Yamaha TENERE 700 2023 Service Manual
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Yamaha TENERE 700 2023 Service Manual

Yamaha TENERE 700 2023 Service Manual

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2023
SERVICE MANUAL
TENERE 700
XTZ690D
XTZ690DP
BAG-F8197-E0

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Summary of Contents for Yamaha TENERE 700 2023

  • Page 1 2023 SERVICE MANUAL TENERE 700 XTZ690D XTZ690DP BAG-F8197-E0...
  • Page 3 It is not possible to include all the knowledge of a mechanic in one manual. Therefore, any- one 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. Please refer to “BA- SIC INFORMATION”...
  • Page 4 EAS20004 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. •...
  • Page 5 EAS20005 SYMBOLS The following symbols are used in this manual for easier understanding. The following symbols are not relevant to every vehicle. SYMBOL DEFINITION SYMBOL DEFINITION Serviceable with engine mounted Gear oil Filling fluid Molybdenum disulfide oil Lubricant Brake fluid Special tool Wheel bearing grease Tightening torque...

  • Page 7: Table Of Contents

    EAS10003 TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE COOLING SYSTEM FUEL SYSTEM ELECTRICAL SYSTEM SELF DIAGNOSTIC...

  • Page 9: General Information

    GENERAL INFORMATION IDENTIFICATION ....................1-1 VEHICLE IDENTIFICATION NUMBER ............1-1 MODEL LABEL ..................1-1 FEATURES ......................1-2 DISPLAY....................1-2 SPECIAL TOOLS ..................1-11...

  • 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 or- der spare parts.

  • Page 11: Features

    FEATURES EAS20008 FEATURES 9 10 EAS31707 DISPLAY The main screen of the display has three differ- ent themes; Explorer, Street, and Raid. Some functions are not available in all themes. EWA18210 WARNING Stop the vehicle before making any setting changes. Changing settings while riding can distract the operator and increase the risk of an accident.
  • Page 12 FEATURES Raid theme Fuel meter The fuel meter indicates the amount of fuel in the fuel tank. The display segments of the meter disappear from “F” (full) towards “E” (empty) as the fuel level decreases. When the last segment starts flashing, refuel as soon as possible.
  • Page 13 FEATURES Turn signal indicators “ ”/“ ” Each indicator flashes when its corresponding If a malfunction is detected, the oil pressure turn signal lights are flashing. warning icon will flash repeatedly. ABS mode indicator ECA26410 This indicator shows the currently selected ABS mode.
  • Page 14 FEATURES Incoming call indicator Incoming message indicator 1. Incoming call indicator 1. Incoming message indicator 1. Incoming call indicator 1. Incoming message indicator The incoming call indicator pops up when the The incoming message indicator pops up when connected smartphone receives a call. It will re- the connected smartphone receives an SMS, E- main on for 30 seconds.
  • Page 15 FEATURES Raid tripmeters (Raid theme only) The odometer shows the total distance traveled “R-TRIP 1” and “R-TRIP 2” show the distance by the vehicle. traveled since they were last set to zero. Short press the “RESET” switch to cycle between “R- The odometer will lock at 999999 km (621370 TRIP 1”...
  • Page 16 FEATURES When the fuel tank reserve level has been • Rotate the “ ” wheel switch to cycle/select reached, “TRIP F” appears automatically and different items or adjust flashing item values. begins recording distance traveled from that • Short press the “ ”...
  • Page 17 FEATURES This menu allows you to turn the anti-lock brak- Telephone ing system on/off or rear wheel only off. The cur- rently selected ABS mode is indicated by the ABS mode indicator on the main screen. Select a menu item and short press the “ ”...
  • Page 18 FEATURES This module allows you to record distance trav- eled between engine oil changes “Oil”, and two other maintenance intervals of your choice “In- terval 1”/ “Interval 2”. After maintenance to one of the items has been completed, short press the “ ”...
  • Page 19 FEATURES Set Default Value R-TRIP Set This module allows selection of how many dec- This function resets the number of sensor puls- es used to measure 1 km (for R-TRIP 1 and R- imals R-TRIP 1 and R-TRIP 2 display. TRIP 2) back to its default value (for OEM wheel dimensions).

  • Page 20: 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, 3-9, 3-12, 90890-03274 4-59, 4-60, 9-2, 9-28, 9-29 Yamaha diagnostic tool (A/I)
  • Page 21 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Carburetor angle driver 2 3-10 90890-03173 Spoke nipple wrench (6–7) 3-17 90890-01521 Spoke nipple wrench (6–7) YM-01521 Steering nut wrench 3-20, 4-82 90890-01403 Exhaust flange nut wrench YU-A9472 Oil filter wrench 3-26 90890-01426 Oil filter wrench YU-38411...
  • Page 22 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Damper rod holder (ø27) 4-73 90890-01423 Damping rod holder YM-01423 Fork seal driver 4-74, 4-74, 4-74 90890-01442 Adjustable fork seal driver (36–46 mm) YM-01442 Rod puller 4-75 90890-01437 Universal damping rod bleeding tool set YM-A8703 YM-A8703 Rod puller attachment (M10 long)
  • Page 23 90890-03081 Engine compression tester YU-33223 YU-33223 Rotor holding tool 5-26, 5-29 90890-01235 Universal magneto and rotor holder YU-01235 Yamaha bond No. 1215 5-32, 5-49, 5-75, 90890-85505 5-77 Three bond No. 1215® Valve spring compressor 5-40, 5-44 90890-04200 Valve spring compressor YM-04019 Valve spring compressor attachment (ø26)
  • Page 24 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Valve guide reamer (ø4.5) 5-41 90890-04118 Valve guide reamer (4.5 mm) YM-04118 Rotor holding tool 5-47, 5-47, 5-48, 90890-04166 5-48 Rotor holding tool YM-04166 Flywheel puller 5-47 90890-01362 Heavy duty puller YU-33270-B Digital circuit tester (CD732) 5-52, 8-38, 8-39, 90890-03243...
  • Page 25 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Piston ring compressor 5-87 90890-05158 Piston ring compressor YM-08037 Radiator cap tester 90890-01325 Mityvac cooling system tester kit YU-24460-A YU-24460-A Radiator cap tester adapter 90890-01352 Pressure tester adapter YU-33984 YU-33984 Mechanical seal installer (ø33) 6-14 90890-04132 Water pump seal installer (ø33)
  • Page 26 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Fuel injector pressure adapter 7-15 90890-03210 Fuel injector pressure adapter YU-03210 Fuel pressure adapter 7-16 90890-03186 Fuel pressure adapter YM-03186 Ignition checker 8-42 90890-06754 Oppama pet–4000 spark checker YM-34487 Test harness– lean angle sensor (6P) 8-43 90890-03209 Test harness–...

  • Page 27: 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............2-12 CABLE ROUTING ..................2-15...

  • Page 28: General Specifications

    GENERAL SPECIFICATIONS EAS20013 GENERAL SPECIFICATIONS Model Model BAG1 (XTZ690D) BAG2 (XTZ690DP) Dimensions Overall length 2370 mm (93.3 in) Overall width 905 mm (35.6 in) Overall height 1490 mm (58.7 in) Wheelbase 1595 mm (62.8 in) Ground clearance 255 mm (10.04 in) Minimum turning radius 2.8 m (9.47 ft) Weight...

  • Page 29: Engine Specifications

    ENGINE SPECIFICATIONS EAS20014 ENGINE SPECIFICATIONS Engine Combustion cycle 4-stroke Cooling system Liquid cooled Valve train DOHC Displacement 689 cm³ Cylinder arrangement Inline Number of cylinders 2-cylinder Bore × stroke 80.0 × 68.6 mm (3.15 × 2.70 in) Compression ratio 11.5 : 1 Compression pressure (#1 cylinder) 770–990 kPa/355 r/min (7.7–9.9 kgf/cm²/355 r/ min, 109.5–140.8 psi/355 r/min)
  • Page 30 ENGINE SPECIFICATIONS Spark plug(s) Manufacturer/model NGK/LMAR8A-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 22.000–22.021 mm (0.8661–0.8670 in) Camshaft journal diameter 21.959–21.972 mm (0.8645–0.8650 in) Camshaft-journal-to-camshaft-cap clearance limit 0.080 mm (0.0032 in) Camshaft lobe dimensions Lobe height limit (Intake)
  • Page 31 ENGINE SPECIFICATIONS Side clearance limit 0.115 mm (0.0045 in) 2nd ring End gap limit 0.80 mm (0.0315 in) Side clearance limit 0.115 mm (0.0045 in) Connecting rod Oil clearance 0.027–0.051 mm (0.0011–0.0020 in) Bearing color code Code 1 Blue Code 2 Black Code 3 Brown...
  • Page 32 ENGINE SPECIFICATIONS Gear ratio 2.846 (37/13) 2.125 (34/16) 1.632 (31/19) 1.300 (26/20) 1.091 (24/22) 0.964 (27/28) Main axle runout limit 0.08 mm (0.0032 in) Drive axle runout limit 0.08 mm (0.0032 in) Secondary reduction ratio 3.067 (46/15) Shifting mechanism Installed shift rod length 273.0–275.0 mm (10.75–10.83 in) Air filter Air filter element...

  • Page 33: Chassis Specifications

    CHASSIS SPECIFICATIONS EAS20015 CHASSIS SPECIFICATIONS Chassis Caster angle 27.0 ° Trail 105 mm (4.1 in) Front wheel Wheel type Spoke wheel 21 × 1.85 Rim size Radial wheel runout limit 2.0 mm (0.08 in) Lateral wheel runout limit 2.0 mm (0.08 in) Rear wheel Wheel type Spoke wheel...
  • Page 34 Fork spring free length limit 458.5 mm (18.05 in) Inner tube bending limit 0.2 mm (0.01 in) Recommended oil Yamaha Suspension Oil 01 Quantity (left) 574.0 cm³ (19.41 US oz, 20.24 Imp.oz) Quantity (right) 574.0 cm³ (19.41 US oz, 20.24 Imp.oz) Level 122.0 mm (4.80 in)
  • Page 35 CHASSIS SPECIFICATIONS Adjustment value from the start position (STD) Adjustment value from the start position (Hard) Compression damping Unit for adjustment Click Adjustment value from the start position (Soft) Adjustment value from the start position (STD) Adjustment value from the start position (Hard) Drive chain Size 525VZ2...

  • Page 36: Electrical Specifications

    ELECTRICAL SPECIFICATIONS EAS20016 ELECTRICAL SPECIFICATIONS Voltage System voltage 12 V Ignition system Ignition timing (B.T.D.C.) 8.0–12.0 °/1350 r/min Engine control unit Model TBDF5D (XTZ690D) TBDF8J (XTZ690DP) Ignition coil 1.19–1.61 Ω Primary coil resistance Secondary coil resistance 8.50–11.50 kΩ Lean angle sensor Operating angle 65 °...
  • Page 37 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 8.0–12.0 Ω Sender unit resistance (full) 267.0–273.0 Ω Sender unit resistance (empty) Fuel injection sensor 228–342 Ω Crankshaft position sensor resistance 5400–6600 Ω...

  • Page 38: 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) Exhaust pipe bracket bolt 20 N·m (2.0 kgf·m, 15 lb·ft) Muffler bolt 47 N·m (4.7 kgf·m, 35 lb·ft) Muffler joint bolt 20 N·m (2.0 kgf·m, 15 lb·ft) Muffler protector bolt...

  • Page 39: Chassis Tightening Torques

    TIGHTENING TORQUES EAS30017 CHASSIS TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Steering stem nut 150 N·m (15 kgf·m, 111 lb·ft) Front wheel axle 72 N·m (7.2 kgf·m, 53 lb·ft) Front wheel axle pinch bolt 21 N·m (2.1 kgf·m, 15 lb·ft) See TIP.
  • Page 40 TIGHTENING TORQUES Lower bracket pinch bolt Tighten the pinch bolt to specification in order Pinch bolt “1” → Pinch bolt “2” → Pinch bolt “1” → Pinch bolt “2” 2-13...
  • Page 41 TIGHTENING TORQUES 2-14...

  • Page 42: Cable Routing

    CABLE ROUTING EAS20021 CABLE ROUTING Steering (front view) 2-15...
  • Page 43 CABLE ROUTING 1. Throttle cable (accelerator cable) 2. Throttle cable (decelerator cable) 3. Handlebar switch lead (left) 4. Clutch cable 5. Wire harness (to meter assembly) 6. Brake hose (front brake master cylinder to hydraulic unit) 7. Handlebar switch lead (right) 8.
  • Page 44 CABLE ROUTING Steering (right side view) 1 2 3 4 12, 19, 22 2-17...
  • Page 45 CABLE ROUTING 1. Throttle cable (accelerator cable) 2. Throttle cable (decelerator cable) 3. Brake hose (front brake master cylinder to hydraulic unit) 4. Clutch cable 5. Handlebar switch lead (right) 6. Main switch lead 7. Handlebar switch lead (left) 8. Wire harness (to meter assembly) 9.
  • Page 46 CABLE ROUTING Engine (right side view) 16,17,18 10,C 11,C 12,C 16,17 16,17 2-19...
  • Page 47 CABLE ROUTING 1. Throttle position sensor coupler 2. Fuel cut solenoid valve coupler 3. Sub-wire harness coupler 4. Wire harness (to sub-wire harness) 5. Oil pressure switch connector 6. Handlebar switch coupler (left) 7. Handlebar switch coupler (right) 8. Purge cut valve solenoid 9.
  • Page 48 CABLE ROUTING Rear frame (right side view) 2-21...
  • Page 49 CABLE ROUTING 1. Relay unit 2. Radiator fan motor relay 3. Resistor (along with wire harness) 4. Rear wheel sensor lead 5. Rear brake light switch lead 6. Battery box 7. Joint coupler 8. Frame 9. Rear brake light switch coupler 10.
  • Page 50 CABLE ROUTING Steering (left side view) 2-23...
  • Page 51 CABLE ROUTING 1. Wire harness (to meter assembly) 2. Throttle cable (accelerator cable) 3. Throttle cable (decelerator cable) 4. Brake hose (front brake master cylinder to hydraulic unit) 5. Handlebar switch lead (left) 6. Clutch cable 7. Main switch 8. Handlebar switch lead (right) 9.
  • Page 52 CABLE ROUTING Engine (left side view) 11,K A 10 11,B 12,C P P P 34,R 35,R 2-25...
  • Page 53 CABLE ROUTING 1. Clutch cable O. Route the stator coil lead and rectifier/regulator lead to the inside of the side cover inner panel. 2. Intake air pressure sensor hose P. To ignition coil #1 3. Coolant reservoir hose Q. To ignition coil #2 4.
  • Page 54 CABLE ROUTING Down tube (left side view) 2-27...
  • Page 55 CABLE ROUTING 1. Coolant reservoir hose 2. Coolant reservoir 3. Horn connector 4. Horn lead 5. Sidestand switch lead 6. Stator coil lead 7. Down tube 8. Coolant reservoir breather hose 9. Footrest bracket (left) A. Fit the plastic band between the two bolts. B.
  • Page 56 CABLE ROUTING Rear frame (left side view) 13,14,15,16 8, 10, 11 13,14,15,16 13 16 6, U 5, T B,4 3 16 13 15 10,11,12 2-29...
  • Page 57 CABLE ROUTING 1. Canister 2. Gear position switch coupler 3. Engine ground terminal 4. Engine ground terminal cover 5. Fuel tank overflow hose 6. Canister breather hose 7. Frame 8. Wire harness 9. ECU (Engine Control Unit) lead 10. Gear position switch lead 11.
  • Page 58 CABLE ROUTING Engine (top view) 18,19,37 20,21,22 23,24 14,15,16 33, M 31, 32, 33, 34 2-31...
  • Page 59 CABLE ROUTING 1. Hydraulic unit J. Face the buckle of the plastic band outward with the end pointing downward. 2. Wire harness (to accessory coupler, front turn “ ” signal light, and ABS ON button) K. Outward 3. Purge cut valve solenoid coupler L.
  • Page 60 CABLE ROUTING Rear frame (top view) 24, 25 2-33...
  • Page 61 CABLE ROUTING 1. Rear wheel sensor lead 2. Rear brake light switch lead 3. Negative battery terminal 4. Joint coupler 5. Fuse box 1 (white mark) 6. Resistor (along with wire harness) 7. Radiator fan motor relay 8. Relay unit 9.
  • Page 62 CABLE ROUTING Rear brake hose (right side view) 2-35...
  • Page 63 CABLE ROUTING 1. Rear brake caliper 2. Rear wheel sensor lead 3. Brake hose (hydraulic unit to rear brake caliper) 4. Brake hose (rear brake master cylinder to hydraulic unit) 5. Rear brake master cylinder 6. Swingarm A. Fasten the brake hose (hydraulic unit to rear brake caliper) and rear wheel sensor lead with the clamp.
  • Page 64 CABLE ROUTING Front brake hose (left and right side view) 2-37...
  • Page 65 CABLE ROUTING 1. Brake hose (front brake master cylinder to hydraulic unit) 2. Front wheel sensor lead 3. Brake hose (hydraulic unit to right front brake caliper) 4. Brake hose (right front brake caliper to left front brake caliper) 5. Protector –...
  • Page 66 CABLE ROUTING Hydraulic unit assembly (top and left side view) 2-39...
  • Page 67 CABLE ROUTING 1. Brake hose (hydraulic unit to rear brake caliper) 2. Brake hose (rear brake master cylinder to hydraulic unit) 3. Brake hose (front brake master cylinder to hydraulic unit) 4. Brake hose (hydraulic unit to right front brake caliper) 2-40...
  • Page 68 CABLE ROUTING Radiator (front and right side view) 2-41...
  • Page 69 CABLE ROUTING 1. Radiator inlet hose 2. Radiator 3. Radiator outlet hose 4. Radiator cap 5. Coolant reservoir hose 6. Radiator cover 7. Coolant reservoir 8. Water jacket joint inlet hose A. Fasten the coolant reservoir hose and radiator inlet hose with clamp. Position of coolant reservoir hose is under the radiator inlet hose.
  • Page 70 CABLE ROUTING Radiator (left side view) 2-43...
  • Page 71 CABLE ROUTING 1. Radiator inlet hose 2. Thermostat housing 3. Oil cooler inlet hose 4. Coolant reservoir breather hose 5. Coolant reservoir 6. Coolant reservoir cap 7. Coolant reservoir hose 8. Radiator 9. Frame A. Fasten the coolant reservoir hose and the radiator inlet hose with the plastic locking tie.
  • Page 72 CABLE ROUTING Fuel tank (left side view) 2-45...
  • Page 73 CABLE ROUTING 1. Fuel hose (right fuel tank to left fuel tank) 2. Fuel hose (fuel pump to fuel rail) 3. Fuel tank breather hose (right fuel tank to canister) 4. Fuel tank overflow hose (left fuel tank to hose joint) 5.
  • Page 74 CABLE ROUTING Canister and purge cut valve solenoid 2-47...
  • Page 75 CABLE ROUTING 1. Starter motor 2. Canister 3. Fuel tank breather hose (right fuel tank to canister) 4. Canister purge hose (canister to purge cut valve solenoid) 5. Fuel tank overflow hose (right fuel tank to hose joint) 6. Fuel tank (right) 7.
  • Page 76 CABLE ROUTING Throttle body and fuel hoses (rear view) 13, G 2-49...
  • Page 77 CABLE ROUTING 1. Fuel tank overflow hose (left fuel tank to hose joint) 2. Sub-wire harness 3. Fuel tank overflow hose (right fuel tank to hose joint) 4. Fuel tank breather hose (right fuel tank to canister) 5. Fuel cut solenoid valve coupler 6.
  • Page 78 CABLE ROUTING 2-51...

  • Page 79: 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.............3-6 CHECKING THE ENGINE IDLING SPEED..........3-9 SYNCHRONIZING THE THROTTLE BODIES..........3-9...
  • Page 80 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 ........3-30 CHECKING THE THROTTLE GRIP OPERATION ........3-31 CHECKING AND CHARGING THE BATTERY.........3-32 CHECKING THE FUSES................3-32 ADJUSTING THE HEADLIGHT BEAMS ..........3-32...

  • Page 82: Periodic Maintenance

    EAS30614 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM • Items marked with an asterisk should be performed by your Yamaha dealer because these items re- quire special tools, data, and technical skills. • From 50000 km (30000 mi), repeat the maintenance intervals starting from 10000 km (6000 mi).
  • Page 83 PERIODIC MAINTENANCE ODOMETER READING CHECK OR MAINTENANCE ANNUAL ITEM CHECK 1000 km 10000 km 20000 km 30000 km 40000 km (600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi) Air filter case √ √ √ √ √ • Clean. check hose •...
  • Page 84 PERIODIC MAINTENANCE ODOMETER READING CHECK OR MAINTENANCE ANNUAL ITEM CHECK 1000 km 10000 km 20000 km 30000 km 40000 km (600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi) Rear suspension relay arm and √ √ √ √ 25 * •...

  • Page 85: Checking The Vehicle Using The Yamaha Diagnostic Tool

    “3” cludes YDT sub harness (6P) (90890-03266). • Fuel tank overflow hose (right fuel tank to • If you already have Yamaha diagnostic tool (A/ hose joint) “4” I) (90890-03262), YDT sub harness (6P) • Fuel tank breather hose (right fuel tank to (90890-03266) is separately required.

  • Page 86: Checking The Spark Plugs

    PERIODIC MAINTENANCE • Engine bracket (left/right) Refer to “ENGINE REMOVAL” on page 5-10. • Fuel tank (left/right) Refer to “FUEL TANK” on page 7-1. 2. Remove: • Brake hose (from the holder “1”) • Holder “2” (from the radiator cover) 3.

  • Page 87: Adjusting The Valve Clearance

    PERIODIC MAINTENANCE 6. Check: 12.Install: • Electrode “1” • Fuel tank (left/right) Damage/wear → Replace the spark plug. Refer to “FUEL TANK” on page 7-1. • Insulator “2” • Engine bracket (left/right) Abnormal color → Replace the spark plug. Refer to “ENGINE REMOVAL” on page 5-10. Normal color is medium-to-light tan.
  • Page 88 PERIODIC MAINTENANCE 3. Remove: • Cylinder head cover Refer to “CAMSHAFTS” on page 5-23. 4. Remove: • Timing mark accessing bolt • Crankshaft end cover Refer to “GENERATOR AND STARTER CLUTCH” on page 5-45. 5. Measure: G088881 • Valve clearance Out of specification →...
  • Page 89 PERIODIC MAINTENANCE • Make a note of the position of each valve lifter and valve pad so that they can be installed in Refer to the following table for the available the correct place. valve pads. b. Calculate the difference between the Valve pad range No.

  • Page 90: Checking The Engine Idling Speed

    • Intake air pressure sensor hose “5” • Yamaha diagnostic tool (A/I) (90890-03273) in- • Vacuum gauge “6” cludes YDT sub harness (6P) (90890-03266). • If you already have Yamaha diagnostic tool (A/ Vacuum gauge I) (90890-03262), YDT sub harness (6P) 90890-03094 (90890-03266) is separately required.
  • Page 91 PERIODIC MAINTENANCE 5. Install: • The difference in vacuum pressure between • Fuel tank (left) the throttle bodies should not exceed 1.33 kPa • Fuel hose (fuel pump to fuel rail) (10 mmHg). • Fuel pump coupler • Fuel sender coupler Carburetor angle driver 2 Refer to “FUEL TANK”...

  • Page 92: Checking The Exhaust System

    PERIODIC MAINTENANCE 5. Adjust: • Throttle grip free play Refer to “CHECKING THE THROTTLE GRIP OPERATION” on page 3-31. Throttle grip free play 3.0–5.0 mm (0.12–0.20 in) EAS30062 CHECKING THE EXHAUST SYSTEM 1. Check: • Muffler assembly “1” • Exhaust pipe “2” Cracks/damage →...

  • Page 93: Adjusting The Exhaust Gas Volume

    • Yamaha diagnostic tool (A/I) (90890-03273) in- 4. Install: cludes YDT sub harness (6P) (90890-03266). • Air filter element • If you already have Yamaha diagnostic tool (A/ • Air filter case cover I) (90890-03262), YDT sub harness (6P) Air filter element screw (90890-03266) is separately required.

  • Page 94: Adjusting The Clutch Lever Free Play

    PERIODIC MAINTENANCE EAS30629 ADJUSTING THE CLUTCH LEVER FREE PLAY 1. Check: • Clutch lever free play “a” Out of specification → Adjust. Clutch lever free play 5.0–10.0 mm (0.20–0.39 in) EAS30801 CHECKING THE BRAKE OPERATION 1. Check: • Brake operation Brake not working properly →...

  • Page 95: Checking The Front Brake Pads

    PERIODIC MAINTENANCE EWA18830 WARNING After adjusting the brake pedal position, check that the end of the adjusting bolt “a” is visible through the hole “b”. c. Tighten the locknut “1” to specification. Rear brake pedal adjusting lock- G088890 18 N·m (1.8 kgf·m, 13 lb·ft) EWA13050 WARNING EWA17030...

  • Page 96: Checking The Brake Hoses

    PERIODIC MAINTENANCE • Be careful not to spill any brake fluid or allow the brake master cylinder reservoir or brake fluid reservoir to overflow. • When bleeding the ABS, make sure that there is always enough brake fluid before applying the brake.

  • Page 97: Checking The Brake Fluid Level

    PERIODIC MAINTENANCE EWA13090 WARNING Loosening the bleed screw will release the pres- • Use only the designated brake fluid. Other sure and cause the brake lever to contact the brake fluids may cause the rubber seals to throttle grip or the brake pedal to fully extend. deteriorate, causing leakage and poor h.

  • Page 98: Checking The Tires

    PERIODIC MAINTENANCE • The tire pressure and the suspension must be adjusted according to the total weight (including cargo, rider, passenger and ac- cessories) and the anticipated riding speed. • Operation of an overloaded vehicle could cause tire damage, an accident or an injury. NEVER OVERLOAD THE VEHICLE.

  • Page 99: Checking The Wheel Bearings

    No guarantee con- cerning handling characteristics can be giv- en if a tire combination other than one approved by Yamaha is used on this vehicle. G088891 EAS30641 CHECKING THE WHEEL BEARINGS...

  • Page 100: Lubricating The Drive Chain

    PERIODIC MAINTENANCE 1. Place the vehicle on the sidestand. 2. Shift the transmission into the neutral posi- tion. 3. Check: • Drive chain slack Out of specification → Adjust. Measure the distance “a” between the rib end “b” on the drive chain guide “1” and the center of the drive chain “2”.

  • Page 101: Lubricating The Steering Head

    PERIODIC MAINTENANCE Lower ring nut (initial tightening Place the vehicle on a suitable stand so that the torque) front wheel is elevated. 75 N·m (7.5 kgf·m, 55 lb·ft) 2. Check: c. Loosen the lower ring nut 165–195°, then • Steering head tighten it to specification.

  • Page 102: Checking The Steering Damper

    PERIODIC MAINTENANCE EAS30653 CHECKING THE FRONT FORK Recommended lubricant 1. Stand the vehicle on a level surface. Lithium-soap-based grease EWA13120 WARNING EAS30098 CHECKING THE STEERING DAMPER Securely support the vehicle so that there is Refer to “CHECKING THE STEERING DAMP- no danger of it falling over.
  • Page 103 PERIODIC MAINTENANCE Rebound damping Unit for adjustment Click Adjustment value from the start position (Soft) Adjustment value from the start position (STD) Adjustment value from the start position (Hard) The spring preload setting is determined by * With the adjusting screw fully turned in measuring the distance “c”...

  • Page 104: Checking The Rear Shock Absorber Assembly

    PERIODIC MAINTENANCE Direction “a” Compression damping is increased (suspension is harder). Direction “b” Compression damping is decreased (suspension is softer). Compression damping Unit for compression damping 4. Wait a few seconds, and then install the adjustment Click bleed screws. Adjustment value from the start Front fork bleed screw position (Soft) 1.3 N·m (0.13 kgf·m, 0.95 lb·ft)
  • Page 105 PERIODIC MAINTENANCE Spring preload Rebound damping Unit for adjustment Unit for adjustment Click Click Adjustment value (Soft) Adjustment value from the start position (Soft) Adjustment value (STD) Adjustment value from the start Adjustment value (Hard) position (STD) Adjustment value from the start * With the adjusting knob fully turned in di- position (Hard) rection “b”...

  • Page 106: Checking The Connecting Arms And Relay Arm

    PERIODIC MAINTENANCE Below the minimum level mark → Add the Compression damping recommended engine oil to the proper level. Unit for adjustment Click Before checking the engine oil level, wait a few Adjustment value from the start minutes until the oil has settled. position (Soft) Adjustment value from the start position (STD)

  • Page 107: Measuring The Engine Oil Pressure

    PERIODIC MAINTENANCE • Engine oil drain bolt “2” 8. Fill: (along with the gasket “3”) • Oil pan (with the specified amount of the recom- mended engine oil) Engine oil quantity Without oil filter cartridge re- placement 2.30 L (2.43 US qt, 2.02 Imp.qt) With oil filter cartridge replace- ment 2.60 L (2.75 US qt, 2.29 Imp.qt)

  • Page 108: Checking The Coolant Level

    PERIODIC MAINTENANCE 3. Remove: 9. Measure: • Engine guard (right) • Engine oil pressure Refer to “ENGINE REMOVAL” on page 5-10. (at the following conditions) 4. Tilt the vehicle to the left so that oil does not Oil pressure flow out of the main gallery. 280.0 kPa/5000 r/min (2.80 kgf/ 5.

  • Page 109: Checking The Cooling System

    PERIODIC MAINTENANCE 2. Check: Refer to “RADIATOR” on page 6-2, “OIL • Coolant level COOLER” on page 6-5, “THERMOSTAT” on The coolant level should be between the page 6-8 and “WATER PUMP” on page minimum level mark “a” and maximum level 6-10.
  • Page 110 PERIODIC MAINTENANCE be blown out, which could cause serious in- 7. Drain: jury. When the engine has cooled, open the • Coolant radiator cap as follows: (from the coolant reservoir) Place a thick rag or a towel over the radiator 8.

  • Page 111: Checking The Front Brake Light Switch

    PERIODIC MAINTENANCE • Use only distilled water. However, if dis- EAS30659 ADJUSTING THE REAR BRAKE LIGHT tilled water is not available, soft water may SWITCH be used. 1. Check: • If coolant comes into contact with painted • Rear brake light operation timing “a” surfaces, immediately wash them with wa- Out of specification →...

  • Page 112: Checking The Throttle Grip Operation

    PERIODIC MAINTENANCE 1. Check: • Outer cable Damage → Replace. 2. Check: • Cable operation Rough movement → Lubricate. Recommended lubricant Engine oil or a suitable cable lu- bricant G088895 4. Adjust: • Throttle grip free play Hold the cable end upright and pour a few drops of lubricant into the cable sheath or use a Prior to adjusting the throttle grip free play, suitable lubricating device.

  • Page 113: Checking And Charging The Battery

    PERIODIC MAINTENANCE d. Tighten the locknut. EAS31831 REPLACING THE LICENSE PLATE LIGHT Throttle cable locknut (handle- BULB bar side) 1. Remove: 4.3 N·m (0.43 kgf·m, 3.2 lb·ft) • Lower fender cover bolts “1” • Lower fender cover “2” e. Slide the rubber cover to its original posi- tion.
  • Page 114 PERIODIC MAINTENANCE 5. Install: • License plate light cover • License plate light unit • Lower fender cover License plate light cover nut 3.8 N·m (0.38 kgf·m, 2.8 lb·ft) Lower fender cover bolt 4.0 N·m (0.40 kgf·m, 3.0 lb·ft) 3-33...

  • Page 115: Chassis

    CHASSIS GENERAL CHASSIS (1)..................4-1 GENERAL CHASSIS (2)..................4-2 REMOVING THE SIDE COVERS ...............4-3 REMOVING THE TAIL COVER ..............4-3 REMOVING THE ECU (engine control unit)..........4-3 INSTALLING THE ECU (engine control unit) ..........4-3 INSTALLING THE TAIL COVER..............4-3 INSTALLING THE SIDE COVERS..............4-3 GENERAL CHASSIS (3)..................4-5 REMOVING THE FRONT SIDE COVERS ..........4-6 INSTALLING THE FRONT SIDE COVERS..........4-6 GENERAL CHASSIS (4)..................4-7...
  • Page 116 MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR..................4-27 ASSEMBLING THE REAR WHEEL ............4-27 ADJUSTING THE REAR WHEEL STATIC BALANCE ......4-28 INSTALLING THE REAR WHEEL ............4-28 FRONT BRAKE .....................4-31 INTRODUCTION..................4-36 CHECKING THE FRONT BRAKE DISCS..........4-36 REPLACING THE FRONT BRAKE PADS ..........4-36 REMOVING THE FRONT BRAKE CALIPERS..........4-37 DISASSEMBLING THE FRONT BRAKE CALIPERS ........4-37 CHECKING THE FRONT BRAKE CALIPERS ..........4-38...
  • Page 117 FRONT FORK....................4-68 REMOVING THE FRONT FORK LEGS ............4-71 DISASSEMBLING THE FRONT FORK LEGS ..........4-71 CHECKING THE FRONT FORK LEGS ............4-72 ASSEMBLING THE FRONT FORK LEGS..........4-73 INSTALLING THE FRONT FORK LEGS ..........4-77 STEERING HEAD..................4-79 REMOVING THE LOWER BRACKET............4-82 CHECKING THE STEERING DAMPER............4-82 CHECKING THE STEERING HEAD ............4-82 INSTALLING THE STEERING HEAD ............4-83 REAR SHOCK ABSORBER ASSEMBLY .............4-84...
  • Page 118 GENERAL CHASSIS (1) EAS20026 GENERAL CHASSIS (1) Removing the seats and battery 7 N·m (0.7 kgf·m, 5.2 lb·ft) 2.3 N·m (0.23 kgf·m, 1.7 lb·ft) ’ Order Job/Parts to remove Remarks Passenger seat Rider seat Battery band Negative battery lead Disconnect. Positive battery lead Disconnect.

  • Page 119: General Chassis (1)

    GENERAL CHASSIS (2) EAS20155 GENERAL CHASSIS (2) Removing the tail/brake light assembly 4.0 N m (0.40 kgf m, 3.0 lb 11 N m (1.1 kgf m, 8.1 lb 3.8 N m (0.38 kgf m, 2.8 lb • • • • •...

  • Page 120: Removing The Side Covers

    GENERAL CHASSIS (2) EAS31264 REMOVING THE SIDE COVERS The following procedure applies to both of the side covers. 1. Remove: • Side cover “1” Remove the projections “a” on the side cover from holes “b” on the tail cover, and then re- move the projections “c”...

  • Page 121: General Chassis (3)

    GENERAL CHASSIS (2) Fit the projections “a” on the side cover to the holes “b” in the tail cover, and then fit the pro- jections “c” to the grommets “d”.
  • Page 122 GENERAL CHASSIS (3) EAS20156 GENERAL CHASSIS (3) Removing the front side covers 4.0 N·m (0.40 kgf·m, 3.0 lb·ft) 4.0 N·m (0.40 kgf·m, 3.0 lb·ft) ’ Order Job/Parts to remove Remarks Front side cover (left) Front turn signal light coupler (left) Disconnect.

  • Page 123: Removing The Front Side Covers

    GENERAL CHASSIS (3) EAS31683 REMOVING THE FRONT SIDE COVERS The following procedure applies to both of the front side covers. 1. Remove: • Front side cover “1” a. Remove the front side cover bolt and quick fasteners. b. Pull the front side cover outward, and then remove the projection “a”...
  • Page 124 GENERAL CHASSIS (4) EAS20157 GENERAL CHASSIS (4) Removing the lower side cover (left) 4.0 N·m (0.40 kgf·m, 3.0 lb·ft) 4.0 N·m (0.40 kgf·m, 3.0 lb·ft) 7 N·m (0.7 kgf·m, 5.2 lb·ft) 7 N·m (0.7 kgf·m, 5.2 lb·ft) ’ Order Job/Parts to remove Remarks Refer to “GENERAL CHASSIS (3)”...
  • Page 125 GENERAL CHASSIS (4) Removing the lower side cover (right) 4.0 N·m (0.40 kgf·m, 3.0 lb·ft) 4.0 N·m (0.40 kgf·m, 3.0 lb·ft) 7 N·m (0.7 kgf·m, 5.2 lb·ft) ’ Order Job/Parts to remove Remarks Refer to “GENERAL CHASSIS (3)” on page Front side cover (right) 4-5.

  • Page 126: Removing The Lower Side Cover Assemblies

    GENERAL CHASSIS (4) EAS33812 REMOVING THE LOWER SIDE COVER ASSEMBLIES The following procedure applies to both of the lower side cover assemblies. 1. Remove: • Lower side cover assembly “1” a. Remove the lower side cover assembly bolt. b. Remove the projections “a” on the lower side cover assembly from the holes “b”.
  • Page 127 GENERAL CHASSIS (5) EAS20158 GENERAL CHASSIS (5) Removing the windshields and meter assembly 7 N·m (0.7 kgf·m, 5.2 lb·ft) 0.6 N·m (0.06 kgf·m, 0.44 lb·ft) 0.6 N·m (0.06 kgf·m, 0.44 lb·ft) 4.0 N·m (0.40 kgf·m, 3.0 lb·ft) 0.6 N·m (0.06 kgf·m, 0.44 lb·ft) 4.0 N·m (0.40 kgf·m, 3.0 lb·ft) 7 N·m (0.7 kgf·m, 5.2 lb·ft) ’...
  • Page 128 GENERAL CHASSIS (6) EAS20159 GENERAL CHASSIS (6) Removing the headlight assembly 9 N·m (0.9 kgf·m, 6.6 lb·ft) 2.8 N·m (0.28 kgf·m, 2.1 lb·ft) 23 N·m (2.3 kgf·m, 17 lb·ft) 2.8 N·m (0.28 kgf·m, 2.1 lb·ft) 7 N·m (0.7 kgf·m, 5.2 lb·ft) 7 N·m (0.7 kgf·m, 5.2 lb·ft) 7 N·m (0.7 kgf·m, 5.2 lb·ft) ’...

  • Page 129: General Chassis (6)

    GENERAL CHASSIS (6) Removing the headlight assembly 9 N·m (0.9 kgf·m, 6.6 lb·ft) 2.8 N·m (0.28 kgf·m, 2.1 lb·ft) 23 N·m (2.3 kgf·m, 17 lb·ft) 2.8 N·m (0.28 kgf·m, 2.1 lb·ft) 7 N·m (0.7 kgf·m, 5.2 lb·ft) 7 N·m (0.7 kgf·m, 5.2 lb·ft) 7 N·m (0.7 kgf·m, 5.2 lb·ft) ’...

  • Page 130: Removing The Windshield Inner Panel (Left)

    GENERAL CHASSIS (6) EAS31400 REMOVING THE WINDSHIELD INNER PANEL (LEFT) 1. Remove: • Windshield inner panel (left) “1” a. Disconnect the “ABS ON” button coupler “2”. b. Remove the holders “3” and turn signal light coupler “4” from the windshield inner panel.
  • Page 131 GENERAL CHASSIS (7) EAS20193 GENERAL CHASSIS (7) Removing the coupler holder 7 N·m (0.7 kgf·m, 5.2 lb·ft) ’ Order Job/Parts to remove Remarks Refer to “GENERAL CHASSIS (1)” on page Rider seat 4-1. Refer to “GENERAL CHASSIS (3)” on page Front side cover (right) 4-5.
  • Page 132 GENERAL CHASSIS (7) Removing the coupler holder 7 N·m (0.7 kgf·m, 5.2 lb·ft) ’ Order Job/Parts to remove Remarks Handlebar switch coupler 1 (left) Disconnect. Handlebar switch coupler 2 (right) Disconnect. Handlebar switch coupler 2 (left) Disconnect. Handlebar switch coupler 3 (right) Disconnect.

  • Page 133: Front Wheel

    FRONT WHEEL EAS20028 FRONT WHEEL Removing the front wheel and brake discs m (0.8 kgf m, 5.9 lb 72 N m (7.2 kgf m, 53 lb • • • • • • 40 N m (4.0 kgf m, 30 lb •...
  • Page 134 FRONT WHEEL Disassembling the front wheel ’ Order Job/Parts to remove Remarks Oil seal Wheel bearing Spacer 4-17...

  • Page 135: Removing The Front Wheel

    FRONT WHEEL EAS30145 REMOVING THE FRONT WHEEL ECA20981 • Keep any type of magnets (including mag- netic pick-up tools, magnetic screwdrivers, etc.) away from the front wheel sensor or front wheel sensor rotor; otherwise, the sensor or rotor may be damaged, resulting in improper performance of the ABS sys- G088896 tem.

  • Page 136: Maintenance Of The Front Wheel Sensor And Sensor Rotor

    FRONT WHEEL 3. Measure: • Wheel sensor rotor deflection Out of specification → Clean the installation surface of the wheel sensor rotor and correct the wheel sensor rotor deflection, or replace the wheel sensor rotor. Wheel sensor rotor deflection limit 0.25 mm (0.0098 in) G088897 5.

  • Page 137: Assembling The Front Wheel

    FRONT WHEEL G088899 EAS30151 EAS30152 ASSEMBLING THE FRONT WHEEL ADJUSTING THE FRONT WHEEL STATIC 1. Install: BALANCE • Wheel bearings • After replacing the tire, wheel or both, the front • Oil seals wheel static balance should be adjusted. a. Install the new wheel bearing (left side). •...
  • Page 138 FRONT WHEEL • Tighten the brake disc bolts and wheel sensor 4. Check: rotor bolts in stages and in a crisscross pat- • Front brake discs tern. Refer to “CHECKING THE FRONT BRAKE DISCS” on page 4-36. 5. Install: • Front wheel sensor •...
  • Page 139 FRONT WHEEL Distance “a” (between the front wheel sensor rotor and front wheel sensor) 0.7–1.6 mm (0.03–0.06 in) 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.

  • Page 140: Rear Wheel

    REAR WHEEL EAS20029 REAR WHEEL Removing the rear wheel 105 N m (10.5 kgf m, 77 lb • • • 16 N m (1.6 kgf m, 12 lb • • • m (0.7 kgf m, 5.2 lb • • • m (0.7 kgf m, 5.2 lb •...
  • Page 141 REAR WHEEL Removing the rear brake disc and rear wheel sprocket 80 N m (8.0 kgf m, 59 lb • • • 30 N m (3.0 kgf m, 22 lb • • • m (0.8 kgf m, 5.9 lb • •...
  • Page 142 REAR WHEEL Disassembling the rear wheel ’ Order Job/Parts to remove Remarks Oil seal Wheel bearing Spacer 4-25...

  • Page 143: Removing The Rear Wheel

    REAR WHEEL EAS30910 EAS30159 REMOVING THE REAR WHEEL CHECKING THE REAR WHEEL ECA21030 1. Check: • Rear wheel axle • Keep any type of magnets (including mag- • Wheel bearings netic pick-up tools, magnetic screwdrivers, • Oil seal etc.) away from the rear wheel sensor or Refer to “CHECKING THE FRONT WHEEL”...

  • Page 144: Maintenance Of The Rear Wheel Sensor And Sensor Rotor

    REAR WHEEL 1. Check: • Rear wheel sensor Refer to “MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR” on page 4-19. 2. Check: • Rear wheel sensor rotor Refer to “MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR” G088904 on page 4-19.

  • Page 145: Adjusting The Rear Wheel Static Balance

    REAR WHEEL Place a suitable washer “1” between the socket • Install the wheel sensor rotor with the stamped “2” and the bearing so that both the inner race mark “a” facing outward. “3” and outer race “4” are pressed at the same •...
  • Page 146 REAR WHEEL 7. Fit the space “a” between the side plates of the drive chain “1” onto the rib “b” on the • Install the rear wheel with the mark “a” on the drive chain guide “2”. rear tire pointing in the direction of wheel rota- tion.
  • Page 147 REAR WHEEL Distance “a” (between the rear wheel sensor rotor and rear wheel sensor) 0.8–1.6 mm (0.03–0.06 in) Measure the distance between the rear wheel sensor rotor and rear wheel sensor in several places in one rotation of the rear wheel. Do not turn the rear wheel while the thickness gauge is installed.

  • Page 148: Front Brake

    FRONT BRAKE EAS20030 FRONT BRAKE Removing the front brake pads 40 N m (4.0 kgf m, 30 lb • • • 10 N m (1.0 kgf m, 7.4 lb • • • ’ Order Job/Parts to remove Remarks The following procedure applies to both of the front brake calipers.
  • Page 149 FRONT BRAKE Removing the front brake master cylinder 1.5 N m (0.15 kgf m, 1.1 lb • • • 10 N m (1.0 kgf m, 7.4 lb • • • 1.0 N m (0.10 kgf m, 0.73 lb • • •...
  • Page 150 FRONT BRAKE Disassembling the front brake master cylinder ’ Order Job/Parts to remove Remarks Brake master cylinder kit Brake master cylinder body 4-33...
  • Page 151 FRONT BRAKE Removing the front brake calipers 40 N m (4.0 kgf m, 30 lb • • • 33 N·m (3.3 kgf·m, 24 lb·ft) ’ Order Job/Parts to remove Remarks The following procedure applies to both of the front brake calipers. Drain.
  • Page 152 FRONT BRAKE Disassembling the front brake calipers 10 N m (1.0 kgf m, 7.4 lb • • • ’ Order Job/Parts to remove Remarks The following procedure applies to both of the front brake calipers. Brake pad clip Brake pad pin Brake pad Brake pad spring Brake pad support...

  • Page 153: 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 G098641 system is disconnected, the entire brake 3.

  • Page 154: Removing The Front Brake Calipers

    FRONT BRAKE 4. Check: • Brake fluid level Always install new brake pads and a new brake Below the minimum level mark → Add the pad spring as a set. specified brake fluid to the proper level. a. Connect a clear plastic hose “1” tightly to Refer to “CHECKING THE BRAKE FLUID the bleed screw “2”.

  • Page 155: Checking The Front Brake Calipers

    FRONT BRAKE b. Blow compressed air into the brake hose EWA13611 WARNING joint opening “b” to force out the left side Whenever a brake caliper is disassembled, pistons from the brake caliper. replace the brake caliper piston dust seals EWAM1070 WARNING and brake caliper piston seals.

  • Page 156: Removing The Front Brake Master Cylinder

    FRONT BRAKE EWA13531 EWA13090 WARNING WARNING Proper brake hose routing is essential to in- • Use only the designated brake fluid. Other sure safe vehicle operation. brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. •...

  • Page 157: Checking The Front Brake Master Cylinder

    FRONT BRAKE To collect any remaining brake fluid, place a Align the end of the front brake master cylinder container under the master cylinder and the end holder with the punch mark “a” on the handle- of the brake hose. bar.
  • Page 158 FRONT BRAKE Specified brake fluid DOT 4 EWA13540 WARNING • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. • Refill with the same type of brake fluid that is already in the system.

  • Page 159: Rear Brake

    REAR BRAKE EAS20031 REAR BRAKE Removing the rear brake pads 10 N m (1.0 kgf m, 7.4 lb • • • ’ Order Job/Parts to remove Remarks Rear wheel Refer to “REAR WHEEL” on page 4-23. Brake pad clip Brake pad pin Brake pad Brake pad spring Brake caliper bleed screw...
  • Page 160 REAR BRAKE Removing the rear brake master cylinder 33 N·m (3.3 kgf·m, 24 lb·ft) 23 N m (2.3 kgf m, 17 lb • • • 4.0 N m (0.40 kgf m, 3.0 lb • • • ’ Order Job/Parts to remove Remarks Drain.
  • Page 161 REAR BRAKE Disassembling the rear brake master cylinder 18 N·m (1.8 kgf·m, 13 lb·ft) ’ Order Job/Parts to remove Remarks Brake master cylinder yoke Brake master cylinder kit Hose joint Bushing Brake master cylinder body 4-44...
  • Page 162 REAR BRAKE Removing the footrest assembly (right) 34 N·m (3.4 kgf·m, 25 lb·ft) ’ Order Job/Parts to remove Remarks Refer to “GENERAL CHASSIS (2)” on page Side cover (right) 4-2. Rear brake light switch coupler Disconnect. Footrest assembly (right) 4-45...
  • Page 163 REAR BRAKE Disassembling the footrest assembly (right) 13 N·m (1.3 kgf·m, 9.6 lb·ft) 55 N·m (5.5 kgf·m, 41 lb·ft) 7 N·m (0.7 kgf·m, 5.2 lb·ft) 7 N·m (0.7 kgf·m, 5.2 lb·ft) 41 N·m (4.1 kgf·m, 30 lb·ft) ’ Order Job/Parts to remove Remarks Footrest (right) Rear brake light switch...
  • Page 164 REAR BRAKE Removing the rear brake caliper 33 N·m (3.3 kgf·m, 24 lb·ft) ’ Order Job/Parts to remove Remarks Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM (ABS)” on page 3-15. Rear wheel Refer to “REAR WHEEL” on page 4-23. Rear brake hose union bolt Brake hose gasket Brake hose (hydraulic unit to rear brake caliper)
  • Page 165 REAR BRAKE Disassembling the rear brake caliper 10 N m (1.0 kgf m, 7.4 lb • • • ’ Order Job/Parts to remove Remarks Brake pad clip Brake pad pin Brake pad Brake pad spring Brake pad support Boot Boot Brake caliper piston Brake caliper piston dust seal Brake caliper piston seal...

  • Page 166: Introduction

    REAR BRAKE 4. Replace: EAS30183 INTRODUCTION • Rear brake disc EWA14101 Refer to “INSTALLING THE REAR WHEEL” WARNING on page 4-28. Disc brake components rarely require disas- sembly. Therefore, always follow these pre- EAS30185 REPLACING THE REAR BRAKE PADS ventive measures: •...

  • Page 167: Removing The Rear Brake Caliper

    REAR BRAKE c. Tighten the bleed screw. • Brake caliper piston seal “3” Rear brake caliper bleed screw 10 N·m (1.0 kgf·m, 7.4 lb·ft) d. Install the brake pads and brake pad spring. 4. Install: • Brake pad pin • Brake pad clip •...

  • Page 168: Assembling The Rear Brake Caliper

    REAR BRAKE • Brake caliper body “3” EAS30190 INSTALLING THE REAR BRAKE CALIPER Cracks/damage → Replace the brake caliper 1. Install: assembly. • Rear brake caliper • Brake fluid delivery passages • Rear wheel (brake caliper body) Refer to “INSTALLING THE REAR WHEEL” Obstruction →...

  • Page 169: Removing The Rear Brake Master Cylinder

    REAR BRAKE • When refilling, be careful that water does 3. Check: not enter the brake fluid reservoir. Water • Brake fluid reservoir will significantly lower the boiling point of • Brake fluid reservoir diaphragm holder Cracks/damage → Replace. the brake fluid and could cause vapor lock. •...

  • Page 170: Assembling The Brake Pedal

    REAR BRAKE Before tightening the brake pedal plate nut “2”, insert the suitable pin (d=4 mm (0.16 in))　“3”, into the brake pedal and brake pedal plate as il- lustration. Brake pedal plate nut 7 N·m (0.7 kgf·m, 5.2 lb·ft) 2. Fill: •...
  • Page 171 ABS (ANTI-LOCK BRAKE SYSTEM) EAS20032 ABS (ANTI-LOCK BRAKE SYSTEM) Removing the hydraulic unit assembly 33 N·m (3.3 kgf·m, 24 lb·ft) 7 N·m (0.7 kgf·m, 5.2 lb·ft) 7 N·m (0.7 kgf·m, 5.2 lb·ft) 3.8 N·m (0.38 kgf·m, 2.8 lb·ft) 7 N·m (0.7 kgf·m, 5.2 lb·ft) ’...

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

    ABS (ANTI-LOCK BRAKE SYSTEM) Removing the hydraulic unit assembly 33 N·m (3.3 kgf·m, 24 lb·ft) 7 N·m (0.7 kgf·m, 5.2 lb·ft) 7 N·m (0.7 kgf·m, 5.2 lb·ft) 3.8 N·m (0.38 kgf·m, 2.8 lb·ft) 7 N·m (0.7 kgf·m, 5.2 lb·ft) ’ Order Job/Parts to remove Remarks...

  • Page 173: Removing The Hydraulic Unit Assembly

    ABS (ANTI-LOCK BRAKE SYSTEM) EAS31036 REMOVING THE HYDRAULIC UNIT Do not operate the brake lever and brake pedal ASSEMBLY while removing the brake hoses. ECA21091 ECA14530 Unless necessary, avoid removing and in- stalling the brake hoses of the hydraulic unit When removing the brake hoses, cover the assembly.
  • Page 174 ABS (ANTI-LOCK BRAKE SYSTEM) Hydraulic unit assembly bolt Make sure that the pipe section “b” of the brake 7 N·m (0.7 kgf·m, 5.2 lb·ft) hose (rear brake master cylinder to hydraulic LOCTITE® unit) does not contact the hydraulic unit. Hydraulic unit bracket bolt 7 N·m (0.7 kgf·m, 5.2 lb·ft) d.

  • Page 175: Hydraulic Unit Operation Tests

    Water • For the brake line routing confirmation, use the will significantly lower the boiling point of diagnosis of function of the Yamaha diagnos- the brake fluid and could cause vapor lock. tic tool.
  • Page 176 90890-03273 order. • Yamaha diagnostic tool (A/I) (90890-03273) in- cludes YDT sub harness (6P) (90890-03266). • If you already have Yamaha diagnostic tool (A/ I) (90890-03262), YDT sub harness (6P) (90890-03266) is separately required. Refer to “YDT” on page 9-2.
  • Page 177 • “ON” and “OFF” on the tool screen indicate cludes YDT sub harness (6P) (90890-03266). when the brakes are being applied and re- • If you already have Yamaha diagnostic tool (A/ leased respectively. I) (90890-03262), YDT sub harness (6P) (90890-03266) is separately required.

  • Page 178: Checking The Abs Warning Light

    10.After the pulsating action has stopped in the 12.Turn the main switch to “OFF”. brake lever, it is generated in the brake pedal 13.Remove the Yamaha diagnostic tool from “1” and continues for a few seconds. the Yamaha diagnostic tool coupler, and then install the protective cap.

  • Page 179: Handlebar

    HANDLEBAR EAS20033 HANDLEBAR Removing the handlebar 18 N m (1.8 kgf m, 13 lb 26 N m (2.6 kgf m, 19 lb 8 N·m (0.8 kgf·m, 5.9 lb·ft) m (0.7 kgf m, 5.2 lb • • • • • • •...
  • Page 180 HANDLEBAR Removing the handlebar 18 N m (1.8 kgf m, 13 lb 26 N m (2.6 kgf m, 19 lb 8 N·m (0.8 kgf·m, 5.9 lb·ft) m (0.7 kgf m, 5.2 lb • • • • • • • • •...

  • Page 181: Removing The Handlebar

    HANDLEBAR EAS30203 EAS30205 REMOVING THE HANDLEBAR INSTALLING THE HANDLEBAR 1. Stand the vehicle on a level surface. 1. Stand the vehicle on a level surface. EWA13120 EWA13120 WARNING WARNING Securely support the vehicle so that there is Securely support the vehicle so that there is no danger of it falling over.
  • Page 182 HANDLEBAR • Fit the projection “b” on the bottom of the bolt head into the slot “c” in the bolt hole in the clutch lever holder. • While squeezing the clutch lever, fit the projec- tion “d” on the clutch switch into the slot “e” in the clutch lever holder.
  • Page 183 HANDLEBAR G088917 8. Install: 10.Install: • Handlebar grip • Throttle cable holder “1” • Grip end (left) “1” Align the throttle cable holder “1” with the edge Grip end of the front brake master cylinder. 26 N·m (2.6 kgf·m, 19 lb·ft) a.
  • Page 184 HANDLEBAR Rearview mirror (left) 17 N·m (1.7 kgf·m, 13 lb·ft) Rearview mirror (right) 17 N·m (1.7 kgf·m, 13 lb·ft) Left-hand threads Handguard bolt (grip end) 18 N·m (1.8 kgf·m, 13 lb·ft) Handguard bolt (rearview mirror) 8 N·m (0.8 kgf·m, 5.9 lb·ft) LOCTITE®...

  • Page 185: Front Fork

    FRONT FORK EAS20034 FRONT FORK Removing the front fork legs 23 N·m (2.3 kgf·m, 17 lb·ft) 23 N·m (2.3 kgf·m, 17 lb·ft) 20 N·m (2.0 kgf·m, 15 lb·ft) ’ Order Job/Parts to remove Remarks The following procedure applies to both of the front fork legs.
  • Page 186 FRONT FORK Disassembling the front fork legs 23 N·m (2.3 kgf·m, 17 lb·ft) 15 N·m (1.5 kgf·m, 11 lb·ft) 55 N·m (5.5 kgf·m, 41 lb·ft) ’ Order Job/Parts to remove Remarks The following procedure applies to both of the front fork legs. Cap bolt O-ring Fork spring seat...
  • Page 187 FRONT FORK Disassembling the front fork legs 23 N·m (2.3 kgf·m, 17 lb·ft) 15 N·m (1.5 kgf·m, 11 lb·ft) 55 N·m (5.5 kgf·m, 41 lb·ft) ’ Order Job/Parts to remove Remarks Inner tube bushing Outer tube bushing Washer Oil seal Oil seal clip Dust seal Damper rod assembly...

  • Page 188: Removing The Front Fork Legs

    FRONT FORK EAS31648 REMOVING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. 3.

  • Page 189: Checking The Front Fork Legs

    FRONT FORK 6. Remove: • Damper rod assembly bolt Stroke the damper rod assembly “1” several • Damper rod assembly times while draining the fork oil. While holding the damper rod with the damper rod holder “1”, loosen the damper rod assembly bolt.

  • Page 190: Assembling The Front Fork Legs

    • Inner tube’s outer surface poor handling and a loss of stability. Recommended oil Yamaha Suspension Oil 01 • When assembling the front fork leg, be sure to replace the following parts: 4. Install: –Inner tube bushing...
  • Page 191 FRONT FORK G088922 G088924 8. Install: • Oil seal clip “1” Adjust the oil seal clip so that it fits into the outer tube’s groove. 5. Install: • Outer tube (to the inner tube) 6. Install: • Outer tube bushing “1” G088925 •...
  • Page 192 FRONT FORK Recommended oil Yamaha Suspension Oil 01 Quantity (left) 574.0 cm³ (19.41 US oz, 20.24 Imp.oz) Quantity (right) 574.0 cm³ (19.41 US oz, 20.24 Imp.oz) G088930 ECA14230 14.Install: • Be sure to use the recommended fork oil. • Damper adjusting rod Other oils may have an adverse effect on •...
  • Page 193 FRONT FORK EWA17040 WARNING Always adjust both front fork legs evenly. Uneven adjustment can result in poor han- dling and loss of stability. Distance “b” At least 14 mm (0.55 in) G088927 16.Install: • Fork spring • Spacer • Fork spring seat a.

  • Page 194: Installing The Front Fork Legs

    FRONT FORK Front fork octagonal cap bolt wrench 44 mm 90890-01910 Damper rod locknut 15 N·m (1.5 kgf·m, 11 lb·ft) 2. Tighten: • Lower bracket pinch bolts Lower bracket pinch bolt 20 N·m (2.0 kgf·m, 15 lb·ft) Tighten each bolt to specification in the order pinch bolt “1”...
  • Page 195 FRONT FORK 4-78...

  • Page 196: Steering Head

    STEERING HEAD EAS20035 STEERING HEAD Removing the lower bracket and steering damper 7 N·m (0.7 kgf·m, 5.2 lb·ft) 32 N·m (3.2 kgf·m, 24 lb·ft) 14 N·m (1.4 kgf·m, 10 lb·ft) 1st 75 N·m (7.5 kgf·m, 55 lb·ft) 2nd 7 N·m (0.7 kgf·m, 5.2 lb·ft) 150 N·m (15 kgf·m, 111 lb·ft) 7 N·m (0.7 kgf·m, 5.2 lb·ft) 7 N·m (0.7 kgf·m, 5.2 lb·ft)
  • Page 197 STEERING HEAD Removing the lower bracket and steering damper 7 N·m (0.7 kgf·m, 5.2 lb·ft) 32 N·m (3.2 kgf·m, 24 lb·ft) 14 N·m (1.4 kgf·m, 10 lb·ft) 1st 75 N·m (7.5 kgf·m, 55 lb·ft) 2nd 7 N·m (0.7 kgf·m, 5.2 lb·ft) 150 N·m (15 kgf·m, 111 lb·ft) 7 N·m (0.7 kgf·m, 5.2 lb·ft) 7 N·m (0.7 kgf·m, 5.2 lb·ft)
  • Page 198 STEERING HEAD Removing the lower bracket and steering damper 7 N·m (0.7 kgf·m, 5.2 lb·ft) 32 N·m (3.2 kgf·m, 24 lb·ft) 14 N·m (1.4 kgf·m, 10 lb·ft) 1st 75 N·m (7.5 kgf·m, 55 lb·ft) 2nd 7 N·m (0.7 kgf·m, 5.2 lb·ft) 150 N·m (15 kgf·m, 111 lb·ft) 7 N·m (0.7 kgf·m, 5.2 lb·ft) 7 N·m (0.7 kgf·m, 5.2 lb·ft)

  • Page 199: Removing The Lower Bracket

    STEERING HEAD • Bearing EAS30213 REMOVING THE LOWER BRACKET Damage/pitting → Replace the steering 1. Stand the vehicle on a level surface. damper assembly. EWA13120 WARNING EAS30214 CHECKING THE STEERING HEAD Securely support the vehicle so that there is 1. Wash: no danger of it falling over.

  • Page 200: Installing The Steering Head

    STEERING HEAD Temporarily tighten the upper and lower brack- et pinch bolts. 5. Tighten: • Steering stem nut Steering stem nut 150 N·m (15 kgf·m, 111 lb·ft) G088934 6. Tighten: 4. Check: • Upper and lower bracket pinch bolts • Upper bracket Upper bracket pinch bolt •...

  • Page 201: Rear Shock Absorber Assembly

    REAR SHOCK ABSORBER ASSEMBLY EAS20036 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly 48 N m (4.8 kgf m, 35 lb • • • 60 N m (6.0 kgf m, 44 lb • • • 45 N m (4.5 kgf m, 33 lb •...

  • Page 202: Handling The Rear Shock Absorber

    REAR SHOCK ABSORBER ASSEMBLY EAS30826 HANDLING THE REAR SHOCK ABSORBER Pass a suitable rod “1” through the holes in the EWA13740 WARNING brackets of the passenger footrests “2” and se- cure the rod to support the vehicle. This rear shock absorber contains highly compressed nitrogen gas.

  • Page 203: Installing The Relay Arm

    REAR SHOCK ABSORBER ASSEMBLY • Install both the rear shock absorber assembly and brake hose bracket “3” using the rear shock absorber assembly bolt. • Install the rear shock absorber assembly bolt “2” so that the bolt head fits between the pro- jections “a”...

  • Page 204: Swingarm

    SWINGARM EAS20037 SWINGARM Removing the swingarm 30 N·m (3.0 kgf·m, 22 lb·ft) 110 N·m (11 kgf·m, 81 lb·ft) 7 N·m (0.7 kgf·m, 5.2 lb·ft) 7 N·m (0.7 kgf·m, 5.2 lb·ft) 30 N·m (3.0 kgf·m, 22 lb·ft) 7 N·m (0.7 kgf·m, 5.2 lb·ft) ’...
  • Page 205 SWINGARM Removing the swingarm 30 N·m (3.0 kgf·m, 22 lb·ft) 110 N·m (11 kgf·m, 81 lb·ft) 7 N·m (0.7 kgf·m, 5.2 lb·ft) 7 N·m (0.7 kgf·m, 5.2 lb·ft) 30 N·m (3.0 kgf·m, 22 lb·ft) 7 N·m (0.7 kgf·m, 5.2 lb·ft) ’...

  • Page 206: Removing The Swingarm

    SWINGARM 3. Loosen: EAS30226 REMOVING THE SWINGARM • Adjusting bolt 1. Stand the vehicle on a level surface. EWA13120 WARNING Loosen the adjusting bolt with the engine align- ment tool “1”. Securely support the vehicle so that there is no danger of it falling over. Engine alignment tool 90890-11097 Pass a suitable rod “1”...

  • Page 207: Installing The Swingarm

    SWINGARM • Collars Damage/scratches → Replace. EAS30228 INSTALLING THE SWINGARM 1. Lubricate: • Oil seals • Pivot shaft Recommended lubricant Lithium-soap-based grease 2. Install: • Bearings “1” • Oil seals “2” (to the swingarm “3”) Installed depth “a” 28.3–29.7 mm (1.11–1.17 in) Installed depth “b”...
  • Page 208 SWINGARM 6. Install: • Washer • Pivot shaft nut Pivot shaft nut 110 N·m (11 kgf·m, 81 lb·ft) 7. Install: • Rear wheel Refer to “REAR WHEEL” on page 4-23. 8. Adjust: • Drive chain slack Refer to “ADJUSTING THE DRIVE CHAIN SLACK”...

  • Page 209: Chain Drive

    CHAIN DRIVE EAS20038 CHAIN DRIVE Removing the drive chain 14 N m (1.4 kgf m, 10 lb • • • 10 N m (1.0 kgf m, 7.4 lb • • • m (0.9 kgf m, 6.6 lb • • • 10 N m (1.0 kgf m, 7.4 lb...
  • Page 210 CHAIN DRIVE Removing the drive chain 14 N m (1.4 kgf m, 10 lb • • • 10 N m (1.0 kgf m, 7.4 lb • • • m (0.9 kgf m, 6.6 lb • • • 10 N m (1.0 kgf m, 7.4 lb •...

  • Page 211: Removing The Drive Sprocket

    CHAIN DRIVE EAS31115 REMOVING THE DRIVE SPROCKET Loosen the drive sprocket nut before removing the rear wheel. 1. Straighten the drive sprocket nut ribs “a”. G088937 2. Loosen: • Drive sprocket nut G088938 Loosen the drive sprocket nut while pressing 2.

  • Page 212: Checking The Drive Sprocket

    CHAIN DRIVE • Do not soak the drive chain in kerosene for EAS30231 CHECKING THE DRIVE SPROCKET more than ten minutes, otherwise the O- 1. Check: rings can be damaged. • Drive sprocket More than 1/4 tooth “a” wear → Replace the drive sprocket, drive chain, and rear wheel sprocket as a set.

  • Page 213: Installing The Drive Chain

    CHAIN DRIVE EAS30234 c. After riveting, make sure the space “c”, INSTALLING THE DRIVE CHAIN which is inside of the connecting link “3” 1. Install: and inside of the connecting plate “1”, is • Drive chain 14.6–14.8 mm (0.57–0.58 in). Install the drive chain joint with the drive chain cut &...
  • Page 214 CHAIN DRIVE Shift rod locknut (shift arm side) 9 N·m (0.9 kgf·m, 6.6 lb·ft) Shift rod locknut (shift pedal side) 9 N·m (0.9 kgf·m, 6.6 lb·ft) Left-hand threads d. Make sure that the angle between the shift arm and the shift rod is about 90°. 4.

  • Page 215: Engine

    ENGINE LUBRICATION SYSTEM CHART AND DIAGRAMS ........5-1 ENGINE OIL LUBRICATION CHART ............5-1 LUBRICATION DIAGRAMS ...............5-2 ENGINE INSPECTION ..................5-8 MEASURE THE COMPRESSION PRESSURE ..........5-8 ENGINE REMOVAL ..................5-10 REMOVING THE ENGINE ...............5-20 INSTALLING THE ENGINE ..............5-20 INSTALLING THE EXHAUST PIPE AND MUFFLER ........5-21 CAMSHAFTS....................5-23 REMOVING THE IGNITION COILS............5-26 REMOVING THE CAMSHAFTS ...............5-26...
  • Page 216 ELECTRIC STARTER ...................5-50 CHECKING THE STARTER MOTOR ............5-52 ASSEMBLING THE STARTER MOTOR...........5-52 INSTALLING THE STARTER MOTOR .............5-53 CLUTCH ......................5-54 REMOVING THE CLUTCH ..............5-58 CHECKING THE FRICTION PLATES ............5-58 CHECKING THE CLUTCH PLATES ............5-59 CHECKING THE CLUTCH SPRINGS ............5-59 CHECKING THE CLUTCH HOUSING .............5-59 CHECKING THE CLUTCH BOSS............5-59 CHECKING THE PRESSURE PLATE ............5-59 CHECKING THE PRIMARY DRIVE GEAR ..........5-59...
  • Page 217 CRANKSHAFT AND BALANCER SHAFT ............5-88 REMOVING THE BALANCER SHAFT JOURNAL BEARINGS....5-89 REMOVING THE CRANKSHAFT JOURNAL BEARINGS ......5-89 CHECKING THE BALANCER SHAFT ASSEMBLY........5-89 CHECKING THE CRANKSHAFT .............5-91 INSTALLING THE CRANKSHAFT ............5-93 INSTALLING THE BALANCER SHAFT ASSEMBLY........5-93 TRANSMISSION ...................5-94 REMOVING THE TRANSMISSION ............5-98 CHECKING THE SHIFT FORKS ..............5-98 CHECKING THE SHIFT DRUM ASSEMBLY ...........5-98 CHECKING THE TRANSMISSION ............5-99...

  • 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 2. Oil pump 3. Relief valve 4. Oil cooler 5. Oil filter cartridge 6. Main gallery 7. Oil pressure switch 8. Crankshaft 9.

  • Page 219: Lubrication Diagrams

    LUBRICATION SYSTEM CHART AND DIAGRAMS EAS32363 LUBRICATION DIAGRAMS Crankcase, cylinder, and cylinder head (right side view) 1. Timing chain tensioner 2. Intake camshaft 3. Exhaust camshaft 4. Crankshaft 5. Oil filter cartridge 6. Oil cooler 7. Oil drain bolt 8. Oil strainer 9.
  • Page 220 LUBRICATION SYSTEM CHART AND DIAGRAMS Crankcase and cylinder (left side view) 1. Crankshaft 2. Balancer shaft assembly 3. Connecting rod 4. Oil cooler 5. Oil filter cartridge...
  • Page 221 LUBRICATION SYSTEM CHART AND DIAGRAMS Oil pump (bottom view) 1. Oil pump 2. Oil pressure switch 3. Oil filter cartridge 4. Oil cooler 5. Oil strainer...
  • Page 222 LUBRICATION SYSTEM CHART AND DIAGRAMS Camshaft (top view) 1. Intake camshaft 2. Cylinder head 3. Exhaust camshaft...
  • Page 223 LUBRICATION SYSTEM CHART AND DIAGRAMS Crankshaft (front view) 1. Oil nozzle 2. Piston 3. Crankshaft 4. Main gallery...
  • Page 224 LUBRICATION SYSTEM CHART AND DIAGRAMS Crankshaft and transmission (top view) 1. Balancer shaft assembly 2. Crankshaft 3. Main axle 4. Drive axle...

  • Page 225: Engine Inspection

    ENGINE INSPECTION 6. Measure: EAS20041 ENGINE INSPECTION • Compression pressure Out of specification → Refer to steps (c) and EAS30249 (d). MEASURE THE COMPRESSION PRESSURE The following procedure applies to all of the cyl- inders. Due to the engine characteristics, the compres- sion pressure is different for cylinder #1 and cyl- inder #2.
  • Page 226 ENGINE INSPECTION 7. Install: • Spark plugs • Ignition coils Spark plug 13 N·m (1.3 kgf·m, 9.6 lb·ft)
  • Page 227 ENGINE REMOVAL EAS20042 ENGINE REMOVAL Removing the engine guards and exhaust pipe 10 N·m (1.0 kgf·m, 7.4 lb·ft) 20 N·m (2.0 kgf·m, 15 lb·ft) 10 N·m (1.0 kgf·m, 7.4 lb·ft) 20 N·m (2.0 kgf·m, 15 lb·ft) 10 N·m (1.0 kgf·m, 7.4 lb·ft) 47 N·m (4.7 kgf·m, 35 lb·ft) 10 N·m (1.0 kgf·m, 7.4 lb·ft) 20 N·m (2.0 kgf·m, 15 lb·ft)

  • Page 228: Engine Removal

    ENGINE REMOVAL Removing the engine guards and exhaust pipe 10 N·m (1.0 kgf·m, 7.4 lb·ft) 20 N·m (2.0 kgf·m, 15 lb·ft) 10 N·m (1.0 kgf·m, 7.4 lb·ft) 20 N·m (2.0 kgf·m, 15 lb·ft) 10 N·m (1.0 kgf·m, 7.4 lb·ft) 47 N·m (4.7 kgf·m, 35 lb·ft) 10 N·m (1.0 kgf·m, 7.4 lb·ft) 20 N·m (2.0 kgf·m, 15 lb·ft) 9 N·m (0.9 kgf·m, 6.6 lb·ft)
  • Page 229 ENGINE REMOVAL Removing the down tubes 34 N·m (3.4 kgf·m, 25 lb·ft) 34 N·m (3.4 kgf·m, 25 lb·ft) 9 N·m (0.9 kgf·m, 6.6 lb·ft) 34 N·m (3.4 kgf·m, 25 lb·ft) 11 N·m (1.1 kgf·m, 8.1 lb·ft) 11 N·m (1.1 kgf·m, 8.1 lb·ft) 34 N·m (3.4 kgf·m, 25 lb·ft) ’...
  • Page 230 ENGINE REMOVAL Removing the down tubes 34 N·m (3.4 kgf·m, 25 lb·ft) 34 N·m (3.4 kgf·m, 25 lb·ft) 9 N·m (0.9 kgf·m, 6.6 lb·ft) 34 N·m (3.4 kgf·m, 25 lb·ft) 11 N·m (1.1 kgf·m, 8.1 lb·ft) 11 N·m (1.1 kgf·m, 8.1 lb·ft) 34 N·m (3.4 kgf·m, 25 lb·ft) ’...
  • Page 231 ENGINE REMOVAL Disconnecting the leads and couplers 10 N·m (1.0 kgf·m, 7.4 lb·ft) ’ Order Job/Parts to remove Remarks Refer to “CHANGING THE ENGINE OIL” on Engine oil page 3-25. Refer to “GENERAL CHASSIS (2)” on page Tail cover 4-2. Canister Refer to “FUEL TANK”...
  • Page 232 ENGINE REMOVAL Disconnecting the leads and couplers 10 N·m (1.0 kgf·m, 7.4 lb·ft) ’ Order Job/Parts to remove Remarks Engine ground lead Disconnect. Gear position sensor coupler Disconnect. Plastic band Lead holder Crankshaft position sensor coupler Disconnect. Ignition coil coupler Disconnect.
  • Page 233 ENGINE REMOVAL Removing the engine 55 N·m (5.5 kgf·m, 41 lb·ft) 30 N·m (3.0 kgf·m, 22 lb·ft) 2.0 N·m (0.20 kgf·m, 1.5 lb·ft) 55 N·m (5.5 kgf·m, 41 lb·ft) 55 N·m (5.5 kgf·m, 41 lb·ft) 30 N·m (3.0 kgf·m, 22 lb·ft) 2.0 N·m (0.20 kgf·m, 1.5 lb·ft) 7 N·m (0.7 kgf·m, 5.2 lb·ft) 7 N·m (0.7 kgf·m, 5.2 lb·ft)
  • Page 234 ENGINE REMOVAL Removing the engine 55 N·m (5.5 kgf·m, 41 lb·ft) 30 N·m (3.0 kgf·m, 22 lb·ft) 2.0 N·m (0.20 kgf·m, 1.5 lb·ft) 55 N·m (5.5 kgf·m, 41 lb·ft) 55 N·m (5.5 kgf·m, 41 lb·ft) 30 N·m (3.0 kgf·m, 22 lb·ft) 2.0 N·m (0.20 kgf·m, 1.5 lb·ft) 7 N·m (0.7 kgf·m, 5.2 lb·ft) 7 N·m (0.7 kgf·m, 5.2 lb·ft)
  • Page 235 ENGINE REMOVAL Removing the engine 55 N·m (5.5 kgf·m, 41 lb·ft) 30 N·m (3.0 kgf·m, 22 lb·ft) 2.0 N·m (0.20 kgf·m, 1.5 lb·ft) 55 N·m (5.5 kgf·m, 41 lb·ft) 55 N·m (5.5 kgf·m, 41 lb·ft) 30 N·m (3.0 kgf·m, 22 lb·ft) 2.0 N·m (0.20 kgf·m, 1.5 lb·ft) 7 N·m (0.7 kgf·m, 5.2 lb·ft) 7 N·m (0.7 kgf·m, 5.2 lb·ft)
  • Page 236 ENGINE REMOVAL Disassembling the footrest assembly (left) 23 N·m (2.3 kgf·m, 17 lb·ft) 22 N·m (2.2 kgf·m, 16 lb·ft) 55 N·m (5.5 kgf·m, 41 lb·ft) 53 N·m (5.3 kgf·m, 39 lb·ft) 7 N·m (0.7 kgf·m, 5.2 lb·ft) 7 N·m (0.7 kgf·m, 5.2 lb·ft) 21 N·m (2.1 kgf·m, 15 lb·ft) 38 N·m (3.8 kgf·m, 28 lb·ft) ’...

  • Page 237: Removing The Engine

    ENGINE REMOVAL EAS30250 REMOVING THE ENGINE The following procedure applies to all of the en- gine mounting adjust bolts. 1. Loosen: • Engine mounting adjust bolt Loosen the engine mounting adjust bolt using a 1/2 inch hexagon bit socket “1” EAS30251 INSTALLING THE ENGINE A.

  • Page 238: Installing The Exhaust Pipe And Muffler

    ENGINE REMOVAL • Engine mounting nut (rear lower side) “15” 12.Tighten: • Engine mounting bolt (left upper side) “19” Engine mounting nut • Engine mounting bolt (right upper side) “20” 55 N·m (5.5 kgf·m, 41 lb·ft) Engine mounting bolt (left upper 8.
  • Page 239 ENGINE REMOVAL 2. Install: • Damper “1” (to the frame) Install the damper with the mark “a” facing rear wheel side. 3. Install: • Exhaust pipe bracket “1” (to the frame) Install the exhaust pipe bracket with the mark “a” facing the left side of the vehicle. 5-22...

  • Page 240: Camshafts

    CAMSHAFTS EAS20043 CAMSHAFTS Removing the cylinder head cover 10 N·m (1.0 kgf·m, 7.4 lb·ft) 13 N·m (1.3 kgf·m, 9.6 lb·ft) 13 N·m (1.3 kgf·m, 9.6 lb·ft) 4.0 N·m (0.40 kgf·m, 3.0 lb·ft) ’ Order Job/Parts to remove Remarks Refer to “GENERAL CHASSIS (1)” on page Rider seat 4-1.
  • Page 241 CAMSHAFTS Removing the cylinder head cover 10 N·m (1.0 kgf·m, 7.4 lb·ft) 13 N·m (1.3 kgf·m, 9.6 lb·ft) 13 N·m (1.3 kgf·m, 9.6 lb·ft) 4.0 N·m (0.40 kgf·m, 3.0 lb·ft) ’ Order Job/Parts to remove Remarks Cylinder head breather hose Ignition coil coupler Disconnect.
  • Page 242 CAMSHAFTS Removing the camshafts 10 N m (1.0 kgf m, 7.4 lb • • • 10 N m (1.0 kgf m, 7.4 lb • • • m (0.7 kgf m, 5.2 lb • • • 10 N m (1.0 kgf m, 7.4 lb •...

  • Page 243: Removing The Ignition Coils

    CAMSHAFTS EAS33146 ECA13720 REMOVING THE IGNITION COILS 1. Remove: To prevent damage to the cylinder head, • Ignition coil camshafts or camshaft caps, loosen the Refer to “CHECKING THE SPARK PLUGS” camshaft cap bolts in stages and in a criss- on page 3-5.

  • Page 244: Checking The Cylinder Head Breather Hose

    CAMSHAFTS 4. Measure: EAS31133 CHECKING THE CYLINDER HEAD • Camshaft-journal-to-camshaft-cap clear- BREATHER HOSE ance Out of specification → Measure the cam- 1. Check: • Cylinder head breather hose shaft journal diameter. Cracks/damage → Replace. Loosen connection → Connect properly. Camshaft-journal-to-camshaft- cap clearance limit 0.080 mm (0.0032 in) EAS30257...

  • Page 245: Checking The Camshaft Sprockets

    CAMSHAFTS EAS30266 CHECKING THE TIMING CHAIN TENSIONER 1. Check: • Timing chain tensioner Cracks/damage/rough movement → Re- place. a. Lightly press the timing chain tensioner rod into the timing chain tensioner hous- ing by hand. G088948 While pressing the timing chain tensioner rod, 5.

  • Page 246: Installing The Camshafts

    CAMSHAFTS Rotor holding tool 90890-01235 Universal magneto and rotor holder YU-01235 EAS30269 INSTALLING THE CAMSHAFTS 1. Align: • Mark “a” on the generator rotor (with the slot “b” in the generator rotor cover) a. Turn the crankshaft counterclockwise. b. When piston #1 is at TDC, align the TDC mark “a”...
  • Page 247 CAMSHAFTS ECA19980 • When installing the timing chain, start with the Be sure to tighten the camshaft sprocket exhaust camshaft and be sure to keep the tim- bolts to the specified torque to avoid the ing chain as tight as possible on the exhaust possibility of the bolts coming loose and side.
  • Page 248 CAMSHAFTS c. Install a new timing chain tensioner gas- ket “3”, the timing chain tensioner “4”, and the timing chain tensioner bolts “5” on the cylinder block. Be sure to install the timing chain tensioner gas- ket so that the portion “a” of the gasket is pro- truding from the upper inner side of the timing chain tensioner.

  • Page 249: Installing The Cylinder Head Cover

    • Cylinder head cover “2” Cylinder head cover bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft) • Apply Yamaha bond No.1215 “3” onto the mating surfaces of the cylinder head cover gasket and cylinder head. • After installing the cylinder head cover gasket “1”...
  • Page 250 CAMSHAFTS A. Exhaust side 2. Install: • Spark plugs • Ignition coils “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. 5-33...

  • Page 251: Cylinder Head

    CYLINDER HEAD EAS20044 CYLINDER HEAD Removing the cylinder head 1st 10 N·m (1.0 kgf·m, 7.4 lb·ft) 40 N·m (4.0 kgf·m, 30lb·ft) 20 N·m (2.0 kgf·m, 15lb·ft) *3rd Specified angle 90–120° 10 N·m (1.0 kgf·m, 7.4 lb·ft) 10 N·m (1.0 kgf·m, 7.4 lb·ft) 10 N·m (1.0 kgf·m, 7.4 lb·ft) * Following the tightening order, loosen the bolt one by one, and then retighten it to specific torque.
  • Page 252 CYLINDER HEAD Removing the cylinder head 1st 10 N·m (1.0 kgf·m, 7.4 lb·ft) 40 N·m (4.0 kgf·m, 30lb·ft) 20 N·m (2.0 kgf·m, 15lb·ft) *3rd Specified angle 90–120° 10 N·m (1.0 kgf·m, 7.4 lb·ft) 10 N·m (1.0 kgf·m, 7.4 lb·ft) 10 N·m (1.0 kgf·m, 7.4 lb·ft) * Following the tightening order, loosen the bolt one by one, and then retighten it to specific torque.
  • Page 253 CYLINDER HEAD Removing the cylinder head 1st 10 N·m (1.0 kgf·m, 7.4 lb·ft) 40 N·m (4.0 kgf·m, 30lb·ft) 20 N·m (2.0 kgf·m, 15lb·ft) *3rd Specified angle 90–120° 10 N·m (1.0 kgf·m, 7.4 lb·ft) 10 N·m (1.0 kgf·m, 7.4 lb·ft) 10 N·m (1.0 kgf·m, 7.4 lb·ft) * Following the tightening order, loosen the bolt one by one, and then retighten it to the specific torque.

  • Page 254: Removing The Cylinder Head

    CYLINDER HEAD 2. Check: EAS30276 REMOVING THE CYLINDER HEAD • Cylinder head 1. Remove: Damage/scratches → Replace. • Cylinder head bolt (M6) (×2) • Cylinder head water jacket • Cylinder head bolt (M10) (×6) Mineral deposits/rust → Eliminate. 3. Measure: •...
  • Page 255 CYLINDER HEAD • Pass the timing chain through the timing chain cavity. • Lubricate the cylinder head bolt (M10) threads and mating surface with engine oil. 2. Tighten: • Cylinder head bolts “1”–“6” • Cylinder head bolts “7”, “8” Cylinder head bolt (“1”–“6”) 1st: 10 N·m (1.0 kgf·m, 7.4 lb·ft) 2nd: 40 N·m (4.0 kgf·m, 30 lb·ft) *3rd: 20 N·m (2.0 kgf·m, 15 lb·ft)

  • Page 256: Valves And Valve Springs

    VALVES AND VALVE SPRINGS EAS20045 VALVES AND VALVE SPRINGS Removing the valves and valve springs ’ Order Job/Parts to remove Remarks Cylinder head Refer to “CYLINDER HEAD” on page 5-34. Valve lifter Valve pad Valve cotter Valve spring retainer Valve spring Exhaust valve Intake valve Valve stem seal...

  • Page 257: 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 Valve spring compressor attach- Before removing the internal parts of the cylin- ment (ø26) der head (e.g., valves, valve springs, valve 90890-01243...
  • Page 258 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, G088964 and to maintain the correct fit, heat the cylinder head to 100 °C (212 °F) in an oven.

  • Page 259: 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 260: Checking The Valve Springs

    VALVES AND VALVE SPRINGS 1. Measure: • Valve spring free length “a” For the best lapping results, lightly tap the valve Out of specification → Replace the valve seat while rotating the valve back and forth be- spring. tween your hands. Free length limit (intake) 38.29 mm (1.51 in) Free length limit (exhaust)
  • Page 261 VALVES AND VALVE SPRINGS 3. Install: 5. To secure the valve cotters onto the valve • Valve spring seat “1” stem, lightly tap the valve tip with a soft-face (into the cylinder head) hammer. ECA13800 • Valve stem seal “2” •...

  • Page 262: Generator And Starter Clutch

    GENERATOR AND STARTER CLUTCH EAS20140 GENERATOR AND STARTER CLUTCH Removing the stator coil, generator rotor and starter clutch 32 N m (3.2 kgf m, 24 lb • • • 10 N m (1.0 kgf m, 7.4 lb • • • 10 N m (1.0 kgf m, 7.4 lb...
  • Page 263 GENERATOR AND STARTER CLUTCH Removing the stator coil, generator rotor and starter clutch 32 N m (3.2 kgf m, 24 lb • • • 10 N m (1.0 kgf m, 7.4 lb • • • 10 N m (1.0 kgf m, 7.4 lb •...

  • Page 264: 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 rotor holding tool “3”, loosen the generator rotor bolt. G088977 Rotor holding tool EAS30868 REMOVING THE STARTER CLUTCH 90890-04166 1.

  • Page 265: Checking The Torque Limiter

    GENERATOR AND STARTER CLUTCH a. Install the starter clutch gear “1” onto the generator rotor “2” and hold the generator rotor. b. When turning the starter clutch gear clockwise “A”, the starter clutch and the starter clutch gear should engage, other- wise the starter clutch is faulty and must be replaced.
  • Page 266 • Apply LOCTITE® to the threads of only the generator cover bolts “1” shown in the illustra- tion. 4. Apply: • Sealant (onto the stator coil lead grommet) Yamaha bond No. 1215 90890-85505 Three bond No. 1215® 7. Connect: • Stator coil coupler • Crankshaft position sensor coupler To route the stator coil lead, refer to “CABLE...

  • Page 267: Electric Starter

    ELECTRIC STARTER EAS20052 ELECTRIC STARTER Removing the starter motor m (0.7 kgf m, 5.2 lb • • • 10 N m (1.0 kgf m, 7.4 lb • • • ’ Order Job/Parts to remove Remarks Canister Refer to “FUEL TANK” on page 7-1. Starter motor lead Disconnect.
  • Page 268 ELECTRIC STARTER Disassembling the starter motor 11 N m (1.1 kgf m, 8.1 lb • • • m (0.5 kgf m, 3.7 lb • • • ’ Order Job/Parts to remove Remarks O-ring Starter motor front cover Starter motor yoke Armature assembly Gasket Brush holder set...

  • Page 269: Checking The Starter Motor

    ELECTRIC STARTER 4. Measure: EAS30325 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 270: Installing The Starter Motor

    ELECTRIC STARTER EAS30327 INSTALLING THE STARTER MOTOR 1. Install: • Canister holder • Starter motor Pass the starter motor front cover bolts “1” through the slots “a” in the canister holder to se- cure it. 5-53...

  • Page 271: Clutch

    CLUTCH EAS20055 CLUTCH Removing the clutch cover and pull lever shaft m (0.7 kgf m, 5.2 lb • • • 12 N m (1.2 kgf m, 8.9 lb • • • 12 N m (1.2 kgf m, 8.9 lb • •...
  • Page 272 CLUTCH Removing the clutch cover and pull lever shaft m (0.7 kgf m, 5.2 lb • • • 12 N m (1.2 kgf m, 8.9 lb • • • 12 N m (1.2 kgf m, 8.9 lb • • • ’...
  • Page 273 CLUTCH Removing the clutch m (0.8 kgf m, 5.9 lb • • • 10 N m (1.0 kgf m, 7.4 lb • • • 95 N m (9.5 kgf m, 70 lb • • • ’ Order Job/Parts to remove Remarks Compression spring Pressure plate...
  • Page 274 CLUTCH Removing the clutch m (0.8 kgf m, 5.9 lb • • • 10 N m (1.0 kgf m, 7.4 lb • • • 95 N m (9.5 kgf m, 70 lb • • • ’ Order Job/Parts to remove Remarks Washer Clutch boss...

  • Page 275: Removing The Clutch

    CLUTCH EAS30346 REMOVING THE CLUTCH 1. Remove: • Clutch cover • 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. G088993 2.

  • Page 276: Checking The Clutch Plates

    CLUTCH EAS30352 CHECKING THE CLUTCH HOUSING 1. Check: • Clutch housing dogs Damage/pitting/wear → Deburr the clutch housing dogs or replace the clutch housing. Pitting on the clutch housing dogs will cause er- ratic clutch operation. 2. Check: A. Friction plate 1 •...

  • Page 277: Checking The Pull Lever Shaft And Pull Rod

    CLUTCH EAS30358 CHECKING THE PULL LEVER SHAFT AND Clutch holder PULL ROD 90890-04199 1. Check: Universal clutch holder YM-91042 • Pull lever shaft pinion gear teeth • Pull rod teeth Damage/wear → Replace the pull rod and pull lever shaft as a set. 2.
  • Page 278 CLUTCH Clutch spring bolt Clutch cover bolt 8 N·m (0.8 kgf·m, 5.9 lb·ft) 12 N·m (1.2 kgf·m, 8.9 lb·ft) Clutch cable holder bolt 12 N·m (1.2 kgf·m, 8.9 lb·ft) LOCTITE® • Apply lithium-soap-based grease onto the pull rod. • Tighten the clutch spring bolts in stages and in •...
  • Page 279 CLUTCH • After installing the clutch cable, bend the pro- jection “b” on the pull lever. 9. Adjust: • Clutch lever free play Refer to “ADJUSTING THE CLUTCH LEVER FREE PLAY” on page 3-13. Clutch lever free play 5.0–10.0 mm (0.20–0.39 in) 5-62...

  • Page 280: 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 Remarks Refer to “GENERAL CHASSIS (1)” on page Rider seat 4-1. Refer to “GENERAL CHASSIS (3)” on page Front side cover (left/right) 4-5.
  • Page 281 SHIFT SHAFT Removing the shift shaft and stopper lever 22 N m (2.2 kgf m, 16 lb • • • ’ Order Job/Parts to remove Remarks Shift arm Refer to “CHAIN DRIVE” on page 4-92. Water pump housing Refer to “WATER PUMP” on page 6-10. Clutch housing Refer to “CLUTCH”...
  • Page 282 SHIFT SHAFT Removing the shift shaft and stopper lever 12 13 22 N m (2.2 kgf m, 16 lb • • • ’ Order Job/Parts to remove Remarks Stopper lever Stopper lever spring Collar Shift shaft spring Shift shaft spring stopper Oil seal Bearing 5-65...

  • Page 283: Checking The Shift Shaft

    SHIFT SHAFT • Hook the ends of the stopper lever spring “3” EAS30377 CHECKING THE SHIFT SHAFT onto the stopper lever “4” and the stopper le- 1. Check: ver spring hook “5”. • Shift shaft • Mesh the stopper lever with the shift drum Bends/damage/wear →...

  • Page 284: Oil Pump

    OIL PUMP EAS20054 OIL PUMP Removing the oil pump 10 N m (1.0 kgf m, 7.4 lb • • • 12 N m (1.2 kgf m, 8.9 lb • • • 12 N m (1.2 kgf m, 8.9 lb • •...
  • Page 285 OIL PUMP Disassembling the oil pump 3.8 N m (0.38 kgf m, 2.8 lb • • • ’ Order Job/Parts to remove Remarks Oil pump cover Oil pump rotor assembly Oil pump inner rotor Oil pump outer rotor Oil pump driven sprocket Hold down the washer when removing the Circlip circlip.

  • Page 286: Checking The Sprocket And Chain

    OIL PUMP 2. Lubricate: EAS30336 CHECKING THE SPROCKET AND CHAIN • Oil pump driven sprocket 1. Check: (with the recommended lubricant) • Oil pump drive sprocket Refer to “CHECKING THE CLUTCH HOUS- Recommended lubricant ING” on page 5-59. Engine oil •...
  • Page 287 OIL PUMP 5-70...

  • Page 288: Oil Pan

    OIL PAN EAS20177 OIL PAN Removing the oil pan 43 N m (4.3 kgf m, 32 lb • • • 10 N m (1.0 kgf m, 7.4 lb 10 N m (1.0 kgf m, 7.4 lb (11) • • • •...

  • Page 289: Removing The Oil Pan

    OIL PAN EAS31068 REMOVING THE OIL PAN 1. Remove: • Oil pan “1” • Oil pan gasket • Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. •...

  • Page 290: Crankcase

    CRANKCASE EAS20059 CRANKCASE Separating the crankcase 24 N m (2.4 kgf m, 18 lb • • • 24 N m (2.4 kgf m, 18 lb • • • 17 N m (1.7 kgf m, 13 lb • • • 10 N m (1.0 kgf m, 7.4 lb •...
  • Page 291 CRANKCASE Separating the crankcase 24 N m (2.4 kgf m, 18 lb 24 N m (2.4 kgf m, 18 lb • • • • • • 17 N m (1.7 kgf m, 13 lb • • • 10 N m (1.0 kgf m, 7.4 lb •...

  • Page 292: Disassembling The Crankcase

    • Sealant ×3 ×2 (onto the crankcase mating surfaces) ×2 ×6 ×5 Yamaha bond No. 1215 90890-85505 Three bond No. 1215® ECA20880 Do not allow any sealant to come into con- tact with the oil gallery, crankshaft journal ×1 bearings, or balancer shaft journal bearings.
  • Page 293 CRANKCASE • Lubricate the bolts “13”–“27” threads and mating surfaces with engine oil. • M9 × 80 mm bolt (×5) (bolts with washers): “1”, “3”–“6” • M9 × 90 mm bolt (×1) (bolt with washer): “2” • M8 × 70 mm bolt (×6) (bolts with new O- rings): “7”–“12”...

  • Page 294: Installing The Oil Pressure Switch

    24 N·m (2.4 kgf·m, 18 lb·ft) (onto the oil pressure switch threads) Crankcase bolts “15”–“27” 10 N·m (1.0 kgf·m, 7.4 lb·ft) Yamaha bond No. 1215 90890-85505 Three bond No. 1215® • Tighten the bolts “7”–“16” in the tightening se- quence cast on the crankcase.
  • Page 295 CRANKCASE 10˚ 45˚ 5-78...
  • Page 296 CONNECTING RODS AND PISTONS EAS20132 CONNECTING RODS AND PISTONS Removing the connecting rods and pistons 1st 20 N m (2.0 kgf m, 15 lb • • • 2nd Specified angle 180° ’ Order Job/Parts to remove Remarks The following procedure applies to all of the connecting rods and pistons.

  • Page 297: Connecting Rods And Pistons

    CONNECTING RODS AND PISTONS • 2nd ring EAS30745 REMOVING THE CONNECTING RODS AND • Oil ring PISTONS The following procedure applies to all of the When removing a piston ring, open the end gap connecting rods and pistons. with your fingers and lift the other side of the 1.

  • Page 298: Checking The Piston Rings

    CONNECTING RODS AND PISTONS b. If out of specification, replace the cylin- der, and replace the piston and piston rings as a set. c. Measure piston skirt diameter “b” with the micrometer. Diameter 79.970–79.985 mm (3.1484– 3.1490 in) G089002 2. Install: •...

  • Page 299: Checking The Connecting Rods

    CONNECTING RODS AND PISTONS 1. Check: ECA13930 • Piston pin Blue discoloration/grooves → Replace the Do not interchange the big end bearings and connecting rods. To obtain the correct piston pin, and then check the lubrication crankshaft-pin-to-big-end-bearing clear- system. ance and prevent engine damage, the big 2.
  • Page 300 CONNECTING RODS AND PISTONS • Make sure that the projection “a” on the con- necting rod cap faces the same direction as • Do not move the connecting rod or crankshaft the “Y” mark “b” on the connecting rod. until the clearance measurement has been •...
  • Page 301 CONNECTING RODS AND PISTONS ECA20890 • The numbers “A” stamped into the crankshaft Do not use a torque wrench to tighten the web and the numbers “B” on the connecting bolt to the specified angle. rods are used to determine the replacement big end bearings sizes.

  • Page 302: Installing The Connecting Rod And Piston

    CONNECTING RODS AND PISTONS ECA18390 Bearing color code Code 1 Tighten the connecting rod bolts using the Blue plastic-region tightening angle method. Al- Code 2 ways install new bolts. Black Code 3 Brown Install by carrying out the following procedures Code 4 in order to assemble in the most suitable condi- Green...
  • Page 303 CONNECTING RODS AND PISTONS • 2nd ring “4” 5. Lubricate: • Top ring “5” • Piston • Piston rings • Cylinder Be sure to install the piston rings so that the (with the recommended lubricant) manufacturer’s marks “a” face up. Recommended lubricant Engine oil 6.
  • Page 304 CONNECTING RODS AND PISTONS Piston ring compressor Connecting rod bolt (final) 90890-05158 Specified angle 180° Piston ring compressor YM-08037 EWA16610 WARNING If the bolt is tightened more than the speci- fied angle, do not loosen the bolt and then retighten it. Instead, replace the bolt with a new one and perform the procedure again.

  • Page 305: Crankshaft And Balancer Shaft

    CRANKSHAFT AND BALANCER SHAFT EAS20178 CRANKSHAFT AND BALANCER SHAFT Removing the crankshaft and balancer shaft ’ Order Job/Parts to remove Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-73. Refer to “CONNECTING RODS AND PIS- Connecting rod TONS” on page 5-79. Balancer shaft assembly Balancer shaft journal lower bearing Balancer shaft journal upper bearing...

  • Page 306: Removing The Balancer Shaft Journal Bearings

    CRANKSHAFT AND BALANCER SHAFT 3. Check: EAS31072 REMOVING THE BALANCER SHAFT • Balancer shaft assembly JOURNAL BEARINGS Cracks/damage/wear → Replace the bal- 1. Remove: ancer shaft assembly and journal bearings. • Balancer shaft journal lower bearings Dirt → Clean. (from the crankcase) •...
  • Page 307 CRANKSHAFT AND BALANCER SHAFT Do not put the Plastigauge® over the oil hole in the balancer shaft journal. 5. Select: • Balancer shaft journal bearings (J –J • The numbers “A” stamped into the crankcase d. Install the balancer shaft journal lower and the numbers “B”...

  • Page 308: Checking The Crankshaft

    CRANKSHAFT AND BALANCER SHAFT For example, if the crankcase J and balanc- 4. Measure: • Crankshaft-journal-to-crankshaft-journal- er shaft web J numbers are 6 and 5 respec- bearing clearance tively, then the bearing size for J Out of specification → Replace the crank- (crankcase) –...
  • Page 309 CRANKSHAFT AND BALANCER SHAFT 5. Select: • Crankshaft journal bearings (J –J • The numbers “A” stamped into the crankcase and the numbers “B” stamped into the crank- shaft web are used to determine the replace- ment crankshaft journal bearing sizes. •...

  • Page 310: Installing The Crankshaft

    CRANKSHAFT AND BALANCER SHAFT Bearing color code Model identification color Pink Code -1 Purple Code 0 White Code 1 Blue G089019 Code 2 Black 2. Install: Code 3 • Balancer shaft “1” Brown Align the punch mark “a” in the balancer drive EAS31077 gear with the punch mark “b”...

  • Page 311: Transmission

    TRANSMISSION EAS20062 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks 10 N m (1.0 kgf m, 7.4 lb • • • 12 N m (1.2 kgf m, 8.9 lb • • • ’ Order Job/Parts to remove Remarks Separate.
  • Page 312 TRANSMISSION Disassembling the main axle assembly ’ Order Job/Parts to remove 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 Main axle 5-95...
  • Page 313 TRANSMISSION Disassembling the drive axle assembly ’ Order Job/Parts to remove 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 5-96...
  • Page 314 TRANSMISSION Disassembling the drive axle assembly ’ Order Job/Parts to remove Remarks Circlip 6th wheel gear Circlip Washer Collar 2nd wheel gear Oil seal Circlip Bearing Collar Drive axle 5-97...

  • Page 315: Removing The Transmission

    TRANSMISSION EAS30430 REMOVING THE TRANSMISSION 1. Remove: • Drive axle assembly “1” • Shift drum retainer “2” • Shift fork guide bars • Shift fork “L” and “R” • Shift drum assembly • Shift fork “C” G089022 2. Check: • Shift fork guide bar Roll the shift fork guide bar on a flat surface.

  • Page 316: Checking The Transmission

    TRANSMISSION • Transmission gear dogs Cracks/damage/rounded edges → Replace the defective gear(s). G089024 EAS30433 CHECKING THE TRANSMISSION G089025 1. Measure: • Main axle runout 4. Check: (with a centering device and dial gauge “1”) • Transmission gear engagement Out of specification → Replace the main ax- (each pinion gear to its respective wheel gear) Incorrect →...

  • Page 317: Installing The Transmission

    TRANSMISSION • Bearing retainer Bearing retainer bolt 12 N·m (1.2 kgf·m, 8.9 lb·ft) LOCTITE® Use a suitable pin “a” to position the bearing housing, and then install the housing until it con- tacts the cylinder. 2. Install: A. Main axle •...
  • Page 318 TRANSMISSION 4. Check: • Transmission Rough movement → Repair. Oil each gear, shaft, and bearing thoroughly. 5-101...

  • Page 319: Cooling System

    COOLING SYSTEM COOLING SYSTEM DIAGRAMS..............6-1 RADIATOR ......................6-2 CHECKING THE RADIATOR ..............6-4 INSTALLING THE RADIATOR ..............6-4 OIL COOLER....................6-5 CHECKING THE OIL COOLER..............6-7 CHECKING THE WATER JACKET JOINT ..........6-7 INSTALLING THE OIL COOLER..............6-7 THERMOSTAT ....................6-8 CHECKING THE THERMOSTAT ...............6-9 INSTALLING THE THERMOSTAT .............6-9 WATER PUMP ....................6-10 DISASSEMBLING THE WATER PUMP ...........6-13 CHECKING THE WATER PUMP .............6-13...

  • Page 320: Cooling System Diagrams

    COOLING SYSTEM DIAGRAMS EAS20299 COOLING SYSTEM DIAGRAMS 1. Thermostat 2. Oil cooler inlet hose 3. Oil cooler 4. Oil cooler outlet hose 5. Water jacket joint inlet hose 6. Water pump outlet pipe 7. Water pump inlet pipe 8. Radiator outlet hose 9.

  • Page 321: Radiator

    RADIATOR EAS20063 RADIATOR Removing the radiator 8 N·m (0.8 kgf·m, 5.9 lb·ft) 1.0 N·m (0.10 kgf·m, 0.73 lb·ft) 7 N·m (0.7 kgf·m, 5.2 lb·ft) 2.0 N·m (0.20 kgf·m, 1.5 lb·ft) 7 N·m (0.7 kgf·m, 5.2 lb·ft) 7 N·m (0.7 kgf·m, 5.2 lb·ft) ’...
  • Page 322 RADIATOR Removing the radiator 8 N·m (0.8 kgf·m, 5.9 lb·ft) 1.0 N·m (0.10 kgf·m, 0.73 lb·ft) 7 N·m (0.7 kgf·m, 5.2 lb·ft) 2.0 N·m (0.20 kgf·m, 1.5 lb·ft) 7 N·m (0.7 kgf·m, 5.2 lb·ft) 7 N·m (0.7 kgf·m, 5.2 lb·ft) ’...

  • Page 323: Checking The Radiator

    RADIATOR EAS30439 CHECKING THE RADIATOR 1. Check: • Radiator fins Obstruction → Clean. Apply compressed air to the rear of the radi- ator. Damage → Repair or replace. Straighten any flattened fins with a thin, flat- G089029 head screwdriver. b. Apply the specified pressure for ten sec- onds and make sure there is no drop in pressure.

  • Page 324: Oil Cooler

    OIL COOLER EAS20064 OIL COOLER Removing the oil cooler 2.0 N·m (0.20 kgf·m, 1.5 lb·ft) 10 N·m (1.0 kgf·m, 7.4 lb·ft) 17 N·m (1.7 kgf·m, 13 lb·ft) 40 N·m (4.0 kgf·m, 30 lb·ft) ’ Order Job/Parts to remove Remarks Refer to “GENERAL CHASSIS (1)” on page Rider seat 4-1.
  • Page 325 OIL COOLER Removing the oil cooler 2.0 N·m (0.20 kgf·m, 1.5 lb·ft) 10 N·m (1.0 kgf·m, 7.4 lb·ft) 17 N·m (1.7 kgf·m, 13 lb·ft) 40 N·m (4.0 kgf·m, 30 lb·ft) ’ Order Job/Parts to remove Remarks Oil filter cartridge Water jacket joint inlet hose Water jacket joint Oil cooler inlet hose Disconnect.

  • Page 326: Checking The Oil Cooler

    OIL COOLER Refer to “CHANGING THE ENGINE OIL” on EAS30441 CHECKING THE OIL COOLER page 3-25. 1. Check: 4. Check: • Oil cooler • Cooling system Cracks/damage → Replace. Leaks → Repair or replace any faulty part. 2. Check: 5. Measure: •...

  • Page 327: Thermostat

    THERMOSTAT EAS20065 THERMOSTAT Removing the thermostat 2.0 N·m (0.20 kgf·m, 1.5 lb·ft) 12 N·m (1.2 kgf·m, 8.9 lb·ft) ’ Order Job/Parts to remove Remarks Refer to “GENERAL CHASSIS (1)” on page Rider seat 4-1. Refer to “GENERAL CHASSIS (3)” on page Front side cover (left/right) 4-5.

  • Page 328: Checking The Thermostat

    THERMOSTAT EAS30443 CHECKING THE THERMOSTAT Install the thermostat with its breather valve “a” 1. Check: facing inward. • Thermostat Does not open at 80–84 °C (176–183.2 °F) → Replace. a. Suspend the thermostat “1” in a container “2” filled with water. b.

  • Page 329: Water Pump

    WATER PUMP EAS20066 WATER PUMP Removing the water pump m (0.7 kgf m, 5.2 lb • • • 12 N m (1.2 kgf m, 8.9 lb • • • 10 N m (1.0 kgf m, 7.4 lb • • • 10 N m (1.0 kgf m, 7.4 lb...
  • Page 330 WATER PUMP Removing the water pump m (0.7 kgf m, 5.2 lb • • • 12 N m (1.2 kgf m, 8.9 lb • • • 10 N m (1.0 kgf m, 7.4 lb • • • 10 N m (1.0 kgf m, 7.4 lb m (0.7 kgf m, 5.2 lb...
  • Page 331 WATER PUMP Removing the water pump m (0.7 kgf m, 5.2 lb • • • 12 N m (1.2 kgf m, 8.9 lb • • • 10 N m (1.0 kgf m, 7.4 lb • • • 10 N m (1.0 kgf m, 7.4 lb m (0.7 kgf m, 5.2 lb...

  • Page 332: Disassembling The Water Pump

    WATER PUMP EAS30446 EAS30447 DISASSEMBLING THE WATER PUMP CHECKING THE WATER PUMP 1. Remove: 1. Check: • Mechanical seal (impeller side) “1” • Water pump housing (from the impeller, with a thin, flat-head • Clutch cover screwdriver) • Impeller shaft Cracks/damage/wear →...
  • Page 333 WATER PUMP Mechanical seal installer (ø33) If the surface “a” of the mechanical seal (impel- 90890-04132 ler side) that contacts the mechanical seal Water pump seal installer (ø33) (housing side) is dirty, clean it. YM-33221-A Middle driven shaft bearing driver 90890-04058 Mechanical seal (impeller side) Middle drive bearing installer 40...

  • Page 334: Installing The Clutch Cover

    WATER PUMP Refer to “CHANGING THE COOLANT” on EAS31117 INSTALLING THE CLUTCH COVER page 3-28. 1. Install: 3. Check: • Dowel pins “1” • Cooling system • Clutch cover gasket “2” Leaks → Repair or replace the faulty part. • Clutch cover “3” 4.

  • Page 335: Fuel System

    FUEL SYSTEM FUEL TANK .....................7-1 REMOVING THE FUEL TANK SIDE COVERS ...........7-5 REMOVING THE FUEL TANK (RIGHT)............7-5 REMOVING THE FUEL TANK (LEFT) ............7-5 REMOVING THE FUEL PUMP ..............7-5 CHECKING THE FUEL PUMP BODY............7-6 CHECKING THE PURGE CUT VALVE SOLENOID........7-6 INSTALLING THE CANISTER..............7-6 INSTALLING THE FUEL PUMP ..............7-6 INSTALLING THE FUEL TANK (LEFT)............7-6 INSTALLING THE FUEL TANK SIDE COVERS .........7-6...

  • Page 336: Fuel Tank

    FUEL TANK EAS20067 FUEL TANK Removing the fuel tank (right) 5 N·m (0.5 kgf·m, 3.7 lb·ft) 15 N·m (1.5 kgf·m, 11 lb·ft) 20 N·m (2.0 kgf·m, 15 lb·ft) 5 N·m (0.5 kgf·m, 3.7 lb·ft) 4.0 N·m (0.40 kgf·m, 3.0 lb·ft) 20 N·m (2.0 kgf·m, 15 lb·ft) ’...
  • Page 337 FUEL TANK Removing the fuel tank (right) 5 N·m (0.5 kgf·m, 3.7 lb·ft) 15 N·m (1.5 kgf·m, 11 lb·ft) 20 N·m (2.0 kgf·m, 15 lb·ft) 5 N·m (0.5 kgf·m, 3.7 lb·ft) 4.0 N·m (0.40 kgf·m, 3.0 lb·ft) 20 N·m (2.0 kgf·m, 15 lb·ft) ’...
  • Page 338 FUEL TANK Removing the fuel tank (left) 5 N·m (0.5 kgf·m, 3.7 lb·ft) 20 N·m (2.0 kgf·m, 15 lb·ft) 5 N·m (0.5 kgf·m, 3.7 lb·ft) 5 N·m (0.5 kgf·m, 3.7 lb·ft) 20 N·m (2.0 kgf·m, 15 lb·ft) 4.0 N·m (0.40 kgf·m, 3.0 lb·ft) ’...
  • Page 339 FUEL TANK Removing the canister 5 N·m (0.5 kgf·m, 3.7 lb·ft) ’ Order Job/Parts to remove Remarks Canister purge hose (canister to purge cut valve solenoid) Fuel tank breather hose (right fuel tank to canis- ter) Canister breather hose Canister Canister purge hose (purge cut valve solenoid to throttle body) Fuel tank overflow hose...

  • Page 340: Removing The Fuel Tank Side Covers

    FUEL TANK EAS31661 EAS33810 REMOVING THE FUEL TANK SIDE COVERS REMOVING THE FUEL TANK (LEFT) The following procedure applies to the both of 1. Extract the fuel in the fuel tank through the the fuel tank side covers. fuel tank cap with a pump. 1.

  • Page 341: Checking The Fuel Pump Body

    FUEL TANK ECA23950 • Do not damage the installation surfaces of the Do not drop the fuel pump or give it a strong fuel tank when installing the fuel pump. shock. • Always use a new fuel pump gasket. • The gasket lip “a” shall face toward the fuel EAS30454 tank.

  • Page 342: Installing The Fuel Tank Center Cover

    FUEL TANK a. Fit the projection “a” into the grommet “b” on the fuel tank. b. Fit the projections “c” on the fuel tank into the grommets “d”. c. Install the fuel tank side cover bolts. Fuel tank side cover bolt 4.0 N·m (0.40 kgf·m, 3.0 lb·ft) EAS33811 INSTALLING THE FUEL TANK CENTER...

  • Page 343: Throttle Bodies

    THROTTLE BODIES EAS20070 THROTTLE BODIES Removing the throttle bodies 15 N·m (1.5 kgf·m, 11 lb·ft) 3.8 N·m (0.38 kgf·m, 2.8 lb·ft) 4.5 N·m (0.45 kgf·m, 3.3 lb·ft) 3.0 N·m (0.30 kgf·m, 2.2 lb·ft) 3.0 N·m (0.30 kgf·m, 2.2 lb·ft) ’ Order Job/Parts to remove Remarks...
  • Page 344 THROTTLE BODIES Removing the throttle bodies 15 N·m (1.5 kgf·m, 11 lb·ft) 3.8 N·m (0.38 kgf·m, 2.8 lb·ft) 3.0 N·m (0.30 kgf·m, 2.2 lb·ft) 4.5 N·m (0.45 kgf·m, 3.3 lb·ft) 3.0 N·m (0.30 kgf·m, 2.2 lb·ft) ’ Order Job/Parts to remove Remarks Sub-wire harness Coolant temperature sensor...
  • Page 345 THROTTLE BODIES Removing the fuel injectors m (0.5 kgf m, 3.7 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 Remarks ISC (Idle Speed Control) valve plate ISC (Idle Speed Control) valve...

  • Page 346: Removing The Throttle Bodies

    THROTTLE BODIES e. Pull the air filter case rearward to remove EAS30979 REMOVING THE THROTTLE BODIES it from the throttle bodies. 1. Remove: f. Remove the throttle bodies. • Throttle bodies a. Remove the battery box bracket “1”. EAS30475 CHECKING THE INJECTORS (BEFORE REMOVING) 1.
  • Page 347 THROTTLE BODIES • Fuel hoses • Exhaust system • Cylinder head breather hose • Canister purge hoses EWA17850 WARNING If the throttle bodies are subjected to strong shocks or dropped during checking, replace them. 1. Check: c. Push the lever in the direction shown in •...
  • Page 348 • O-ring 2. Clean: • ISC (Idle Speed Control) valve “1” Recommended cleaning agent: 3. Install: Yamaha oil & brake cleaner • O-ring ECA21230 • ISC (Idle Speed Control) valve • ISC (Idle Speed Control) valve plate • Be sure to use the recommended cleaning agent.

  • Page 349: Replacing The Throttle Bodies

    Use the diagnostic code number “67”. tool to coupler. Refer to “SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE” on page For information about using the Yamaha diag- 9-30. nostic tool, refer to the operation manual that is 4. Reset: included with the tool.

  • Page 350: Installing The Fuel Injectors

    THROTTLE BODIES 1. Check: Throttle position sensor screw • Injector pressure 3.5 N·m (0.35 kgf·m, 2.6 lb·ft) a. Connect the fuel injector pressure adapt- er “1” to the fuel rail “2”, and then connect an air compressor “3” to the adapter. b.

  • Page 351: Checking The Fuel Pressure

    THROTTLE BODIES EAS30482 CHECKING THE FUEL PRESSURE 1. Remove: • Front side cover (left) Refer to “GENERAL CHASSIS (3)” on page 4-5. • Side cover inner panel (left) Refer to “GENERAL CHASSIS (4)” on page 4-7. • Engine bracket (left) Refer to “ENGINE REMOVAL”...

  • Page 352: Installing The Air Filter Case Joints

    THROTTLE BODIES c. Place the wire harness “1” in its original position, and then insert the projections on the holders “2” into the holes in the frame and battery box. 45˚ 70˚ a. #1 cylinder b. #2 cylinder A. Left B.

  • Page 353: 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..................8-12 CIRCUIT DIAGRAM .................8-12 TROUBLESHOOTING ................8-13 LIGHTING SYSTEM ..................8-15 CIRCUIT DIAGRAM .................8-15 TROUBLESHOOTING ................8-17 SIGNALING SYSTEM ...................8-19...
  • Page 354 ELECTRICAL COMPONENTS ..............8-35 CHECKING THE SWITCHES..............8-37 CHECKING THE FUSES................8-38 REPLACING THE ECU (engine control unit) ...........8-38 CHECKING AND CHARGING THE BATTERY.........8-38 CHECKING THE RELAYS ...............8-39 CHECKING THE DIODE ................8-40 CHECKING THE RELAY UNIT (DIODE)...........8-41 CHECKING THE IGNITION COILS ............8-42 CHECKING THE IGNITION SPARK GAP ..........8-42 CHECKING THE CRANKSHAFT POSITION SENSOR ......8-43 CHECKING THE LEAN ANGLE SENSOR ..........8-43 CHECKING THE STARTER MOTOR OPERATION........8-44...

  • Page 356: Ignition System

    IGNITION SYSTEM EAS20072 IGNITION SYSTEM EAS30490 CIRCUIT DIAGRAM...
  • Page 357 IGNITION SYSTEM 1. Main switch 7. Ignition fuse 16.Battery 17.Engine ground 18.Main fuse 22.Relay unit (diode) 27.Joint coupler 28.Crankshaft position sensor 31.ECU (Engine Control Unit) 32.Ignition coil #1 33.Ignition coil #2 34.Spark plug 42.Lean angle sensor 57.Gear position switch 58.Sidestand switch 59.Handlebar switch (right) 61.Engine start/stop switch...

  • Page 358: 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 gear position switch (neutral circuit) or sidestand switch is open.

  • Page 359: 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. Tail cover 3. Front side cover (left/right) 4. Side cover inner panel (left/right) 5. Fuel tank (left/right) 6.
  • Page 360 IGNITION SYSTEM NG → 8. Check the engine start/stop switch. • The engine start/stop switch is faulty. Refer to “CHECKING THE • Replace the right handlebar switch. SWITCHES” on page 8-37. OK ↓ NG → 9. Check the gear position switch. Refer to “CHECKING THE GEAR Replace the gear position switch.
  • Page 361 IGNITION SYSTEM...

  • Page 362: Electric Starting System

    ELECTRIC STARTING SYSTEM EAS20073 ELECTRIC STARTING SYSTEM EAS30493 CIRCUIT DIAGRAM...
  • Page 363 ELECTRIC STARTING SYSTEM 1. Main switch 7. Ignition fuse 16.Battery 17.Engine ground 18.Main fuse 19.Starter relay 20.Starter motor 22.Relay unit (diode) 23.Starting circuit cut-off relay 26.Diode 27.Joint coupler 57.Gear position switch 58.Sidestand switch 59.Handlebar switch (right) 61.Engine start/stop switch 63.Handlebar switch (left) 64.Clutch switch...

  • Page 364: 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 engine start/stop switch is pushed, the starter motor can only operate if at least one of the following conditions is met: •...

  • Page 365: Troubleshooting

    ELECTRIC STARTING SYSTEM EAS30495 TROUBLESHOOTING The starter motor fails to turn. • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Tail cover 3. Drive chain cover NG → 1. Check the fuses. (Ignition and main) Replace the fuse(s). Refer to “CHECKING THE FUSES”...
  • Page 366 ELECTRIC STARTING SYSTEM NG → 9. Check the gear position switch. Refer to “CHECKING THE GEAR Replace the gear position switch. POSITION SWITCH” on page 8-48. OK ↓ NG → 10.Check the sidestand switch. Refer to “CHECKING THE Replace the sidestand switch. SWITCHES”...

  • Page 367: Charging System

    CHARGING SYSTEM EAS20074 CHARGING SYSTEM EAS30496 CIRCUIT DIAGRAM 14.Stator coil 15.Rectifier/regulator 16.Battery 17.Engine ground 18.Main fuse 8-12...

  • Page 368: Troubleshooting

    CHARGING SYSTEM EAS30497 TROUBLESHOOTING The battery is not being charged. • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Front side cover (left) 3. Side cover inner panel (left) NG → 1. Check the fuse. (Main) Replace the fuse. Refer to “CHECKING THE FUSES”...
  • Page 369 CHARGING SYSTEM 8-14...

  • Page 370: Lighting System

    LIGHTING SYSTEM EAS20075 LIGHTING SYSTEM EAS30498 CIRCUIT DIAGRAM 8-15...
  • Page 371 LIGHTING SYSTEM 1. Main switch 7. Ignition fuse 8. Signaling system fuse 9. Headlight fuse 11.Backup fuse 16.Battery 17.Engine ground 18.Main fuse 27.Joint coupler 31.ECU (Engine Control Unit) 52.Meter assembly 54.Multi-function meter 63.Handlebar switch (left) 65.Dimmer switch 66.Pass switch 75.Headlight assembly 76.Headlight (high beam) 77.Headlight (low beam) 78.Auxiliary light...

  • Page 372: Troubleshooting

    LIGHTING SYSTEM EAS30499 TROUBLESHOOTING Any of the following fail to light: headlight (high beam), headlight (low beam), auxiliary light, license plate light, taillight, meter light or high beam indicator light. • Before troubleshooting, remove the following part(s): 1. Rider seat 2.
  • Page 373 LIGHTING SYSTEM NG → 7. Check the entire lighting system wiring. Properly connect or replace the wiring Refer to “CIRCUIT DIAGRAM” on harness. page 8-15. OK ↓ Replace the ECU, meter assembly, headlight assembly or tail/brake light. Refer to “REPLACING THE ECU (en- gine control unit)”...

  • Page 374: Signaling System

    SIGNALING SYSTEM EAS20076 SIGNALING SYSTEM EAS30500 CIRCUIT DIAGRAM 8-19...
  • Page 375 SIGNALING SYSTEM 1. Main switch 5. ABS control unit fuse 7. Ignition fuse 8. Signaling system fuse 11.Backup fuse 16.Battery 17.Engine ground 18.Main fuse 21.Rear brake light switch 22.Relay unit (diode) 27.Joint coupler 28.Crankshaft position sensor 31.ECU (Engine Control Unit) 40.Coolant temperature sensor 44.Front wheel sensor 46.ABS ECU...

  • Page 376: Troubleshooting

    SIGNALING SYSTEM EAS30501 TROUBLESHOOTING • Any of the following fail to light: turn signal light, brake light or indicator light. • The horn fails to sound. • The fuel meter fails to come on. • The speedometer fails to operate. •...
  • Page 377 SIGNALING SYSTEM Checking the signaling system The horn fails to sound. NG → 1. Check the horn switch. • The horn switch is faulty. Refer to “CHECKING THE • Replace the left handlebar switch. SWITCHES” on page 8-37. OK ↓ NG →...
  • Page 378 SIGNALING SYSTEM NG → 3. Check the entire signaling system wiring. Properly connect or replace the wiring Refer to “CIRCUIT DIAGRAM” on harness. page 8-19. OK ↓ Replace the turn signal light or meter assembly. The neutral indicator light fails to come on. NG →...
  • Page 379 SIGNALING SYSTEM The oil pressure warning light remains on after the engine is started. NG → 1. Check the entire signaling system wiring. Properly connect or replace the wiring Refer to “CIRCUIT DIAGRAM” on harness. page 8-19. OK ↓ NG → 2.
  • Page 380 SIGNALING SYSTEM The speedometer fails to operate. NG → 1. Check the front wheel sensor. Refer to “MAINTENANCE OF THE Replace the front wheel sensor. FRONT WHEEL SENSOR AND SENSOR ROTOR” on page 4-19. OK ↓ NG → 2. Check the entire front wheel sensor Properly connect or replace the wiring wiring.
  • Page 381 SIGNALING SYSTEM 8-26...

  • Page 382: Cooling System

    COOLING SYSTEM EAS20077 COOLING SYSTEM EAS30502 CIRCUIT DIAGRAM 8-27...
  • Page 383 COOLING SYSTEM 1. Main switch 7. Ignition fuse 12.Radiator fan motor fuse 16.Battery 17.Engine ground 18.Main fuse 27.Joint coupler 31.ECU (Engine Control Unit) 40.Coolant temperature sensor 81.Radiator fan motor relay 82.Radiator fan motor A. Wire harness B. Sub-wire harness 8-28...

  • Page 384: Troubleshooting

    COOLING SYSTEM EAS30503 TROUBLESHOOTING The radiator fan motor fails to turn. • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Front side cover (left/right) 3. Side cover inner panel (left/right) 4. Fuel tank (right) 5. Canister NG → 1.
  • Page 385 COOLING SYSTEM NG → 7. Check the entire cooling system wiring. Properly connect or replace the wiring Refer to “CIRCUIT DIAGRAM” on harness. page 8-27. OK ↓ Replace the ECU. Refer to “REPLAC- ING THE ECU (engine control unit)” on page 8-38.

  • Page 386: Fuel Pump System

    FUEL PUMP SYSTEM EAS20081 FUEL PUMP SYSTEM EAS30513 CIRCUIT DIAGRAM 8-31...
  • Page 387 FUEL PUMP SYSTEM 1. Main switch 7. Ignition fuse 16.Battery 17.Engine ground 18.Main fuse 22.Relay unit (diode) 24.Fuel pump relay 26.Diode 27.Joint coupler 31.ECU (Engine Control Unit) 48.Fuel pump 59.Handlebar switch (right) 61.Engine start/stop switch 8-32...

  • Page 388: Troubleshooting

    FUEL PUMP SYSTEM EAS30514 TROUBLESHOOTING If the fuel pump fails to operate. • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Front side cover (left/right) 3. Side cover inner panel (left/right) 4. Fuel tank (right) NG → 1. Check the fuses. (Ignition and main) Replace the fuse(s).
  • Page 389 FUEL PUMP SYSTEM NG → 8. Check the entire fuel pump system wiring. Properly connect or replace the wiring Refer to “CIRCUIT DIAGRAM” on harness. page 8-31. OK ↓ Replace the ECU. Refer to “REPLAC- ING THE ECU (engine control unit)” on page 8-38.

  • Page 390: Electrical Components

    ELECTRICAL COMPONENTS EAS20089 ELECTRICAL COMPONENTS 1. Main switch/Immobilizer unit 2. Intake air temperature sensor 3. Front brake light switch 4. Clutch switch 5. Rectifier/regulator 6. Ignition coil 7. Gear position switch 8. Battery 9. Lean angle sensor 10. Fuse box 1 11.
  • Page 391 ELECTRICAL COMPONENTS 1. Fuel pump 2. Purge cut valve solenoid 3. Hydraulic unit assembly 4. Fuel sender 5. Intake air pressure sensor 6. Main fuse 7. Starter relay 8. Relay unit (diode) 9. ECU (Engine Control Unit) 10. Rear wheel sensor 11.

  • Page 392: Checking The Switches

    ELECTRICAL COMPONENTS EAS30549 CHECKING THE SWITCHES Check each switch for continuity with the digital circuit tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. Br/L Br/L G G/W R/BL/W B START G/B G/Y G W/B B/Y R COUNT W/G R...

  • Page 393: Checking The Fuses

    ELECTRICAL COMPONENTS EAS30551 Amperage CHECKING THE FUSES Fuses Q’ty rating The following procedure applies to all of the fus- Spare 10 A ECA13680 Spare 7.5 A Spare 2.0 A To avoid a short circuit, always set the main switch to “OFF” when checking or replacing EWA13310 WARNING a fuse.

  • Page 394: Checking The Relays

    ELECTRICAL COMPONENTS 9. Install: ECA13640 • Rider seat First, disconnect the negative battery lead Refer to “GENERAL CHASSIS (1)” on page “1”, and then positive battery lead “2”. 4-1. EAS30553 CHECKING THE RELAYS Check each switch for continuity with the digital circuit tester.

  • Page 395: Checking The Diode

    ELECTRICAL COMPONENTS Starting circuit cut-off relay 2. Negative battery terminal 3. Positive tester probe 4. Negative tester probe Result Continuity (between “3” and “4”) R/W L/W L/W L/Y R/W L/G B/R B/Y Sb/W EAS30555 CHECKING THE DIODE 1. Check: • Diode 1.

  • Page 396: Checking The Relay Unit (Diode)

    ELECTRICAL COMPONENTS b. Connect the digital circuit tester to the di- Continuity ode terminals as shown. Positive tester probe c. Check the diode for continuity. black/yellow “1” d. Check the diode for no continuity. Negative tester probe sky blue “2” EAS30795 CHECKING THE RELAY UNIT (DIODE) No continuity...

  • Page 397: Checking The Ignition Coils

    ELECTRICAL COMPONENTS c. Check the relay unit (diode) for continuity. Digital circuit tester (CD732) d. Check the relay unit (diode) for no conti- 90890-03243 nuity. Model 88 Multimeter with ta- chometer EAS30558 CHECKING THE IGNITION COILS YU-A1927 The following procedure applies to all of the ig- nition coils.

  • Page 398: Checking The Crankshaft Position Sensor

    ELECTRICAL COMPONENTS Gy B G089051 b. Measure the crankshaft position sensor 2. Ignition coil resistance. c. Turn the main switch to “ON”. d. Measure the ignition spark gap “a”. EAS30561 CHECKING THE LEAN ANGLE SENSOR e. Crank the engine by pushing the start 1.

  • Page 399: Checking The Starter Motor Operation

    ELECTRICAL COMPONENTS 2. Check: • Stator coil resistance Out of specification → Replace the stator coil. Stator coil resistance 0.128–0.192 Ω a. Connect the digital circuit tester to the stator coil coupler as shown. G089053 c. Set the main switch to “ON”. Digital circuit tester (CD732) d.

  • Page 400: Checking The Fuel Sender

    ELECTRICAL COMPONENTS b. Move the fuel sender float to minimum “3” Digital circuit tester (CD732) and maximum “4” level position. 90890-03243 c. Measure the fuel sender resistance. Model 88 Multimeter with ta- chometer EAS31372 CHECKING THE FUEL METER YU-A1927 This model is equipped with a self-diagnosis device for the fuel level detection circuit.

  • Page 401: Checking The Throttle Position Sensor

    ELECTRICAL COMPONENTS • Never subject the coolant temperature EAS30581 CHECKING THE THROTTLE POSITION sensor to strong shocks. If the coolant SENSOR temperature sensor is dropped, replace it. 1. Remove: 2. Check: • Throttle position sensor • Coolant temperature sensor resistance (from the throttle body) Out of specification →...

  • Page 402: Checking The Intake Air Pressure Sensor

    ELECTRICAL COMPONENTS c. Set the main switch to “ON”. d. Measure the intake air pressure sensor When installing the throttle position sensor, ad- output voltage. just its angle properly. Refer to “ADJUSTING THE THROTTLE POSITION SENSOR” on page EAS30594 7-14. CHECKING THE INTAKE AIR TEMPERATURE SENSOR 1.

  • Page 403: Checking The Gear Position Switch

    ELECTRICAL COMPONENTS Result Neutral position Continuity Positive tester probe sky blue “1” Negative tester probe Switch terminal “a” 1st position Continuity G089057 Positive tester probe d. Slowly heat the water, then let it cool pink “2” Negative tester probe down to the specified temperature. Switch terminal “b”...

  • Page 404: Checking The Fuel Injectors

    ELECTRICAL COMPONENTS b. Connect the digital circuit tester to the EAS30681 CHECKING THE FUEL INJECTORS purge cut valve solenoid terminals as The following procedure applies to all of the fuel shown. injectors. 1. Remove: Digital circuit tester (CD732) • Fuel injector 90890-03243 Refer to “THROTTLE BODIES”...
  • Page 405 ELECTRICAL COMPONENTS • Positive tester probe → Fuel cut solenoid valve terminal “1” • Negative tester probe → Fuel cut solenoid valve terminal “2” L/B L d. Measure the fuel cut solenoid valve resis- tance. 8-50...
  • Page 406 ELECTRICAL COMPONENTS 8-51...

  • Page 407: Self Diagnostic

    SELF DIAGNOSTIC SELF-DIAGNOSTIC FUNCTION ..............9-1 GLOSSARY ....................9-1 OUTLINE ....................9-1 CHECKING THE WARNING LIGHT............9-1 YDT......................9-2 PARTS CONNECTED TO THE ECU ............9-3 PARTS CONNECTED TO THE ABS ECU..........9-3 PRECAUTIONS FOR ROAD TEST ............9-3 COPE WITH THE MIL FLASHING .............9-3 SYSTEM DIAGRAM ..................9-5 ECU CIRCUIT DIAGRAM................9-5 ECU COUPLER LAYOUT ................9-7 FUEL INJECTION SYSTEM................9-9...
  • Page 408 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE..9-30 DTC TABLE .....................9-30 SELF-DIAGNOSTIC FUNCTION TABLE (FOR FUEL INJECTION SYSTEM)............9-33 SELF-DIAGNOSTIC FUNCTION TABLE (FOR IMMOBILIZER SYSTEM) ...............9-43 SELF-DIAGNOSTIC FUNCTION TABLE (FOR ABS (Anti-lock Brake System))............9-43 COMMUNICATION ERROR WITH THE METER ........9-48 DIAGNOSTIC CODE: SENSOR OPERATION TABLE......9-49 DIAGNOSTIC CODE: ACTUATOR OPERATION TABLE ......9-51 EVENT CODE TABLE ...................9-53 30_EVENT .....................9-56...
  • Page 409 P0115......................9-85 TROUBLESHOOTING ................9-85 P0116......................9-86 TROUBLESHOOTING ................9-86 P0117, P0118 ....................9-89 TROUBLESHOOTING ................9-89 P0122, P0123 ....................9-93 TROUBLESHOOTING ................9-93 P0132......................9-97 TROUBLESHOOTING ................9-97 P0133......................9-100 OUTLINE ....................9-100 FAIL-SAFE SYSTEM................9-100 TROUBLESHOOTING ................9-101 P0134......................9-102 TROUBLESHOOTING ................9-102 P0201......................9-104 TROUBLESHOOTING ................9-104 P0202......................9-108 TROUBLESHOOTING ................9-108 P0300, P0301, P0302 ..................9-112 OUTLINE ....................9-112 FAIL-SAFE SYSTEM................9-113 TROUBLESHOOTING ................9-113 P0335......................9-116...
  • Page 410 P0480......................9-131 TROUBLESHOOTING ................9-131 P0507......................9-134 TROUBLESHOOTING ................9-134 P0511......................9-140 TROUBLESHOOTING ................9-140 P0560, P0563 ....................9-144 TROUBLESHOOTING ................9-144 P0601......................9-145 TROUBLESHOOTING ................9-145 P062F......................9-146 TROUBLESHOOTING ................9-146 P0657......................9-148 TROUBLESHOOTING ................9-148 P1500......................9-152 TROUBLESHOOTING ................9-152 P1601......................9-163 TROUBLESHOOTING ................9-163 P1602......................9-167 TROUBLESHOOTING ................9-167 P1604, P1605 ....................9-171 TROUBLESHOOTING ................9-171 U0155 or Err....................9-174 TROUBLESHOOTING ................9-174 51_IMMOBILIZER ..................9-177 TROUBLESHOOTING ................9-177...
  • Page 411 54_IMMOBILIZER ..................9-180 TROUBLESHOOTING ................9-180 55_IMMOBILIZER ..................9-181 TROUBLESHOOTING ................9-181 56_IMMOBILIZER ..................9-182 TROUBLESHOOTING ................9-182 11, 25_ABS ....................9-183 TROUBLESHOOTING ................9-183 12_ABS ......................9-184 TROUBLESHOOTING ................9-184 13, 26_ABS ....................9-185 TROUBLESHOOTING ................9-185 14, 27_ABS ....................9-186 TROUBLESHOOTING ................9-186 15_ABS ......................9-187 TROUBLESHOOTING ................9-187 16_ABS ......................9-189 TROUBLESHOOTING ................9-189 17, 45_ABS ....................9-191 TROUBLESHOOTING ................9-191 18, 46_ABS ....................9-192 TROUBLESHOOTING ................9-192...
  • Page 412 33_ABS ......................9-199 TROUBLESHOOTING ................9-199 34_ABS ......................9-201 TROUBLESHOOTING ................9-201 41_ABS ......................9-202 TROUBLESHOOTING ................9-202 42, 47_ABS ....................9-203 TROUBLESHOOTING ................9-203 43_ABS ......................9-204 TROUBLESHOOTING ................9-204 44_ABS ......................9-205 TROUBLESHOOTING ................9-205 51, 52_ABS ....................9-206 TROUBLESHOOTING ................9-206 53_ABS ......................9-207 TROUBLESHOOTING ................9-207 54_ABS ......................9-209 TROUBLESHOOTING ................9-209 56_ABS ......................9-211 TROUBLESHOOTING ................9-211 63_ABS ......................9-212 TROUBLESHOOTING ................9-212...

  • Page 414: Glossary

    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 oper- ating normally.

  • Page 415: Ydt

    90890-03273 • Yamaha diagnostic tool (A/I) (90890-03273) 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 416: Parts Connected To The Ecu

    SELF-DIAGNOSTIC FUNCTION Connecting the YDT Disconnect the coupler “1” from the CCU, and then connect the YDT to the coupler. 1 1 1 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.
  • Page 417 SELF-DIAGNOSTIC FUNCTION...

  • Page 418: System Diagram

    SYSTEM DIAGRAM EAS20387 SYSTEM DIAGRAM EAS32920 ECU CIRCUIT DIAGRAM 25. Ignition coil #1 9. Fuel pump 4. Fuel injection relay system fuse 8. Engine 2. Main fuse 26. Ignition coil #2 start/stop switch 12.Multi-function 15. Ignition fuse 5. Starter meter relay 3.
  • Page 419 SYSTEM DIAGRAM 1. ECU (Engine Control Unit) 2. Main fuse 3. Battery 4. Fuel injection system fuse 5. Starter relay 6. Starter motor 7. Starting circuit cut-off relay 8. Engine start/stop switch 9. Fuel pump relay 10. Clutch switch 11. Sidestand switch 12.

  • Page 420: Ecu Coupler Layout

    SYSTEM DIAGRAM EAS33369 ECU COUPLER LAYOUT 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 Wire harness Wire harness...
  • Page 421 SYSTEM DIAGRAM Wire harness Connected parts color Fuel injection system fuse sensor heater — — — — Ground Headlight assembly, dimmer switch, pass switch Ground...

  • Page 422: Fuel Injection System

    FUEL INJECTION SYSTEM EAS20440 FUEL INJECTION SYSTEM EAS32871 CIRCUIT DIAGRAM...
  • Page 423 FUEL INJECTION SYSTEM 1. Main switch 5. ABS control unit fuse 7. Ignition fuse 9. Headlight fuse 10.Fuel injection system fuse 11.Backup fuse 16.Battery 17.Engine ground 18.Main fuse 22.Relay unit (diode) 23.Starting circuit cut-off relay 24.Fuel pump relay 26.Diode 27.Joint coupler 28.Crankshaft position sensor 29.O sensor...

  • Page 424: 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 425: [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 426: Immobilizer System

    IMMOBILIZER SYSTEM EAS20442 IMMOBILIZER SYSTEM EAS32885 CIRCUIT DIAGRAM 9-13...
  • Page 427 IMMOBILIZER SYSTEM 1. Main switch 7. Ignition fuse 11.Backup fuse 13.Immobilizer unit 16.Battery 17.Engine ground 18.Main fuse 27.Joint coupler 31.ECU (Engine Control Unit) 52.Meter assembly 53.Immobilizer system indicator light 9-14...

  • Page 428: 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 429 IMMOBILIZER SYSTEM Parts to be replaced Main switch/ Key registration re- Accessory immobilizer unit Standard quirement lock* and Main Immobilizer switch unit √ Standard key is lost New standard key All keys have been lost Code re-registering √ √ √ √...
  • Page 430 IMMOBILIZER SYSTEM Standard key registration: Standard key registration is required when a standard key is lost and needs to be replaced, or when the code re-registering key is re-registered after the immobilizer unit or ECU are replaced. Do not start the engine with a standard key that has not been registered. If the main switch is turned “ON”...
  • Page 431 IMMOBILIZER SYSTEM Voiding the standard key code: If a standard key has been lost, it is possible to disable its use by re-registering the remaining standard key. Standard key registration erases the stored standard key code from the memory, thus disabling the lost standard key.

  • Page 432: Troubleshooting

    IMMOBILIZER SYSTEM EAS32888 TROUBLESHOOTING When the main switch is turned to “ON”, the immobilizer system indicator light does not come on nor flashes. NG → 1. Check the fuses. (Main, ignition, and backup) Replace the fuse(s). Refer to “CHECKING THE FUSES” on page 8-38.

  • Page 433: 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 434: Circuit Diagram

    ABS (Anti-lock Brake System) EAS20443 ABS (Anti-lock Brake System) EAS32890 CIRCUIT DIAGRAM 9-21...
  • Page 435 ABS (Anti-lock Brake System) 1. Main switch 2. ABS solenoid fuse 3. ABS motor fuse 5. ABS control unit fuse 7. Ignition fuse 8. Signaling system fuse 10.Fuel injection system fuse 11.Backup fuse 16.Battery 17.Engine ground 18.Main fuse 21.Rear brake light switch 27.Joint coupler 31.ECU (Engine Control Unit) 43.Resistor unit...
  • Page 436 ABS (Anti-lock Brake System) EAS32892 ABS COUPLER LOCATION CHART R/W O/L G/B G/R L/B L/R Dg Y/G R/G B/G W/B W/Y Ch Br/B Br/W B/W Y W/B W Gy W/R R W/G P Sb/W O Y/W G/W G/Y B W B W G R/B Br/W L/R L/B B/G...

  • Page 437: 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 438: 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 439 ABS (Anti-lock Brake System) Fails to Turn the main switch to “ON”, [A-1] Does only the ABS • The ABS warning light (LED) is come on and check the ABS warning Return to [A]. warning light fail to defective. light. •...

  • Page 440: [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 441: [A-5] Abs Ecu And Fi Ecu Fail To Communicate

    90890-03273 • Yamaha diagnostic tool (A/I) (90890-03273) 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 vehicle.

  • Page 442: [B-3] Deleting The Dtc

    90890-03274 Yamaha diagnostic tool (A/I) 90890-03273 • Yamaha diagnostic tool (A/I) (90890-03273) includes YDT sub harness (6P) (90890-03266). • If you already have Yamaha diagnostic tool (A/I) (90890-03262), YDT sub harness (6P) (90890-03266) is separately required. EAS32905 [C-1] FINAL CHECK...

  • Page 443: 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 Diagnostic Symptom Starting the Driving the code engine vehicle “11, Front wheel sensor (intermittent pulses or no — — — 25_ABS” pulses) Rear wheel sensor (intermittent pulses or no “12_ABS”...
  • Page 444 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Fail-safe system Diagnostic Symptom Starting the Driving the code engine vehicle “53_IMMO- Codes cannot be transmitted between the Unable Unable — BILIZER” ECU and the immobilizer unit. Hydraulic unit assembly (defective ABS sole- “54_ABS” —...
  • Page 445 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Fail-safe system Diagnostic Symptom Starting the Driving the code engine vehicle [P0117] Coolant temperature sensor: ground “P0117, short circuit detected. Able Able P0118” [P0118] Coolant temperature sensor: open or power short circuit detected. [P0122] Throttle position sensor: open or “P0122, ground short circuit detected.

  • Page 446: Self-Diagnostic Function Table (For Fuel Injection System)

    SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Fail-safe system Diagnostic Symptom Starting the Driving the code engine vehicle EEPROM DTC: an error is detected while “P062F” Able/Unable Able/Unable reading or writing on EEPROM. Fuel system voltage: incorrect voltage sup- “P0657” Able Able 09, 50 plied to the fuel injector and fuel pump.
  • Page 447 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Probable cause of Fail-safe system op- Item Vehicle symptom malfunction eration P00D1 sensor: heater • Improperly installed Increased exhaust feedback is not sensor. emissions. performance deterio- carried out. ration • Defective coupler learning is not car- between O sensor ried out.
  • Page 448 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Probable cause of Fail-safe system op- Item Vehicle symptom malfunction eration α–N is fixed. P0107 [P0107] Intake air [P0107] Low voltage Engine idling speed is P0108 pressure sensor: of the intake air pres- unstable. Fuel is not cut off due ground short circuit sure sensor circuit...
  • Page 449 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Probable cause of Fail-safe system op- Item Vehicle symptom malfunction eration P0112 [P0112] Intake air [P0112] Low voltage Engine is difficult to The intake air tem- P0113 temperature sensor: of the intake air tem- start.
  • Page 450 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Probable cause of Fail-safe system op- Item Vehicle symptom malfunction eration P0117 [P0117] Coolant tem- [P0117] Low voltage Engine is difficult to The radiator fan mo- P0118 perature sensor: of the coolant tem- start. tor relay is on only ground short circuit perature sensor cir-...
  • Page 451 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Probable cause of Fail-safe system op- Item Vehicle symptom malfunction eration P0132 sensor: short cir- High voltage of the Increased exhaust feedback is not sensor circuit (4.8 emissions. cuit detected (power carried out. short circuit). V or more) feedback learning •...
  • Page 452 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Probable cause of Fail-safe system op- Item Vehicle symptom malfunction eration P0301 Cylinder-#1 misfire • Ignition system mal- Engine is difficult to – detection function/abnormal start. • Fuel system mal- Loss of engine pow- function/abnormal Engine idling speed is unstable.
  • Page 453 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Probable cause of Fail-safe system op- Item Vehicle symptom malfunction eration P0480 Radiator fan motor • Open or short cir- Engine is difficult to Radiator fan motor relay: open or short cuit in wire harness. start.
  • Page 454 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Probable cause of Fail-safe system op- Item Vehicle symptom malfunction eration P0601 Internal malfunction • Malfunction in ECU. Engine cannot be Engine cannot be in ECU. (When this started. started. malfunction is detect- ed in the ECU, the DTC might not ap- pear on the tool dis- play.)
  • Page 455 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Probable cause of Fail-safe system op- Item Vehicle symptom malfunction eration P1601 Sidestand switch: • Defective coupler Engine cannot be Engine is forcefully open or short circuit between relay unit started. stopped (the injector of the black/red lead and ECU.

  • Page 456: Self-Diagnostic Function Table (For Immobilizer System)

    SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Probable cause of Fail-safe system op- Item Vehicle symptom malfunction eration P2195 sensor: open cir- • Signal voltage is Increased exhaust feedback is not 0.18–0.49 V. emissions. cuit detected. carried out. • Improperly installed feedback learning sensor.
  • Page 457 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Item Symptom Check point Front wheel sensor (intermit- Front wheel sensor signal is • Foreign material adhered tent pulses or no pulses) not received properly. (Puls- around the front wheel es are not received or are re- sensor ceived intermittently while •...
  • Page 458 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Item Symptom Check point Rear wheel sensor (open or Open or short circuit is de- • Defective coupler between short circuit) tected in the rear wheel sen- the rear wheel sensor and sor. the hydraulic unit assembly •...
  • Page 459 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Item Symptom Check point Hydraulic unit assembly (de- Power is not supplied to the • Blown ABS solenoid fuse fective ABS solenoid power solenoid circuit in the hy- • Defective coupler between circuit) draulic unit assembly. the battery and the hydrau- lic unit assembly •...
  • Page 460 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Item Symptom Check point Front wheel sensor (missing Front wheel sensor signal is • Foreign material adhered pulses) not received properly. (Miss- around the front wheel ing pulses are detected in sensor the signal while the vehicle is •...

  • Page 461: Communication Error With The Meter

    SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Item Symptom Check point Front wheel sensor power Power voltage supplied from • Short circuit in the wire supply (voltage of power the ABS ECU to the front harness between the front supply is low) wheel sensor is too low.

  • Page 462: Diagnostic Code: Sensor Operation Table

    SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE EAS33031 DIAGNOSTIC CODE: SENSOR OPERATION TABLE Diagnostic Item Tool display Procedure code No. Throttle position sensor sig- • Fully closed position 11–21 Check with throttle valves fully closed. • Fully open position 96–106 Check with throttle valves fully open.
  • Page 463 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Diagnostic Item Tool display Procedure code No. Gear position switch and Operate the transmission, clutch switch clutch lever, and sidestand. • Transmission is in neutral • Transmission is in gear or the clutch lever released •...

  • Page 464: Diagnostic Code: Actuator Operation Table

    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 ig- Check that a spark is gener- nition coil five times at one- ated five times. second intervals.
  • Page 465 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Diagnostic Item Actuation Procedure code No. ISC valve Fully closes the ISC valve, Check that the ISC unit is and then opens the valve. actuated three times by lis- This operation is performed tening for the operating 3 times and takes approxi- sound.

  • Page 466: Event Code Table

    EVENT CODE TABLE EAS20707 EVENT CODE TABLE Fuel injection system 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 de- Same as for DTC num- Perform the inspection...
  • Page 467 EVENT CODE TABLE Item Symptom Possible causes Note During idling, the ad- Idling engine speed is • Implement diagnosis (Stuck at the up- justment is main- slow mode D67, and check the per limit for ad- tained at the upper •...
  • Page 468 EVENT CODE TABLE ABS system 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 ABS condition Records ABS condi- ABS condition of last —...

  • Page 469: 30_Event

    30_EVENT EAS20552 30_EVENT EAS33033 TROUBLESHOOTING Item Latch up 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 470 30_EVENT 4. Malfunction in ECU. • Replace the ECU, and complete the service. Refer to “REPLACING THE ECU (engine control unit)” on page 8-38. 9-57...

  • Page 471: 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 DTC is displayed at the same time, check the other DTC first and repair it. 1. Allow to idle for a long period. •...

  • Page 472: Troubleshooting

    EAS20901 EAS33980 TROUBLESHOOTING Item Records ABS condition of last drive. FFD check item with tool • Rear ABS • ABS Procedure 1. Check ABS condition • Check the FFD details recorded for this event code with the tool. • Check “Rear ABS OFF” and “ABS OFF” in the FFD display item. When “Rear ABS OFF”...

  • Page 473: P0030

    P0030 EAS20397 P0030 EAS33134 TROUBLESHOOTING Item sensor heater: defective heater controller detected. Fail-safe system • Able to start engine • Able to drive vehicle Procedure If more than one DTC is detected at the same time, perform troubleshooting of DTC listed below first. •...
  • Page 474 P0030 a. Connect the coupler securely or replace the wire harness. b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode of the YDT. Is it in the “Recovered” condition? → Go to step 6, and complete the service. →...
  • Page 475 P0030 → Go to step 6, and complete the service. → Go to step 4. For this check, also set the engine start/stop switch to “ ”. • Short circuit check Disconnect the ECU related connectors before checking. Refer to “PARTS CONNECTED TO THE ECU” on page 9-3. Ground short circuit check “A”...
  • Page 476 P0030 For this check, also set the engine start/stop switch to “ ”. 4. Defective O sensor. • Replace the O sensor. Refer to “ENGINE REMOVAL” on page 5-10. • Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode of the YDT.

  • Page 477: P00D1, P2195

    P00D1, P2195 EAS20660 P00D1, P2195 EAS33115 TROUBLESHOOTING Item • [P00D1] O sensor: heater performance deterioration. • [P2195] O sensor: open circuit detected. Fail-safe system • Able to start engine • Able to drive vehicle Procedure If more than one DTC is detected at the same time, perform troubleshooting of DTC listed below first. 1.
  • Page 478 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 479 P00D1, P2195 • Short circuit check Disconnect the ECU related connectors before checking. Refer to “PARTS CONNECTED TO THE ECU” on page 9-3. Ground short circuit check “A” gray/green–ground pink/black–ground Between O sensor coupler “1” and ground black/blue–ground red/white–ground Between main switch coupler “4” and ground brown/blue–ground Lines short circuit check “B”...
  • Page 480 P00D1, P2195 a. Replace the fuel pump. Refer to “FUEL TANK” on page 7-1. b. Start the engine and let it idle for approximately 1 minute. c. Check the condition of the DTC using the malfunction mode of the YDT. Is it in the “Recovered”...

  • Page 481: P0105

    P0105 EAS20420 P0105 EAS32838 TROUBLESHOOTING Item Intake air pressure sensor: signal out of range Fail-safe system • Able to start engine • Able to drive vehicle Procedure If more than one DTC is detected at the same time, perform troubleshooting of DTC listed below first. •...
  • Page 482 P0105 → Go to step 4. 4. Malfunction in ECU. • Replace the ECU, and complete the service. Refer to “REPLACING THE ECU (engine control unit)” on page 8-38. 5. Delete the DTC and check that the MIL goes off. •...

  • Page 483: P0106

    P0106 EAS20421 P0106 EAS32840 TROUBLESHOOTING Item Intake air pressure sensor: clogging of hose or sensor disconnection Fail-safe system • Able to start engine • Able to drive vehicle Procedure If more than one DTC is detected at the same time, perform troubleshooting of DTC listed below first. •...
  • Page 484 P0106 3. 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. 9-71...

  • Page 485: P0107, P0108

    P0107, P0108 EAS20567 P0107, P0108 EAS33047 TROUBLESHOOTING Item • [P0107] Intake air pressure sensor: ground short circuit detected. • [P0108] Intake air pressure sensor: open or power short circuit detected. Fail-safe system • Able to start engine • Able to drive vehicle Procedure 1.
  • Page 486 P0107, P0108 blue–blue Between intake air pressure sensor coupler and pink/white–pink/white ECU coupler black/blue–black/blue Gy B/L B/R Gy/R G/Y O Br/L Br/W Br/R G/B B/Y R/B Gy/G R/L R/B P/B B/W R/Y B Is resistance 0 Ω? → Go to “Short circuit check”. a.
  • Page 487 P0107, P0108 Is resistance ∞ Ω? → Go to step 4. a. Replace the wire harness. b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode of the YDT. Is it in the “Recovered” condition? →...
  • Page 488 P0107, P0108 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 8-38. 7.

  • Page 489: P0110

    P0110 EAS20426 P0110 EAS32845 TROUBLESHOOTING Item Intake air temperature sensor: signal stuck Fail-safe system • Able to start engine • Able to drive vehicle Procedure • Perform this procedure when the engine is cold. • If more than one DTC is detected at the same time, perform troubleshooting of DTC listed below first. •...
  • Page 490 P0110 a. Replace the intake air temperature sensor. Refer to “GENERAL CHASSIS (5)” on page 4-10. b. Turn the main switch to “ON”, then heat the intake air temperature sensor using warm water or hot air. c. Check the condition of the DTC using the malfunction mode of the YDT. Is it in the “Recovered”...

  • Page 491: P0111

    P0111 EAS20425 P0111 EAS32844 TROUBLESHOOTING Item Intake air temperature sensor: signal out of range Fail-safe system • Able to start engine • Able to drive vehicle Procedure • Perform this procedure when the engine is cold. • If more than one DTC is detected at the same time, perform troubleshooting of DTC listed below first. •...
  • Page 492 P0111 3. Installed condition of intake air temperature sensor. • Check for looseness or pinching. Refer to “GENERAL CHASSIS (5)” on page 4-10. Is check result OK? → Go to step 4. a. Reinstall the sensor. b. Execute the diagnostic mode. (Code 05) •...
  • Page 493 P0111 → 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 8-38. 7. Delete the DTC and check that the MIL goes off. •...

  • Page 494: P0112, P0113

    P0112, P0113 EAS20568 P0112, P0113 EAS33048 TROUBLESHOOTING Item • [P0112] Intake air temperature sensor: ground short circuit detected. • [P0113] Intake air temperature sensor: open or power short circuit detected. Fail-safe system • Able to start engine • Able to drive vehicle Procedure Perform this procedure when the engine is cold.
  • Page 495 P0112, P0113 • Open circuit check Between intake air temperature sensor coupler and brown/white–brown/white ECU coupler black/blue–black/blue Gy B/L B/R Gy/R G/Y O Br/W Br/L Br/W Br/R G/B B/Y R/B Gy/G R/L R/B P/B B/W R/Y B Is resistance 0 Ω? →...
  • Page 496 P0112, P0113 Is resistance ∞ Ω? → Go to step 4. a. Replace the wire harness. b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode of the YDT. Is it in the “Recovered” condition? →...
  • Page 497 P0112, P0113 6. Malfunction in ECU. • Replace the ECU, and complete the service. Refer to “REPLACING THE ECU (engine control unit)” on page 8-38. 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. 9-84...

  • Page 498: P0115

    P0115 EAS20424 P0115 EAS32843 TROUBLESHOOTING Item Coolant temperature sensor: signal stuck Fail-safe system • Able to start engine • Able to drive vehicle Procedure • Perform this procedure when the engine is cold. • If more than one DTC is detected at the same time, perform troubleshooting of DTC listed below first. •...

  • Page 499: P0116

    P0116 EAS20423 P0116 EAS32842 TROUBLESHOOTING Item Coolant temperature sensor: signal out of range Fail-safe system • Able to start engine • Able to drive vehicle Procedure • Perform this procedure when the engine is cold. • If more than one DTC is detected at the same time, perform troubleshooting of DTC listed below first. •...
  • Page 500 P0116 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 501 P0116 a. Replace the coolant temperature sensor. Refer to “THROTTLE BODIES” on page 7-8. b. Execute the diagnostic mode. (Code 06) • When engine is cold: Displayed temperature is close to the ambient temperature. c. Submerge the coolant temperature sensor in a container filled with water at 20 °C (68 °F) and 100 °C (212 °F).

  • Page 502: P0117, P0118

    P0117, P0118 EAS20569 P0117, P0118 EAS33049 TROUBLESHOOTING Item • [P0117] Coolant temperature sensor: ground short circuit detected. • [P0118] Coolant temperature sensor: open or power short circuit detected. Fail-safe system • Able to start engine • Able to drive vehicle Procedure Perform this procedure when the engine is cold.
  • Page 503 P0117, P0118 • 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. Connect the coupler securely or replace the wire harness. b.
  • Page 504 P0117, P0118 Refer to “PARTS CONNECTED TO THE ECU” on page 9-3. Ground short circuit check “A” Between coolant temperature sensor coupler “1” green/white–ground and ground Between wire harness coupler (sub-wire harness green/white–ground side) “3” and ground Lines short circuit check “B” Coolant temperature sensor coupler green/white–black/blue green/white–any other coupler terminal...
  • Page 505 P0117, P0118 Is it in the “Recovered” condition? → Go to step 8, and complete the service. → Go to step 6. 6. Defective coolant temperature sensor. • Execute the diagnostic mode. (Code 06) • When engine is cold: Displayed temperature is close to the ambient temperature. •...

  • Page 506: P0122, P0123

    P0122, P0123 EAS20757 P0122, P0123 EAS33050 TROUBLESHOOTING Item • [P0122] Throttle position sensor: open or ground short circuit detected. • [P0123] Throttle position sensor: power short circuit detected. Fail-safe system • Able/Unable to start engine • Able/Unable to drive vehicle Procedure 1.
  • Page 507 P0122, P0123 Is the coupler condition normal? → Go to step 4. a. Connect the coupler securely or replace the wire harness. b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode of the YDT.
  • Page 508 P0122, P0123 Refer to “PARTS CONNECTED TO THE ECU” on page 9-3. Ground short circuit check “A” Between throttle position sensor coupler “1” and white–ground ground blue–ground Between wire harness coupler (sub-wire harness white–ground side) “3” and ground blue–ground Lines short circuit check “B” black/blue–any other coupler terminal Throttle position sensor coupler white–any other coupler terminal...
  • Page 509 P0122, P0123 Is it in the “Recovered” condition? → Go to step 9, and complete the service. → Go to step 6. 6. Throttle position sensor resistance. • Measure the throttle position sensor resistance. Refer to “CHECKING THE THROTTLE POSITION SENSOR” on page 8-46. Is check result OK? →...

  • Page 510: P0132

    P0132 EAS20571 P0132 EAS33051 TROUBLESHOOTING Item sensor: short circuit detected (power short circuit). Fail-safe system • Able to start engine • Able to drive vehicle Procedure 1. Installed condition of O sensor. • Check for looseness or pinching. Refer to “ENGINE REMOVAL” on page 5-10. Is check result OK? →...
  • Page 511 P0132 → Go to step 4. a. Connect the coupler securely or replace the wire harness. b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode of the YDT. Is it in the “Recovered” condition? →...
  • Page 512 P0132 black/blue–any other coupler terminal ECU coupler “2” gray/green–any other coupler terminal Gy B/L B/R Gy/R G/Y O Br/L Br/W Br/R G/B B/Y R/B Gy/G R/L R/B P/B B/W R/Y B Is resistance ∞ Ω? → Go to step 5. a.

  • Page 513: P0133

    P0133 EAS20767 P0133 sensor: deterioration detected EAS33291 OUTLINE Explanation of detection method The O sensor detects the oxygen concentration in the exhaust gas, converts it into an electrical sig- nal, and sends it to the ECU. The ECU determines whether there is any deterioration by comparing the output value from the O sensor with a predetermined threshold value such as response time.

  • Page 514: Troubleshooting

    P0133 EAS32813 TROUBLESHOOTING If more than one DTC is detected at the same time, perform troubleshooting of DTC listed below first. • DTCs except P0133 1. Connect the YDT to check and delete the DTC stored in the ECU. 2. Perform the reproduction test under the following conditions, then go to step 3. Reproduction test conditions A.

  • Page 515: P0134

    P0134 EAS20414 P0134 EAS32834 TROUBLESHOOTING Item sensor: signal stuck Fail-safe system • Able to start engine • Able to drive vehicle Procedure If more than one DTC is detected at the same time, perform troubleshooting of DTC listed below first. 1.
  • Page 516 P0134 → 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 7-16. Is check result OK? → Go to step 4. a.

  • Page 517: P0201

    P0201 EAS20574 P0201 EAS33054 TROUBLESHOOTING Item Fuel injector #1: malfunction in fuel injector #1. Fail-safe system • Able to start engine (depending on the number of faulty cylinders) • Able to drive vehicle (depending on the number of faulty cylinders) Procedure 1.
  • Page 518 P0201 → Go to step 4. a. Connect the coupler securely or replace the wire harness. b. Execute the diagnostic mode. (Code 36) Is the fuel injector operating sound heard? → Go to step 7. → Go to step 4. 4.
  • Page 519 P0201 Is resistance 0 Ω? → Go to “Short circuit check”. a. Replace the wire harness and/or sub-wire harness. b. Execute the diagnostic mode. (Code 36) Is the fuel injector operating sound heard? → Go to step 7. → Go to step 6. •...
  • Page 520 P0201 → 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 8-38. 7. Delete the DTC and check that the MIL goes off. •...

  • Page 521: P0202

    P0202 EAS20575 P0202 EAS33055 TROUBLESHOOTING Item Fuel injector #2: malfunction in fuel injector #2. Fail-safe system • Able to start engine (depending on the number of faulty cylinders) • Able to drive vehicle (depending on the number of faulty cylinders) Procedure 1.
  • Page 522 P0202 → Go to step 4. a. Connect the coupler securely or replace the wire harness. b. Execute the diagnostic mode. (Code 37) Is the fuel injector operating sound heard? → Go to step 7. → Go to step 4. 4.
  • Page 523 P0202 Is resistance 0 Ω? → Go to “Short circuit check”. a. Replace the wire harness and/or sub-wire harness. b. Execute the diagnostic mode. (Code 37) Is the fuel injector operating sound heard? → Go to step 7. → Go to step 6. •...
  • Page 524 P0202 → 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 8-38. 7. Delete the DTC and check that the MIL goes off. •...

  • Page 525: Outline

    P0300, P0301, P0302 EAS20713 P0300, P0301, P0302 • [P0300] Misfire in multiple cylinders • [P0301] Misfire in cylinder #1 • [P0302] Misfire in cylinder #2 EAS33318 OUTLINE Explanation of detection method The ECU monitors the consistency of the crankshaft rotation by crankshaft position sensor, and if the angular velocity fluctuates irregularly, the ECU determines that there is a misfire.

  • Page 526: Fail-Safe System

    P0300, P0301, P0302 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 527 P0300, P0301, P0302 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 528 P0300, P0301, P0302 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. • Intake air pressure sensor •...

  • Page 529: P0335

    P0335 EAS20578 P0335 EAS33058 TROUBLESHOOTING Item Crankshaft position sensor: no normal signals are received from the crankshaft position sensor. Fail-safe system • Unable to start engine • Unable to drive vehicle Procedure 1. Connection of crankshaft position sensor coupler. • Check the locking condition of the coupler. •...
  • Page 530 P0335 B/R Gy/R G/Y O Gy B/L Gy B/L Br/L Br/W Br/R G/B B/Y R/B Gy/G R/L R/B P/B B/W R/Y B Is resistance 0 Ω? → Go to “Short circuit check”. a. Replace the wire harness. b. Crank the engine, and then check the condition of the DTC using the malfunction mode of the YDT.
  • Page 531 P0335 a. Replace the wire harness. b. Crank the engine, and then check the condition of the DTC using the malfunction mode of the YDT. Is it in the “Recovered” condition? → Go to step 7, and complete the service. →...

  • Page 532: P0351

    P0351 EAS20580 P0351 EAS33060 TROUBLESHOOTING Item Cylinder-#1 ignition coil: open or short circuit detected in the primary lead of the cylinder-#1 ignition coil. Fail-safe system • Unable to start engine • Unable to drive vehicle Procedure 1. Connection of cylinder-#1 ignition coil coupler. •...
  • Page 533 P0351 Between cylinder-#1 ignition coil coupler and ECU orange–orange coupler Between cylinder-#1 ignition coil coupler and han- red/black–red/black dlebar switch (right) coupler Gy B/L B/R Gy/R G/Y O Br/L Br/W Br/R G/B B/Y R/B Gy/G R/L R/B P/B B/W R/Y B Is resistance 0 Ω? →...
  • Page 534 P0351 Is resistance ∞ Ω? → Go to step 4. a. Replace the wire harness. b. Start the engine and let it idle for approximately 5 seconds. c. Check the condition of the DTC using the malfunction mode of the YDT. Is it in the “Recovered”...
  • Page 535 P0351 • Replace the ECU, and complete the service. Refer to “REPLACING THE ECU (engine control unit)” on page 8-38. 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. 9-122...

  • Page 536: P0352

    P0352 EAS20581 P0352 EAS33061 TROUBLESHOOTING Item Cylinder-#2 ignition coil: open or short circuit detected in the primary lead of the cylinder-#2 ignition coil. Fail-safe system • Unable to start engine • Unable to drive vehicle Procedure 1. Connection of cylinder-#2 ignition coil coupler. •...
  • Page 537 P0352 Between cylinder-#2 ignition coil coupler and ECU gray/red–gray/red coupler Between cylinder-#2 ignition coil coupler and han- red/black–red/black dlebar switch (right) coupler Gy/R Gy B/L B/R Gy/R G/Y O Br/L Br/W Br/R G/B B/Y R/B Gy/G R/L R/B P/B B/W R/Y B Is resistance 0 Ω? →...
  • Page 538 P0352 Is resistance ∞ Ω? → Go to step 4. a. Replace the wire harness. b. Start the engine and let it idle for approximately 5 seconds. c. Check the condition of the DTC using the malfunction mode of the YDT. Is it in the “Recovered”...
  • Page 539 P0352 • Replace the ECU, and complete the service. Refer to “REPLACING THE ECU (engine control unit)” on page 8-38. 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. 9-126...

  • Page 540: P0458

    P0458 EAS20785 P0458 EAS33528 TROUBLESHOOTING Item Purge cut valve solenoid: open circuit detected. Fail-safe system • Able to start engine • Able to drive vehicle Procedure 1. Connection of purge cut valve solenoid coupler. • Check the locking condition of the coupler. •...
  • Page 541 P0458 Between ignition fuse holder and purge cut valve red/white–red/white solenoid coupler Between purge cut valve solenoid coupler and ECU brown/red–brown/red coupler Between main switch coupler and ignition fuse brown/blue–brown/blue holder Gy B/L B/R Gy/R G/Y O Br/R Br/L Br/W Br/R G/B B/Y R/B Br/L...
  • Page 542 P0458 Br/R Br/R Br/L Br/L Gy B/L B/R Gy/R G/Y O Br/L Br/W Br/R G/B B/Y R/B Gy/G R/L R/B P/B B/W R/Y B Is resistance ∞ Ω? →Go to step 4. a. Replace the wire harness. b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode of the YDT.
  • Page 543 P0458 Is the solenoid operating sound heard? → Go to step 7, and complete the service. → Check the purge cut valve solenoid. Refer to “CHECKING THE PURGE CUT VALVE SOLENOID” on page 8-49. Is check result OK? → Go to step 6. a.

  • Page 544: P0480

    P0480 EAS20585 P0480 EAS33065 TROUBLESHOOTING Item Radiator fan motor relay: open or short circuit detected. Fail-safe system • Able to start engine • Able to drive vehicle Procedure 1. Connection of radiator fan motor relay coupler. • Check the locking condition of the coupler. •...
  • Page 545 P0480 Between radiator fan motor relay and ECU coupler green/yellow–green/yellow Gy B/L B/R Gy/R G/Y O Br/L Br/W Br/R G/B B/Y R/B Gy/G R/L R/B P/B B/W R/Y B Is resistance 0 Ω? → Go to “Short circuit check”. a. Replace the wire harness. b.
  • Page 546 P0480 a. Replace the wire harness. b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode of the YDT. Is it in the “Recovered” condition? → Go to step 6, and complete the service. →...

  • Page 547: P0507

    P0507 EAS20589 P0507 EAS33069 TROUBLESHOOTING Item Engine idling speed is too high. 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 548 P0507 a. Replace the cables. b. Start the engine and let it idle for approximately 10 seconds. c. Check the condition of the DTC using the malfunction mode of the YDT. Is it in the “Recovered” condition? → Go to step 6, and complete the service. →...
  • Page 549 P0507 • 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 9. a. Connect the coupler securely or replace the wire harness and/or sub-wire harness. b.
  • Page 550 P0507 Gy B/L B/R Gy/R G/Y O R/G W/G Br/L P/L Br/L W/G Br/L Br/W Br/R G/B B/Y R/B Br/L P/L Gy/G R/L R/B P/B B/W R/Y B Is resistance 0 Ω? → Go to “Short circuit check”. a. Replace the wire harness and/or sub-wire harness. b.
  • Page 551 P0507 Br/L P/L Br/L P/L Gy B/L B/R Gy/R G/Y O Br/L Br/W Br/R G/B B/Y R/B Gy B/L B/R Gy/R G/Y O Gy/G R/L R/B P/B B/W R/Y B Br/L Br/W Br/R G/B B/Y R/B Gy/G R/L R/B P/B B/W R/Y B Is resistance ∞...
  • Page 552 P0507 → Go to step 14, and complete the service. → Go to step 13. 13.Malfunction in ECU. • Replace the ECU. Refer to “REPLACING THE ECU (engine control unit)” on page 8-38. 14.Delete the DTC and check that the MIL goes off. •...

  • Page 553: P0511

    P0511 EAS20590 P0511 EAS33070 TROUBLESHOOTING Item ISC (Idle Speed Control) valve: ISC valve does not operate. Fail-safe system • Able to start engine • Able to drive vehicle Procedure Do not remove the ISC valve from the throttle body. 1. Connection of ISC unit coupler. •...
  • Page 554 P0511 • 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. Connect the coupler securely or replace the wire harness. b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode of the YDT.
  • Page 555 P0511 • Short circuit check Disconnect the ECU related connectors before checking. Refer to “PARTS CONNECTED TO THE ECU” on page 9-3. Ground short circuit check “A” red/green–ground Between ISC (Idle Speed Control) unit “1” coupler white/green–ground and ground brown/blue–ground pink/blue–ground red/green–ground white/green–ground...
  • Page 556 P0511 a. Replace the ISC valve. Refer to “CHECKING AND CLEANING THE THROTTLE BODIES” on page 7-11. b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode of the YDT. Is it in the “Recovered” condition? →...

  • Page 557: P0560, P0563

    P0560, P0563 EAS20434 P0560, P0563 EAS33304 TROUBLESHOOTING Item • [P0560] Charging voltage is abnormal. • [P0563] Vehicle system power voltage out of range. Fail-safe system • Able to start engine • Able to drive vehicle Procedure If more than one DTC is detected at the same time, perform troubleshooting of DTC listed below first. •...

  • Page 558: P0601

    P0601 EAS20676 P0601 EAS33305 TROUBLESHOOTING Item Internal malfunction in ECU. (When this malfunction is detected in the ECU, the DTC might not appear on the tool display.) Fail-safe system • Unable to start engine • Unable to drive vehicle Procedure 1.

  • Page 559: P062F

    P062F EAS20598 P062F EAS33078 TROUBLESHOOTING Item EEPROM DTC: an error is detected while reading or writing on EEPROM. Fail-safe system • Able/Unable to start engine • Able/Unable to drive vehicle Procedure 1. Locate the malfunction. • Execute the diagnostic mode (Code 60) Go to step 5.
  • Page 560 P062F • Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode of the YDT. Is it in the “Recovered” condition? → Go to step 6, and complete the service. a. Repeat step 1. b.

  • Page 561: P0657

    P0657 EAS20601 P0657 EAS33081 TROUBLESHOOTING Item Fuel system voltage: incorrect voltage supplied to the fuel injector and fuel pump. Fail-safe system • Able to start engine • Able to drive vehicle Procedure If more than one DTC is detected at the same time, perform troubleshooting of DTC listed below first. •...
  • Page 562 P0657 3. Wire harness continuity. • Disconnect the battery terminal “1”, main fuse coupler “2”, main switch coupler “3”, ignition fuse holder “4”, relay unit coupler “5” and ECU coupler “6”. • Open circuit check Between battery terminal and main fuse coupler red–red Between main fuse coupler and main switch cou- red–red...
  • Page 563 P0657 Lines short circuit check “B” Main fuse coupler red–any other coupler terminal Main switch coupler red–brown/blue red/white–any other coupler terminal Relay unit coupler red/blue–any other coupler terminal blue/yellow–any other coupler terminal red/blue–any other coupler terminal ECU coupler blue/yellow–any other coupler terminal R/W L/W R/W L/W L/W L/Y R/W L/G B/R...
  • Page 564 P0657 → Go to step 5. 5. Defective relay unit. • Execute the diagnostic mode. (Code 09) Is the fuel system voltage less than 3V? a. Replace the relay unit. b. Start the engine and let it idle for approximately 5 seconds. c.

  • Page 565: P1500

    P1500 EAS20764 P1500 EAS33303 TROUBLESHOOTING Item • Rear wheel sensor: no normal signals are received from the rear wheel sensor. • Neutral switch: open or short circuit is detected. • Clutch switch: open or short circuit is detected. Fail-safe system •...
  • Page 566 P1500 Perform the procedure from step 15 to step 21. 2. Connection of rear wheel sensor coupler. • Check the locking condition of the coupler. • Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the pins).
  • Page 567 P1500 → Go to step 21, and complete the service. → Go to step 5. 5. Wire harness continuity. • Disconnect the rear wheel sensor coupler “1”, ABS ECU coupler “2” and ECU coupler “3”. • Open circuit check Between rear wheel sensor coupler and ABS ECU black–black coupler white–white...
  • Page 568 P1500 B W G B W G Br/W L/R L/B B/G Br/W L/R L/B B/G Gy B/L B/R Gy/R G/Y O Br/L Br/W Br/R G/B B/Y R/B Gy/G R/L R/B P/B B/W R/Y B Is resistance ∞ Ω? → Go to step 6. a.
  • Page 569 P1500 a. Connect the coupler securely or replace the wire harness. b. Execute the diagnostic mode. (Code 21) When the transmission is in neutral When the transmission is in gear with the clutch lever released Is it correct indication? → Go to step 21, and complete the service. →...
  • Page 570 P1500 → Go to “Short circuit check”. a. Replace the wire harness. b. Execute the diagnostic mode. (Code 21) When the transmission is in neutral When the transmission is in gear with the clutch lever released Is it correct indication? →...
  • Page 571 P1500 Is it correct indication? → Go to step 21, and complete the service. → Go to step 11. 11.Defective relay unit (diode). • Check the relay unit (diode). Refer to “CHECKING THE RELAY UNIT (DIODE)” on page 8-41. Is check result OK? →...
  • Page 572 P1500 → Go to step 14. → Replace the shift drum and go to step 21. Refer to “TRANSMISSION” on page 5-94. 14.Malfunction in ECU. • Replace the ECU, and complete the service. Refer to “REPLACING THE ECU (engine control unit)” on page 8-38. 15.Clutch lever adjustment.
  • Page 573 P1500 Is the coupler condition normal? → Go to step 18. a. Connect the coupler securely or 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 the sidestand is retracted...
  • Page 574 P1500 → Go to step 19. • Short circuit check Disconnect the ECU related connectors before checking. Refer to “PARTS CONNECTED TO THE ECU” on page 9-3. Ground short circuit check “A” Between handlebar switch (left) coupler “2” and black/yellow–ground ground black/red–ground Lines short circuit check “B”...
  • Page 575 P1500 Is check result OK? → Go to step 20. a. Replace the clutch switch. Refer to “HANDLEBAR” on page 4-62. 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 the sidestand is retracted...

  • Page 576: P1601

    P1601 EAS20614 P1601 EAS33094 TROUBLESHOOTING Item Sidestand switch: open or short circuit of the black/red lead of the ECU is detected. Fail-safe system • Unable to start engine • Unable to drive vehicle Procedure 1. Connection of sidestand switch coupler. •...
  • Page 577 P1601 Is the coupler condition normal? → Go to step 4. a. Connect the coupler securely or replace the wire harness. b. Turn the main switch to “ON”, and then extend and retract the sidestand. c. Check the condition of the DTC using the malfunction mode of the YDT. Is it in the “Recovered”...
  • Page 578 P1601 Lines short circuit check “B” black/red–any other coupler terminal Relay unit coupler blue/green–any other coupler terminal ECU coupler “2” black/red–any other coupler terminal Sidestand switch coupler “3” blue/green–black R/W L/W R/W L/W L/W L/Y R/W L/G B/R B/Y Sb/W L/W L/Y R/W L/G B/R B/Y Sb/W Gy B/L...
  • Page 579 P1601 → 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 8-38. 7. Delete the DTC and check that the MIL goes off. •...

  • Page 580: P1602

    P1602 EAS20615 P1602 EAS33095 TROUBLESHOOTING Item Malfunction in ECU internal circuit (malfunction of ECU power cut-off function). Fail-safe system • Able/Unable to start engine • Able/Unable to drive vehicle Procedure 1. Installed condition of battery leads. • Check the installed condition of the battery and battery leads (loose bolts). Is check result OK? →...
  • Page 581 P1602 → Go to step 4. a. Connect the coupler securely or replace the wire harness. b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode of the YDT. Is it in the “Recovered” condition? →...
  • Page 582 P1602 Gy B/L B/R Gy/R G/Y O Br/L Br/W Br/R G/B B/Y R/B Gy/G R/L R/B P/B B/W R/Y B Br/L Is resistance 0 Ω? → Go to “Short circuit check”. a. Replace the wire harness. b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode of the YDT.
  • Page 583 P1602 Br/L Br/L Gy B/L B/R Gy/R G/Y O Br/L Br/W Br/R G/B B/Y R/B Gy/G R/L R/B P/B B/W R/Y B Gy B/L B/R Gy/R G/Y O Br/L Br/W Br/R G/B B/Y R/B Gy/G R/L R/B P/B B/W R/Y B Is resistance ∞...

  • Page 584: P1604, P1605

    P1604, P1605 EAS20617 P1604, P1605 EAS33097 TROUBLESHOOTING Item • [P1604] Lean angle sensor: ground short circuit detected. • [P1605] Lean angle sensor: open or power short circuit detected. Fail-safe system • Unable to start engine • Unable to drive vehicle Procedure 1.
  • Page 585 P1604, P1605 blue–blue Between ECU coupler and lean angle sensor cou- yellow/green–yellow/green pler black/blue–black/blue Gy B/L B/R Gy/R G/Y O Br/L Br/W Br/R G/B B/Y R/B Gy/G R/L R/B P/B B/W R/Y B Is resistance 0 Ω? → Go to “Short circuit check”. a.
  • Page 586 P1604, P1605 Is resistance ∞ Ω? → Go to step 4. a. Replace the wire harness. b. Turn the main switch to “ON”, then to “OFF”, and back to “ON”. c. Check the condition of the DTC using the malfunction mode of the YDT. Is it in the “Recovered”...

  • Page 587: 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 multi-function meter, but the MIL does not come on. 1.
  • Page 588 U0155 or Err blue/red–blue/red Between meter assembly coupler and ECU coupler blue/black–blue/black R/W O/L G/B G/R L/B L/R Dg Y/G R/G Gy B/L B/R Gy/R G/Y O B/G W/B W/Y Ch Br/B Br/W B/W Br/L Br/W Br/R G/B B/Y R/B Y W/B W Gy W/R R R/L R/B P/B B/W R/Y B...
  • Page 589 U0155 or Err R/W O/L G/B G/R L/B L/R Dg Y/G R/G R/W O/L G/B G/R L/B L/R Dg Y/G R/G B/G W/B W/Y Ch Br/B Br/W B/W B/G W/B W/Y Ch Br/B Br/W B/W Y W/B W Gy W/R R Y W/B W Gy W/R R W/G P Sb/W O Y/W G/W G/Y W/G P Sb/W O Y/W G/W G/Y...

  • Page 590: 51_Immobilizer

    51_IMMOBILIZER EAS20680 51_IMMOBILIZER EAS33309 TROUBLESHOOTING Item Code cannot be transmitted between the key and the immobilizer unit. Cause • Radio wave interference caused by objects around the keys and antennas. • Immobilizer unit malfunction. • Key malfunction. Procedure When a system malfunction occurs, the DTC number is indicated in the meter display and the immo- bilizer system indicator light flashes at the same time.

  • Page 591: 52_Immobilizer

    52_IMMOBILIZER EAS20679 52_IMMOBILIZER EAS33308 TROUBLESHOOTING Item Codes between the key and immobilizer unit do not match. Cause • Signal received from other transponder (failed to recognize code after ten consecutive attempts). • Signal received from unregistered standard key. Procedure When a system malfunction occurs, the DTC number is indicated in the meter display and the immo- bilizer system indicator light flashes at the same time.

  • Page 592: 53_Immobilizer

    53_IMMOBILIZER EAS20681 53_IMMOBILIZER EAS33310 TROUBLESHOOTING Item Codes cannot be transmitted between the ECU and the immobilizer unit. Cause • Noise interference or disconnected lead/cable. • Interference due to radio wave noise. • Disconnected communication harness. • Immobilizer unit malfunction. • ECU malfunction. Procedure When a system malfunction occurs, the DTC number is indicated in the meter display and the immo- bilizer system indicator light flashes at the same time.

  • Page 593: 54_Immobilizer

    54_IMMOBILIZER EAS20682 54_IMMOBILIZER EAS33311 TROUBLESHOOTING Item Codes transmitted between the ECU and the immobilizer unit do not match. Cause • Noise interference or disconnected lead/cable. • Interference due to radio wave noise. • Disconnected communication harness. • Immobilizer unit malfunction. •...

  • Page 594: 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 DTC number is indicated in the meter display and the immo- bilizer system indicator light flashes at the same time.

  • Page 595: 56_Immobilizer

    56_IMMOBILIZER EAS20684 56_IMMOBILIZER EAS33313 TROUBLESHOOTING Item Unidentified code is received. Cause • Noise interference or disconnected lead/cable. Procedure When a system malfunction occurs, the DTC number is indicated in the meter display and the immo- bilizer system indicator light flashes at the same time. The pattern of flashing also shows the DTC. Re- fer to “HOW TO CHECK DTC”...

  • Page 596: 11, 25_Abs

    11, 25_ABS EAS20765 11, 25_ABS EAS33314 TROUBLESHOOTING Item Front wheel sensor (intermittent pulses or no pulses) Procedure With the front wheel stopped, the rear wheel was rotated for longer than about 20 seconds (DTC No. 11) or for longer than about 2 seconds (DTC No. 25). 1.

  • Page 597: 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 598: 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 599: 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 600: 15_Abs

    15_ABS EAS20662 15_ABS EAS33040 TROUBLESHOOTING Item Front wheel sensor (open or short circuit) Procedure 1. Defective coupler between the front wheel sensor and the hydraulic unit assembly. • Check the coupler for any pins that may be pulled out. • Check the locking condition of the coupler. Turn the main switch to “OFF”...
  • Page 601 15_ABS Lines short circuit check “B” white–any other coupler terminal ABS ECU coupler black–any other coupler terminal B W G B W G Br/W L/R L/B Br/W L/R L/B B/G Is resistance ∞ Ω? → Go to step 3. → Replace the wire harness. 3.

  • Page 602: 16_Abs

    16_ABS EAS20663 16_ABS EAS33285 TROUBLESHOOTING Item Rear wheel sensor (open or short circuit) Procedure 1. Defective coupler between the rear wheel sensor and the hydraulic unit assembly. • Check the coupler for any pins that may be pulled out. • Check the locking condition of the coupler. Turn the main switch to “OFF”...
  • Page 603 16_ABS Lines short circuit check “B” white–any other coupler terminal ABS ECU coupler black–any other coupler terminal B W G B W G Br/W L/R L/B Br/W L/R L/B B/G Is resistance ∞ Ω? → Go to step 3. → Replace the wire harness. 3.

  • Page 604: 17, 45_Abs

    17, 45_ABS EAS20708 17, 45_ABS EAS33330 TROUBLESHOOTING Item Front wheel sensor (missing pulses) Procedure If pulse gaps are detected when the vehicle is traveling at a speed of 30 km/h (19 mi/h) or more, DTC No. 17 will be recorded. If the vehicle is traveling at a speed of 29 km/h (18 mi/h) or less, DTC No. 45 will be recorded first and DTC No.

  • Page 605: 18, 46_Abs

    18, 46_ABS EAS20709 18, 46_ABS EAS33325 TROUBLESHOOTING Item Rear wheel sensor (missing pulses) Procedure If pulse gaps are detected when the vehicle is traveling at a speed of 30 km/h (19 mi/h) or more, DTC No. 18 will be recorded. If the vehicle is traveling at a speed of 29 km/h (18 mi/h) or less, DTC No. 46 will be recorded first and DTC No.

  • Page 606: 21_Abs

    21_ABS EAS20690 21_ABS EAS33320 TROUBLESHOOTING Item Hydraulic unit assembly (defective solenoid drive circuit) Procedure 1. Defective hydraulic unit assembly. • Replace the hydraulic unit assembly. Refer to “ABS (ANTI-LOCK BRAKE SYSTEM)” on page 4-54. 9-193...

  • Page 607: 24_Abs

    24_ABS EAS20710 24_ABS EAS33374 TROUBLESHOOTING Item Brake light switch or tail/brake light Procedure 1. Defective signaling system. (tail/brake light or brake light switch) • Check the brake light switches. Refer to “CHECKING THE SWITCHES” on page 8-37. Is check result OK? →...
  • Page 608 24_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 9-3. Ground short circuit check “A” Between ABS ECU coupler “5”...

  • Page 609: 31_Abs

    31_ABS EAS20691 31_ABS EAS33321 TROUBLESHOOTING Hydraulic unit assembly (defective ABS solenoid power circuit) Procedure 1. Blown ABS solenoid fuse. • Check the ABS solenoid fuse. Refer to “CHECKING THE FUSES” on page 8-38. Is check result OK? → Go to step 2. →...
  • Page 610 31_ABS Disconnect the ABS ECU related connectors before checking. Refer to “PARTS CONNECTED TO THE ABS ECU” on page 9-3. Ground short circuit check “A” Between ABS ECU coupler “1” and ground red/white–ground Lines short circuit check “B” ABS ECU coupler red/white–any other coupler terminal B W G B W G...

  • Page 611: 32_Abs

    32_ABS EAS20712 32_ABS EAS33376 TROUBLESHOOTING Item Hydraulic unit assembly (short circuit in ABS solenoid power supply circuit) Procedure 1. Defective hydraulic unit assembly. • Replace the hydraulic unit assembly. Refer to “ABS (ANTI-LOCK BRAKE SYSTEM)” on page 4-54. 9-198...

  • Page 612: 33_Abs

    33_ABS EAS20692 33_ABS EAS33322 TROUBLESHOOTING Item Hydraulic unit assembly (abnormal ABS motor power supply) Procedure 1. Blown ABS motor fuse. • Check the ABS motor fuse. Refer to “CHECKING THE FUSES” on page 8-38. Is check result OK? → Go to step 2. →...
  • Page 613 33_ABS Disconnect the ABS ECU related connectors before checking. Refer to “PARTS CONNECTED TO THE ABS ECU” on page 9-3. Ground short circuit check “A” Between ABS ECU coupler “1” and ground red/blue–ground Lines short circuit check “B” ABS ECU coupler red/blue–any other coupler terminal B W G B W G...

  • Page 614: 34_Abs

    34_ABS EAS20693 34_ABS EAS33323 TROUBLESHOOTING Item Hydraulic unit assembly (short circuit in ABS motor power supply circuit) Procedure 1. Defective hydraulic unit assembly. • Replace the hydraulic unit assembly. Refer to “ABS (ANTI-LOCK BRAKE SYSTEM)” on page 4-54. 9-201...

  • Page 615: 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 4-19. Is check result OK? →...

  • Page 616: 42, 47_Abs

    42, 47_ABS EAS20746 42, 47_ABS EAS33324 TROUBLESHOOTING Item Rear wheel ABS (intermittent wheel speed pulses or incorrect depressurization) Procedure 1. Conditions when the malfunction occurred. • If the rear wheel locks intermittently due to rapid down shifting or due to engine braking on a slip- pery road surface, DTC No.

  • Page 617: 43_Abs

    43_ABS EAS20768 43_ABS EAS33484 TROUBLESHOOTING Item Front wheel sensor (missing pulses) Procedure 1. Foreign material adhered around the front wheel sensor. • Check the surface of the sensor rotor and wheel sensor for foreign material, such as metal particles. Is check result OK? →...

  • Page 618: 44_Abs

    44_ABS EAS20747 44_ABS EAS33452 TROUBLESHOOTING Item Rear wheel sensor (missing 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 619: 51, 52_Abs

    51, 52_ABS EAS20766 51, 52_ABS EAS33326 TROUBLESHOOTING Item • Vehicle system power supply (voltage of ABS ECU power supply is high) (for DTC No. 51) • Vehicle system power supply (voltage of wheel sensor power supply is high) (for DTC No. 52) Procedure 1.

  • Page 620: 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 8-38. 2.
  • Page 621 53_ABS Lines short circuit check “B” ABS ECU coupler brown/white–any other coupler terminal B W G B W G Br/W L/R L/B Br/W L/R L/B Is resistance ∞ Ω? → Go to step 4. → Replace the wire harness. 4. Defective charging system. •...

  • Page 622: 54_Abs

    54_ABS EAS20711 54_ABS EAS33375 TROUBLESHOOTING Item Hydraulic unit assembly (defective ABS solenoid and ABS motor power supply circuits) Procedure 1. Defective battery. • Recharge or replace the battery, and check again. Refer to “CHECKING AND CHARGING THE BATTERY” on page 8-38. 2.
  • Page 623 54_ABS Ground short circuit check “A” red/blue–ground Between ABS ECU coupler “1” and ground red/white–ground Lines short circuit check “B” red/blue–any other coupler terminal ABS ECU coupler red/white–any other coupler terminal B W G B W G Br/W L/R L/B Br/W L/R L/B Is resistance ∞...

  • Page 624: 56_Abs

    56_ABS EAS20701 56_ABS EAS33329 TROUBLESHOOTING Item Hydraulic unit assembly (abnormal internal power supply) Procedure 1. Defective hydraulic unit assembly. • Replace the hydraulic unit assembly. Refer to “ABS (ANTI-LOCK BRAKE SYSTEM)” on page 4-54. 9-211...

  • Page 625: 63_Abs

    63_ABS EAS20703 63_ABS EAS33334 TROUBLESHOOTING Item Front wheel sensor power supply (voltage of power supply is low) Procedure 1. Wire harness continuity. • Disconnect the ABS ECU coupler “1” and front wheel sensor coupler “2”. • Open circuit check Between front wheel sensor coupler and ABS ECU white–white coupler black–black...
  • Page 626 63_ABS Is resistance ∞ Ω? → Go to step 2. → Replace the wire harness. 2. Defective front wheel sensor. • Replace the front wheel sensor. 3. Defective hydraulic unit assembly. • Replace the hydraulic unit assembly. Refer to “ABS (ANTI-LOCK BRAKE SYSTEM)” on page 4-54. 9-213...

  • Page 627: 64_Abs

    64_ABS EAS20704 64_ABS EAS33335 TROUBLESHOOTING Item Rear wheel sensor power supply (voltage of power supply is low) Procedure 1. Wire harness continuity. • Disconnect the ABS ECU coupler “1” and rear wheel sensor coupler “2”. • Open circuit check Between rear wheel sensor coupler and ABS ECU white–white coupler black–black...
  • Page 628 64_ABS Is resistance ∞ Ω? → Go to step 2. → Replace the wire harness. 2. Defective rear wheel sensor. • Replace the rear wheel sensor. 3. Defective hydraulic unit assembly. • Replace the hydraulic unit assembly. Refer to “ABS (ANTI-LOCK BRAKE SYSTEM)” on page 4-54. 9-215...

  • Page 629: 89_Abs

    89_ABS EAS20669 89_ABS EAS33299 TROUBLESHOOTING Item CAN communication (between meter assembly and hydraulic unit assembly) Procedure 1. Defective coupler between the meter assembly and the hydraulic unit assembly • Check the coupler for any pins that may be pulled out. •...
  • Page 630 89_ABS Lines short circuit check “B” blue/red–any other coupler terminal Meter assembly coupler blue/black–any other coupler terminal blue/red–any other coupler terminal ABS ECU coupler blue/black–any other coupler terminal R/W O/L G/B G/R L/B L/R Dg Y/G R/G B/G W/B W/Y Ch Br/B Br/W B/W R/W O/L G/B G/R L/B L/R Dg Y/G R/G...

  • Page 631: 90_Abs

    90_ABS EAS20670 90_ABS EAS33300 TROUBLESHOOTING Item CAN communication (between ECU and hydraulic unit assembly) Procedure 1. Defective coupler between the ECU and the hydraulic unit assembly • Check the coupler for any pins that may be pulled out. • Check the locking condition of the coupler. Turn the main switch to “OFF”...
  • Page 632 90_ABS blue/red–ground Between ABS ECU coupler “2” and ground blue/black–ground Lines short circuit check “B” blue/red–any other coupler terminal ECU coupler blue/black–any other coupler terminal blue/red–any other coupler terminal ABS ECU coupler blue/black–any other coupler terminal Gy B/L B/R Gy/R G/Y O Gy B/L B/R Gy/R G/Y O Br/L...
  • Page 633 90_ABS 9-220...
  • Page 634 EAS20091 57. Gear position switch EAS30613 WIRING DIAGRAM COLOR CODE 58. Sidestand switch Black 59. Handlebar switch (right) XTZ690D/XTZ690DP Brown 60. Front brake light switch 1. Main switch Chocolate 61. Engine start/stop switch 2. ABS solenoid fuse Dark green 62. Wheel switch 3.
  • Page 637 XTZ690D/XTZ690DP 2023 XTZ690D/XTZ690DP 2023 XTZ690D/XTZ690DP 2023 XTZ690D/XTZ690DP 2023 XTZ690D/XTZ690DP 2023 WIRING DIAGRAM SCHÉMA DE CÂBLAGE SCHALTPLAN SCHEMA ELETTRICO DIAGRAMA ELÉCTRICO R/B L W G/W B/L L R/B P/L Br/L W/G R/G G/B R/L R/L R/G W/GBr/LP/L L/R L/B Y/L L/Y B/R Gy/R G/Y O L/W L/W L/W L/W R/W R/W R/W R/W R/W R/W R/W R/W...
  • Page 638 XTZ690D/XTZ690DP 2023 XTZ690D/XTZ690DP 2023 XTZ690D/XTZ690DP 2023 XTZ690D/XTZ690DP 2023 XTZ690D/XTZ690DP 2023 WIRING DIAGRAM SCHÉMA DE CÂBLAGE SCHALTPLAN SCHEMA ELETTRICO DIAGRAMA ELÉCTRICO (Gy) (Gy) COUNT DIRECTION START PUSH FREE DOWN (Gy) (Gy)

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