Replacing The Ecu (Engine Control Unit)

    ELECTRICAL COMPONENTS 4. Install: 1. Remove: • Fuse box cover • Rider seat • Rider seat • Side cover (left and right) Refer to “GENERAL CHASSIS (1)” on • Bracket page 4-1. Refer to “GENERAL CHASSIS (1)” on ECA27250 page 4-1. NOTICE 2.

  • Page 389: Checking The Relays

    ELECTRICAL COMPONENTS EAS30553 Relay unit (starting circuit cut-off relay) CHECKING THE RELAYS Check each switch for continuity with the digital circuit tester. If the continuity reading is incor- rect, replace the relay. Digital circuit tester (CD732) 90890-03243 Model 88 Multimeter with ta- Sb B Sb/W chometer YU-A1927...

  • Page 390: Checking The Relay Unit (Diode)

    ELECTRICAL COMPONENTS Radiator fan motor relay The digital circuit tester readings are shown in the following table. No continuity Positive tester probe sky blue “1” Negative tester probe black “2” Continuity Positive tester probe 1. Positive battery terminal black “2” 2.

  • Page 391: Checking The Ignition Coils

    ELECTRICAL COMPONENTS 2. Check: a. Disconnect the relay unit coupler from the • Secondary coil resistance wire harness. Out of specification → Replace. b. Connect the digital circuit tester (Ω) to the relay unit terminal as shown. Secondary coil resistance c.

  • Page 392: Checking The Crankshaft Position Sensor

    ELECTRICAL COMPONENTS b. Connect the ignition checker “1” as shown. Ignition checker 90890-06754 Oppama pet–4000 spark checker YM-34487 Gy B b. Measure the crankshaft position sensor re- sistance. EAS30562 CHECKING THE STARTER MOTOR OPERATION 1. Check: G089048 • Starter motor operation 2.

  • Page 393: Checking The Stator Coil

    ELECTRICAL COMPONENTS EAS30566 EAS30680 CHECKING THE STATOR COIL CHECKING THE RECTIFIER/REGULATOR 1. Disconnect: 1. Check: • Stator coil coupler • Battery charging voltage Out of specification → Check the stator coil (from the wire harness) 2. Check: condition. If the stator coil does not have a •...

  • Page 394: Checking The Fuel Level Warning Light

    ELECTRICAL COMPONENTS 4. Check: • Fuel sender resistance Out of specification → Replace the fuel pump assembly. Sender unit resistance (full) 9.0–12.0 Ω Sender unit resistance (empty) 213.0–219.0 Ω a. Connect the digital circuit tester (Ω) to the EAS30577 fuel sender terminals as shown. CHECKING THE RADIATOR FAN MOTOR 1.

  • Page 395: Checking The Throttle Servo Motor

    ELECTRICAL COMPONENTS 2. Check: EAS30592 CHECKING THE THROTTLE SERVO MOTOR • Coolant temperature sensor resistance 1. Remove: Out of specification → Replace. • Air filter case Refer to “GENERAL CHASSIS (5)” on Coolant temperature sensor re- page 4-11. sistance 2. Check: 2513–2777 Ω...

  • Page 396: Checking The Intake Air Temperature Sensor

    ELECTRICAL COMPONENTS EAS30594 d. Slowly heat the water, then let it cool down CHECKING THE INTAKE AIR to the specified temperature. TEMPERATURE SENSOR e. Measure the intake air temperature sensor 1. Remove: resistance. • Intake air temperature sensor 3. Install: EWA14110 WARNING •...

  • Page 397: Checking The Purge Cut Valve Solenoid

    ELECTRICAL COMPONENTS EAS32604 • Positive tester probe CHECKING THE PURGE CUT VALVE white/green “2” SOLENOID • Negative tester probe 1. Check: black/white “3” • Purge cut valve solenoid resistance Out of specification → Replace. b. Turn the main switch to “ON”. c.
  • Page 398 ELECTRICAL COMPONENTS 8-51...

  • Page 399: 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 400 ABS (Anti-lock Brake System) ..............9-32 CIRCUIT DIAGRAM ................9-32 ABS COMPONENTS CHART ..............9-34 ABS COUPLER LOCATION CHART ............9-35 MAINTENANCE OF THE ABS ECU ............9-36 ABS TROUBLESHOOTING OUTLINE............9-36 BASIC INSTRUCTIONS FOR TROUBLESHOOTING ......9-37 [A] CHECKING THE ABS WARNING LIGHT..........9-39 [A-1] ONLY THE ABS WARNING LIGHT FAILS TO COME ON.....
  • Page 401 P0105......................9-102 TROUBLESHOOTING ................9-102 P0106......................9-104 TROUBLESHOOTING ................9-104 P0107, P0108 ....................9-106 TROUBLESHOOTING ................9-106 P0110......................9-110 TROUBLESHOOTING ................9-110 P0111......................9-112 TROUBLESHOOTING ................9-112 P0112, P0113 ....................9-115 TROUBLESHOOTING ................9-115 P0115......................9-119 TROUBLESHOOTING ................9-119 P0116......................9-120 TROUBLESHOOTING ................9-120 P0117, P0118 ....................9-123 TROUBLESHOOTING ................9-123 P0122, P0123, P0222, P0223 ..............9-127 TROUBLESHOOTING ................9-127 P0132......................9-132 TROUBLESHOOTING ................9-132 P0133......................9-136...
  • Page 402 P0202......................9-143 TROUBLESHOOTING ................9-143 P0203......................9-146 TROUBLESHOOTING ................9-146 P0300, P0301, P0302, P0303 ..............9-149 OUTLINE ....................9-149 FAIL-SAFE SYSTEM................9-150 TROUBLESHOOTING ................9-150 P0335......................9-153 TROUBLESHOOTING ................9-153 P0351......................9-157 TROUBLESHOOTING ................9-157 P0352......................9-161 TROUBLESHOOTING ................9-161 P0353......................9-165 TROUBLESHOOTING ................9-165 P0458......................9-169 TROUBLESHOOTING ................9-169 P0480......................
  • Page 403 P0606......................9-203 TROUBLESHOOTING ................9-203 P062F ......................9-204 TROUBLESHOOTING ................9-204 P0638......................9-206 TROUBLESHOOTING ................9-206 P0657......................9-210 TROUBLESHOOTING ................9-210 P0914......................9-214 TROUBLESHOOTING ................9-214 P0915......................9-216 TROUBLESHOOTING ................9-216 P0916, P0917 ....................9-218 TROUBLESHOOTING ................9-218 P1004......................9-222 TROUBLESHOOTING ................9-222 P1600......................9-224 TROUBLESHOOTING ................9-224 P1601......................9-228 TROUBLESHOOTING ................9-228 P1602......................9-232 TROUBLESHOOTING ................9-232 P1606, P1607 ....................9-236 TROUBLESHOOTING ................9-236 P1608......................9-240 TROUBLESHOOTING ................9-240 P1609......................9-242...
  • Page 404 P1806, P1807 ....................9-244 TROUBLESHOOTING ................9-244 P2122, P2123, P2127, P2128, P2138 ............9-248 TROUBLESHOOTING ................9-248 P2135......................9-252 TROUBLESHOOTING ................9-252 P2158......................9-255 TROUBLESHOOTING ................9-255 U0125 ......................9-260 TROUBLESHOOTING ................9-260 U0155 or Err....................9-263 TROUBLESHOOTING ................9-263 51_IMMOBILIZER ..................9-267 TROUBLESHOOTING ................9-267 52_IMMOBILIZER ..................9-268 TROUBLESHOOTING ................9-268 53_IMMOBILIZER ..................
  • Page 405 13, 26_ABS ....................9-279 TROUBLESHOOTING ................9-279 14, 27_ABS ....................9-280 TROUBLESHOOTING ................9-280 15_ABS .......................9-281 TROUBLESHOOTING ................9-281 16_ABS .......................9-283 TROUBLESHOOTING ................9-283 21_ABS .......................9-285 TROUBLESHOOTING ................9-285 31_ABS .......................9-286 TROUBLESHOOTING ................9-286 33_ABS .......................9-288 TROUBLESHOOTING ................9-288 34_ABS .......................9-290 TROUBLESHOOTING ................9-290 41_ABS .......................9-291 TROUBLESHOOTING ................9-291 42_ABS .......................9-292 TROUBLESHOOTING ................9-292 43, 45_ABS ....................9-293 TROUBLESHOOTING ................9-293...
  • Page 406 55_ABS .......................9-298 TROUBLESHOOTING ................9-298 56_ABS .......................9-299 TROUBLESHOOTING ................9-299 57_ABS .......................9-300 TROUBLESHOOTING ................9-300 62_ABS .......................9-304 TROUBLESHOOTING ................9-304 68_ABS .......................9-305 TROUBLESHOOTING ................9-305 89_ABS .......................9-306 TROUBLESHOOTING ................9-306 90_ABS .......................9-309 TROUBLESHOOTING ................9-309 91_ABS .......................9-312 TROUBLESHOOTING ................9-312...

  • Page 407: 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 408: 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 409: 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 410: 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 411: System Diagram

    SYSTEM DIAGRAM EAS20387 SYSTEM DIAGRAM EAS32920 ECU CIRCUIT DIAGRAM 38. Injector #1 8. Fuel pump relay 39. Injector #2 14. Engine stop 23. Fuel switch pump 40. Injector #3 6. Ignition 9. Starter 25. Neutral fuse 2 relay indicator light 11.
  • Page 412 SYSTEM DIAGRAM 46. Grip 47. Grip warmer (left) warmer (right) (OPTION) (OPTION) 35. Throttle 48. Purge cut position sensor valve solenoid 49. Radiator fan motor 52. Headlight control unit 36. Accelerator position sensor 53. Meter assembly 37. Hydraulic unit assembly 54.
  • Page 413 SYSTEM DIAGRAM 53. Meter assembly 1. ECU (Engine Control Unit) 2. Battery 54. CAN communication circuit 3. Main fuse 4. Electronic throttle valve fuse 5. Backup fuse 2 6. Ignition fuse 2 7. Starting circuit cut-off relay 8. Fuel pump relay 9.

  • Page 414: 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 415 SYSTEM DIAGRAM Wire harness Wire harness Connected parts Connected parts color color Throttle position CAN communica- sensor tion circuit — — — — Accelerator position — — sensor Starting circuit cut- — — off relay, Clutch switch — — — —...
  • Page 416 SYSTEM DIAGRAM Wire harness Connected parts color Coolant tempera- ture sensor Gear position sen- — — Hydraulic unit as- sembly (ABS ECU) — — Hydraulic unit as- sembly (ABS ECU) — — 9-10...
  • Page 417 SYSTEM DIAGRAM 9-11...

  • Page 418: Fuel Injection System

    FUEL INJECTION SYSTEM EAS20440 FUEL INJECTION SYSTEM EAS32871 CIRCUIT DIAGRAM 9-12...
  • Page 419 FUEL INJECTION SYSTEM 76. MIL (Malfunction indicator light) 1. AC magneto 2. Rectifier/regulator 95. Radiator fan motor 3. Fuse box 4. Main fuse 5. Main switch 6. Radiator fan motor relay 7. Fuel injection system fuse 8. Electronic throttle valve fuse 9.

  • Page 420: 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 421: [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 422: Immobilizer System

    IMMOBILIZER SYSTEM EAS20442 IMMOBILIZER SYSTEM EAS32885 CIRCUIT DIAGRAM 9-16...
  • Page 423 IMMOBILIZER SYSTEM 3. Fuse box 4. Main fuse 5. Main switch 9. Backup fuse 2 11. Ignition fuse 2 12. Ignition fuse 20. Backup fuse 23. Battery 24. Engine ground 27. Immobilizer unit 49. ECU (Engine Control Unit) 67. YDT coupler 68.

  • Page 424: 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 425: 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 426 IMMOBILIZER SYSTEM Standby mode: To enable the immobilizer system, turn the ignition key to “OFF”. 30 seconds later, the indicator light will start flashing continuously in the standby flashing mode pattern for up to 24 hours. After that time, the indicator light will stop flashing, but the immobilizer system is still enabled.
  • Page 427 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 428: 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, ignition 2, backup, and backup 2) NG→ Replace the fuse(s). Refer to “CHECKING THE FUS- ES”...

  • Page 429: 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 430: Cruise Control System

    CRUISE CONTROL SYSTEM EAS20441 CRUISE CONTROL SYSTEM EAS32875 CIRCUIT DIAGRAM 9-24...
  • Page 431 CRUISE CONTROL 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 16. Brake light fuse 17. Cruise control fuse 20. Backup fuse 23. Battery 24.

  • Page 432: Cruise Control Circuit Operation

    CRUISE CONTROL SYSTEM EAS32876 CRUISE CONTROL CIRCUIT OPERATION 7. Ignition 8. Cruise control 9. Cruise control fuse fuse power switch 10.Cruise control setting switch 12.Front brake 13.Rear brake 11.Clutch light switch light switch switch 16.ECU (Engine 5. Signaling 6. Brake Control Unit) system light...

  • Page 433: Basic Instructions For Troubleshooting

    CRUISE CONTROL SYSTEM 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 434: Basic Process For Troubleshooting

    CRUISE CONTROL SYSTEM 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 435: [A] Checking The Cruise Control System Indicator Light

    CRUISE CONTROL SYSTEM 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- 39.

  • Page 436: [C-1] Erasing The Dtc

    CRUISE CONTROL SYSTEM Automatic deactivation of the cruise control system The cruise control system is electronically controlled and linked with other control systems. The cruise control system will automatically deactivate under the following conditions: • The cruise control system is not able to maintain the set cruising speed (such as when going up a steep hill).
  • Page 437 CRUISE CONTROL SYSTEM 9-31...

  • Page 438: Abs (Anti-Lock Brake System)

    ABS (Anti-lock Brake System) EAS20443 ABS (Anti-lock Brake System) EAS32890 CIRCUIT DIAGRAM 9-32...
  • Page 439 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 14. ABS ECU fuse 16. Brake light fuse 17. Cruise control fuse 18.

  • Page 440: 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 441: 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 442: 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 443: 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 444 ABS (Anti-lock Brake System) 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 445: [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 446: [A-4] Only The Abs Ecu Fails To Communicate

    ABS (Anti-lock Brake System) EAS32901 [A-4] ONLY THE ABS ECU FAILS TO COMMUNICATE 1. ABS ECU fuse • Check the ABS ECU fuse for continuity. Refer to “CHECKING THE FUSES” on page 8-40. • If the ABS ECU fuse is blown, replace the fuse. 2.

  • Page 447: [B-2] Diagnosis Using The Dtc

    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 448 ABS (Anti-lock Brake System) Checking procedures 1. Check the brake fluid level in the front brake master cylinder reservoir and the rear brake master cyl- inder reservoir. Refer to “CHECKING THE BRAKE FLUID LEVEL” on page 3-13. 2. Check the wheel sensors for proper installation. Refer to “INSTALLING THE FRONT WHEEL (FRONT BRAKE DISCS)”...

  • Page 449: 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 450 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Fail-safe system Diagnos- Symptom Starting the Driving the tic code engine vehicle “53_IMMO- Code cannot be transmitted between the — — — BILIZER” ECU and immobilizer unit. “54_IMMO- Data of immobilizer and ECU are not —...
  • Page 451 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Fail-safe system Diagnos- Symptom Starting the Driving the tic code engine vehicle Intake air pressure sensor 1: clogging of “P0106” hose or sensor installation improperly. Able Able Stable pressure is not supplied. [P0107] Intake air pressure sensor 1: short to ground circuit is detected.
  • Page 452 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Fail-safe system Diagnos- Symptom Starting the Driving the tic code engine vehicle [P0122] Throttle position sensor: short to ground circuit is detected. Normal signal is not received from the throttle position sensor circuit. [P0123] Throttle position sensor: open or short to power circuit is detected.
  • Page 453 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Fail-safe system Diagnos- Symptom Starting the Driving the tic code engine vehicle [P0300] Misfire in multiple cylinders. Large difference value in angular velocity of crankshaft. [P0301] Misfire in cylinder #1. Large dif- “P0300, ference value in angular velocity of Able/Unable Able/Unable P0301,...
  • Page 454 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Fail-safe system Diagnos- Symptom Starting the Driving the tic code engine vehicle [P0560] Battery charging voltage is ab- normal. Poor charging performance (dis- charged condition). Vehicle system power voltage is abnormal. (Regulator is not operated properly or battery is not “P0560, charged properly.) Able...
  • Page 455 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Fail-safe system Diagnos- Symptom Starting the Driving the tic code engine vehicle [P0916] Gear position sensor: open or short to ground circuit is detected. Nor- mal signal is not received from the gear “P0916, position sensor to ECU.
  • Page 456 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Fail-safe system Diagnos- Symptom Starting the Driving the tic code engine vehicle [P2122] Accelerator position sensor: open or short to ground circuit is detect- ed. Normal signal is not received from the accelerator position sensor. [P2123] Accelerator position sensor: short to power circuit is detected.

  • Page 457: 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 9-14. Probable cause of Fail-safe system Item Vehicle symptom malfunction operation 30_EVEN Overturn is detect- •...
  • Page 458 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 is de- carried out. teriorated. Normal • Defective coupler learning is not signal is not re- between O...
  • Page 459 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 in- not installed.
  • Page 460 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.
  • Page 461 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 short to ground cir- perature sensor cir-...
  • Page 462 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 Radiator fan motor ture sensor: signal between coolant start. relay is ON only out of range. Normal temperature sen- Increased exhaust when the vehicle is...
  • Page 463 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Probable cause of Fail-safe system Item Vehicle symptom malfunction operation P0117 [P0117] Coolant [P0117] Low voltage Engine is difficult to Radiator fan motor P0118 temperature sensor: of the coolant tem- start. relay is ON only short to ground cir- perature sensor cir- Increased exhaust...
  • Page 464 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: short voltage of the throt- is high. tle opening is 0 P0222 to ground circuit is...
  • Page 465 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Probable cause of Fail-safe system Item Vehicle symptom malfunction operation P0132 sensor: short to High voltage of the feedback is not Increased exhaust sensor circuit emissions. power circuit is de- carried out. tected. Normal sig- (4.8 V or more) feedback learn- nal is not received...
  • Page 466 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Probable cause of Fail-safe system Item Vehicle symptom malfunction operation P0300 Misfire in multiple • Ignition system Engine is difficult to cylinders. Large dif- malfunction/abnor- start. ference value in an- Loss of engine pow- gular velocity of •...
  • Page 467 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Probable cause of Fail-safe system Item Vehicle symptom malfunction operation P0335 Crankshaft position • Defective coupler Engine cannot be Does not operate. sensor: normal sig- between crank- started. ISC feedback is not nals are not re- shaft position sen- carried out.
  • Page 468 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Probable cause of Fail-safe system Item Vehicle symptom malfunction operation P0480 Radiator fan motor • Open or short cir- Engine is difficult to Radiator fan motor relay: open or short cuit in wire har- start.
  • Page 469 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Probable cause of Fail-safe system Item Vehicle symptom malfunction operation P0563 Battery charging feedback is not • Battery overcharg- Engine is difficult to voltage is abnormal. ing (defective rec- start. carried out. Charging voltage is tifier/regulator).
  • Page 470 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Probable cause of Fail-safe system Item Vehicle symptom malfunction operation P0606 Processor error. In- • Malfunction in Engine cannot be Engine cannot be ternal malfunction in ECU (Processor started. started. ECU. (When this error). Engine response is Ignition and injec- malfunction is de-...
  • Page 471 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Probable cause of Fail-safe system Item Vehicle symptom malfunction operation P0657 Fuel system volt- • Open or short cir- Engine is difficult to Monitor voltage = 12 age: incorrect volt- cuit in wire har- start.
  • Page 472 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Probable cause of Fail-safe system Item Vehicle symptom malfunction operation P0916 [P0916] Gear posi- [P0916] Low voltage Improper display for Maintains the gear P0917 tion sensor: open or of the gear position gear position. position value at the short to ground cir- sensor circuit (0.2 V...
  • Page 473 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Probable cause of Fail-safe system Item Vehicle symptom malfunction operation P1500 Neutral switch: open • Open or short cir- Vehicle speed is not Vehicle speed dis- or short circuit is de- cuit in wire har- displayed on the played on the meter tected.
  • Page 474 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Probable cause of Fail-safe system Item Vehicle symptom malfunction operation P1601 Sidestand switch: • Defective coupler Engine cannot be Engine is forcefully open or short circuit between relay unit started. stopped (the injector in wire harness of and ECU.
  • Page 475 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Probable cause of Fail-safe system Item Vehicle symptom malfunction operation α–N is fixed. P1606 [P1606] Intake air • Defective coupler Engine is difficult to P1607 pressure sensor 2: between intake air start. Intake air pressure P1608 short to ground cir- pressure sensor 2...
  • Page 476 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Probable cause of Fail-safe system Item Vehicle symptom malfunction operation P2122 [P2122] Accelerator [P2122, P2127] Low Engine response is No change in accel- P2123 position sensor: voltage of the accel- poor. erator opening P2127 open or short to erator position sen- Loss of engine pow-...

  • Page 477: Self-Diagnostic Function Table (For Immobilizer System)

    SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Probable cause of Fail-safe system Item Vehicle symptom malfunction operation P2195 sensor: open cir- Low voltage of the feedback is not Increased exhaust sensor circuit emissions. cuit is detected. carried out. Normal signal is not (0.18–0.49 V).

  • Page 478: Self-Diagnostic Function Table (For Abs (Anti-Lock Brake System))

    SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE EAS33286 SELF-DIAGNOSTIC FUNCTION TABLE (FOR ABS (Anti-lock Brake System)) For details of the DTC, refer to “BASIC INSTRUCTIONS FOR TROUBLESHOOTING” on page 9-37. Item Symptom Check point Front wheel sensor (inter- Front wheel sensor signal •...
  • Page 479 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Item Symptom Check point Front wheel sensor (open Open or short circuit is de- • Defective coupler be- or short circuit) tected in the front wheel tween the front wheel sensor. sensor and the hydraulic unit assembly (ABS ECU) •...
  • Page 480 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Item Symptom Check point Hydraulic unit assembly Power is not supplied to • Blown ABS motor fuse (ABS ECU) (abnormal the motor circuit in the hy- • Defective coupler be- ABS motor power supply) draulic unit assembly tween the battery and the (ABS ECU).
  • Page 481 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Item Symptom Check point Rear wheel sensor (miss- Rear wheel sensor signal • Foreign material ad- ing pulses) is not received properly. hered around the rear (Missing pulses are de- wheel sensor tected in the signal while •...
  • Page 482 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Item Symptom Check point Defective hydraulic unit Abnormality detected in In case of electrical inter- assembly (ABS ECU) (de- pressure sensor circuit at locking brake fective front pressure sen- front caliper side of hy- •...

  • Page 483: Communication Error With The Meter

    SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE 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 switching: (YDT) function meter: sig- tween the ECU and play.
  • Page 484 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Diagnostic Item Tool display Procedure code No. Intake air temperature Displays the intake air Compare the actually temperature. measured air temperature -30–120°C with the tool display value. When engine is cold: Dis- plays temperature closer to air temperature.
  • Page 485 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Diagnostic Item Tool display Procedure code No. Accelerator position sen- 0–125 sor signal 2 • Fully closed position 14–18 Check with throttle grip ful- ly closed position. • Fully opened position 82–92 Check with throttle grip ful- ly opened position.
  • Page 486 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Diagnostic Item Tool display Procedure code No. EEPROM DTC display — • No history • No malfunctions detect- ed (If the DTC P062F is indicated, the ECU is de- fective.) • History exists 01–03 (CO adjustment val- •...
  • Page 487 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Diagnostic Item Tool display Procedure code No. Cruise control cancel cir- Operate the clutch lever, cuit brake lever and brake ped- • Clutch lever is squeezed ON • Clutch lever is released • Brake lever is squeezed •...
  • Page 488 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE EAS33032 DIAGNOSTIC CODE: ACTUATOR OPERATION TABLE Diagnostic Item Actuation Procedure code No. Cylinder-#1 ignition coil Actuates the cylinder-#1 Check that a spark is gen- ignition coil five times at erated five times. one-second intervals. •...
  • Page 489 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Diagnostic Item Actuation Procedure code No. Relay unit Actuates the relay unit five Check that the relay unit is times at one-second inter- actuated five times by lis- vals. tening for the operating The “check” indicator on sound.

  • Page 490: 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 1 detected in the in-...
  • Page 491 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 492 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 493: 30_Event

    30_EVENT EAS20552 30_EVENT EAS33033 TROUBLESHOOTING Item Overturn is 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 494 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 8-41. 9-88...

  • Page 495: 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 496: C0520

    C0520 EAS20560 C0520 EAS33319 TROUBLESHOOTING Item Abnormal IMU: Normal signal is not received from the IMU or failure signal is received from IMU. Fail-safe system • Able/Unable to start engine (depending on the situation) • Able/Unable to drive vehicle (depending on the situation) Procedure 1.
  • Page 497 C0520 blue/white–blue/white Between ECU coupler “1” and joint coupler “2” blue/black–blue/black blue/white–blue/white Between joint coupler “2” and IMU coupler “3” blue/black–blue/black Between IMU coupler “3” and ground black/white–ground Between ignition fuse 2 holder “4” and IMU cou- red/white–red/white pler “3” Lg/L Br/L Gy/G...
  • Page 498 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 Br/L Gy/G...
  • Page 499 C0520 5. Defective IMU. • Replace the IMU. Refer to “GENERAL CHASSIS (1)” on page 4-1. • Turn the main switch to “ON”, and then check the DTC using the malfunction mode of the YDT. Is it in the “Recovered” condition? →...

  • Page 500: P0030

    P0030 EAS20397 P0030 EAS33134 TROUBLESHOOTING Item sensor heater: defective heater or heater driver ON/OFF command and error signal is mismatching. 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 501 P0030 Is it in the “Recovered” condition? → Go to step 6, and complete the service. → Start the engine, and then check the DTC. Is it in the “Recovered” condition? → Go to step 6, and complete the service. →...
  • Page 502 P0030 For this check, also set the stop/run/start switch to “ON”. • 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” red–ground Between O sensor coupler “1”...
  • Page 503 P0030 Is it in the “Recovered” condition? → Go to step 6, and complete the service. → Start the engine, and then check the DTC. Is it in the “Recovered” condition? → Go to step 6, and complete the service. →...

  • Page 504: P00D1, P2195

    P00D1, P2195 EAS20660 P00D1, P2195 EAS33115 TROUBLESHOOTING Item • [P00D1] O sensor: heater performance is deteriorated. Normal signal is not received from the O sen- sor while driving the O sensor heater. • [P2195] O sensor: open circuit is detected. Normal signal is not received from the O sensor.
  • Page 505 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 506 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 507 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 7-11. Is check result OK? →...

  • Page 508: P0105

    P0105 EAS20420 P0105 EAS32838 TROUBLESHOOTING Item Intake air pressure sensor 1: signal out of range. Normal signal is not received from the intake air pres- sure sensor 1 circuit. 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 509 P0105 4. Malfunction in ECU. • Replace the ECU, and complete the service. Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-41. 5. 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. 9-103...

  • Page 510: P0106

    P0106 EAS20421 P0106 EAS32840 TROUBLESHOOTING Item Intake air pressure sensor 1: clogging of hose or sensor installation improperly. Stable pressure is not supplied. 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 511 P0106 Is check result OK? → Go to step 3, and complete the service. a. Replace the intake air pressure sensor 1. Refer to “THROTTLE BODIES” on page 7-6. b. Start the engine and let it idle for approximately 5 seconds with the throttle fully closed, and then check the DTC using the malfunction mode of the YDT.

  • Page 512: P0107, P0108

    P0107, P0108 EAS20567 P0107, P0108 EAS33047 TROUBLESHOOTING Item • [P0107] Intake air pressure sensor 1: short to ground circuit is detected. Normal signal is not received from the intake air pressure sensor 1 circuit. • [P0108] Intake air pressure sensor 1: open or short to power circuit is detected. Normal signal is not received from the intake air pressure sensor 1 circuit.
  • Page 513 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 514 P0107, P0108 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 Intake air pressure sensor 1 coupler “1” [P0107, P0108] pink/white–any other coupler terminal [P0108] black/blue–any other coupler terminal...
  • Page 515 P0107, P0108 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 DTC using the malfunction mode of the YDT. Is it in the “Recovered” condition? →...

  • Page 516: P0110

    P0110 EAS20426 P0110 EAS32845 TROUBLESHOOTING Item Intake air temperature sensor: signal stuck. Normal signal is not received from the intake air tempera- ture sensor circuit. Fail-safe system • Able to start engine • Able to drive vehicle Procedure • Perform this procedure when the engine is cold. •...
  • Page 517 P0110 Is it in the “Recovered” condition? → Go to step 4, and complete the service. → 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 8-41. 4.

  • Page 518: P0111

    P0111 EAS20425 P0111 EAS32844 TROUBLESHOOTING Item Intake air temperature sensor: signal out of range. Normal signal is not received from the intake air tem- perature sensor circuit. Fail-safe system • Able to start engine • Able to drive vehicle Procedure •...
  • Page 519 P0111 3. Installed condition of intake air temperature sensor. • Check for looseness or pinching. Refer to “GENERAL CHASSIS (5)” on page 4-11. Is check result OK? → Go to step 4. a. Reinstall or replace the sensor. b. Execute the diagnostic mode. (Code 05) •...
  • Page 520 P0111 6. Malfunction in ECU. • Replace the ECU, and complete the service. Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-41. 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. 9-114...

  • Page 521: P0112, P0113

    P0112, P0113 EAS20568 P0112, P0113 EAS33048 TROUBLESHOOTING Item • [P0112] Intake air temperature sensor: short to ground circuit is detected. Normal signal is not re- ceived from the intake air temperature sensor circuit. • [P0113] Intake air temperature sensor: open or short to power circuit is detected. Normal signal is not received from the intake air temperature sensor circuit.
  • Page 522 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- [P0112, P0113] brown/white–brown/white perature sensor coupler “1”...
  • Page 523 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 524 P0112, P0113 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 DTC using the malfunction mode of the YDT. Is it in the “Recovered” condition? →...

  • Page 525: P0115

    P0115 EAS20424 P0115 EAS32843 TROUBLESHOOTING Item Coolant temperature sensor: signal stuck. Normal signal is not received from the coolant temperature sensor circuit. Fail-safe system • Able to start engine • Able to drive vehicle Procedure • Perform this procedure when the engine is cold. •...

  • Page 526: P0116

    P0116 EAS20423 P0116 EAS32842 TROUBLESHOOTING Item Coolant temperature sensor: signal out of range. Normal signal is not received from the coolant tem- perature sensor circuit. Fail-safe system • Able to start engine • Able to drive vehicle Procedure • Perform this procedure when the engine is cold. •...
  • Page 527 P0116 3. Installed condition of coolant temperature sensor. • Check for looseness or pinching. Refer to “CYLINDER HEAD” on page 5-27. Is check result OK? → Go to step 4. a. Reinstall or replace the sensor. b. Execute the diagnostic mode. (Code 06) •...
  • Page 528 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 8-41. 7.

  • Page 529: P0117, P0118

    P0117, P0118 EAS20569 P0117, P0118 EAS33049 TROUBLESHOOTING Item • [P0117] Coolant temperature sensor: short to ground circuit is detected. Normal signal is not received from the coolant temperature sensor circuit. • [P0118] Coolant temperature sensor: open or short to power circuit is detected. Normal signal is not received from the coolant temperature sensor circuit.
  • Page 530 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 531 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 532 P0117, P0118 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 DTC using the malfunction mode of the YDT. Is it in the “Recovered” condition? →...

  • Page 533: P0122, P0123, P0222, P0223

    P0122, P0123, P0222, P0223 EAS20813 P0122, P0123, P0222, P0223 EAS33050 TROUBLESHOOTING Item • [P0122] Throttle position sensor: short to ground circuit is detected. Normal signal is not received from the throttle position sensor circuit. • [P0123] Throttle position sensor: open or short to power circuit is detected. Normal signal is not re- ceived from the throttle position sensor circuit.
  • Page 534 P0122, P0123, P0222, P0223 3. Wire harness continuity. • Disconnect the throttle position sensor coupler “1” and ECU coupler “2”. • Open circuit check [P0122, P0123, P0222, P0223] white–white Between throttle position sensor coupler “1” and [P0123, P0223] black/blue–black/blue ECU coupler “2” [P0122, P0222] blue–blue [P0122, P0123, P0222, P0223] black–black Br/Y...
  • Page 535 P0122, P0123, P0222, P0223 Ground short circuit check “A” [P0122, P0123, P0222, P0223] white–ground Between throttle position sensor coupler “1” and [P0122, P0222] blue–ground ground [P0122, P0123, P0222, P0223] black–ground Lines short circuit check “B” [P0122, P0123, P0222, P0223] white–any other coupler terminal [P0123, P0223] black/blue–any other coupler Throttle position sensor coupler “1”...
  • Page 536 P0122, P0123, P0222, P0223 4. Installed condition of throttle position sensor. • Check for looseness or pinching. Refer to “ADJUSTING THE THROTTLE POSITION SENSOR” on page 7-12. Is check result OK? → Go to step 5. a. Reinstall or adjust the sensor. b.
  • Page 537 P0122, P0123, P0222, P0223 Is it in the “Recovered” condition? → Go to step 8, and complete the service. → Go to step 7. 7. Malfunction in ECU. • Replace the ECU, and complete the service. Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-41. 8.

  • Page 538: P0132

    P0132 EAS20571 P0132 EAS33051 TROUBLESHOOTING Item sensor: short to power circuit is detected. Normal signal is not received from the O sensor. Fail-safe system • Able to start engine • Able to drive vehicle Procedure 1. Installed condition of O sensor.
  • Page 539 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 DTC using the malfunction mode of the YDT. Is it in the “Recovered”...
  • Page 540 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 541 P0132 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 DTC using the malfunction mode of the YDT. Is it in the “Recovered” condition? →...

  • Page 542: P0133

    P0133 EAS20767 P0133 • O sensor: deterioration is detected. O sensor output signal response speed is slow. 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.

  • Page 543: Fail-Safe System

    P0133 EAS33153 FAIL-SAFE SYSTEM • Able to start engine • Able to drive vehicle 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.

  • Page 544: P0134

    P0134 EAS20414 P0134 EAS32834 TROUBLESHOOTING Item sensor: signal stuck. O sensor signal value does not change. 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 545 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 7-11. Is check result OK? →...

  • Page 546: P0201

    P0201 EAS20574 P0201 EAS33054 TROUBLESHOOTING Item Injector #1: malfunction in injector #1. Normal signal is not received from the injector circuit. Fail-safe system • Able to start engine (depending on the number of faulty cylinder) • Able to drive vehicle (depending on the number of faulty cylinder) Procedure 1.
  • Page 547 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 548 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 549: P0202

    P0202 EAS20575 P0202 EAS33055 TROUBLESHOOTING Item Injector #2: malfunction in injector #2. Normal signal is not received from the injector circuit. Fail-safe system • Able to start engine (depending on the number of faulty cylinder) • Able to drive vehicle (depending on the number of faulty cylinder) Procedure 1.
  • Page 550 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 551 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 552: P0203

    P0203 EAS20576 P0203 EAS33056 TROUBLESHOOTING Item Injector #3: malfunction in injector #3. Normal signal is not received from the injector circuit. Fail-safe system • Able to start engine (depending on the number of faulty cylinder) • Able to drive vehicle (depending on the number of faulty cylinder) Procedure 1.
  • Page 553 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 554 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 555: Outline

    P0300, P0301, P0302, P0303 EAS20773 P0300, P0301, P0302, P0303 • [P0300] Misfire in multiple cylinders. Large difference value in angular velocity of crankshaft. • [P0301] Misfire in cylinder #1. Large difference value in angular velocity of crankshaft. • [P0302] Misfire in cylinder #2. Large difference value in angular velocity of crankshaft. •...

  • Page 556: 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 557 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 558 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 559: P0335

    P0335 EAS20578 P0335 EAS33058 TROUBLESHOOTING Item Crankshaft position sensor: normal signals are not 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 560 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 Lg/B L/B W L/B L/B L/B B L/B L/B L/B L/B B B/L B B B B B L/B L/B L/B...
  • Page 561 P0335 Gy B Gy B Lg/L Br/L Gy/G Br/W Lg/B 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 Is resistance ∞ Ω? → Go to step 4. a. Replace the wire harness. b.
  • Page 562 P0335 Is check result OK? → Go to step 6. a. Replace the stator coil assembly. Refer to “GENERATOR AND STARTER CLUTCH” on page 5-37. b. Crank the engine, and then check the DTC using the malfunction mode of the YDT. Is it in the “Recovered”...

  • Page 563: P0351

    P0351 EAS20580 P0351 EAS33060 TROUBLESHOOTING Item Cylinder-#1 ignition coil: open or short circuit is detected in the primary lead of the cylinder-#1 ignition coil. Normal signal is not received from the ignition circuit. Fail-safe system • Able to start engine (depending on the number of faulty cylinder) •...
  • Page 564 P0351 3. Wire harness continuity. • Disconnect the cylinder-#1 ignition coil coupler “1” and ECU coupler “2”. • Open circuit check Between cylinder-#1 ignition coil coupler “1” and orange–orange ECU coupler “2” Gy/R Lg/R O R/W Is resistance 0 Ω? →...
  • Page 565 P0351 Gy/R O R/W O R/W Lg/R 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 DTC using the malfunction mode of the YDT. Is it in the “Recovered”...
  • Page 566 P0351 Is check result OK? → Go to step 6. a. Replace the cylinder-#1 ignition coil. Refer to “CAMSHAFTS” on page 5-16. b. Start the engine and let it idle for approximately 5 seconds. c. Check the DTC using the malfunction mode of the YDT. Is it in the “Recovered”...

  • Page 567: P0352

    P0352 EAS20581 P0352 EAS33061 TROUBLESHOOTING Item Cylinder-#2 ignition coil: open or short circuit is detected in the primary lead of the cylinder-#2 ignition coil. Normal signal is not received from the ignition circuit. Fail-safe system • Able to start engine (depending on the number of faulty cylinder) •...
  • Page 568 P0352 3. Wire harness continuity. • Disconnect the cylinder-#2 ignition coil coupler “1” and ECU coupler “2”. • Open circuit check Between cylinder-#2 ignition coil coupler “1” and gray/red–gray/red ECU coupler “2” Gy/R Lg/R Gy/R R/W Is resistance 0 Ω? →...
  • Page 569 P0352 Gy/R Gy/R R/W Gy/R R/W Lg/R 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 DTC using the malfunction mode of the YDT. Is it in the “Recovered”...
  • Page 570 P0352 Is check result OK? → Go to step 6. a. Replace the cylinder-#2 ignition coil. Refer to “CAMSHAFTS” on page 5-16. b. Start the engine and let it idle for approximately 5 seconds. c. Check the DTC using the malfunction mode of the YDT. Is it in the “Recovered”...

  • Page 571: P0353

    P0353 EAS20582 P0353 EAS33062 TROUBLESHOOTING Item Cylinder-#3 ignition coil: open or short circuit is detected in the primary lead of the cylinder-#3 ignition coil. Normal signal is not received from the ignition circuit. Fail-safe system • Able to start engine (depending on the number of faulty cylinder) •...
  • Page 572 P0353 3. Wire harness continuity. • Disconnect the cylinder-#3 ignition coil coupler “1” and ECU coupler “2”. • Open circuit check Between cylinder-#3 ignition coil coupler “1” and orange/green–orange/green ECU coupler “2” Gy/R Lg/R O/G R/W Is resistance 0 Ω? →...
  • Page 573 P0353 O/G R/W O/G R/W Gy/R Lg/R 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 DTC using the malfunction mode of the YDT. Is it in the “Recovered”...
  • Page 574 P0353 Is check result OK? → Go to step 6. a. Replace the cylinder-#3 ignition coil. Refer to “CAMSHAFTS” on page 5-16. b. Start the engine and let it idle for approximately 5 seconds. c. Check the DTC using the malfunction mode of the YDT. Is it in the “Recovered”...

  • Page 575: P0458

    P0458 EAS20785 P0458 EAS33528 TROUBLESHOOTING Item Purge cut valve solenoid: open circuit is detected. PCV solenoid is not operated. Fail-safe system • Able to start engine • Able to drive vehicle Procedure 1. Connection of purge cut valve solenoid coupler. •...
  • Page 576 P0458 Between ignition fuse 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 holder “1” Gy/R Lg/R Br/L Is resistance 0 Ω? →...
  • Page 577 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 DTC using the malfunction mode of the YDT. Is it in the “Recovered” condition? →...
  • Page 578 P0458 Is it hear operating 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 8-50. Is check result OK? → Go to step 6. a.

  • Page 579: P0480

    P0480 EAS20585 P0480 EAS33065 TROUBLESHOOTING Item Radiator fan motor relay: open or short circuit is detected. Normal signal is not received from the radi- ator fan motor relay. Fail-safe system • Able to start engine • Able to drive vehicle Procedure 1.
  • Page 580 P0480 3. Wire harness continuity. • Disconnect the radiator fan motor relay “1”, ECU coupler “2” and ignition fuse “3”. • Open circuit check Between radiator fan motor relay “1” and igni- red–red tion fuse holder “3” Between radiator fan motor relay “1” and ECU green/yellow–green/yellow coupler “2”...
  • Page 581 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 DTC using the malfunction mode of the YDT. Is it in the “Recovered” condition? →...

  • Page 582: P0500, P1500

    P0500, P1500 EAS20774 P0500, P1500 EAS33303 TROUBLESHOOTING Item • [P0500] Rear wheel sensor: open or short circuit is detected. Normal signal is not received from the rear wheel sensor or hydraulic unit assembly (ABS ECU) to ECU. • [P1500] Neutral switch: open or short circuit is detected. Normal signal is not received from the rear wheel sensor to ECU when the gear–in.
  • Page 583 P0500, P1500 When the transmission is in gear with the clutch lever squeezed and the sidestand retracted Is check result OK? → Go to step 20. → Go to step 15. Perform the procedure from step 14 to step 20. 2.
  • Page 584 P0500, P1500 4. 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 5. a.
  • Page 585 P0500, P1500 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 586 P0500, P1500 Is that value increased? → Go to step 20. → Go to step 7. 7. Malfunction in hydraulic unit assembly (ABS ECU). • Replace the hydraulic unit assembly (ABS ECU). Refer to “ABS (ANTI-LOCK BRAKE SYSTEM)” on page 4-52. •...
  • Page 587 P0500, P1500 10.Wire harness continuity. • Disconnect the relay unit coupler “1”, ECU coupler “2” and neutral switch coupler “3”. • Remove the joint coupler cap “4”. • Open circuit check Between relay unit coupler “1” and joint coupler black–black/yellow “4”...
  • Page 588 P0500, P1500 Ground short circuit check “A” black–ground Between relay unit coupler “1” and ground sky blue–ground Lines short circuit check “B” black–any other coupler terminal Relay unit coupler “1” sky blue–any other coupler terminal ECU coupler “2” black/yellow–any other coupler terminal L/W R W L/W R L/B L B Sb/W...
  • Page 589 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 20. → Go to step 12. 12.Faulty shift drum (neutral detection area). • Check the shift drum. Refer to “CHECKING THE SHIFT DRUM ASSEMBLY”...
  • Page 590 P0500, P1500 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 the sidestand is retracted Is it correct indication? →...
  • Page 591 P0500, P1500 L/W R W L/W R L/B L B Sb/W Lg/L Br/L Gy/G Br/W Lg/B Y/B B/Y Y/W L/Y Is resistance 0 Ω? → Go to “Short circuit check”. a. Replace the wire harness. 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 592 P0500, P1500 L/W R Y/B B/Y W L/W R L/B L B Sb/W Y/W L/Y L/W R W L/W R L/B L B Sb/W Lg/L Br/L Gy/G Br/W Lg/B Is resistance ∞ Ω? → Go to step 18. a. Replace the wire harness. b.
  • Page 593 P0500, P1500 Is it correct indication? → Go to step 20. → Go to step 19. 19.Malfunction in ECU. • Replace the ECU, and complete the service. Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-41. 20.Delete the DTC and check that the MIL goes off. •...

  • Page 594: P0560, P0563

    P0560, P0563 EAS20434 P0560, P0563 EAS33304 TROUBLESHOOTING Item • [P0560] Battery charging voltage is abnormal. Poor charging performance (discharged condition). Ve- hicle system power voltage is abnormal. (Regulator is not operated properly or battery is not charged properly.) • [P0563] Battery charging voltage is abnormal. Charging voltage is not within range (overcharged con- dition).

  • Page 595: P0564

    P0564 EAS20594 P0564 EAS33074 TROUBLESHOOTING Item • Cruise control setting switch “RES+”: open or short circuit is detected. Normal signal is not sent to ECU. • Cruise control setting switch “SET–”: open or short circuit is detected. Normal signal is not sent to ECU.
  • Page 596 P0564 c. Confirm that it is defective. d. Go to step 6. Perform the procedure from step 6 to step 10. 3. Check the fuse. • Check the ignition fuse and cruise control fuse. Is check result OK? →Go to step 4. a.
  • Page 597 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 DTC using the malfunction mode of the YDT.
  • Page 598 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). Refer to “HANDLEBAR” on page 4-60. • Turn the main switch to “ON”. •...
  • Page 599 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 DTC using the malfunction mode of the YDT.
  • Page 600 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 DTC using the malfunction mode of the YDT.

  • Page 601: P056C

    P056C EAS20595 P056C EAS33075 TROUBLESHOOTING Item • Front brake light switch: open or short circuit is detected. Normal signal is not sent to ECU. • Rear brake light switch: open or short circuit is detected. Normal signal is not sent to ECU. Fail-safe system •...
  • Page 602 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 603 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 DTC using the malfunction mode of the YDT. Is it in the “Recovered”...
  • Page 604 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 DTC using the malfunction mode of the YDT. Is it in the “Recovered” condition? →Go to step 11, and complete the service.
  • Page 605 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 DTC using the malfunction mode of the YDT. Is it in the “Recovered”...
  • Page 606 P056C Is it in the “Recovered” condition? →Go to step 11, 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 607 P056C Is it in the “Recovered” condition? →Go to step 11, and complete the service. →Go to step 9. 9. Defective rear brake light switch. • Replace the rear brake light switch. Refer to “REAR BRAKE” on page 4-40. Is check result OK? →Go to step 10.

  • Page 608: P0601

    P0601 EAS20676 P0601 EAS33305 TROUBLESHOOTING Item ROM error. 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 609: P0606

    P0606 EAS20677 P0606 EAS33306 TROUBLESHOOTING Item Processor error. 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 (depending on the situation) •...

  • Page 610: 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 (depending on the situation) • Able/Unable to drive vehicle (depending on the situation) Procedure 1. Locate the malfunction. •...
  • Page 611 P062F 4. “03” is indicated in diagnostic mode (Code 60). 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 612: P0638

    P0638 EAS20599 P0638 EAS33079 TROUBLESHOOTING Item YCC-T drive system: malfunction detected. Fail-safe system • Able/Unable to start engine (depending on the situation) • Able/Unable to drive vehicle (depending on the situation) Procedure 1. Connection of throttle servo motor coupler. • Check the locking condition of the coupler. •...
  • Page 613 P0638 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 DTC using the malfunction mode of the YDT. Is it in the “Recovered” condition? →...
  • Page 614 P0638 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” light green/red–any other coupler terminal yellow/red–any other coupler terminal ECU coupler “2” light green/red–any other coupler terminal red/blue–any other coupler terminal Y/R Lg/R...
  • Page 615 P0638 6. Malfunction in ECU. • Replace the ECU, and complete the service. Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-41. 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. 9-209...

  • Page 616: P0657

    P0657 EAS20601 P0657 EAS33081 TROUBLESHOOTING Item Fuel system voltage: incorrect voltage supplied to the injector, fuel pump and relay unit. 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 617 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 618 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 DTC using the malfunction mode of the YDT. Is it in the “Recovered” condition? →...
  • Page 619 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 DTC using the malfunction mode of the YDT. Is it in the “Recovered” condition? →...

  • Page 620: P0914

    P0914 EAS20417 P0914 EAS32837 TROUBLESHOOTING Item Gear position sensor: signal stuck and sensor signal does not change. 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 621 P0914 Is the resistance change? → Go to step 3. a. Replace the gear position sensor. Refer to “CRANKCASE” on page 5-64. b. Make sure that the position of each gear is correctly displayed on the meter. Is check result OK? →...

  • Page 622: P0915

    P0915 EAS20416 P0915 EAS32836 TROUBLESHOOTING Item Gear position sensor: out of control signal range and normal signal is not received from the gear posi- tion sensor to ECU. 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 623 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 624: P0916, P0917

    P0916, P0917 EAS20611 P0916, P0917 EAS33091 TROUBLESHOOTING Item • [P0916] Gear position sensor: open or short to ground circuit is detected. Normal signal is not received from the gear position sensor to ECU. • [P0917] Gear position sensor: short to power circuit is detected. Normal signal is not received from the gear position sensor to ECU.
  • Page 625 P0916, P0917 3. Wire harness continuity. • Disconnect the gear position sensor coupler “1” and ECU coupler “2”. • Open circuit check 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 Br/L Gy/G Br/W...
  • Page 626 P0916, P0917 L G/W B/L L G/W B/L Lg/L Br/L Gy/G Br/W Lg/B Is resistance ∞ Ω? → Go to step 4. a. Replace the wire harness. b. Turn the main switch to “ON”, and then check the DTC using the malfunction mode of the YDT. Is it in the “Recovered”...
  • Page 627 P0916, P0917 Is it in the “Recovered” condition? → 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 8-41. 7.

  • Page 628: P1004

    P1004 EAS20786 P1004 EAS33529 TROUBLESHOOTING Item Intake air pressure sensor 1 and intake air pressure sensor 2: When the main switch is “ON”, the stan- dard voltage values of Intake air pressure sensor 1 and intake air pressure sensor 2 are large different. Fail-safe system •...
  • Page 629 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 630: P1600

    P1600 EAS20613 P1600 EAS33093 TROUBLESHOOTING Item Lean angle sensor: open or short circuit is detected. Normal signal is not received from IMU or defective IMU. 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 631 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 632 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 633 P1600 Is check result OK? → Go to step 5. a. Fix the IMU installation condition. b. Turn the main switch to “ON. c. Check the DTC using the malfunction mode of the YDT. Is it in the “Recovered” condition? →...

  • Page 634: P1601

    P1601 EAS20614 P1601 EAS33094 TROUBLESHOOTING Item Sidestand switch: open or short circuit in wire harness of the ECU is detected. Normal signal is not re- ceived from the sidestand switch. Fail-safe system • Unable to start engine • Unable to drive vehicle Procedure 1.
  • Page 635 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 DTC using the malfunction mode of the YDT. Is it in the “Recovered”...
  • Page 636 P1601 Disconnect the ECU related connectors before checking. Refer to “PARTS CONNECTED TO THE ECU” on page 9-4. Ground short circuit check “A” blue–ground Between relay unit coupler “1” and ground blue/black–ground Lines short circuit check “B” blue–any other coupler terminal Relay unit coupler “1”...
  • Page 637 P1601 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. Check the DTC using the malfunction mode of the YDT. Is it in the “Recovered”...

  • Page 638: 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 (depending on the situation) • Able/Unable to drive vehicle (depending on the situation) Procedure 1. Installed condition of battery leads. •...
  • Page 639 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 DTC using the malfunction mode of the YDT. Is it in the “Recovered”...
  • Page 640 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 DTC using the malfunction mode of the YDT. Is it in the “Recovered” condition? →...
  • Page 641 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 DTC using the malfunction mode of the YDT. Is it in the “Recovered”...

  • Page 642: P1606, P1607

    P1606, P1607 EAS20787 P1606, P1607 EAS33530 TROUBLESHOOTING Item • [P1606] Intake air pressure sensor 2: short to ground circuit is detected. Normal signal is not received from the intake air pressure sensor 2 circuit. • [P1607] Intake air pressure sensor 2: open or short to power circuit is detected. Normal signal is not received from the intake air pressure sensor 2 circuit.
  • Page 643 P1606, P1607 3. Wire harness continuity. • Disconnect the intake air pressure sensor 2 coupler “1” and ECU coupler “3”. • Remove the joint coupler cap “2”. • Open circuit check Between ECU coupler “3” and joint coupler “2” [P1607] black/blue–black/blue Between ECU coupler “3”...
  • Page 644 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 645 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 DTC using the malfunction mode of the YDT. Is it in the “Recovered” condition? →...

  • Page 646: P1608

    P1608 EAS20788 P1608 EAS33531 TROUBLESHOOTING Item Intake air pressure sensor 2: signal out of range. Normal signal is not received from the intake air pres- sure sensor 2 circuit. 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 647 P1608 4. Malfunction in ECU. • Replace the ECU, and complete the service. Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-41. 5. 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. 9-241...

  • Page 648: P1609

    P1609 EAS20789 P1609 EAS33532 TROUBLESHOOTING Item Intake air pressure sensor 2: clogging of hose or sensor installation improperly. Stable pressure is not supplied. 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 649 P1609 • When engine is cranking: Make sure that the indication value changes. 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 7-6 b.

  • Page 650: P1806, P1807

    P1806, P1807 EAS20623 P1806, P1807 EAS33103 TROUBLESHOOTING Item • [P1806] Shift sensor: open or short to ground circuit is detected. Normal signal is not received from the shift sensor to ECU. • [P1807] Shift sensor: short to power circuit is detected. Normal signal is not received from the shift sensor to ECU.
  • Page 651 P1806, P1807 3. Wire harness continuity • Disconnect the shift sensor coupler “1” and ECU coupler “2”. • Remove the joint coupler cap “3”. • Open circuit check Between shift sensor coupler “1” and ECU cou- blue–blue pler “2” violet–violet Between shift sensor coupler “1”...
  • Page 652 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 653 P1806, P1807 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 auxiliary system warning. Is the auxiliary system warning “OFF”? →...

  • Page 654: 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 short to ground circuit is detected. Normal signal is not received from the accelerator position sensor. • [P2123] Accelerator position sensor: short to power circuit is detected. Normal signal is not received from the accelerator position sensor.
  • Page 655 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 656 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 657 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 DTC using the malfunction mode of the YDT. Is it in the “Recovered” condition? →...

  • Page 658: P2135

    P2135 EAS20812 P2135 EAS33652 TROUBLESHOOTING Item • Throttle position sensor: output voltage deviation error. Normal signal is not received from the throttle position sensor circuit. Fail-safe system • Able to start engine (depending on the situation) • Able to drive vehicle (depending on the situation) Procedure If more than one DTC is detected at the same time, perform troubleshooting of DTC listed below first.
  • Page 659 P2135 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 660 P2135 Is it in the “Recovered” condition? → Go to step 8, and complete the service. → Go to step 6. 6. Defective throttle position sensor. • Check throttle position sensor signal 2. • Execute the diagnostic mode. (Code 13) When the throttle valves are fully closed 9–23 When throttle valves are fully open...

  • Page 661: P2158

    P2158 EAS20633 P2158 EAS33113 TROUBLESHOOTING Item Front wheel sensor: normal signal is not 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 662 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 663 P2158 Is resistance 0 Ω? → Go to “Short circuit check”. a. 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 664 P2158 Is resistance ∞ Ω? → Go to step 7. a. 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 665 P2158 10.Delete the DTC and check that the MIL goes off. • Turn the main switch to “ON”, and then rotate the front wheel by hand. • Start the engine, and input the vehicle speed signals by operating the vehicle at 20 to 30 km/h (12 to 19 mph).

  • Page 666: 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 (depending on the situation) Procedure If more than one DTC is detected at the same time, perform troubleshooting of DTC listed below first. •...
  • Page 667 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 668 U0125 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” blue/black–any other coupler terminal blue/white–any other coupler terminal IMU coupler “3” blue/black–any other coupler terminal red/white–any other coupler terminal Lg/L Br/L Gy/G...

  • Page 669: 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. •...
  • Page 670 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 671 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 672 U0155 or Err 5. Malfunction in ECU. • Replace the ECU, and complete the service. Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-41. 6. 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. 9-266...

  • Page 673: 51_Immobilizer

    51_IMMOBILIZER EAS20680 51_IMMOBILIZER EAS33309 TROUBLESHOOTING Item Code cannot be transmitted between the key and 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 674: 52_Immobilizer

    52_IMMOBILIZER EAS20679 52_IMMOBILIZER EAS33308 TROUBLESHOOTING Item Code of immobilizer unit and key are not matched. Cause • Signal received from other transponder (failed to recognize code after ten consecutive attempts). • Signal received from unregistered standard key. • Immobilizer unit malfunction •...

  • Page 675: 53_Immobilizer

    53_IMMOBILIZER EAS20681 53_IMMOBILIZER EAS33310 TROUBLESHOOTING Item Code cannot be transmitted between the ECU and 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 676 53_IMMOBILIZER Y/L Lg Lg/L Br/L Gy/G Br/W Lg/B 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 “PARTS CONNECTED TO THE ECU” on page 9-4. Ground short circuit check “A”...
  • Page 677 53_IMMOBILIZER 4. Turn the main switch to “ON”. Is DTC displayed? → Go to step 5. → Service is completed. 5. Replace the main switch/immobilizer unit, ECU and all key, and complete the service. Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-41. 9-271...

  • Page 678: 54_Immobilizer

    54_IMMOBILIZER EAS20682 54_IMMOBILIZER EAS33311 TROUBLESHOOTING Item Data of immobilizer and ECU are not matched. Cause • Disconnected lead/cable. • Immobilizer unit malfunction. • ECU failure. (The ECU or immobilizer unit was replaced with a used unit from another vehicle.) • ECU malfunction. Procedure When a system malfunction occurs, the immobilizer system indicator light will flash.

  • Page 679: 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 680: 56_Immobilizer

    56_IMMOBILIZER EAS20684 56_IMMOBILIZER EAS33313 TROUBLESHOOTING Item Unidentified code is received. 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. The DTC can be identified by the flashing pattern.
  • Page 681 56_IMMOBILIZER Y/L Lg Lg/L Br/L Gy/G Br/W Lg/B 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 “PARTS CONNECTED TO THE ECU” on page 9-4. Ground short circuit check “A”...
  • Page 682 56_IMMOBILIZER 4. Turn the main switch to “ON”. Is DTC displayed? → Go to step 5. → Service is completed. 5. Replace the main switch/immobilizer unit, ECU and all key, and complete the service. Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-41. 9-276...

  • Page 683: 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 684: 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 685: 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 686: 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 687: 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 (ABS ECU) • Check the coupler for any pins that may be pulled out. •...
  • Page 688 15_ABS Ground short circuit check “A” yellow–ground Between ABS ECU coupler “1” and ground brown–ground 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 689: 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 (ABS ECU) • Check the coupler for any pins that may be pulled out. •...
  • Page 690 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 691: 21_Abs

    21_ABS EAS20690 21_ABS EAS33320 TROUBLESHOOTING Item Hydraulic unit assembly (ABS ECU) (defective solenoid drive circuit) Procedure 1. Defective hydraulic unit assembly (ABS ECU) • Replace the hydraulic unit assembly (ABS ECU). Refer to “ABS (ANTI-LOCK BRAKE SYSTEM)” on page 4-52. 9-285...

  • Page 692: 31_Abs

    31_ABS EAS20691 31_ABS EAS33321 TROUBLESHOOTING Hydraulic unit assembly (ABS ECU) (defective ABS solenoid power circuit) Procedure 1. Blown ABS solenoid fuse • Check the ABS solenoid fuse. Refer to “CHECKING THE FUSES” on page 8-40. Is check result OK? → Go to step 2. →...
  • Page 693 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 694: 33_Abs

    33_ABS EAS20692 33_ABS EAS33322 TROUBLESHOOTING Item Hydraulic unit assembly (ABS ECU) (abnormal ABS motor power supply) Procedure 1. Blown ABS motor fuse • Check the ABS motor fuse. Refer to “CHECKING THE FUSES” on page 8-40. Is check result OK? →...
  • Page 695 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 696: 34_Abs

    34_ABS EAS20693 34_ABS EAS33323 TROUBLESHOOTING Item Hydraulic unit assembly (ABS ECU) (short circuit in ABS motor power supply circuit) Procedure 1. Defective hydraulic unit assembly (ABS ECU) • Replace the hydraulic unit assembly (ABS ECU). Refer to “ABS (ANTI-LOCK BRAKE SYSTEM)” on page 4-52. 9-290...

  • Page 697: 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 698: 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 699: 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 700: 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 701: 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 8-41. 2.

  • Page 702: 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 8-41. 2.
  • Page 703 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 704: 55_Abs

    55_ABS EAS20700 55_ABS EAS33328 TROUBLESHOOTING Item Hydraulic unit assembly (ABS ECU) (defective ABS ECU) Procedure 1. Defective hydraulic unit assembly (ABS ECU) • Replace the hydraulic unit assembly (ABS ECU). Refer to “ABS (ANTI-LOCK BRAKE SYSTEM)” on page 4-52. 9-298...

  • Page 705: 56_Abs

    56_ABS EAS20701 56_ABS EAS33329 TROUBLESHOOTING Item Hydraulic unit assembly (ABS ECU) (abnormal internal circuit) Procedure 1. Defective hydraulic unit assembly (ABS ECU) • Replace the hydraulic unit assembly (ABS ECU). Refer to “ABS (ANTI-LOCK BRAKE SYSTEM)” on page 4-52. 9-299...

  • Page 706: 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 707 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 708 57_ABS 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 709 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 710: 62_Abs

    62_ABS EAS20702 62_ABS EAS33333 TROUBLESHOOTING Item Power supply voltage failure in pressure sensor Procedure 1. Defective hydraulic unit assembly (ABS ECU) • Replace the hydraulic unit assembly (ABS ECU). Refer to “ABS (ANTI-LOCK BRAKE SYSTEM)” on page 4-52. 9-304...

  • Page 711: 68_Abs

    68_ABS EAS20705 68_ABS EAS33336 TROUBLESHOOTING Item Defective hydraulic unit assembly (ABS ECU) (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 712: 89_Abs

    89_ABS EAS20669 89_ABS EAS33299 TROUBLESHOOTING Item CAN communication (between meter assembly and hydraulic unit assembly (ABS ECU)) Procedure 1. Defective coupler between the meter assembly and the hydraulic unit assembly (ABS ECU) • Check the coupler for any pins that may be pulled out. •...
  • Page 713 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 714 89_ABS 3. Defective meter assembly • Replace the meter assembly, and check again. 4. Defective hydraulic unit assembly (ABS ECU) • Replace the hydraulic unit assembly (ABS ECU). Refer to “ABS (ANTI-LOCK BRAKE SYSTEM)” on page 4-52. 9-308...

  • Page 715: 90_Abs

    90_ABS EAS20670 90_ABS EAS33300 TROUBLESHOOTING Item CAN communication (between ECU and hydraulic unit assembly (ABS ECU)) Procedure 1. Defective coupler between the ECU and the hydraulic unit assembly (ABS ECU) • Check the coupler for any pins that may be pulled out. •...
  • Page 716 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 717 90_ABS 3. Defective ECU • Replace the ECU, and check again. Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-41. 4. Defective hydraulic unit assembly (ABS ECU) • Replace the hydraulic unit assembly (ABS ECU). Refer to “ABS (ANTI-LOCK BRAKE SYSTEM)” on page 4-52. 9-311...

  • Page 718: 91_Abs

    91_ABS EAS20671 91_ABS EAS33301 TROUBLESHOOTING Item CAN communication (between IMU and hydraulic unit assembly (ABS ECU)) Procedure 1. Defective coupler between the IMU and the hydraulic unit assembly (ABS ECU) • Check the coupler for any pins that may be pulled out. •...
  • Page 719 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 720 91_ABS 3. Defective IMU • Replace the IMU, and check again. Refer to “GENERAL CHASSIS (1)” on page 4-1. 4. Defective hydraulic unit assembly (ABS ECU) • Replace the hydraulic unit assembly (ABS ECU). Refer to “ABS (ANTI-LOCK BRAKE SYSTEM)” on page 4-52. 9-314...
  • Page 721 58. Grip warmer (right) (OPTION) EAS20091 WIRING DIAGRAM 59. Throttle position sensor 60. Throttle servo motor MTM890 2022 61. Hydraulic unit assembly (ABS 1. AC magneto ECU) 2. Rectifier/regulator 62. Front wheel sensor 3. Fuse box 63. Rear wheel sensor 4.
  • Page 722 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 725 MTM890 2022 MTM890 2022 MTM890 2022 MTM890 2022 MTM890 2022 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 726 MTM890 2022 MTM890 2022 MTM890 2022 MTM890 2022 MTM890 2022 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 92 (Gy) (Gy) (Gy)

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