Yamaha MT-10 2022 Service Manual
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Yamaha MT-10 2022 Service Manual

Yamaha MT-10 2022 Service Manual

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Table of Contents

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2022
SERVICE MANUAL
MT-10
MT-10SP
MT10N
MT10NC
MT10SPN
MT10SPNC
LIT-11616-35-64
B5Y-28197-10

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Summary of Contents for Yamaha MT-10 2022

  • Page 1 2022 SERVICE MANUAL MT-10 MT-10SP MT10N MT10NC MT10SPN MT10SPNC LIT-11616-35-64 B5Y-28197-10...

  • Page 3: Important Manual Information

    If there is any question about a service procedure, it is imperative that you contact a Yamaha dealer for any service information changes that apply to this model. This policy is in- tended to provide the customer with the most satisfaction from their vehicle and to conform to federal environmental quality objectives.

  • Page 4: How To Use This Manual

    EAS20004 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive ex- planations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. •...
  • Page 5 EAS20005 SYMBOLS The following symbols are used in this manual for easier understanding. The following symbols are not relevant to every vehicle. SYMBOL DEFINITION SYMBOL DEFINITION Serviceable with engine mounted Gear oil Filling fluid Molybdenum disulfide oil Lubricant Brake fluid Special tool Wheel bearing grease Tightening torque...

  • Page 7: Table Of Contents

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

  • Page 9: General Information

    GENERAL INFORMATION IDENTIFICATION .................... 1-1 VEHICLE IDENTIFICATION NUMBER .............1-1 MODEL LABEL..................1-1 FEATURES...................... 1-2 GLOSSARY....................1-2 DISPLAY ....................1-2 MENU SCREEN ..................1-8 BASIC SERVICE INFORMATION..............1-17 ELECTRICAL SYSTEM................1-17 SPECIAL TOOLS ..................1-18...

  • Page 10: Identification

    IDENTIFICATION EAS20007 IDENTIFICATION EAS30002 VEHICLE IDENTIFICATION NUMBER The vehicle identification number “1” is stamped into the right side of the steering head pipe. EAS30003 MODEL LABEL The model label “1” is affixed to the frame under the passenger seat. This information will be needed to order spare parts.

  • Page 11: Glossary

    SCU - Suspension Control Unit (MT10SPN/MT10SPNC) TCS - Traction Control System 8. Speedometer YRC - Yamaha Ride Control 9. Tachometer YVSL - Yamaha variable speed limiter EWA18210 WARNING EAS31707 DISPLAY Stop the vehicle before making any setting The display has two different main screen dis- changes.
  • Page 12 This small bar momentarily appears within the • If all the fuel meter display segments flash re- tachometer to mark the most recent peak engine peatedly, have a Yamaha dealer check the re- speed. lated circuits. • When the YVSL system is operating in...
  • Page 13 FEATURES Coolant temperature warning Information display This icon appears when the coolant temperature The information display items are: is high. Stop the vehicle and turn off the engine. A.TEMP: air temperature Allow the engine to cool. C.TEMP: coolant temperature ECA10022 TRIP-1: tripmeter 1 NOTICE TRIP-2: tripmeter 2...
  • Page 14 FEATURES Fuel reserve tripmeter: • “– –” will be displayed if the detected tempera- ture is lower. • “– –” will be displayed if the detected tempera- ture is higher. F-TRIP mile F-TRIP mile Coolant temperature: 1. Display in STREET MODE C. TEMP 2.
  • Page 15 FEATURES Cruise control speed setting: The current fuel consumption display can be set to “km/L” or “L/100km”. When using miles, only MPG will be available. If traveling at speeds under 10 km/h (6 mi/h), “– –.–” will be displayed. Fuel consumption trip meter: 1.
  • Page 16 FEATURES To activate the grip warmer MODE-A: suitable for track riding 1. Use the wheel switch to highlight the grip MODE-B: softer track-riding setting warmer display with the cursor. MODE-C: suitable for road use 2. Short push the wheel switch and the indicator MODE-D: street use or rainy weather will start flashing.

  • Page 17: Menu Screen

    FEATURES Lap timer EAS31708 MENU SCREEN This stopwatch function measures and records up to forty laps. On the main screen, the lap tim- 10 : 00 MENU er shows the current lap time and lap number (indicated by the LAP mark). Use the Dimmer/ Display Mode Pass switch “...
  • Page 18 FEATURES MENU access and operation Access the MENU by pressing and holding the • The traction control system has 5 setting levels wheel switch (long push) while the vehicle is not and ERS has 6 modes. in motion. • Whenever there are more selections (setting Rotate the wheel switch up or down to highlight levels or modes) available than can be shown modules/items or increase/decrease values.
  • Page 19 FEATURES 1. System intervention 1. System intervention 2. Lean angle 2. Wheel lift SCS can be set to OFF, 1, 2, and 3. OFF turns This system has two settings. Level 1 provides the slide control system off, setting level 1 pro- the least system intervention, and therefore the vides the least system intervention, and setting strongest engine braking.
  • Page 20 FEATURES 2. Select the YRC item PWR, TCS, SCS, QS The ERS consists of three semi-active automat- , LIF, EBM, BC, or ERS (MT10SPN/ ic presets (A-1, A-2, and A-3) and three manual setting presets (M-1, M-2, and M-3). When an MT10SPNC) that you want to adjust.
  • Page 21 FEATURES Manual presets (M-1/M-2/M-3) adjustable set- 10 : 00 YRC Setting tings: Fr COM: front compression damping M - 1 Fr REB: front rebound damping M - 2 Rr COM: rear compression damping M - 3 Rr REB: rear rebound damping To adjust the ERS mode settings SETTING Fr COM...
  • Page 22 FEATURES “Maintenance” “Wallpaper” This module allows you to record distance trav- This module allows you to individually set the eled between engine oil changes (use the OIL STREET MODE and TRACK MODE display item), and for two other items of your choice (use background colors to black or white for both day INTERVAL 1 and INTERVAL 2).
  • Page 23 FEATURES To make setting changes 1. Select “Shift IND Setting”. 12 : 00 Shift Indicator 1000 r/min 10 : 00 Shift Indicator GP GPS Shift IND Setting Shift IND Setting IND Mode Shift IND Brightness IND Start 8000 r/min 13000 Tach IND Setting IND Stop r/min...
  • Page 24 FEATURES 2. Select ON to turn the tachometer color dis- 5. Select “Tach IND 2nd”. play mode on (or select OFF to turn this func- tion off). 12 : 00 Shift Indicator 1000 r/min 12 : 00 Shift Indicator Tach IND Setting 1000 r/min IND Mode Tach IND 1st...
  • Page 25 FEATURES The information display items which can be se- 12 : 00 EBM 1 lected are: 1000 r/min A.TEMP: air temperature GEAR C.TEMP: coolant temperature TRIP-1: tripmeter 1 TRIP-1 1234.5 TRIP-2: tripmeter 2 mile ODO: odometer MODE- SPEED: cruise control speed setting FUEL AVG: average fuel consumption 1.

  • Page 26: Basic Service Information

    BASIC SERVICE INFORMATION EAS20010 BASIC SERVICE INFORMATION EAS30014 ELECTRICAL SYSTEM Electrical parts handling ECA22611 NOTICE • Do not perform angle adjustment of the IMU and battery box by pinching the washer and related parts. • When installing the IMU, apply a thin coat of silicone grease onto the washer where con- tacting the IMU grommet.

  • Page 27: Special Tools

    • For U.S.A. and Canada, use part numbers starting with “YM-”, “YU-”, or “ACC-”. • For others, use part numbers starting with “90890-”. Reference Tool name/Tool No. Illustration pages Yamaha diagnostic tool USB (US) 3-4, 4-68, 4-69, 90890-03269 7-17, 9-3, 9-32, 9-33 Yamaha diagnostic tool (A/I)
  • Page 28 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Oil filter wrench 3-29 90890-01426 Oil filter wrench YU-38411 Oil pressure gauge joint 18 mm 3-30 90890-04176 YU-04176 ø18 Oil pressure gauge set 3-31 90890-03120 Wheel bearing ring nut tool 4-33, 4-35 90890-01574 YM-01574 Fork spring compressor...
  • Page 29 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Rod puller 4-82, 4-83 90890-01437 Universal damping rod bleeding tool set YM-A8703 YM-A8703 Rod puller attachment (M10) 4-82, 4-83 90890-01436 Universal damping rod bleeding tool set YM-A8703 YM-A8703 Front fork cap bolt wrench 42mm 4-88, 4-88, 4-94 90890-01575 YM-01575...
  • Page 30 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Damper rod holder (ø22) 4-110, 4-112 90890-01365 Drive chain cut & rivet tool 4-115, 4-117 90890-01550 Drive chain cut & rivet tool YM-01550 Compression gauge 90890-03081 90890-03081 Engine compression tester YU-33223 YU-33223 Pivot shaft wrench 5-15, 5-15 90890-01485...
  • Page 31 15mm pin type rotor holding tool 5-44, 5-45 90890-04171 YM-04171 Crankshaft protector 5-44 90890-01382 Crankshaft protector YM-01382 Flywheel puller 5-44 90890-01404 Flywheel puller YM-01404 Yamaha bond No. 1215 5-45, 5-71 90890-85505 Three bond No. 1215® Sheave holder 5-47, 5-47 90890-01903 Primary clutch holder YS-01880-A 1-22...
  • Page 32 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Digital circuit tester (CD732) 5-50, 8-40, 90890-03243 8-41, 8-42, Model 88 Multimeter with tachometer 8-43, 8-44, YU-A1927 8-44, 8-45, 8-46, 8-46, 8-47, 8-48, 8-48, 8-49, 8-50, 8-50, 8-50 Clutch holder 5-61, 5-64 90890-04199 Universal clutch holder YM-91042...
  • Page 33 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Radiator cap tester adapter 6-4, 6-5 90890-01352 Pressure tester adapter YU-33984 YU-33984 Mechanical seal installer (ø33) 6-14 90890-04132 Water pump seal installer (ø33) YM-33221-A Middle driven shaft bearing driver 6-14 90890-04058 Middle drive bearing installer 40 & 50 mm YM-04058 Pressure gauge 7-15, 7-16...
  • Page 34 SPECIAL TOOLS Yamaha diagnostic tool (A/I) 90890-03264 This special tool includes the YDT sub harness (6P) (90890-03266). 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. 1-25...

  • Page 35: Specifications

    SPECIFICATIONS GENERAL SPECIFICATIONS ................ 2-1 ENGINE SPECIFICATIONS ................2-2 CHASSIS SPECIFICATIONS ................2-7 ELECTRICAL SPECIFICATIONS ..............2-10 TIGHTENING TORQUES ................2-12 ENGINE TIGHTENING TORQUES............2-12 CHASSIS TIGHTENING TORQUES............2-12 CABLE ROUTING ..................2-15...

  • Page 36: General Specifications

    GENERAL SPECIFICATIONS EAS20013 GENERAL SPECIFICATIONS Model Model B5Y2 (MT10N) B5Y3 (MT10NC) BGG2 (MT10SPN) BGG3 (MT10SPNC) Dimensions Overall length 2100 mm (82.7 in) Overall width 800 mm (31.5 in) Overall height 1165 mm (45.9 in) Wheelbase 1405 mm (55.3 in) Ground clearance 135 mm (5.31 in) Minimum turning radius 3.4 m (11.16 ft)

  • Page 37: Engine Specifications

    ENGINE SPECIFICATIONS EAS20014 ENGINE SPECIFICATIONS Engine Combustion cycle 4-stroke Cooling system Liquid cooled Valve train DOHC Displacement 998 cm³ Cylinder arrangement Inline Number of cylinders 4-cylinder Bore × stroke 79.0 × 50.9 mm (3.11 × 2.00 in) Compression ratio 12.0 : 1 Compression pressure 1305–1680 kPa/250 r/min (13.1–16.8 kgf/cm²/ 250 r/min, 185.6–238.9 psi/250 r/min)
  • Page 38 ENGINE SPECIFICATIONS Spark plug(s) Manufacturer/model NGK/LMAR9E-J Spark plug gap 0.6–0.7 mm (0.024–0.028 in) Cylinder head Warpage limit 0.10 mm (0.0039 in) Camshaft Camshaft cap inside diameter 25.500–25.521 mm (1.0039–1.0048 in) Camshaft journal diameter 25.459–25.472 mm (1.0023–1.0028 in) Camshaft-journal-to-camshaft-cap clearance limit 0.080 mm (0.0032 in) Camshaft lobe dimensions Lobe height limit (Intake)
  • Page 39 ENGINE SPECIFICATIONS Piston Diameter 78.970–78.985 mm (3.1090–3.1096 in) Measuring point (from piston skirt bottom) 8.0 mm (0.31 in) Piston-to-cylinder clearance 0.015–0.040 mm (0.0006–0.0016 in) Piston pin bore inside diameter limit 17.043 mm (0.6710 in) Piston pin outside diameter limit 16.971 mm (0.6681 in) Piston ring Top ring End gap limit...
  • Page 40 ENGINE SPECIFICATIONS Clutch Clutch type Wet, multiple-disc Clutch lever free play 10.0–15.0 mm (0.39–0.59 in) Assembly width 48.3–49.3 mm (1.90–1.94 in) Friction plate 1 thickness 2.72–2.88 mm (0.107–0.113 in) Wear limit 2.62 mm (0.103 in) Plate quantity 3 pcs Friction plate 2 thickness 2.72–2.88 mm (0.107–0.113 in) Wear limit 2.62 mm (0.103 in)
  • Page 41 ENGINE SPECIFICATIONS Idling condition Engine idling speed 1200–1400 r/min AI system Inactive O2 feedback control Inactive 90–110 °C (194–230 °F) Coolant temperature Difference in vacuum pressure between the cylinders 0 kPa–1.3 kPa (0 mmHg–10 mmHg, 0 inHg–0.4 inHg) 0.5–4.5 % Fuel line pressure (at idle) 300–390 kPa (3.0–3.9 kgf/cm², 43.5–56.6 psi) Air induction system...

  • Page 42: Chassis Specifications

    CHASSIS SPECIFICATIONS EAS20015 CHASSIS SPECIFICATIONS Chassis 24.0 ° Caster angle Trail 102 mm (4.0 in) Front wheel Wheel type Cast wheel Rim size 17M/C X MT3.50 Radial wheel runout limit 1.0 mm (0.04 in) Lateral wheel runout limit 0.5 mm (0.02 in) Wheel axle bending limit 0.40 mm (0.02 in) Rear wheel...
  • Page 43 Hydraulic damper Fork spring free length limit 214.5 mm (8.45 in) (MT10N, MT10NC) 254.8 mm (10.03 in) (MT10SPN, MT10SPNC) Recommended oil Yamaha Suspension Oil 01 (MT10N, MT10NC) Yamaha Suspension Oil M1 (MT10SPN, MT10SPNC) Inner tube bending limit 0.2 mm (0.01 in) Quantity (left) 350.0 cm³...
  • Page 44 CHASSIS SPECIFICATIONS Rear suspension Shock absorber Gas-hydraulic damper Spring preload Adjustment value (Soft) 0.0 mm (0.00 in) (MT10SPN, MT10SPNC) 76.5 mm (3.01 in) (MT10N, MT10NC) Adjustment value (STD) 4.0 mm (0.16 in) (MT10SPN, MT10SPNC) 80.5 mm (3.17 in) (MT10N, MT10NC) Adjustment value (Hard) 84.5 mm (3.33 in) (MT10N, MT10NC) 9.0 mm (0.35 in) (MT10SPN, MT10SPNC)

  • Page 45: Electrical Specifications

    ELECTRICAL SPECIFICATIONS EAS20016 ELECTRICAL SPECIFICATIONS Voltage System voltage 12 V Ignition system 3.0–7.0 °/1300 r/min Ignition timing (B.T.D.C.) Engine control unit Model TBDF8S Ignition coil 1.19–1.61 Ω Primary coil resistance Secondary coil resistance 8.50–11.50 kΩ Charging system Charging system AC magneto Standard output 14.0 V, 28.3 A at 5000 r/min 0.112–0.168 Ω...
  • Page 46 ELECTRICAL SPECIFICATIONS Starter motor Brush overall length limit 5.5 mm (0.22 in) Mica undercut (depth) 2.40 mm (0.09 in) Fuel sender unit 9.0–12.0 Ω Sender unit resistance (full) 213.0–219.0 Ω Sender unit resistance (empty) Fuel injection sensor 189–231 Ω Crankshaft position sensor resistance Cylinder identification sensor output voltage (ON) 4.8 V...

  • Page 47: 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) EXUP valve pulley cover bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft) Spark plug 13 N·m (1.3 kgf·m, 9.6 lb·ft) Spark plug (new) 18 N·m (1.8 kgf·m, 13 lb·ft) Cylinder head cover bolt...
  • Page 48 TIGHTENING TORQUES Lower ring nut 1. Tighten the ring nut to 52 N·m (5.2 kgf·m, 38 lb·ft) with a torque wrench, then loosen the lower ring nut completely. 2. Tighten the lower ring nut to 14 N·m (1.4 kgf·m, 10 lb·ft). Front wheel axle pinch bolt 1.
  • Page 49 TIGHTENING TORQUES 2-14...

  • Page 50: Cable Routing

    CABLE ROUTING EAS20021 CABLE ROUTING Handlebar 1 (front view) 12,R 2-15...
  • Page 51 CABLE ROUTING 1. Clutch cable N. Fasten the horn lead at the tape with the clamp. Install the clamp at the same height 2. Clutch switch lead as the clutch switch lead mounting clamp. 3. Handlebar switch lead (left) Face the clamp opening face toward the 4.
  • Page 52 CABLE ROUTING Handlebar 2 (front view) 2-17...
  • Page 53 CABLE ROUTING 1. Handlebar switch lead (right) 2. Front brake light switch lead 3. Clutch switch lead 4. Clamp 5. Handlebar switch lead (left) 6. Main switch lead 7. Wire harness 8. Clutch cable 9. Front fork stepping motor sub-lead A.
  • Page 54 CABLE ROUTING Handlebar 3 (front view) 2-19...
  • Page 55 CABLE ROUTING 1. Handlebar switch lead (left) (to horn) 2. Clutch switch lead 3. Auxiliary DC jack lead 4. Auxiliary DC jack coupler 5. Front fork stepping motor sub-lead 6. Wire harness guide A. Route the auxiliary DC jack lead through the upside on the clutch switch lead and handlebar switch lead (left).
  • Page 56 CABLE ROUTING Handlebar 4 (front view) 12,G 2-21...
  • Page 57 CABLE ROUTING 1. Horn lead 2. Clutch switch lead 3. Main switch lead 4. Auxiliary DC jack lead 5. Handlebar switch lead (right) 6. Plastic locking tie 7. Main switch 8. Wire harness guide 9. Front fork stepping motor sub-lead 10.
  • Page 58 CABLE ROUTING Handlebar 5 (side view) 10,P 2-23...
  • Page 59 CABLE ROUTING 1. Handlebar switch lead (right) Q. 10 mm (0.39 in) or less 2. Clutch switch lead R. With the plastic locking tie passed through the hose, install the plastic locking tie to 3. Front brake light switch lead the range “a”...
  • Page 60 CABLE ROUTING Headlight (front view) 2-25...
  • Page 61 CABLE ROUTING 1. Auxiliary light coupler 2. Meter coupler (gray) 3. Wire harness 4. Main switch coupler 5. Headlight bracket A. Insert the auxiliary light coupler into the rib of the bracket. B. Insert the main switch coupler into the rib of the headlight bracket.
  • Page 62 CABLE ROUTING Frame and engine 1 (left side view) 16,F 15,F 17,F 2-27...
  • Page 63 CABLE ROUTING 1. Air scoop stay bracket 2. Wire harness 3. Air scoop stay (left) 4. Air filter case duct 5. Front brake hose bracket 6. Brake hose (front brake hose joint to front brake calipers) 7. Brake hose (front brake master cylinder to front brake hose joint) 8.
  • Page 64 CABLE ROUTING Frame and engine 2 (left side view) 18,L 14,D 22,O 22,N 10,R 2-29...
  • Page 65 CABLE ROUTING 1. Shift sensor lead K. Inside of the vehicle 2. Gear position sensor lead L. Fasten the thermostat housing cover and positioning tape of the shift sensor lead 3. Gear position sensor coupler (black) with the plastic locking tie. Point the end of 4.
  • Page 66 CABLE ROUTING Frame and engine 3 (right side view) 2-31...
  • Page 67 CABLE ROUTING 1. Wire harness O. Route the sub-wire harness (SCU) into the C-shaped hole. 2. Relay unit P. Insert the projection on the wire harness 3. Front turn signal/position light lead (right) clamp into the hole in the air scoop stay 4.
  • Page 68 CABLE ROUTING Frame 1 (top view) 23,J 22,J 21,J 10,C 19,J 18,I 11,E 17,H 12,O 2-33...
  • Page 69 CABLE ROUTING 1. Injector #4 coupler (gray) Insert the projection on the clutch switch coupler holder into the hole in the air filter 2. Injector #3 coupler (gray) case duct. 3. Rear brake light switch coupler (black) J. Insert the projection on the handlebar 4.
  • Page 70 CABLE ROUTING Frame 2 (top view) 16,G 19,H 16,I 2-35...
  • Page 71 CABLE ROUTING 1. Engine ground 2. Wire harness 3. Rear brake light switch lead 4. Canister 5. Brake hose (front brake master cylinder to brake hose joint) 6. Brake hose (brake hose joint to front brake caliper (left)) 7. Cooling system air bleed hose 8.
  • Page 72 CABLE ROUTING Frame 3 (top view) 12,D 14,E 14,F 24,J 18,D 20,D 19,D 23,I 2-37...
  • Page 73 CABLE ROUTING 1. Air induction system hose (air filter case to air cut-off valve) 2. Ignition coil #1 coupler 3. Wire harness 4. Ignition coil #2 coupler 5. Air cut-off valve 6. Cylinder identification sensor 7. Ignition coil #3 coupler 8.
  • Page 74 CABLE ROUTING Frame 4 (top view) 13,F 13,F 13,F 13,F 10,E 2-39...
  • Page 75 CABLE ROUTING 1. Sidestand switch coupler (black) 2. Coolant temperature sensor coupler (white) 3. Sidestand switch lead 4. Rear brake light switch coupler 5. Shift sensor coupler 6. Shift sensor lead 7. Oil pressure switch lead 8. Wire harness 9. Wire harness (to joint coupler) 10.
  • Page 76 CABLE ROUTING Rear fender 1 (top view) 28,J 25,G 28,J 32,K 11,L 12,C 15,E 17,M 17,M 33,N 35,O 2-41...
  • Page 77 CABLE ROUTING 1. Clamp K. Insert the rubber part of the YDT coupler into the step of the battery box rib. 2. Starter motor lead L. Route the positive battery lead under bat- 3. Tail/brake light relay tery box 2 and wire it from the back to the 4.
  • Page 78 CABLE ROUTING Rear fender 2 (top view) 2-43...
  • Page 79 CABLE ROUTING 1. Rear turn signal light lead (right) 2. Rear turn signal light resistor (right) 3. Rear turn signal light lead (left) 4. Rear turn signal light resistor (left) 5. Rear turn signal light lead (resistor side) 6. Tail/brake light lead 7.
  • Page 80 CABLE ROUTING Rear fender 3 (left side view) 12,13 2-45...
  • Page 81 CABLE ROUTING 1. Main fuse 2. Battery box 2 3. Positive battery lead 4. EXUP cable 1 5. EXUP cable 2 6. Wire harness (to ECU 1 coupler) 7. Wire harness (to ECU 2 coupler) 8. Battery box 1 9. Wire harness (fuse box) 10.
  • Page 82 CABLE ROUTING EXUP cable (top side view) 2-47...
  • Page 83 CABLE ROUTING 1. Battery box 1 2. EXUP cable 2 3. Cover 4. EXUP cable 1 A. Route the EXUP cable 1 and EXUP cable 2 to the outside of the vehicle of the battery box 1 protrusion. B. Route the EXUP cable 1 and EXUP cable 2 to the bottom side of the vehicle of the battery box 1 protrusions.
  • Page 84 CABLE ROUTING Front brake hose 1 (left side view) 2-49...
  • Page 85 CABLE ROUTING 1. Brake hose (front brake master cylinder to front brake master cylinder hose joint) 2. Brake hose (front brake caliper hose joint to front brake calipers) 3. Front wheel sensor lead 4. Front brake caliper 5. Front fork 6.
  • Page 86 CABLE ROUTING Front brake hose 2 (left side view) 2-51...
  • Page 87 CABLE ROUTING 1. Clamp 2. Brake hose bracket 3. Brake hose joint bracket 4. Brake hose (hydraulic unit to front brake cali- per hose joint) 5. Brake hose (front brake master cylinder hose joint to hydraulic unit) 6. Hydraulic unit assembly 7.
  • Page 88 CABLE ROUTING Rear brake hose 1 (right side view) 11,B 10,A 13,E 2-53...
  • Page 89 CABLE ROUTING 1. Rear brake hose (hydraulic unit to rear brake caliper) 2. Rear brake light switch lead 3. Rear brake hose (rear brake master cylinder to hydraulic unit) 4. Rear wheel sensor lead 5. EXUP cable 1 6. EXUP cable 2 7.
  • Page 90 CABLE ROUTING Rear brake hose 2 (right side view) 2-55...
  • Page 91 CABLE ROUTING 1. Rear brake hose (hydraulic unit to rear brake caliper) 2. Rear wheel sensor cover 3. Rear wheel sensor protector 4. Rear wheel sensor lead 5. Swingarm 6. Rear brake caliper 7. Rear brake hose holder 8. Clamp 9.
  • Page 92 CABLE ROUTING Hydraulic unit (top view) 2-57...
  • Page 93 CABLE ROUTING 1. Front brake hose (hydraulic unit to front brake caliper hose joint) 2. Front brake hose (front brake master cylinder hose joint to hydraulic unit) 3. Rear brake hose (rear brake master cylinder to hydraulic unit) 4. Rear brake hose (hydraulic unit to rear brake caliper) 5.
  • Page 94 CABLE ROUTING Fuel tank (front side view) (except for California) 2-59...
  • Page 95 CABLE ROUTING 1. Clip 2. Fuel tank drain hose 3. Fuel tank breather hose A. Face the white paint mark on the fuel tank breather hose toward the front of the vehi- cle. B. Make sure that the clip does not go on top of the spool part.
  • Page 96 CABLE ROUTING Canister (front side view) (for California) 2-61...
  • Page 97 CABLE ROUTING 1. Clip 2. Fuel tank breather hose (fuel tank to canis- ter) 3. Purge cut valve 4. Fuel tank drain hose 5. Canister purge hose (purge cut valve to canister) 6. Canister 7. Canister purge hose (purge cut valve to hose joint) 8.
  • Page 98 CABLE ROUTING Canister (top and left side view) (for California) 2-63...
  • Page 99 CABLE ROUTING 1. Canister 2. Hose clamp 3. Fuel tank breather hose (fuel tank to canis- ter) 4. Canister purge hose (purge cut valve to canister) 5. Fuel hose 6. Canister purge hose (purge cut valve to hose joint) 7. Throttle body assembly 8.
  • Page 100 CABLE ROUTING Air filter case and throttle bodies (rear side view) 2-65...
  • Page 101 CABLE ROUTING 1. Air filter case 2. Hose clamp 3. Canister purge hose (purge cut valve to hose joint) (for California) 4. Fuel hose 5. Throttle body assembly 6. Crankcase breather hose A. Install the crankcase breather hose com- pletely. B.
  • Page 102 CABLE ROUTING Air cut-off valve (front side view) 2-67...
  • Page 103 CABLE ROUTING 1. Air filter case 2. Air induction system hose (air filter case to air cut-off valve) 3. Cylinder head cover 4. Reed valve cover 5. Air induction system hose (air cut-off valve to reed valve cover) 6. Air cut-off valve 7.
  • Page 104 CABLE ROUTING Radiator (both side view) 2-69...
  • Page 105 CABLE ROUTING 1. Clamp 2. Radiator 3. Radiator outlet hose 4. Radiator inlet hose 5. Coolant reservoir hose 6. Clip 7. Hose clamp A. Fasten the radiator fan motor lead (left) and radiator fan motor lead (right) with the clamp. B.
  • Page 106 CABLE ROUTING Water hose (right side view) 2-71...
  • Page 107 CABLE ROUTING 1. Cooling system air bleed hose 2. Clamp 3. Hose clamp 4. Radiator outlet hose 5. Water pump inlet pipe A. Install the clamp with the end pointing upward. Do not locate the clamp onto the spool part. B.
  • Page 108 CABLE ROUTING Water hose (left side view) 2-73...
  • Page 109 CABLE ROUTING 1. Radiator inlet hose 2. Cooling system air bleed hose 3. Clamp 4. Thermostat assembly 5. Hose clamp A. Face the clamp end to the white paint mark on the cooling system air bleed hose. Do not locate the clamp onto the spool part. B.
  • Page 110 CABLE ROUTING Muffler (top and left side view) 2-75...
  • Page 111 CABLE ROUTING 1. Exhaust chamber 2. EXUP valve pulley cover 3. Muffler 4. EXUP servo motor 5. Right footrest assembly 6. EXUP cable 1 7. EXUP cable 2 A. Route the EXUP cables through the hole in the front side of the battery box 1. B.
  • Page 112 CABLE ROUTING 2-77...

  • Page 113: Periodic Checks And Adjustments

    INTRODUCTION ..................3-1 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM ....................3-1 GENERAL MAINTENANCE AND LUBRICATION CHART .......3-1 CHECKING THE VEHICLE USING THE YAMAHA DIAGNOSTIC TOOL ......................3-4 CHECKING THE FUEL LINE ..............3-4 CHECKING THE SPARK PLUGS ............. 3-5 ADJUSTING THE VALVE CLEARANCE ..........3-5 CHECKING THE ENGINE IDLING SPEED ..........3-9...
  • Page 114 ADJUSTING THE DAMPING FORCE OF THE FRONT FORK LEGS AND REAR SHOCK ABSORBER (for MT10SPN/MT10SPNC) ..... 3-24 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY ....3-25 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY (for MT10N/MT10NC) ................3-25 ADJUSTING THE PRELOAD OF THE REAR SHOCK ABSORBER ASSEMBLY (for MT10SPN/MT10SPNC) ..........

  • Page 115: Periodic Maintenance

    • From 24000 mi (37000 km) or 36 months, repeat the maintenance intervals starting from 8000 mi (13000 km) or 12 months. • Items marked with an asterisk require special tools, data and technical skills, have a Yamaha dealer perform the service.
  • Page 116 PERIODIC MAINTENANCE INITIAL ODOMETER READINGS 8000 mi 12000 mi 16000 mi 20000 mi 600 mi 4000 mi ITEM ROUTINE (13000 (19000 (25000 (31000 (1000 km) (7000 km) 1 month 6 months 12 months 18 months 24 months 30 months • Check operation. √...
  • Page 117 Front and rear √ √ √ √ √ √ 29 * • Check operation. brake switches • Apply Yamaha cable lubricant √ √ √ √ √ √ 30 * Control cables or other suitable cable lubri- cant thoroughly. • Check operation.

  • Page 118: Checking The Vehicle Using The Yamaha Diagnostic Tool

    • Yamaha diagnostic tool (A/I) (90890-03264) in- Cracks/damage → Replace. cludes YDT sub harness (6P) (90890-03266). Loose connection → Connect properly. • If you already have Yamaha diagnostic tool (A/ ECA14940 NOTICE I) (90890-03262), YDT sub harness (6P) (90890-03266) is separately required.

  • Page 119: Checking The Spark Plugs

    PERIODIC MAINTENANCE EAS30620 CHECKING THE SPARK PLUGS The following procedure applies to all of the spark plugs. 1. Remove: • Rider seat Refer to “GENERAL CHASSIS (1)” on page 4-1. • Air scoop • Fuel tank cover G088880 • Fuel tank side cover 7.
  • Page 120 PERIODIC MAINTENANCE 1. Remove: a. Turn the crankshaft counterclockwise. • Rider seat b. When piston #1 is at TDC on the compres- Refer to “GENERAL CHASSIS (1)” on sion stroke, align the TDC mark “a” on the page 4-1. generator rotor with the generator rotor cov- •...
  • Page 121 PERIODIC MAINTENANCE i. Measure the valve clearance #2 with a thickness gauge. Thickness gauge 90890-03268 Feeler gauge set YU-26900-9 j. Turn the crankshaft counterclockwise. k. When piston #4 is at TDC on the compres- G088883 sion stroke, align the TDC mark “f” on the A.
  • Page 122 PERIODIC MAINTENANCE e. Round off the valve pad number according to the following table, and then select the • Cover the timing chain opening with a rag to suitable valve pad. prevent the valve pad from falling into the crankcase. Last digit Rounded value •...

  • Page 123: Checking The Engine Idling Speed

    PERIODIC MAINTENANCE a. Connect the YDT. Use the diagnostic code number “67”. • Refer to “CAMSHAFTS” on page 5-17. Refer to “SELF-DIAGNOSTIC FUNCTION • Lubricate the camshaft lobes and camshaft AND DIAGNOSTIC CODE TABLE” on journals. page 9-39. • First, install the exhaust camshaft. b.
  • Page 124 PERIODIC MAINTENANCE 4. Install: b. Using the throttle body that has the bypass • Vacuum gauge “1” air screw “1” with a white paint mark as the standard, adjust the other throttle bodies by Vacuum gauge turning its bypass air screw in or out. 90890-03094 ECA21300 NOTICE...

  • Page 125: Checking The Throttle Body Joints

    PERIODIC MAINTENANCE 4. Install: • Air filter case Refer to “AIR FILTER CASE” on page 7-6. • Fuel tank Refer to “FUEL TANK” on page 7-1. • Fuel tank side cover • Fuel tank cover • Air scoop Refer to “GENERAL CHASSIS (2)” on page 4-8.

  • Page 126: Checking The Canister (For California)

    PERIODIC MAINTENANCE 3. Install: • Fuel tank Refer to “FUEL TANK” on page 7-1. • Fuel tank side cover • Fuel tank cover • Air scoop Refer to “GENERAL CHASSIS (2)” on page 4-8. • Rider seat Refer to “GENERAL CHASSIS (1)” on page 4-1.

  • Page 127: Adjusting The Clutch Lever Free Play

    PERIODIC MAINTENANCE 4. Install: 2. Adjust: • Air filter element • Clutch lever free play • Air filter case cover Handlebar side Refer to “AIR FILTER CASE” on page 7-6. a. Turn the adjusting bolt “1” until the specified ECA20710 clutch lever free play is obtained.

  • Page 128: Checking The Brake Fluid Level

    PERIODIC MAINTENANCE EAS30632 EAS30630 CHECKING THE BRAKE FLUID LEVEL ADJUSTING THE FRONT DISC BRAKE 1. Stand the vehicle on a level surface. 1. Adjust: • Brake lever position (distance “a” from the throttle grip to the brake • Place the vehicle on a maintenance stand. lever) •...

  • Page 129: Checking The Front Brake Pads

    PERIODIC MAINTENANCE EAS30633 CHECKING THE FRONT BRAKE PADS The following procedure applies to all of the brake pads. 1. Operate the brake. 2. Check: • Front brake pad Wear indicators “1” almost touch the brake disc → Replace the brake pads as a set. Refer to “FRONT BRAKE”...

  • Page 130: Checking The Rear Brake Hose

    PERIODIC MAINTENANCE 5. Check: • Brake hose • Be careful not to spill any brake fluid or allow Brake fluid leakage → Replace the damaged the brake fluid reservoir to overflow. hose. • When bleeding the ABS, make sure that there Refer to “FRONT BRAKE”...

  • Page 131: Checking The Wheels

    PERIODIC MAINTENANCE d. Place the other end of the hose into a con- EWA13260 WARNING tainer. Never attempt to make any repairs to the e. Slowly apply the brake several times. wheel. f. Fully squeeze the brake lever or fully de- press the brake pedal and hold it in position.

  • Page 132: Checking The Wheel Bearings

    1. Check: approved by Yamaha is used on this vehicle. • Wheel bearings Refer to “CHECKING THE FRONT WHEEL” on page 4-24 and “CHECKING THE REAR Front tire WHEEL”...

  • Page 133: Lubricating The Drive Chain

    PERIODIC MAINTENANCE ECA13550 NOTICE A drive chain that is too tight will overload the engine and other vital parts, and one that is too loose can skip and damage the swing- arm or cause an accident. Therefore, keep the drive chain slack within the specified lim- its.

  • Page 134: Checking And Adjusting The Steering Head

    PERIODIC MAINTENANCE EAS30645 CHECKING AND ADJUSTING THE Steering nut wrench STEERING HEAD 90890-01403 1. Stand the vehicle on a level surface. Exhaust flange nut wrench EWA13120 YU-A9472 WARNING Securely support the vehicle so that there is no danger of it falling over. Lower ring nut (initial tightening torque) 52 N·m (5.2 kgf·m, 38 lb·ft)

  • Page 135: Lubricating The Steering Head

    PERIODIC MAINTENANCE EAS30646 EAS30651 LUBRICATING THE STEERING HEAD LUBRICATING THE SIDESTAND 1. Lubricate: Lubricate the pivoting point, metal-to-metal mov- • Upper bearing ing parts and spring contact point of the side- • Lower bearing stand. • Bearing race Recommended lubricant Lithium-soap-based grease Recommended lubricant Lithium-soap-based grease...
  • Page 136 PERIODIC MAINTENANCE Spring preload a. Turn the adjusting bolt “1” in direction “a” or EWA17040 “b”. WARNING Always adjust both front fork legs evenly. Direction “a” Uneven adjustment can result in poor han- Rebound damping is increased (sus- dling and loss of stability. pension is harder).

  • Page 137: Adjusting The Preload Of The Front Fork Legs (For Mt10Spn/Mt10Spnc)

    PERIODIC MAINTENANCE Spring preload a. Turn the adjusting bolt “1” in direction “a” or EWA17040 “b”. WARNING Always adjust both front fork legs evenly. Direction “a” Uneven adjustment can result in poor han- Compression damping is increased dling and loss of stability. (suspension is harder).

  • Page 138: Adjusting The Damping Force Of The Front Fork Legs And Rear Shock Absorber (For Mt10Spn/Mt10Spnc)

    PERIODIC MAINTENANCE The factory preset levels are intended as fol- lows: • A-1/M-1 are preset for track use with racing slick tires. • A-2/M-2 are preset for track use with street tires. • A-3/M-3 are preset for road use with street tires.

  • Page 139: Checking The Rear Shock Absorber Assembly

    PERIODIC MAINTENANCE 1. Adjust: f. The display will change to the relevant sus- • Damping force pension setting screen (automatic/manual) with the ERS mode selection box “SET- a. Turn the main switch to “ON”. TING” highlighted. Short push the wheel b.
  • Page 140 PERIODIC MAINTENANCE a. Loosen the locknut “1”. Rebound damping b. Adjust the spring preload with the special ECA13590 NOTICE wrench included in the owner’s tool kit. Never go beyond the maximum or minimum c. Turn the adjusting ring “2” in direction “a” or adjustment positions.
  • Page 141 PERIODIC MAINTENANCE Compression damping (for fast compres- Compression damping (for slow compres- sion damping) sion damping) ECA13590 ECA13590 NOTICE NOTICE Never go beyond the maximum or minimum Never go beyond the maximum or minimum adjustment positions. adjustment positions. 1. Adjust: 1.

  • Page 142: Adjusting The Preload Of The Rear Shock Absorber Assembly (For Mt10Spn/Mt10Spnc)

    PERIODIC MAINTENANCE EAS30942 ADJUSTING THE PRELOAD OF THE REAR SHOCK ABSORBER ASSEMBLY (for MT10SPN/MT10SPNC) EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. Spring preload ECA13590 NOTICE Spring preload Never go beyond the maximum or minimum Minimum adjustment positions.

  • Page 143: Changing The Engine Oil

    PERIODIC MAINTENANCE 3. Remove: • Engine oil filler cap “1” • Engine oil drain bolt “2” • Gasket “3” Recommended brand YAMALUBE Type Full synthetic SAE viscosity grades 10W-40, 15W-50 Recommended engine oil grade API service SG type or higher, JASO standard MA ECA13361 NOTICE...

  • Page 144: Measuring The Engine Oil Pressure

    PERIODIC MAINTENANCE c. Lubricate the O-ring of the new oil filter car- EAS30810 MEASURING THE ENGINE OIL PRESSURE tridge with a thin coat of lithium-soap-based 1. Check: grease. • Engine oil level ECA25890 Below the minimum level mark “a” → Add the NOTICE recommended engine oil to the proper level.

  • Page 145: Checking The Coolant Level

    PERIODIC MAINTENANCE 8. Remove: • Oil pressure gauge • Adapter C • Oil pressure switch joint bolt • Oil pressure switch joint (with the O-ring) 9. Install: • O-ring “1” • Oil pressure switch joint (with the oil pressure switch) “2” •...

  • Page 146: Checking The Cooling System

    PERIODIC MAINTENANCE ECA21281 EAS30813 CHANGING THE COOLANT NOTICE 1. Remove: • Adding water instead of coolant dilutes the • Radiator cover (right) antifreeze concentration of the coolant. If • Coolant reservoir cover water is used instead of coolant; check, Refer to “GENERAL CHASSIS (2)” on and if necessary, correct the antifreeze page 4-8.
  • Page 147 PERIODIC MAINTENANCE 5. Install: 10.Fill: • Water pump drain bolt • Cooling system (with the specified amount of the recom- • Copper washer mended coolant) Water pump drain bolt Recommended antifreeze 10 N·m (1.0 kgf·m, 7.4 lb·ft) High-quality ethylene glycol anti- 6.

  • Page 148: Adjusting The Exup Cables

    PERIODIC MAINTENANCE 11.Fill: • Coolant reservoir Before checking the coolant level, wait a few (with the recommended coolant to the maxi- minutes until the coolant has settled. mum level mark “a”) 19.Install: • Coolant reservoir cover • Radiator cover (right) Refer to “GENERAL CHASSIS (2)”...

  • Page 149: Checking The Front Brake Light Switch

    PERIODIC MAINTENANCE f. Tighten the locknut. 4. Install: • EXUP valve pulley cover Refer to “ENGINE REMOVAL” on page 5-11. EXUP valve pulley cover bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft) LOCTITE® EAS31145 CHECKING THE FRONT BRAKE LIGHT SWITCH Refer to “ELECTRICAL COMPONENTS” on page 8-37.

  • Page 150: Checking And Lubricating The Cables

    PERIODIC MAINTENANCE EAS31147 EAS30664 CHECKING AND LUBRICATING THE ADJUSTING THE HEADLIGHT BEAMS CABLES 1. Adjust: The following procedure applies to all of the in- • Headlight beam (vertically) ner and outer cables. EWA13270 To adjust the headlight beam (vertically), insert a WARNING crosshead screwdriver into the cutout “a”...
  • Page 151 PERIODIC MAINTENANCE c. Removing the cover “3”. d. Turn the adjusting screw “4”. 3. Install: • Cover a. Installing the cover bolt “1”. Cover bolt 1.3 N·m (0.13 kgf·m, 0.95 lb·ft) LOCTITE® b. Installing the quick fastener “2”. 3-37...
  • Page 152 PERIODIC MAINTENANCE 3-38...

  • Page 153: Chassis

    CHASSIS GENERAL CHASSIS (1) ................. 4-1 REMOVING THE SEAT ................4-6 REMOVING THE REAR COWLING (CENTER) ........4-6 REMOVING THE ECU (engine control unit) ..........4-6 INSTALLING THE IMU................4-6 INSTALLING THE ECU (engine control unit) ..........4-7 INSTALLING THE REAR COWLING (CENTER) ........4-7 INSTALLING THE SEAT ................4-7 GENERAL CHASSIS (2) .................
  • Page 154 FRONT BRAKE ..................... 4-39 INTRODUCTION ..................4-45 CHECKING THE FRONT BRAKE DISCS..........4-45 REPLACING THE FRONT BRAKE PADS ..........4-45 REMOVING THE FRONT BRAKE CALIPERS ........4-47 DISASSEMBLING THE FRONT BRAKE CALIPERS......4-47 CHECKING THE FRONT BRAKE CALIPERS ........4-47 ASSEMBLING THE FRONT BRAKE CALIPERS........4-48 INSTALLING THE FRONT BRAKE CALIPERS ........
  • Page 155 FRONT FORK (for MT10SPN/MT10SPNC)..........4-86 REMOVING THE FRONT FORK LEGS..........4-88 DISASSEMBLING THE FRONT FORK LEG ..........4-88 CHECKING THE FRONT FORK LEGS ..........4-89 ASSEMBLING THE FRONT FORK LEGS ..........4-90 INSTALLING THE FRONT FORK LEGS ..........4-93 STEERING HEAD..................4-96 REMOVING THE LOWER BRACKET.............4-98 CHECKING THE STEERING HEAD ............4-98 INSTALLING THE STEERING HEAD .............4-99...

  • Page 156: General Chassis (1)

    GENERAL CHASSIS (1) EAS20026 GENERAL CHASSIS (1) Removing the seat and battery 2.2 N m (0.22 kgf m, 1.6 lb • • • m (0.7 kgf m, 5.2 lb • • • m (0.7 kgf m, 5.2 lb • • •...
  • Page 157 GENERAL CHASSIS (1) Removing the rear side covers and rear cowlings 1.5 N m (0.15 kgf m, 1.1 lb • • • 1.5 N m (0.15 kgf m, 1.1 lb • • • 10 N ・ m (1.0 kgf ・ m, 7.4 ft ・ lb) 1.5 N m (0.15 kgf m, 1.1 lb...
  • Page 158 GENERAL CHASSIS (1) Removing the tail/brake light and mudguard assembly 2.1 N m (0.21 kgf m, 1.5 lb • • • m (0.7 kgf m, 5.2 lb • • • m (0.7 kgf m, 5.2 lb • • • m (0.7 kgf m, 5.2 lb •...
  • Page 159 GENERAL CHASSIS (1) Disassembling the mudguard assembly 10 N m (1.0 kgf m, 7.4 lb • • • 2.3 N m (0.23 kgf m, 1.7 lb • • • 3.8 N m (0.38 kgf m, 2.8 lb • • • 3.8 N m (0.38 kgf m, 2.8 lb...
  • Page 160 GENERAL CHASSIS (1) Removing the battery box 1 and rear frame 4.3 N m (0.43 kgf m, 3.2 lb • • • 50 N m (5.0 k gf m, 37 lb • • • m (0.7 kgf m, 5.2 lb •...

  • Page 161: Removing The Seat

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

  • Page 162: Installing The Ecu (Engine Control Unit)

    GENERAL CHASSIS (1) EAS31842 INSTALLING THE REAR COWLING Apply a thin coat of silicone grease onto the (CENTER) washers where contacting the grommets. 1. Install: • Rear cowling (center) “1” a. Insert the projection “a” on the rear cowling Recommended lubricant Silicone grease (center) into the tail / brake light.
  • Page 163 GENERAL CHASSIS (2) EAS20155 GENERAL CHASSIS (2) Removing the radiator covers and air scoops 1.5 N m (0.15 kgf m, 1.1 lb • • • 1.5 N m (0.15 kgf m, 1.1 lb • • • 1.5 N ・ m (0.15 kgf ・ m, 1.11 ft ・ lb) m (0.7 kgf m, 5.2 lb •...
  • Page 164 GENERAL CHASSIS (2) Removing the fuel tank cover and air duct (left) m (0.7 kgf m, 5.2 lb • • • 0.8 N ・ m (0.08 kgf ・ m, 0.59 ft ・ lb) 0.4 N ・ m (0.04 kgf ・ m, 0.30 ft ・ lb) 3.8 N m (0.38 kgf m, 2.8 lb...
  • Page 165 GENERAL CHASSIS (2) Removing the fuel tank side cover and air duct (right) 0.8 N m (0.08 kgf m, 0.59 lb • • • m (0.7 kgf m, 5.2 lb • • • 0.4 N m (0.04 kgf m, 0.30 lb •...
  • Page 166 GENERAL CHASSIS (2) Removing the bottom cowling (for MT10SPN/MT10SPNC) m (0.9 kgf m, 6.6 lb • • • m (0.9 kgf m, 6.6 lb • • • 0.3 N m (0.03 kgf m, 0.22 lb • • • m (0.9 kgf m, 6.6 lb •...

  • Page 167: Removing The Air Scoop

    GENERAL CHASSIS (2) EAS31772 REMOVING THE AIR SCOOP The following procedure applies to both of the air scoop. 1. Remove: • Air scoop (left) “1” a. Remove the air scoop bolts (left) “2”. b. Disengage projections “a” on the air scoop (left) from air scoop stay.

  • Page 168: Removing The Fuel Tank Cover

    GENERAL CHASSIS (2) EAS31685 EAS33575 REMOVING THE FUEL TANK COVER INSTALLING THE FUEL TANK SIDE COVER 1. Remove: ASSEMBLY • Fuel tank cover “1” The following procedure applies to both of the fuel tank side cover assembly. a. Remove the quick fasteners “a”. 1.

  • Page 169: Installing The Side Cover (Left)

    GENERAL CHASSIS (2) EAS31520 EAS32174 INSTALLING THE SIDE COVER (LEFT) INSTALLING THE SIDE COVER (RIGHT) 1. Install: 1. Install: • Side cover bracket (left) “1” • Side cover bracket (right) “1” a. Insert the projection “a” on the side cover a.

  • Page 170: Installing The Air Scoop

    GENERAL CHASSIS (2) EAS31773 INSTALLING THE AIR SCOOP The following procedure applies to both of the air scoop. 1. Install: • Air scoop (left) “1” a. Insert the projections “a” on the air scoop (left) into the air scoop stay. b.
  • Page 171 GENERAL CHASSIS (3) EAS20156 GENERAL CHASSIS (3) Removing the meter assembly and auxiliary light 2.8 N m (0.28 kgf m, 2.1 lb • • • m (0.7 kgf m, 5.2 lb • • • 0.4 N m (0.04 kgf m, 0.30 lb •...
  • Page 172 GENERAL CHASSIS (3) Removing the headlight assembly and headlight stay 18 N m (1.8 k gf m, 13 lb • • • 1.8 N m (0.18 kgf m, 1.3 lb • • • 1.0 N m (0.10 kgf m, 0.73 lb •...
  • Page 173 GENERAL CHASSIS (3) Disassembling the headlight assembly 1.2 N m (0.12 k gf m, 0.88 lb • • • Order Job/Parts to remove Q’ty Remarks Headlight control unit coupler Disconnect. Headlight control unit 4-18...
  • Page 174 GENERAL CHASSIS (3) Removing the air scoop stay bracket (left) m (0.7 kgf m, 5.2 lb • • • m (0.7 kgf m, 5.2 lb • • • Order Job/Parts to remove Q’ty Remarks Air scoop/Air scoop stay/Fuel tank cover/Fuel Refer to “GENERAL CHASSIS (2)”...
  • Page 175 GENERAL CHASSIS (3) Removing the air scoop stay bracket (right) 1.8 N m (0.18 kgf m, 1.3 lb • • • 10 N m (1.0 k gf m, 7.4 lb • • • m (0.7 kgf m, 5.2 lb • •...

  • Page 176: Front Wheel

    FRONT WHEEL EAS20028 FRONT WHEEL Removing the front wheel and brake discs (for MT10N/MT10NC) 6 N ・ m (0.6 kgf ・ m, 4.4 lb ・ ft) 3.8 N ・ m (0.38 kgf ・ m, 2.8 lb ・ ft) 6 N ・ m (0.6 kgf ・ m, 4.4 lb ・ ft) 35 N ・...
  • Page 177 FRONT WHEEL Removing the front wheel and brake discs (for MT10SPN/MT10SPNC) 6 N ・ m (0.6 kgf ・ m, 4.4 lb ・ ft) 3.8 N m (0.38 kgf m, 2.8 lb • • • 6 N ・ m (0.6 kgf ・ m, 4.4 lb ・ ft) 35 N ・...
  • Page 178 FRONT WHEEL Disassembling the front wheel m (0.7 kgf m, 5.2 lb • • • m (0.8 kgf m, 5.9 lb • • • Order Job/Parts to remove Q’ty Remarks Front wheel sensor rotor Oil seal Wheel bearing Spacer Tire air valve 4-23...

  • Page 179: Removing The Front Wheel

    FRONT WHEEL EAS30145 1. Remove: REMOVING THE FRONT WHEEL • Oil seal ECA20981 • Wheel bearing NOTICE a. Clean the surface of the front wheel hub. • Keep any type of magnets (including mag- b. Remove the oil seals “1” with a flat-head netic pick-up tools, magnetic screwdrivers, screwdriver.

  • Page 180: Assembling The Front Wheel

    FRONT WHEEL Place a suitable washer “1” between the socket “2” and the bearing so that both the inner race “3” and outer race “4” are pressed at the same time, and then press the bearing until the inner race makes contact with the spacer “5”. G088897 4.

  • Page 181: Maintenance Of The Front Wheel Sensor And Sensor Rotor

    • Do not allow grease to contact the O-ring. since they have been accurately adjusted. Keep them away from dirt and do not sub- • Use only the specified genuine YAMAHA tire air valve. Using a different air valve may ject them to shocks.

  • Page 182: Adjusting The Front Wheel Static Balance

    FRONT WHEEL a. Hold the dial gauge at a right angle against 2. Check: the wheel sensor rotor surface. • Front brake disc b. Measure the wheel sensor rotor deflection. Refer to “CHECKING THE FRONT BRAKE DISCS” on page 4-45. 3.
  • Page 183 FRONT WHEEL 8. Measure: • Distance “a” (between the front wheel sensor rotor “1” and front wheel sensor “2”) Out of specification → Check the wheel bear- ing for looseness, and the front wheel sensor and sensor rotor installation conditions (warpage caused by overtorque, wrong in- stallation direction, rotor decentering, LOC- TITE®...
  • Page 184 FRONT WHEEL 9. Install: • Front wheel sensor protector (for MT10SPN/ MT10SPNC) • Front brake caliper • Front brake hose holder Front wheel sensor protector bolt (for MT10SPN/MT10SPNC) 7 N·m (0.7 kgf·m, 5.2 lb·ft) Front brake caliper bolt 35 N·m (3.5 kgf·m, 26 lb·ft) Front brake hose holder bolt 6 N·m (0.6 kgf·m, 4.4 lb·ft) EWA13500...

  • Page 185: Rear Wheel

    REAR WHEEL EAS20029 REAR WHEEL Removing the rear wheel 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 190 N ・ m (19 kgf ・ m, 140 lb ・ ft) 16 N ・ m (1.6 kgf ・ m, 12 lb ・ ft) 16 N ・...
  • Page 186 REAR WHEEL Removing the brake disc and rear wheel sprocket 30 N m (3.0 k gf m, 22 lb • • • m (0.8 kgf m, 5.9 lb • • • m (0.8 kgf m, 5.9 lb • • • 80 N m (8.0 k gf m, 59 lb...
  • Page 187 REAR WHEEL Disassembling the rear wheel 80 N m (8.0 k gf m, 59 lb • • • m (0.7 kgf m, 5.2 lb • • • Order Job/Parts to remove Q’ty Remarks Collar Wheel bearing Spacer Oil seal Wheel bearing ring nut Wheel bearing Tire air valve 4-32...

  • Page 188: Removing The Rear Wheel

    REAR WHEEL EAS30910 REMOVING THE REAR WHEEL Push the rear wheel forward and remove the ECA21030 NOTICE drive chain from the rear wheel sprocket. • Keep any type of magnets (including mag- netic pick-up tools, magnetic screwdrivers, EAS30158 DISASSEMBLING THE REAR WHEEL etc.) away from the rear wheel sensor or ECA21340 rear wheel sensor rotor;...

  • Page 189: Checking The Rear Wheel

    REAR WHEEL EAS30159 2. Replace: CHECKING THE REAR WHEEL • Rear wheel sprocket 1. Check: a. Remove the rear wheel sprocket nuts, rear • Wheel axle wheel sprocket bracket and the rear wheel • Wheel bearing sprocket. • Oil seal b.
  • Page 190 (along with the O-ring) ECA27760 NOTICE • Do not allow grease to contact the O-ring. • Use only the specified genuine YAMAHA tire air valve. Using a different air valve may cause leakage. • Make sure there are no foreign materials in a.

  • Page 191: Maintenance Of The Rear Wheel Sensor And Sensor Rotor

    REAR WHEEL 3. Measure: • Wheel sensor rotor runout Refer to “MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR” on page 4-26. EAS30164 ADJUSTING THE REAR WHEEL STATIC BALANCE • After replacing the tire, wheel or both, the rear wheel static balance should be adjusted.
  • Page 192 REAR WHEEL 4. Install: 6. Tighten: • Collar • Rear wheel axle nut • Brake caliper bracket • Rear brake caliper bolt • Rear wheel • Adjusting block Rear wheel axle nut 190 N·m (19 kgf·m, 140 lb·ft) • Rear wheel axle Rear brake caliper bolt (front) •...
  • Page 193 REAR WHEEL 8. Measure: • Distance “a” (between the rear wheel sensor rotor “1” and rear wheel sensor “2”) Out of specification → Check the wheel bear- ing for looseness, and the rear wheel sensor and sensor rotor installation conditions (warpage caused by overtorque, wrong in- stallation direction, rotor decentering, LOC- TITE®...

  • Page 194: Front Brake

    FRONT BRAKE EAS20030 FRONT BRAKE Removing the front brake pads 6 N ・ m (0.6 kgf ・ m, 4.4 lb ・ ft) 5 N ・ m (0.5 kgf ・ m, 3.7 lb ・ ft) 35 N ・ m (3.5 kgf ・ m, 26 lb ・ ft) Order Job/Parts to remove Q’ty...
  • Page 195 FRONT BRAKE Removing the front brake master cylinder 1.2 N m (0.12 kgf m, 0.88 lb • • • 17 N m (1.7 k gf m, 13 lb • • • 2.5 N m (0.25 kgf m, 1.8 lb • •...
  • Page 196 FRONT BRAKE Removing the front brake master cylinder 1.2 N m (0.12 kgf m, 0.88 lb • • • 17 N m (1.7 k gf m, 13 lb • • • 2.5 N m (0.25 kgf m, 1.8 lb • •...
  • Page 197 FRONT BRAKE Disassembling the front brake master cylinder m (0.6 kgf m, 4.4 lb • • • Order Job/Parts to remove Q’ty Remarks Brake master cylinder kit Bleed screw Brake master cylinder body 4-42...
  • Page 198 FRONT BRAKE Removing the front brake calipers 6 N ・ m (0.6 kgf ・ m, 4.4 lb ・ ft) 32 N ・ m (3.2 kgf ・ m, 24 lb ・ ft) 35 N ・ m (3.5 kgf ・ m, 26 lb ・ ft) Order Job/Parts to remove Q’ty...
  • Page 199 FRONT BRAKE Disassembling the front brake calipers 5 N ・ m (0.5 kgf ・ m, 3.7 lb ・ ft) 5 N ・ m (0.5 kgf ・ m, 3.7 lb ・ ft) Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers.

  • Page 200: 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 201 FRONT BRAKE 1. Remove: a. Connect a clear plastic hose “1” tightly to • Brake pad clip “1” the bleed screw “2”. Put the other end of the • Brake pad pin “2” hose into an open container. • Brake pad spring “3” b.

  • Page 202: Removing The Front Brake Calipers

    FRONT BRAKE 8. Check: c. Remove the brake caliper piston dust seals • Brake lever operation and brake caliper piston seals. Soft or spongy feeling → Bleed the brake sys- d. Repeat the previous steps to force out the tem. right side pistons from the brake caliper.

  • Page 203: Assembling The Front Brake Calipers

    FRONT BRAKE EAS30174 ASSEMBLING THE FRONT BRAKE CALIPERS EWA16560 WARNING • Before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. • Never use solvents on internal brake com- ponents as they will cause the brake caliper piston dust seals and brake caliper piston 2.

  • Page 204: Removing The Front Brake Master Cylinder

    FRONT BRAKE 5. Bleed: 4. Check: • Brake system • Brake hose Cracks/damage/wear → Replace. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM (ABS)” on page 3-16. EAS30181 6. Check: ASSEMBLING THE FRONT BRAKE MASTER • Brake fluid level CYLINDER Below the minimum level mark → Add the EWA13520 specified brake fluid to the proper level.
  • Page 205 FRONT BRAKE 3. Fill: • Brake master cylinder reservoir (with the specified amount of the specified brake fluid) Specified brake fluid DOT 4 EWA13540 WARNING • Use only the designated brake fluid. Other 2. Install: brake fluids may cause the rubber seals to •...

  • Page 206: Rear Brake

    REAR BRAKE EAS20031 REAR BRAKE Removing the rear brake pads 27 N ・ m (2.7 kgf ・ m, 20 lb ・ ft) 5 N ・ m (0.5 kgf ・ m, 3.7 lb ・ ft) 22 N ・ m (2.2 kgf ・ m, 16 lb ・ ft) 17 N ・...
  • Page 207 REAR BRAKE Removing the rear brake master cylinder 2.5 N m (0.25 kgf m, 1.8 lb • • • 32 N m (3.2 k gf m, 23 lb • • • m (0.7 kgf m, 5.2 lb • • • m (0.7 kgf m, 5.2 lb •...
  • Page 208 REAR BRAKE Removing the rear brake master cylinder 2.5 N m (0.25 kgf m, 1.8 lb • • • 32 N m (3.2 k gf m, 23 lb • • • m (0.7 kgf m, 5.2 lb • • • m (0.7 kgf m, 5.2 lb •...
  • Page 209 REAR BRAKE Disassembling the rear brake master cylinder 18 N ・ m (1.8 kgf ・ m, 13 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Brake master cylinder yoke Brake master cylinder kit Hose joint Bushing Brake master cylinder body 4-54...
  • Page 210 REAR BRAKE Removing the rear brake caliper 27 N ・ m (2.7 kgf ・ m, 20 lb ・ ft) 32 N ・ m (3.2 kgf ・ m, 24 lb ・ ft) 22 N ・ m (2.2 kgf ・ m, 16 lb ・ ft) Order Job/Parts to remove Q’ty...
  • Page 211 REAR BRAKE Disassembling the rear brake caliper 5 N ・ m (0.5 kgf ・ m, 3.7 lb ・ ft) 17 N ・ m (1.7 kgf ・ m, 13 lb ・ ft) 2.5 N m (0.25 kgf m, 1.8 lb • •...

  • Page 212: Introduction

    REAR BRAKE EAS30183 4. Adjust: INTRODUCTION • Brake disc deflection EWA14101 Refer to “CHECKING THE FRONT BRAKE WARNING DISCS” on page 4-45. Disc brake components rarely require disas- sembly. Therefore, always follow these pre- Rear brake disc bolt ventive measures: 30 N·m (3.0 kgf·m, 22 lb·ft) •...

  • Page 213: Removing The Rear Brake Caliper

    REAR BRAKE b. Loosen the bleed screw and push the brake ECA14150 NOTICE caliper piston into the brake caliper with • Do not allow grease to contact the brake your finger. pads. • Remove any excess grease. 4. Install: • Rear brake caliper •...

  • Page 214: Disassembling The Rear Brake Caliper

    REAR BRAKE EAS30187 1. Check: DISASSEMBLING THE REAR BRAKE • Brake caliper piston CALIPER Rust/scratches/wear → Replace the brake 1. Remove: caliper piston. • Brake caliper piston • Brake caliper cylinder • Brake caliper piston dust seal Scratches/wear → Replace the brake caliper •...

  • Page 215: Removing The Rear Brake Master Cylinder

    REAR 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 ECA19080 brake performance.

  • Page 216: Checking The Rear Brake Master Cylinder

    REAR BRAKE EAS30194 EWA13531 CHECKING THE REAR BRAKE MASTER WARNING CYLINDER Proper brake hose routing is essential to in- 1. Check: sure safe vehicle operation. • Brake master cylinder Damage/scratches/wear → Replace. ECA14160 NOTICE • Brake fluid delivery passage When installing the brake hose onto the (brake master cylinder body) brake master cylinder, make sure the brake Obstruction →...
  • Page 217 REAR BRAKE 4. Check: • Brake fluid level Below the minimum level mark “a” → Add the specified brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL” on page 3-14. 5. Adjust: • Brake pedal position Refer to “ADJUSTING THE REAR DISC BRAKE”...

  • Page 218: Abs (Anti-Lock Brake System)

    ABS (Anti-lock Brake System) EAS20032 ABS (Anti-lock Brake System) Removing the hydraulic unit assembly 32 N ・ m (3.2 kgf ・ m, 24 lb ・ ft) m (0.9 kgf m, 6.6 lb • • • 16 N m (1.6 k gf m, 12 lb •...
  • Page 219 ABS (Anti-lock Brake System) Removing the hydraulic unit assembly 32 N ・ m (3.2 kgf ・ m, 24 lb ・ ft) m (0.9 kgf m, 6.6 lb • • • 16 N m (1.6 k gf m, 12 lb • •...

  • Page 220: Removing The Hydraulic Unit Assembly

    ABS (Anti-lock Brake System) EAS30197 REMOVING THE HYDRAULIC UNIT ASSEMBLY ECA18230 NOTICE Unless necessary, avoid removing and in- stalling the brake pipes of the hydraulic unit assembly. EWA13930 WARNING Refill with the same type of brake fluid that is 2. Remove: already in the system.

  • Page 221: Checking The Hydraulic Unit Assembly

    ABS (Anti-lock Brake System) Hydraulic unit assembly bolt 7 N·m (0.7 kgf·m, 5.2 lb·ft) EAS30198 CHECKING THE HYDRAULIC UNIT ASSEMBLY 1. Check: • Hydraulic unit assembly 2. Remove: • Rubber plug or bolt (M10 × 1.0) Cracks/damage → Replace the hydraulic unit assembly and the brake pipes that are con- 3.

  • Page 222: Hydraulic Unit Operation Test

    ABS (Anti-lock Brake System) ECA13540 NOTICE Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. 8. Bleed: • Brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM (ABS)” on page 3-16. 9.
  • Page 223 “2”, and again in the brake lever “1”, in this or- der. • Yamaha diagnostic tool (A/I) (90890-03264) in- cludes YDT sub harness (6P) (90890-03266). • If you already have Yamaha diagnostic tool (A/ I) (90890-03262), YDT sub harness (6P) (90890-03266) is separately required. Refer to “YDT” on page 9-3.
  • Page 224 YDT sub harness (6P) (90890-03266). • If you already have Yamaha diagnostic tool (A/ rectly to the hydraulic unit assembly. I) (90890-03262), YDT sub harness (6P) 10.If the operation of the hydraulic unit is normal,...

  • Page 225: Checking The Abs Warning Light

    ABS (Anti-lock Brake System) 9. A reaction-force pulsating action is generated 11.After the pulsating action has stopped in the in the brake lever “1” and continues for a few brake pedal, it is generated in the brake lever seconds. and continues for a few seconds. •...

  • Page 226: Handlebar

    HANDLEBAR EAS20033 HANDLEBAR Removing the handlebar 11 N m (1.1 k gf m, 8.1 lb 22 N m (2.2 k gf m, 16 lb • • • • • • 2.5 N m (0.25 kgf m, 1.8 lb • • •...
  • Page 227 HANDLEBAR Removing the handlebar 11 N m (1.1 k gf m, 8.1 lb 22 N m (2.2 k gf m, 16 lb • • • • • • 2.5 N m (0.25 kgf m, 1.8 lb • • • 17 N m (1.7 k gf m, 13 lb •...

  • Page 228: Removing The Handlebar

    HANDLEBAR EAS30203 ECA18300 REMOVING THE HANDLEBAR NOTICE 1. Stand the vehicle on a level surface. First, tighten the bolts on the front side of the EWA13120 handlebar holder, and then on the rear side. WARNING Securely support the vehicle so that there is no danger of it falling over.
  • Page 229 HANDLEBAR b. Make sure that the throttle grip “1” turns 6. Install: smoothly. • Clutch lever holder “1” • Clutch cable Clutch lever holder pinch bolt 11 N·m (1.1 kgf·m, 8.1 lb·ft) Align the center of slit on the clutch lever holder with the punch mark “a”...
  • Page 230 HANDLEBAR 8. Install: • Handlebar grip • Grip end (left) “1” Grip end 26 N·m (2.6 kgf·m, 19 lb·ft) a. Apply a thin coat of rubber adhesive onto the end of the handlebar (left). b. Slide the handlebar grip over the end of the handlebar (left).

  • Page 231: Front Fork (For Mt10N/Mt10Nc)

    FRONT FORK (for MT10N/MT10NC) EAS20034 FRONT FORK (for MT10N/MT10NC) Removing the front fork legs 26 N m (2.6 k gf m, 19 lb • • • 23 N m (2.3 k gf m, 17 lb • • • m (0.6 kgf m, 4.4 lb •...
  • Page 232 FRONT FORK (for MT10N/MT10NC) Removing the front fork legs 23 N ・ m (2.3 kgf ・ m, 17 lb ・ ft) 15 N ・ m (1.5 kgf ・ m, 11 lb ・ ft) 21 N ・ m (2.1 kgf ・ m, 15 lb ・ ft) 40 N ・...

  • Page 233: Removing The Front Fork Legs

    FRONT FORK (for MT10N/MT10NC) EAS30206 EAS30207 REMOVING THE FRONT FORK LEGS DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the The following procedure applies to both of the front fork legs. front fork legs. 1. Stand the vehicle on a level surface. 1.
  • Page 234 FRONT FORK (for MT10N/MT10NC) c. Hold the cap bolt “1” and loosen the locknut “4”. ECA17390 NOTICE When loosening the nut, be sure not to break the projections on the cap bolt collar of the cap bolt. G088920 5. Remove: •...

  • Page 235: Checking The Front Fork Legs

    FRONT FORK (for MT10N/MT10NC) 4. Check: • Cap bolt “1” • Cap bolt collar projection “2” Cracks/damage → Replace. EAS30208 CHECKING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Check: EAS30209 • Inner tube ASSEMBLING THE FRONT FORK LEGS •...
  • Page 236 3. Lubricate: (with the fork seal driver “3”) • Inner tube’s outer surface Fork seal driver 90890-01442 Recommended oil Yamaha Suspension Oil 01 Adjustable fork seal driver (36– 46 mm) 4. Install: YM-01442 • Dust seal “1” • Oil seal clip “2”...
  • Page 237 • Front fork leg (with the specified amount of the recom- mended fork oil) G088925 Recommended oil 9. Install: Yamaha Suspension Oil 01 • Dust seal “1” Quantity (left) (with the fork seal driver “2”) 350.0 cm³ (11.83 US oz, 12.34 Imp.oz)
  • Page 238 FRONT FORK (for MT10N/MT10NC) 13.Before measuring the fork oil level, wait ten minutes until the oil has settled and the air bubbles have dispersed. Be sure to bleed the front fork leg of any residual air. 14.Measure: • Front fork leg oil level “a” (from the top of the outer tube, with the outer G088931 c.

  • Page 239: Installing The Front Fork Legs

    FRONT FORK (for MT10N/MT10NC) i. Remove the rod puller and rod puller at- tachment. When installing the front fork leg, set the groove j. Install the damper adjusting rods and cap “a” on the outer tube is level with the top of the bolt, and then finger tighten the cap bolt.
  • Page 240 FRONT FORK (for MT10N/MT10NC) 3. Install: 5. Tighten: • Cap bolt “1” • Protector “1” (right side only) a. Before attaching the protector, clean the Front fork cap bolt front fork leg (right) surface. 23 N·m (2.3 kgf·m, 17 lb·ft) b.

  • Page 241: Front Fork (For Mt10Spn/Mt10Spnc)

    FRONT FORK (for MT10SPN/MT10SPNC) EAS20169 FRONT FORK (for MT10SPN/MT10SPNC) Removing the front fork legs 26 N m (2.6 k gf m, 19 lb • • • 23 N m (2.3 k gf m, 17 lb • • • m (0.6 kgf m, 4.4 lb •...
  • Page 242 FRONT FORK (for MT10SPN/MT10SPNC) Disassembling the front fork leg 20 N ・ m (2.0 kgf ・ m, 15 lb ・ ft) 19 N ・ m (1.9 kgf ・ m, 14 lb ・ ft) 21 N ・ m (2.1 kgf ・ m, 15 lb ・ ft) 68 N ・...

  • Page 243: Removing The Front Fork Legs

    FRONT FORK (for MT10SPN/MT10SPNC) EAS31052 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. Place the vehicle on a maintenance stand so that the front wheel is elevated.

  • Page 244: Checking The Front Fork Legs

    FRONT FORK (for MT10SPN/MT10SPNC) G088920 6. Remove: b. Hold the spring preload adjusting bolt “5” • Damper rod assembly and loosen the locknut. Remove the damper rod assembly with the damper rod holder “1”. Damper rod holder (ø37) 90890-01504 Damper rod holder YM-01504 c.

  • Page 245: Assembling The Front Fork Legs

    3. Lubricate: • Inner tube’s outer surface • When assembling the front fork leg, be sure to Recommended oil replace the following parts: Yamaha Suspension Oil M1 – Oil seal – Dust seal 4. Install: – O-ring • Dust seal “1”...
  • Page 246 FRONT FORK (for MT10SPN/MT10SPNC) 7. Install: • Oil seal clip “1” • Before installing the oil seal, lubricate its lips with lithium-soap-based grease. • Lubricate the outer surface of the inner tube Adjust the oil seal clip so that it fits into the outer with fork oil.
  • Page 247 180 mm (7.1 in) (with the specified amount of the recom- Level (right) mended fork oil) 180 mm (7.1 in) Recommended oil Yamaha Suspension Oil M1 Quantity (left) 448.0 cm³ (15.15 US oz, 15.80 Imp.oz) Quantity (right) 448.0 cm³ (15.15 US oz, 15.80 Imp.oz)

  • Page 248: Installing The Front Fork Legs

    FRONT FORK (for MT10SPN/MT10SPNC) EWA13680 WARNING Make sure the brake hoses are routed prop- erly. When installing the front fork leg, set the groove “a” on the outer tube is level with the top of the upper bracket. e. Remove the rod puller. f.
  • Page 249 FRONT FORK (for MT10SPN/MT10SPNC) 3. Install: • Protector “1” (right side only) Tighten the cap bolt “1” using the front fork cap bolt wrench “2”. a. Before attaching the protector, clean the front fork leg (right) surface. b. Attach the protector with the reference to Front fork cap bolt wrench 42mm the lower end of the lower bracket “2”...
  • Page 250 FRONT FORK (for MT10SPN/MT10SPNC) 6. Check: • Cable routing Make sure the brake hose, clutch cable, and handlebar switch leads are routed properly. Re- fer to “CABLE ROUTING” on page 2-15. 7. Adjust: • Spring preload • Rebound damping • Compression damping Refer to “ADJUSTING THE PRELOAD OF THE FRONT FORK LEGS (for MT10SPN/ MT10SPNC)”...

  • Page 251: Steering Head

    STEERING HEAD EAS20035 STEERING HEAD Removing the lower bracket m (0.7 kgf m, 5.2 lb 52 N m ( 5.2 kgf m, 38 lb • • • • • • *2nd 14 N m ( 1.4 kgf m, 10 lb •...
  • Page 252 STEERING HEAD Removing the lower bracket m (0.7 kgf m, 5.2 lb 52 N m ( 5.2 kgf m, 38 lb • • • • • • *2nd 14 N m ( 1.4 kgf m, 10 lb • • • m (0.7 kgf m, 5.2 lb •...

  • Page 253: Removing The Lower Bracket

    STEERING HEAD EAS30213 2. Check: REMOVING THE LOWER BRACKET • Bearing 1. Stand the vehicle on a level surface. • Bearing race EWA13120 Damage/pitting → Replace the bearings and WARNING bearing races as a set. Securely support the vehicle so that there is 3.

  • Page 254: Installing The Steering Head

    STEERING HEAD EAS30216 INSTALLING THE STEERING HEAD 1. Lubricate: • Upper bearing • Lower bearing Recommended lubricant Lithium-soap-based grease 2. Install: • Lower ring nut “1” • Rubber washer “2” • Upper ring nut “3” • Lock washer “4” Refer to “CHECKING AND ADJUSTING THE STEERING HEAD”...

  • Page 255: Rear Shock Absorber Assembly

    REAR SHOCK ABSORBER ASSEMBLY EAS20036 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly (for MT10N/MT10NC) 35 N m (3.5 k gf m, 26 lb • • • 40 N m (4.0 k gf m, 30 lb • • •...
  • Page 256 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly (for MT10N/MT10NC) 35 N m (3.5 k gf m, 26 lb • • • 40 N m (4.0 k gf m, 30 lb • • • 40 N m (4.0 k gf m, 30 lb •...
  • Page 257 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly (for MT10SPN/MT10SPNC) 35 N m (3.5 k gf m, 26 lb • • • 40 N m (4.0 k gf m, 30 lb • • • 40 N m (4.0 k gf m, 30 lb •...
  • Page 258 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly (for MT10SPN/MT10SPNC) 35 N m (3.5 k gf m, 26 lb • • • 40 N m (4.0 k gf m, 30 lb • • • 40 N m (4.0 k gf m, 30 lb •...

  • Page 259: Handling The Rear Shock Absorber

    REAR SHOCK ABSORBER ASSEMBLY EAS30826 HANDLING THE REAR SHOCK ABSORBER EWA13740 WARNING This rear shock absorber contains highly compressed nitrogen gas. Before handling the rear shock absorber, read and make sure you understand the following information. The manufacturer cannot be held responsi- ble for property damage or personal injury that may result from improper handling of the rear shock absorber.

  • Page 260: Disassembling The Rear Shock Absorber Assembly

    REAR SHOCK ABSORBER ASSEMBLY 3. Remove: 3. Remove: • Rear shock absorber assembly upper nut • Bushing “1” (for MT10SPN/MT10SPNC) • Rear shock absorber assembly upper bolt 4. Remove: Remove the bushing with a socket “2” that • Relay arm nut “1” matches its outside diameter.

  • Page 261: Checking The Rear Shock Absorber Assembly

    REAR SHOCK ABSORBER ASSEMBLY EAS30220 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 1. Check: • Rear shock absorber rod Bends/damage → Replace the rear shock absorber assembly. • Rear shock absorber assembly Gas leaks/oil leaks → Replace the rear shock absorber assembly. •...

  • Page 262: Installing The Rear Shock Absorber Assembly

    REAR SHOCK ABSORBER ASSEMBLY 2. Tighten: • Relay arm nut • When installing the oil seals “2” to the relay • Rear shock absorber assembly upper nut arm, face the character stamp of the oil seals • Connecting arm lower nut outside.

  • Page 263: Swingarm

    SWINGARM EAS20037 SWINGARM Removing the swingarm 65 N m (6.5 k gf m, 48 lb • • • m (0.7 kgf m, 5.2 lb • • • m (0.7 kgf m, 5.2 lb • • • m (0.7 kgf m, 5.2 lb •...
  • Page 264 SWINGARM Removing the swingarm 65 N m (6.5 k gf m, 48 lb • • • m (0.7 kgf m, 5.2 lb • • • m (0.7 kgf m, 5.2 lb • • • m (0.7 kgf m, 5.2 lb •...

  • Page 265: Removing The Swingarm

    SWINGARM EAS30226 5. Remove: REMOVING THE SWINGARM • Pivot shaft nut 1. Stand the vehicle on a level surface. • Pivot shaft ring nut “1” EWA13120 WARNING Loosen the pivot shaft ring nut with the ring nut Securely support the vehicle so that there is wrench “2”.

  • Page 266: Checking The Swingarm

    SWINGARM EAS30227 EAS30228 CHECKING THE SWINGARM INSTALLING THE SWINGARM 1. Check: 1. Lubricate: • Swingarm • Dust cover Bends/cracks/damage → Replace. • Pivot shaft 2. Check: • Oil seal • Pivot shaft • Collar Roll the pivot shaft on a flat surface. •...
  • Page 267 SWINGARM 3. Install: 5. Install: • Swingarm • Pivot shaft nut • Pivot shaft “1” Pivot shaft nut 105 N·m (10.5 kgf·m, 77 lb·ft) Pivot shaft 7 N·m (0.7 kgf·m, 5.2 lb·ft) 6. Install: • Drive chain Refer to “INSTALLING THE DRIVE CHAIN” Tighten the pivot shaft with the damper rod hold- on page 4-117.

  • Page 268: Chain Drive

    CHAIN DRIVE EAS20038 CHAIN DRIVE Removing the drive chain 10 N m (1.0 k gf m, 7.4 lb • • • 140 N m (14 kgf m, 103 lb • • • m (0.7 kgf m, 5.2 lb • • •...
  • Page 269 CHAIN DRIVE Removing the drive chain 10 N m (1.0 k gf m, 7.4 lb • • • 140 N m (14 kgf m, 103 lb • • • m (0.7 kgf m, 5.2 lb • • • 28 N m (2.8 k gf m, 21 lb 10 N...

  • Page 270: Removing The Drive Chain

    CHAIN DRIVE EAS30229 a. Measure the length “a” between the inner REMOVING THE DRIVE CHAIN sides of the pins and the length “b” between 1. Stand the vehicle on a level surface. the outer sides of the pins on a 15-link sec- EWA13120 tion of the drive chain as shown in the illus- WARNING...

  • Page 271: Checking The Drive Sprocket

    CHAIN DRIVE 3. Clean: • Drive chain a. Wipe the drive chain with a clean cloth. b. Put the drive chain in kerosene and remove any remaining dirt. c. Remove the drive chain from the kerosene and completely dry it. ECA19090 NOTICE G088943...

  • Page 272: 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” and 1. Install: inside of the connecting plate “1”, is 15.10– • Drive chain 15.30 mm (0.594–0.602 in). ECA17410 NOTICE Be sure to put on safety goggles when work-...

  • Page 273: Adjusting The Shift Pedal

    CHAIN DRIVE 6. Adjust: Shift arm bolt • Installed shift rod length 10 N·m (1.0 kgf·m, 7.4 lb·ft) Refer to “ADJUSTING THE SHIFT PEDAL” on page 4-118. 7. Adjust: • Drive chain slack Refer to “Adjusting the drive chain slack” on page 3-19.
  • Page 274 CHAIN DRIVE 2. Adjust: • Installed shift rod length a. Loosen both locknuts. b. Turn the shift rod until the specified installed shift rod length is obtained. c. Tighten both locknuts. Be sure to place the shift rod joints in parallel. The allowable twist of the shift rod joints is ±5°.
  • Page 275 ENGINE LUBRICATION SYSTEM CHART AND DIAGRAMS........5-1 ENGINE OIL LUBRICATION CHART ............5-1 LUBRICATION DIAGRAMS ..............5-2 ENGINE INSPECTION ..................5-9 MEASURE THE COMPRESSION PRESSURE........5-9 ENGINE REMOVAL ..................5-11 REMOVING THE ENGINE ..............5-15 INSTALLING THE ENGINE..............5-15 INSTALLING THE EXHAUST PIPE AND MUFFLER......5-16 CAMSHAFTS....................5-17 REMOVING THE CAMSHAFTS..............5-22 REMOVING THE ROCKER ARMS AND ROCKER ARM SHAFTS..
  • Page 276 STARTER CLUTCH ..................5-46 REMOVING THE STARTER CLUTCH ...........5-47 CHECKING THE STARTER CLUTCH ............5-47 INSTALLING THE STARTER CLUTCH ..........5-47 ELECTRIC STARTER ...................5-48 CHECKING THE STARTER MOTOR .............5-50 ASSEMBLING THE STARTER MOTOR..........5-50 OIL PUMP...................... 5-51 REMOVING THE OIL PAN..............5-54 CHECKING THE SPROCKET AND CHAIN..........5-54 CHECKING THE OIL PUMP ..............
  • Page 277 CONNECTING RODS AND PISTONS ............5-75 REMOVING THE CONNECTING RODS AND PISTONS.......5-76 CHECKING THE CYLINDER AND PISTON ...........5-76 CHECKING THE PISTON RINGS............5-77 CHECKING THE PISTON PIN ..............5-78 CHECKING THE CONNECTING RODS..........5-78 INSTALLING THE CONNECTING ROD AND PISTON ......5-81 CRANKSHAFT AND BALANCER SHAFT ...........5-86 REMOVING THE CRANKSHAFT AND BALANCER SHAFT....

  • Page 278: Lubrication System Chart And Diagrams

    LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20298 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS32362 ENGINE OIL LUBRICATION CHART 1. Oil strainer 17. Exhaust camshaft 2. Oil pump 18. Shift fork guide bar (upper) 3. Relief valve 19. Main axle 4. Oil cooler 20.

  • Page 279: Lubrication Diagrams

    LUBRICATION SYSTEM CHART AND DIAGRAMS EAS32363 LUBRICATION DIAGRAMS Crankcase, cylinder, and cylinder head (left side view) 1. Intake camshaft 2. Oil nozzle 3. Oil delivery pipe 2 4. Oil filter cartridge 5. Crankshaft 6. Exhaust camshaft 7. Sub gallery...
  • Page 280 LUBRICATION SYSTEM CHART AND DIAGRAMS Crankcase and cylinder (right side view) 1. Timing chain tensioner 2. Intake camshaft 3. Exhaust camshaft 4. Crankshaft 5. Relief valve 6. Oil pipe 1 7. Oil delivery pipe 1 8. Oil pan 9. Oil strainer 10.
  • Page 281 LUBRICATION SYSTEM CHART AND DIAGRAMS Timing chain cover and oil pipe (right side view) 1. Timing chain cover 2. Oil pipe 3 3. Oil pipe 2 4. Crankshaft 5. Crankcase...
  • Page 282 LUBRICATION SYSTEM CHART AND DIAGRAMS Oil pump and oil cooler (bottom view) 1. Oil cooler 2. Oil delivery pipe 1 3. Oil cooler outlet hose 4. Oil filter cartridge 5. Oil pressure switch 6. Oil delivery pipe 2 7. Oil strainer 8.
  • Page 283 LUBRICATION SYSTEM CHART AND DIAGRAMS Camshaft and balancer shaft (top view) 1. Cylinder head 2. Exhaust camshaft 3. Intake camshaft 4. Balancer shaft...
  • Page 284 LUBRICATION SYSTEM CHART AND DIAGRAMS Crankshaft (rear view) 1. Oil nozzle 2. Oil pipe 3 3. Timing chain cover 4. Crankshaft 5. Oil pipe 2 6. Oil pressure switch 7. Generator rotor 8. Shaft...
  • Page 285 LUBRICATION SYSTEM CHART AND DIAGRAMS Crankshaft and transmission (top view) 1. Oil pump 2. Main axle 3. Clutch housing 4. Drive axle 5. Oil delivery pipe 3...

  • Page 286: Engine Inspection

    ENGINE INSPECTION EAS20041 ENGINE INSPECTION EAS30249 MEASURE THE COMPRESSION PRESSURE The following procedure applies to all of the cyl- inders. Insufficient compression pressure will result in a loss of performance. 1. Measure: 5. Measure: • Valve clearance • Compression pressure Out of specification →...
  • Page 287 ENGINE INSPECTION Compression pressure (with oil applied into the cylinder) Reading Diagnosis Higher than without Piston ring(s) wear or damage → Repair. Same as without oil Piston, valves, cylin- der head gasket pos- sibly defective → Repair. 6. Install: • Spark plug Spark plug 13 N·m (1.3 kgf·m, 9.6 lb·ft) Spark plug (new)

  • Page 288: Engine Removal

    ENGINE REMOVAL EAS20042 ENGINE REMOVAL Removing the muffler and exhaust pipe 2.0 N m (0.20 kgf m, 1.5 lb • • • 20 N m (2.0 kgf m, 15 lb • • • 10 N m (1.0 kgf m, 7.4 lb •...
  • Page 289 ENGINE REMOVAL Removing the muffler and exhaust pipe 2.0 N m (0.20 kgf m, 1.5 lb • • • 20 N m (2.0 kgf m, 15 lb • • • 10 N m (1.0 kgf m, 7.4 lb • • •...
  • Page 290 ENGINE REMOVAL Disconnecting the leads and hoses m (0.6 kgf m, 4.4 lb • • • m (0.7 kgf m, 5.2 lb • • • 1.8 N m (0.18 kgf m, 1.3 lb • • • Order Job/Parts to remove Q’ty Remarks Disconnect.
  • Page 291 ENGINE REMOVAL Removing the engine 56 N m (5.6 kgf m, 41 lb • • • 70 N m (7.0 kgf m, 52 lb • • • 56 N m (5.6 kgf m, 41 lb • • • 70 N m (7.0 kgf m, 52 lb •...

  • Page 292: Removing The Engine

    ENGINE REMOVAL EAS30250 5. Install: REMOVING THE ENGINE • Collar “5” 1. Loosen: • Collar “6” • Engine mounting adjust bolt • Engine mounting bolt (right front side) “7” (temporarily tighten) Loosen the engine mounting adjust bolt with the 6. Tighten: pivot shaft wrench “1”.

  • Page 293: Installing The Exhaust Pipe And Muffler

    ENGINE REMOVAL 11.Tighten: • Engine mounting bolt (right front side) “7” Engine mounting bolt 70 N·m (7.0 kgf·m, 52 lb·ft) EAS30252 INSTALLING THE EXHAUST PIPE AND MUFFLER 1. Install: • Exhaust pipe • Gasket “1” (to exhaust chamber) • Muffler When installing the gasket, install it so that the chamfered side “a”...

  • Page 294: Camshafts

    CAMSHAFTS EAS20043 CAMSHAFTS Removing the cylinder head cover 13 N m (1.3 kgf m, 9.6 lb • • • m (0.8 kgf m, 5.9 lb • • • 10 N m (1.0 kgf m, 7.4 lb • • • * Three bond No. 1541C® Order Job/Parts to remove Q’ty...
  • Page 295 CAMSHAFTS Removing the cylinder head cover 13 N m (1.3 kgf m, 9.6 lb • • • m (0.8 kgf m, 5.9 lb • • • 10 N m (1.0 kgf m, 7.4 lb • • • * Three bond No. 1541C® Order Job/Parts to remove Q’ty...
  • Page 296 CAMSHAFTS Removing the camshafts m (0.8 kgf m, 5.9 lb ft)    ft)    • • • 10 N m (1.0 kgf m, 7.4 lb • • • ft)    m (0.8 kgf m, 5.9 lb • • • Order Job/Parts to remove Q’ty Remarks...
  • Page 297 CAMSHAFTS Removing the timing chain and timing chain guide 72 N m (7.2 kgf m, 53 lb ft)    • • • 9 10 ft)    10 N m (1.0 kgf m, 7.4 lb • • • 12 N m (1.2 kgf m, 8.9 lb ft)   ...

  • Page 298: Engine

    CAMSHAFTS Removing the rocker arms 10 N m (1.0 kgf m, 7.4 lb ft)    • • • ft)    m (0.6 kgf m, 4.4 lb • • • ft)    10 N m (1.0 kgf m, 7.4 lb • •...

  • Page 299: Removing The Camshafts

    CAMSHAFTS EAS30256 5. Remove: REMOVING THE CAMSHAFTS • Intake camshaft 1. Remove: • Exhaust camshaft • Timing mark accessing bolt • Crankshaft end cover To prevent the timing chain from falling into the Refer to “GENERATOR” on page 5-42. crankcase, fasten it with a wire “1”. 2.
  • Page 300 CAMSHAFTS 3. Measure: • Camshaft runout Out of specification → Replace. Camshaft runout limit 0.030 mm (0.0012 in) a. Camshaft cap bolt (black): 40 mm (1.57 in) b. Camshaft cap bolt (silver): 35 mm (1.38 in) A. Intake side B. Exhaust side •...

  • Page 301: Checking The Rocker Arms And Rocker Arm Shafts

    CAMSHAFTS Camshaft journal diameter 25.459–25.472 mm (1.0023– 1.0028 in) G088952 EAS30258 CHECKING THE TIMING CHAIN AND CAMSHAFT SPROCKET 1. Check: G088949 • Timing chain Damage/stiffness → Replace the timing EAS30259 CHECKING THE ROCKER ARMS AND chain and camshaft and camshaft sprocket ROCKER ARM SHAFTS as a set.

  • Page 302: Checking The Timing Chain Tensioner

    CAMSHAFTS EAS30266 CHECKING THE TIMING CHAIN TENSIONER 1. Check: • Timing chain tensioner Cracks/damage/rough movement → Re- place. a. Using the valve spring compressor “1”, push and insert timing chain tensioner rod “2” into the timing chain tensioner housing. Push the timing chain tensioner rod in direction EAS31744 “a”, and turn the timing chain tensioner body “3”...

  • Page 303: Installing The Timing Chain Cover

    CAMSHAFTS Rocker arm shaft bolt 6 N·m (0.6 kgf·m, 4.4 lb·ft) LOCTITE® Straight plug (rocker arm shaft) 10 N·m (1.0 kgf·m, 7.4 lb·ft) LOCTITE® c. Install the oil pipe bolt “3” and tighten it tem- porarily until there is no clearance at “a” (timing chain cover to oil pipe) and “b”...

  • Page 304: Installing The Camshafts

    CAMSHAFTS g. Tighten the oil pipe bolts to the specified torque following the tightening order shown • Hang the timing chain on the sprocket from the in the illustration. exhaust camshaft to the intake camshaft. • The intake camshaft sprocket timing mark “a” Oil pipe 3 bolt and exhaust camshaft sprocket timing mark “b”...
  • Page 305 CAMSHAFTS Valve spring compressor • If the camshaft cap bolt is a new one, it is not 90890-04200 necessary to apply engine oil onto the mating Valve spring compressor surface and threads of the bolt. YM-04019 • If the camshaft cap bolt is a new one, tighten it to 10 N·m (1.0 kgf·m, 7.4 lb·ft).
  • Page 306 CAMSHAFTS 7. Turn: 10.Install: • Crankshaft • Timing mark accessing bolt (several turns counterclockwise) 8. Check: Timing mark accessing bolt 15 N·m (1.5 kgf·m, 11 lb·ft) • Mark “a” Make sure the mark “a” on the generator rotor • Crankshaft end cover is aligned with the generator rotor cover slot “b”.
  • Page 307 CAMSHAFTS 12.Install: • Spark plug • Ignition coil “1” Spark plug 13 N·m (1.3 kgf·m, 9.6 lb·ft) Spark plug (new) 18 N·m (1.8 kgf·m, 13 lb·ft) • Before installing the spark plug, clean the spark plug and gasket surface. • If the spark plug is a new one, tighten it to 18 N·m (1.8 kgf·m, 13 lb·ft).

  • Page 308: Cylinder Head

    CYLINDER HEAD EAS20044 CYLINDER HEAD Removing the cylinder head 12 N m (1.2 kgf m, 8.9 lb ft)    • • • 15 N m (1.5 kgf m, 11 lb ft)    • • • ft)    10 N m (1.0 kgf m, 7.4 lb •...

  • Page 309: Removing The Cylinder Head

    CYLINDER HEAD EAS30276 REMOVING THE CYLINDER HEAD 1. Remove: • Intake camshaft • Exhaust camshaft Refer to “REMOVING THE CAMSHAFTS” on page 5-22. 2. Remove: • Cylinder head bolt (M6) (× 2) • Cylinder head bolt (M9) (× 10) G088956 a.
  • Page 310 CYLINDER HEAD 3. Tighten: • Cylinder head bolt “1”–“10” • Cylinder head bolt “11”, “12” Cylinder head bolt “1”–“10” 1st: 10 N·m (1.0 kgf·m, 7.4 lb·ft) 2nd: 25 N·m (2.5 kgf·m, 18 lb·ft) 3rd: 45 N·m (4.5 kgf·m, 33 lb·ft) *4th: 15 N·m (1.5 kgf·m, 11 lb·ft) Specified angle 160°...

  • Page 311: Valves And Valve Springs

    VALVES AND VALVE SPRINGS EAS20045 VALVES AND VALVE SPRINGS Removing the valves and valve springs Order Job/Parts to remove Q’ty Remarks Cylinder head Refer to “CYLINDER HEAD” on page 5-31. Exhaust valve pad Exhaust valve cotter Exhaust valve spring retainer Exhaust valve spring Exhaust valve Exhaust valve stem seal...
  • Page 312 VALVES AND VALVE SPRINGS Removing the valves and valve springs Order Job/Parts to remove Q’ty Remarks Intake valve spring retainer Intake valve spring Intake valve Intake valve stem seal Intake valve spring seat Circlip Intake valve guide 5-35...

  • Page 313: Removing The Valves

    VALVES AND VALVE SPRINGS EAS30283 REMOVING THE VALVES Valve spring compressor The following procedure applies to all of the 90890-04200 valves and related components. Valve spring compressor YM-04019 Before removing the internal parts of the cylinder Valve spring compressor attach- ment (ø26) head (e.g., valves, valve springs, valve seats), 90890-01243...
  • Page 314 VALVES AND VALVE SPRINGS G088960 G088963 a. Valve guide position c. After installing the valve guide, bore the valve guide with the valve guide reamer “3” to obtain the proper valve-stem-to-valve- guide clearance. G088961 2. Replace: • Valve guide To ease valve guide removal and installation, and to maintain the correct fit, heat the cylinder G088964 head to 100 °C (212 °F) in an oven.

  • Page 315: Checking The Valve Seats

    VALVES AND VALVE SPRINGS 3. Eliminate: • Carbon deposits (from the valve face and valve seat) 4. Check: • Valve face Pitting/wear → Grind the valve face. • Valve stem end Mushroom shape or diameter larger than the body of the valve stem → Replace the valve. G088966 5.

  • Page 316: Checking The Valve Springs

    VALVES AND VALVE SPRINGS g. Apply blue layout fluid “b” onto the valve face. • When replacing the intake valves, replace the intake valves without lapping the valve seats and valve faces. • When replacing the cylinder head or intake valve guides, use new valves to lap the valve seats, and then replace them with new intake valves.

  • Page 317: Checking The Valve Spring Seat

    VALVES AND VALVE SPRINGS EAS31716 CHECKING THE VALVE SPRING SEAT The following procedure applies to all of the valve lifters. 1. Check: • Valve spring seat Damage/scratches → Replace the valve spring seat. EAS30288 INSTALLING THE VALVES G088973 The following procedure applies to all of the b.
  • Page 318 VALVES AND VALVE SPRINGS 5. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a soft-face hammer. ECA13800 NOTICE Hitting the valve tip with excessive force could damage the valve. G088975 6. Lubricate: • Valve pad (with the recommended lubricant) Recommended lubricant Molybdenum disulfide oil...

  • Page 319: Generator

    • • 15 N m (1.5 kgf m, 11 lb • • • * YAMAHA bond No. 1215 (Three bond No. 1215®) Order Job/Parts to remove Q’ty Remarks Drain. Engine oil Refer to “CHANGING THE ENGINE OIL” on page 3-29.
  • Page 320 8.9 lb • • • 15 N m (1.5 kgf m, 11 lb • • • * YAMAHA bond No. 1215 (Three bond No. 1215®) Order Job/Parts to remove Q’ty Remarks Woodruff key Crankshaft end cover Timing mark accessing bolt 5-43...

  • Page 321: Removing The Generator

    GENERATOR EAS30829 REMOVING THE GENERATOR Flywheel puller 1. Remove: 90890-01404 • Generator rotor bolt “1” Flywheel puller • Washer YM-01404 While holding the generator rotor “2” with the 15mm pin type rotor holding tool “3”, loosen the generator rotor bolt. 15mm pin type rotor holding tool 90890-04171 YM-04171...
  • Page 322 “CABLE ROUTING” on page 2-15. 15mm pin type rotor holding tool 90890-04171 YM-04171 3. Apply: • Sealant (onto the stator coil assembly lead grommet) Yamaha bond No. 1215 90890-85505 Three bond No. 1215® G088980 4. Install: • Generator cover gasket • Generator cover •...

  • Page 323: Starter Clutch

    STARTER CLUTCH EAS20049 STARTER CLUTCH Removing the starter clutch 14 N m (1.4 kgf m, 10 lb • • • Order Job/Parts to remove Q’ty Remarks Clutch housing assembly Refer to “CLUTCH” on page 5-57. Starter clutch gear Bearing Starter clutch assembly Circlip Starter clutch idle gear 5-46...

  • Page 324: Removing The Starter Clutch

    STARTER CLUTCH EAS30305 c. When turning the starter clutch gear coun- REMOVING THE STARTER CLUTCH terclockwise “B”, it should turn freely, other- 1. Remove: wise the starter clutch is faulty and must be • Starter clutch bolt “1” replaced. • While holding the clutch housing assembly “2” with the sheave holder “3”, remove the starter clutch bolts.

  • Page 325: Electric Starter

    ELECTRIC STARTER EAS20052 ELECTRIC STARTER Removing the starter motor 10 N m (1.0 kgf m, 7.4 lb ft)    • • • ft)    m (0.6 kgf m, 4.4 lb • • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS (1)” on Rider seat page 4-1.
  • Page 326 ELECTRIC STARTER Disassembling the starter motor 4.5 N ・ m (0.45 kgf ・ m, 3.3 lb ・ ft) Order Job/Parts to remove Q’ty Remarks O-ring Starter motor front cover Starter motor yoke Armature assembly Gasket Brush holder set Starter motor rear cover 5-49...

  • Page 327: Checking The Starter Motor

    ELECTRIC STARTER EAS30325 4. Measure: CHECKING THE STARTER MOTOR • Brush length “a” 1. Check: Out of specification → Replace the brush • Commutator holder set. Dirt → Clean with 600 grit sandpaper. 2. Measure: Brush overall length limit • Mica undercut “a” 5.5 mm (0.22 in) Out of specification →...

  • Page 328: Oil Pump

    OIL PUMP EAS20054 OIL PUMP Removing the oil pan and oil pump 10 N m (1.0 kgf m, 7.4 lb ft)    • • • ft)    10 N m (1.0 kgf m, 7.4 lb • • • ft)    10 N m (1.0 kgf m, 7.4 lb...
  • Page 329 OIL PUMP Removing the oil pan and oil pump ft)    10 N m (1.0 kgf m, 7.4 lb • • • ft)    10 N m (1.0 kgf m, 7.4 lb • • • 10 N m (1.0 kgf m, 7.4 lb ft)   ...
  • Page 330 OIL PUMP Disassembling the oil pump 10 N m (1.0 kgf m, 7.4 lb ft)    • • • Order Job/Parts to remove Q’ty Remarks Oil pump cover Dowel pin Oil pump outer rotor Oil pump inner rotor Oil pump driven sprocket 5-53...

  • Page 331: Removing The Oil Pan

    OIL PUMP EAS30333 EAS30338 REMOVING THE OIL PAN CHECKING THE RELIEF VALVE 1. Remove: 1. Check: • Oil pan • Relief valve body “1” • Gasket • Relief valve “2” • Dowel pin • Spring “3” • Damage/wear → Replace the defective part(s).

  • Page 332: Installing The Oil Pump

    OIL PUMP 2. Install: 2. Install: • Oil pump driven sprocket “1” • Washer • Pin “2” • Oil pump drive chain “1” • Inner rotor “3” • Oil pump drive sprocket “2” • Outer rotor “4” • Collar • Oil pump cover “5” •...

  • Page 333: Installing The Oil Pan

    OIL PUMP 5. Install: • O-ring • Oil delivery pipe 2 Oil delivery pipe 2 bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft) LOCTITE® EAS30345 INSTALLING THE OIL PAN 1. Install: • Oil pan gasket • Oil pan • Oil pan bolt (× 12) Tighten the oil pan bolts in stages and in a criss- cross pattern.

  • Page 334: Clutch

    CLUTCH EAS20055 CLUTCH Removing the clutch cover m (0.7 kgf m, 5.2 lb • • • (10) 12 N m (1.2 kgf m, 8.9 lb • • • Order Job/Parts to remove Q’ty Remarks Drain. Engine oil Refer to “CHANGING THE ENGINE OIL” on page 3-29.
  • Page 335 CLUTCH Removing the pull lever shaft Order Job/Parts to remove Q’ty Remarks Circlip Pull lever Pull lever spring Circlip Pull lever shaft Oil seal Bearing Bearing 5-58...
  • Page 336 CLUTCH Removing the clutch 125 N m (12.5 kgf m, 92 lb ft)    • • • 10 N m (1.0 kgf m, 7.4 lb ft)    • • • Order Job/Parts to remove Q’ty Remarks Pressure plate 1 Compression spring Pressure plate 2 Pull rod Bearing...
  • Page 337 CLUTCH Removing the clutch 125 N m (12.5kgf m, 92 lb ft)    • • • ft)    10 N m (1.0 kgf m, 7.4 lb • • • Order Job/Parts to remove Q’ty Remarks Clutch damper spring Clutch damper spring seat Clutch boss nut Conical spring washer Clutch boss...

  • Page 338: 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 6.

  • Page 339: Checking The Clutch Springs

    CLUTCH 2. Measure: Clutch plate “1” • Clutch plate 1, 2 warpage Part No. Thickness (with a surface plate and thickness gauge) Out of specification → Replace the clutch 2CR-16325-10 2.0 mm (0.079 in) plates as a set. 2CR-16325-00 2.3 mm (0.091 in) 2CR-16325-20 2.6 mm (0.102 in) Thickness gauge...

  • Page 340: Checking The Clutch Boss

    CLUTCH 2. Check: EAS30358 CHECKING THE PULL LEVER SHAFT AND • Bearing PULL ROD Damage/wear → Replace the bearing and 1. Check: clutch housing. • Pull lever shaft pinion gear teeth • Pull rod teeth EAS30353 CHECKING THE CLUTCH BOSS Damage/wear →...
  • Page 341 CLUTCH 2. Install: 3. Lubricate: • Thrust plate • Friction plates • Clutch boss “1” • Clutch plates • Conical spring washer “2” (with the recommended lubricant) • Clutch boss nut “3” Recommended lubricant Engine oil Clutch boss nut 125 N·m (12.5 kgf·m, 92 lb·ft) 4.
  • Page 342 CLUTCH 5. Install: 8. Install: • Pull rod • Pull lever spring “1” • Pressure plate 2 • Pull lever “2” • Clutch spring • Washer • Pressure plate 1 • Circlip • Clutch spring bolt • The end of the pull lever should be closest to Clutch spring bolt the clutch cover match mark “a”...

  • Page 343: Shift Shaft

    SHIFT SHAFT EAS20057 SHIFT SHAFT Removing the shift shaft and stopper lever 22 N m (2.2 kgf m, 16 lb • • • Order Job/Parts to remove Q’ty Remarks Clutch assembly Refer to “CLUTCH” on page 5-57. Shift arm Refer to “CHAIN DRIVE” on page 4-113. Circlip Washer Shift shaft...

  • Page 344: Checking The Shift Shaft

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

  • Page 345: Crankcase

    (1.3 kgf m, 9.6 lb • • • • • • * YAMAHA bond No. 1215 (Three Bond No.1215®) Order Job/Parts to remove Q’ty Remarks Engine Refer to “ENGINE REMOVAL” on page 5-11. Cylinder head cover/Intake camshaft/Exhaust Refer to “CAMSHAFTS” on page 5-17.
  • Page 346 13 N m (1.3 kgf m, 9.6 lb ft)    • • • • • • * YAMAHA bond No. 1215 (Three Bond No.1215®) Order Job/Parts to remove Q’ty Remarks Crankcase breather cover gasket Clutch cable holder Neutral switch Gasket Holder...
  • Page 347 CRANKCASE Separating the crankcase 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 20 N ・ m (2.0 kgf ・ m, 15 lb ・ ft) 15 N ・ m (1.5 kgf ・ m, 11 lb ・ ft) 24 N ・...

  • Page 348: Disassembling The Crankcase

    (with the recommended lubricant) Recommended lubricant Engine oil 2. Apply: • Sealant (onto the crankcase mating surfaces) 3. Remove: Yamaha bond No. 1215 • Lower crankcase 90890-85505 ECA13900 Three bond No. 1215® NOTICE Tap on one side of the crankcase with a soft- face hammer.
  • Page 349 CRANKCASE 6. Install: • Crankcase bolt (× 40) • Lubricate the bolts “1”–“10” thread, mating sur- faces and washers with engine oil. • Lubricate the bolts “11”–“18” thread, mating surfaces and O-rings with engine oil. • Lubricate the bolts “19”–“27”, “29”–“39” thread and mating surfaces with engine oil.
  • Page 350 CRANKCASE 7. Tighten: 8. Tighten: • Crankcase bolts “1”–“10” • Crankcase bolts “11”–“40” Crankcase bolts “1”–“10” Crankcase bolts “11”–“20” 1st: 20 N·m (2.0 kgf·m, 15 lb·ft) 24 N·m (2.4 kgf·m, 18 lb·ft) *2nd: 15 N·m (1.5 kgf·m, 11 lb·ft) Crankcase bolts “21”–“40” 3rd: Specified angle 75°...

  • Page 351: Installing The Oil Pressure Switch

    CRANKCASE EAS31071 EAS31658 INSTALLING THE OIL PRESSURE SWITCH INSTALLING THE GEAR POSITION SENSOR 1. Install: ECA22630 NOTICE • Oil pressure switch “1” To prevent damage to the gear position sen- • Oil pressure switch lead “2” sor, keep magnets (including any pickup tool with a magnet, magnetized screwdrivers, Oil pressure switch etc.) away from the gear position sensor.

  • Page 352: Connecting Rods And Pistons

    CONNECTING RODS AND PISTONS EAS20132 CONNECTING RODS AND PISTONS Removing the connecting rods and pistons 24 N m (2.4 kgf m, 18 lb • • • Specified angle 150˚   Order Job/Parts to remove Q’ty Remarks Lower crankcase Refer to “CRANKCASE” on page 5-68. Connecting rod cap Big end lower bearing Big end upper bearing...

  • Page 353: Removing The Connecting Rods And Pistons

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

  • Page 354: Checking The Piston Rings

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

  • Page 355: Checking The Piston Pin

    CONNECTING RODS AND PISTONS EAS30750 CHECKING THE CONNECTING RODS 1. Measure: • Crankshaft-pin-to-big-end-bearing clearance Out of specification → Replace the big end bearings. Oil clearance 0.032–0.054 mm (0.0013–0.0021 b. Upper of cylinder The following procedure applies to all of the con- necting rods.
  • Page 356 CONNECTING RODS AND PISTONS d. Put a piece of Plastigauge® “1” on the crankshaft pin. • From the 3 types, choose the connecting rod big end metal installer “1” that fits exactly, and install it to the connecting rod and connecting rod cap as shown in the illustration.
  • Page 357 CONNECTING RODS AND PISTONS To install the connecting rod cap, care should be taken not to install it at an angle and the position should not be out of alignment. h. Tighten the connecting rod bolts with a torque wrench. Connecting rod bolt (1st) 24 N·m (2.4 kgf·m, 18 lb·ft) a.

  • Page 358: Installing The Connecting Rod And Piston

    CONNECTING RODS AND PISTONS k. After the installation, check that the section shown “a” is flush with each other by touch- Bearing color code ing the surface. Code 2 Black Code 3 Brown Code 4 Green Code 5 Yellow Code 6 Pink l.
  • Page 359 CONNECTING RODS AND PISTONS • Clean the big end bearings, crankshaft pins, and the connecting rods with oil cleaner, and then wait five minutes to dry the remaining oil cleaner component. • When cleaning the connecting rod, clean the bearing surface “a” of the connecting rod bolt and threads “b”.
  • Page 360 CONNECTING RODS AND PISTONS d. Tighten the connecting rod bolt while 4. Install: checking that the sections shown “a” and • Piston “1” “b” are flush with each other by touching the (onto the respective connecting rod “2”) surface. • Piston pin “3” •...
  • Page 361 CONNECTING RODS AND PISTONS 6. Offset: 9. Install: • Piston ring end gap • Cylinder gasket • Dowel pin • Cylinder assembly • Connecting rod cap • Connecting rod bolt • Make sure the “Y” marks “a” on the connecting rods face towards the left side of the crank- shaft.
  • Page 362 CONNECTING RODS AND PISTONS b. Put a mark “1” on the corner of the connect- ing rod bolt “2” and the connecting rod cap “3”. c. Tighten the connecting rod bolts further to reach the specified angle 145°–155°. Connecting rod bolt (final) Specified angle 145°–155°...

  • Page 363: Crankshaft And Balancer Shaft

    CRANKSHAFT AND BALANCER SHAFT EAS20178 CRANKSHAFT AND BALANCER SHAFT Removing the crankshaft and balancer shaft 3.0 N m (0.30 kgf m, 2.2 lb ft)    • • • 10 N m (1.0 kgf m, 7.4 lb ft)    • • •...

  • Page 364: Removing The Crankshaft And Balancer Shaft

    CRANKSHAFT AND BALANCER SHAFT EAS31171 2. Check: REMOVING THE CRANKSHAFT AND • Crankshaft journal surfaces BALANCER SHAFT • Crankshaft pin surfaces 1. Remove: Scratches/wear → Replace the crankshaft. • Balancer shaft “1” • Bearing surfaces • Balancer shaft journal bearing Scratches/wear →...
  • Page 365 CRANKSHAFT AND BALANCER SHAFT d. Put a piece of Plastigauge® “1” on each crankshaft journal. Do not put the Plastigauge® over the oil hole in the crankshaft journal. G089021 4. Select: • Crankshaft journal bearing (J –J • The numbers “A” stamped into the crankshaft web and the numbers “B”...

  • Page 366: Checking The Balancer Shaft

    CRANKSHAFT AND BALANCER SHAFT Balancer shaft journal to balanc- er shaft bearing clearance 0.028–0.046 mm (0.0011–0.0018 ECA18400 NOTICE Do not interchange the balancer shaft jour- nal bearings. To obtain the correct balancer shaft-journal-to-balancer shaft-journal-bear- ing clearance and prevent engine damage, the balancer shaft journal bearings must be installed in their original positions.
  • Page 367 CRANKSHAFT AND BALANCER SHAFT e. Install the balancer shaft journal lower bear- For example, if the crankcase “J ” and bal- ings “1” into the lower crankcase and as- ancer shaft web “J ” numbers are 6 and 2 re- semble the crankcase halves.

  • Page 368: Installing The Crankshaft

    CRANKSHAFT AND BALANCER SHAFT a. Insert the thrust bearing “1” into the slot of EAS31077 INSTALLING THE CRANKSHAFT the upper crankcase as shown in the illus- 1. Install: tration and slide it in the direction of the ar- • Crankshaft journal upper bearing row.

  • Page 369: Installing The Balancer Assembly

    CRANKSHAFT AND BALANCER SHAFT c. Check that the thrust bearing is inserted properly into the groove of the crankcase. EAS31172 INSTALLING THE BALANCER ASSEMBLY 1. Install: • Balancer shaft journal upper bearing (into the upper crankcase) • Balancer shaft journal lower bearing (into the lower crankcase) •...

  • Page 370: Transmission

    TRANSMISSION EAS20062 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks 12 N ・ m (1.2 kgf ・ m, 8.9 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) Order Job/Parts to remove Q’ty...
  • Page 371 TRANSMISSION Disassembling the main axle assembly Order Job/Parts to remove Q’ty Remarks Make sure the chamfered side of the pinion 2nd pinion gear gear faces to the left. Toothed lock washer Toothed lock washer retainer 6th pinion gear Collar Washer Circlip 3rd pinion gear Circlip...
  • Page 372 TRANSMISSION Disassembling the drive axle assembly Order Job/Parts to remove Q’ty Remarks Circlip Bearing Washer 1st wheel gear Collar 5th wheel gear Circlip Washer 3rd wheel gear Collar Toothed lock washer Toothed lock washer retainer 5-95...
  • Page 373 TRANSMISSION Disassembling the drive axle assembly Order Job/Parts to remove Q’ty Remarks 4th wheel gear Collar Washer Circlip 6th wheel gear Circlip Washer 2nd wheel gear Collar Collar Oil seal Circlip Bearing Drive axle 5-96...

  • Page 374: Removing The Transmission

    TRANSMISSION EAS30430 EAS30431 REMOVING THE TRANSMISSION CHECKING THE SHIFT FORKS 1. Remove: The following procedure applies to all of the shift • Drive axle assembly “1” forks. • Shift drum retainer “2” 1. Check: • Shift fork guide bar • Shift fork cam follower “1” •...

  • Page 375: Checking The Shift Drum Assembly

    TRANSMISSION EAS30432 CHECKING THE SHIFT DRUM ASSEMBLY 1. Check: • Shift drum groove Damage/scratches/wear → Replace the shift drum assembly. • Shift drum segment “1” Damage/wear → Replace the shift drum as- sembly. • Shift drum bearing “2” Damage/pitting → Replace the shift drum as- 3.

  • Page 376: Assembling The Main Axle And Drive Axle

    TRANSMISSION EAS30435 ASSEMBLING THE MAIN AXLE AND DRIVE AXLE 1. Install: • Toothed washer “1” • Circlip “2” • Be sure the circlip sharp-edged corner “a” is positioned opposite side to the toothed washer and gear. • Install the circlip so that a spline “b” is in the center of the gap between the circlip ends “c”...
  • Page 377 TRANSMISSION 2. Install: • Main axle assembly “1” • Bearing housing “2” Main axle bearing housing bolt 12 N·m (1.2 kgf·m, 8.9 lb·ft) LOCTITE® 3. Install: • Shift fork-C “1” • Shift drum assembly “2” 4. Install: • Shift fork guide bar “3” •...
  • Page 378 TRANSMISSION 5. Check: • Transmission Rough movement → Repair. Oil each gear, shaft, and bearing thoroughly. 5-101...

  • Page 379: Cooling System

    COOLING SYSTEM COOLING SYSTEM DIAGRAMS ..............6-1 RADIATOR ...................... 6-3 REMOVING THE RADIATOR ..............6-4 CHECKING THE RADIATOR..............6-4 INSTALLING THE RADIATOR..............6-5 OIL COOLER....................6-6 CHECKING THE OIL COOLER ..............6-7 INSTALLING THE OIL COOLER .............. 6-7 THERMOSTAT ....................6-8 REMOVING THE THERMOSTAT ASSEMBLY......... 6-9 CHECKING THE THERMOSTAT..............

  • Page 380: Cooling System Diagrams

    COOLING SYSTEM DIAGRAMS EAS20299 COOLING SYSTEM DIAGRAMS 1. Radiator outlet hose 2. Cooling system air bleed hose 3. Thermostat assembly 4. Radiator inlet hose 5. Radiator 6. Water pump outlet pipe 7. Water pump 8. Water pump inlet pipe...
  • Page 381 COOLING SYSTEM DIAGRAMS 1. Cooling system air bleed hose 2. Radiator 3. Radiator outlet hose 4. Radiator inlet hose 5. Water pump inlet pipe 6. Water pump outlet pipe 7. Water pump 8. Thermostat assembly...

  • Page 382: Radiator

    RADIATOR EAS20063 RADIATOR Removing the radiator m (0.8 kgf m, 5.9 lb • • • 10 N m (1.0 k gf m, 7.4 lb • • • 10 N m (1.0 k gf m, 7.4 lb • • • m (0.7 kgf m, 5.2 lb 10 N m (1.0 k gf...

  • Page 383: Removing The Radiator

    RADIATOR EAS31659 3. Measure: REMOVING THE RADIATOR • Radiator cap valve opening pressure 1. Remove: Below the specified pressure → Replace the • Hose clamp (Clic-R) “1” radiator cap. • Remove the hose clamp using the hose clamp Radiator cap valve opening pres- pliers “2”.

  • Page 384: Installing The Radiator

    RADIATOR EAS30440 INSTALLING THE RADIATOR 1. Install: • Radiator 2. Connect: • Radiator inlet hose • Radiator outlet hose 3. Install: • Hose clamp (Clic-R) “1” G089031 b. Apply the specified pressure. • Install the hose clamp using the hose clamp pli- ers “2”.

  • Page 385: Oil Cooler

    OIL COOLER EAS20064 OIL COOLER Removing the oil cooler 10 N m (1.0 k gf m, 7.4 lb • • • 10 N m (1.0 k gf m, 7.4 lb • • • 10 N m (1.0 k gf m, 7.4 lb •...

  • Page 386: Checking The Oil Cooler

    OIL COOLER EAS30441 4. Tighten: CHECKING THE OIL COOLER • Radiator bolt 1. Check: • Oil cooler Radiator bolt Cracks/damage → Replace. 10 N·m (1.0 kgf·m, 7.4 lb·ft) • Oil cooler fin Obstruction → Clean. 5. Fill: Apply compressed air to the rear of the oil •...

  • Page 387: Thermostat

    THERMOSTAT EAS20065 THERMOSTAT Removing the thermostat 10 N m (1.0 k gf m, 7.4 lb • • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS (1)” on Rider seat page 4-1. Refer to “GENERAL CHASSIS (2)” on Air scoop/Fuel tank cover/Fuel tank side cover page 4-8.

  • Page 388: Removing The Thermostat Assembly

    THERMOSTAT EAS31660 EAS30444 REMOVING THE THERMOSTAT ASSEMBLY ASSEMBLING THE THERMOSTAT 1. Remove: ASSEMBLY • Hose clamp (Clic-R) 1. Install: Refer to “REMOVING THE RADIATOR” on • Thermostat housing “1” page 6-4. • Thermostat “2” • Radiator inlet hose • O-ring “3” 2.
  • Page 389 THERMOSTAT 5. Measure: • Radiator cap valve opening pressure Below the specified pressure → Replace the radiator cap. Refer to “CHECKING THE RADIATOR” on page 6-4. 6-10...

  • Page 390: Water Pump

    WATER PUMP EAS20066 WATER PUMP Removing the water pump 10 N m (1.0 k gf m, 7.4 lb • • • 10 N m (1.0 k gf m, 7.4 lb • • • 10 N m (1.0 k gf m, 7.4 lb •...
  • Page 391 WATER PUMP Disassembling the water pump 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Water pump housing cover O-ring Circlip Impeller shaft...

  • Page 392: Disassembling The Water Pump

    WATER PUMP EAS30446 EAS30447 DISASSEMBLING THE WATER PUMP CHECKING THE WATER PUMP 1. Remove: 1. Check: • Mechanical seal (housing side) “1” • Water pump housing cover • Impeller shaft Cracks/damage/wear → Replace. Remove the mechanical seal (housing side) • Water pump housing from the inside of the water pump housing “2”.

  • Page 393: Installing The Water Pump

    WATER PUMP EAS30449 INSTALLING THE WATER PUMP Mechanical seal installer (ø33) 1. Install: 90890-04132 • Water pump assembly “1” Water pump seal installer (ø33) YM-33221-A Align the slit “a” on the impeller shaft with the Middle driven shaft bearing driv- projection “b”...
  • Page 394 WATER PUMP 6-15...

  • Page 395: Fuel System

    FUEL SYSTEM FUEL TANK..................... 7-1 REMOVING THE FUEL TANK ..............7-3 REMOVING THE FUEL PUMP ..............7-3 CHECKING THE FUEL PUMP BODY............7-3 CHECKING THE FUEL PUMP OPERATION..........7-3 CHECKING THE PURGE CUT VALVE (for California)......7-4 INSTALLING THE FUEL PUMP..............7-4 INSTALLING THE FUEL TANK..............7-4 AIR FILTER CASE ..................

  • Page 396: Fuel Tank

    FUEL TANK EAS20067 FUEL TANK Removing the fuel tank 4.0 N m (0.40 kgf m, 3.0 lb • • • m (0.7 kgf m, 5.2 lb • • • m (0.7 kgf m, 5.2 lb • • • m (0.7 kgf m, 5.2 lb •...
  • Page 397 FUEL TANK Removing the purge cut valve and canister (for California) 10 N m (1.0 k gf m, 7.4 lb • • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS (1)” on Rider seat page 4-1. Refer to “GENERAL CHASSIS (2)” on Air scoop/Fuel tank cover/Fuel tank side cover page 4-8.

  • Page 398: Removing The Fuel Tank

    FUEL TANK EAS30450 REMOVING THE FUEL TANK 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. 2. Remove: • Rider seat Refer to “GENERAL CHASSIS (1)” on page 4-1. • Air scoop • Fuel tank cover/Fuel tank side cover Refer to “GENERAL CHASSIS (2)”...

  • Page 399: Checking The Purge Cut Valve (For California)

    FUEL TANK EAS33654 CHECKING THE PURGE CUT VALVE (for California) 1. Check: • Purge cut valve “1” Damage/faulty → Replace. Check that air flows smoothly only in the direc- tion of the arrow shown in the illustration. A. Forward EAS30457 INSTALLING THE FUEL TANK 1.
  • Page 400 FUEL TANK 4. Tighten: • Front fuel tank bolt Front fuel tank bolt 7 N·m (0.7 kgf·m, 5.2 lb·ft) 5. Tighten: • Rear fuel tank bolt Rear fuel tank bolt 7 N·m (0.7 kgf·m, 5.2 lb·ft)

  • Page 401: Air Filter Case

    AIR FILTER CASE EAS20068 AIR FILTER CASE Removing the air filter case 0.8 N m (0.08 kgf m, 0.59 lb • • • 2.0 N m (0.20 kgf m, 1.5 lb • • • 2.0 N m (0.20 kgf m, 1.5 lb •...

  • Page 402: Removing The Air Filter Case

    AIR FILTER CASE EAS31663 EAS31664 REMOVING THE AIR FILTER CASE CHECKING THE AIR FILTER CASE SEAL 1. Remove: 1. Check: • Air filter case cover • Air filter case seal Damage → Replace. 2. Loosen: • Intake funnel assembly bolt “1” EAS30463 CHECKING THE INTAKE FUNNEL 1.

  • Page 403: Installing The Air Duct Cover

    AIR FILTER CASE EAS33675 INSTALLING THE AIR DUCT COVER The following procedure applies to both of the air duct cover. 1. Install: • Air duct cover “1” a. Wrap the air duct cover around the air duct, and then fix the ends of the portion “a” into the slit “b”...

  • Page 404: Throttle Bodies

    THROTTLE BODIES EAS20070 THROTTLE BODIES Removing the throttle bodies 3.0 N m (0.30 kgf m, 2.2 lb • • • 10 N m (1.0 k gf m, 7.4 lb • • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS (1)” on Rider seat page 4-1.
  • Page 405 THROTTLE BODIES Removing the throttle bodies 3.0 N m (0.30 kgf m, 2.2 lb • • • 10 N m (1.0 k gf m, 7.4 lb • • • Order Job/Parts to remove Q’ty Remarks Throttle body joint clamp screw Loosen.
  • Page 406 THROTTLE BODIES Removing the sensors 3.5 N m (0.35 kgf m, 2.6 lb 3.5 N m (0.35 kgf m, 2.6 lb • • • • • • 3.5 N m (0.35 kgf m, 2.6 lb • • • 3.5 N m (0.35 kgf m, 2.6 lb •...

  • Page 407: Checking The Injectors (Before Removing)

    THROTTLE BODIES EAS30475 EAS30476 CHECKING THE INJECTORS (BEFORE REMOVING THE INJECTORS REMOVING) EWA17330 WARNING 1. Check: • Check the injectors in a well-ventilated area • Injector free of combustible materials. Make sure Use the diagnostic code numbers “36”–“39”. that there is no smoking or use of electric Refer to “SELF-DIAGNOSTIC FUNCTION tools in the vicinity of the injectors.

  • Page 408: Checking And Cleaning The Throttle Bodies

    • Be careful not to remove the white paint mark that identifies the standard throttle body. • Do not turn the bypass air screws “a”; oth- erwise, the throttle body synchronization G089040 will be affected. Recommended cleaning solvent Yamaha Oil & Brake Cleaner 7-13...

  • Page 409: Replacing The Throttle Bodies

    THROTTLE BODIES d. Apply the recommended cleaning solvent 4. Reset: to the throttle valves and the inside of the • ISC (Idle Speed Control) learning value throttle bodies to remove any carbon de- Use the diagnostic code number “67”. posits. Refer to “DIAGNOSTIC CODE: SENSOR OPERATION TABLE”...

  • Page 410: Installing The Injectors

    THROTTLE BODIES EAS30480 INSTALLING THE INJECTORS Pressure gauge ECA21550 90890-03153 NOTICE Pressure gauge • Always use new O-rings. YU-03153 • When installing the injectors, do not allow Fuel injector pressure adapter any foreign material to enter or adhere to 90890-03210 the injectors, fuel rails, or O-rings.

  • Page 411: Checking The Fuel Pressure

    THROTTLE BODIES EAS30482 CHECKING THE FUEL PRESSURE 1. Remove: • Rider seat Refer to “GENERAL CHASSIS (1)” on page 4-1. • Air scoop Refer to “GENERAL CHASSIS (2)” on page 4-8. • Fuel tank cover/Fuel tank side cover Refer to “GENERAL CHASSIS (2)” on d.

  • Page 412: Adjusting The Throttle Position Sensor

    THROTTLE BODIES • Yamaha diagnostic tool (A/I) (90890-03264) in- cludes YDT sub harness (6P) (90890-03266). • If you already have Yamaha diagnostic tool (A/ I) (90890-03262), YDT sub harness (6P) (90890-03266) is separately required. Refer to “DIAGNOSTIC CODE: SENSOR OPERATION TABLE” on page 9-77.

  • Page 413: Air Induction System

    AIR INDUCTION SYSTEM EAS20071 AIR INDUCTION SYSTEM 1. Air filter case 2. Cylinder head cover 3. Air cut-off valve 4. Air induction system hose (air filter case to air cut-off valve) 5. Air induction system hose (air cut-off valve to reed valve cover) 7-18...
  • Page 414 AIR INDUCTION SYSTEM Removing the air cut-off valve assembly and reed valves m (0.9 kgf m, 6.6 lb • • • 10 N m (1.0 k gf m, 7.2 lb • • • 0.3 N m (0.03 kgf m, 0.22 lb •...
  • Page 415 AIR INDUCTION SYSTEM Removing the air cut-off valve assembly and reed valves m (0.9 kgf m, 6.6 lb • • • 10 N m (1.0 k gf m, 7.2 lb • • • 0.3 N m (0.03 kgf m, 0.22 lb •...

  • Page 416: Checking The Air Induction System

    AIR INDUCTION SYSTEM EAS30488 A. From the air filter case CHECKING THE AIR INDUCTION SYSTEM B. To the cylinder head Air injection 1. Check: The air induction system burns unburned ex- • Hose Loose connections → Connect properly. haust gases by injecting fresh air (secondary air) Cracks/damage →...

  • Page 417: Installing The Air Induction System

    AIR INDUCTION SYSTEM EAS30489 INSTALLING THE AIR INDUCTION SYSTEM 1. Install: • Reed valve plate Align the projection “a” on the cylinder head cov- er “1” with the hole “b” in the reed valve plate. 2. Install: • Reed valve assembly Install the reed valve assembly so that the open side turns to the exhaust side of the engine.
  • Page 418 AIR INDUCTION SYSTEM 7-23...

  • Page 419: Electrical System

    ELECTRICAL SYSTEM IGNITION SYSTEM ..................8-1 CIRCUIT DIAGRAM .................. 8-1 ENGINE STOPPING DUE TO SIDESTAND OPERATION.......8-3 TROUBLESHOOTING ................8-4 ELECTRIC STARTING SYSTEM ..............8-7 CIRCUIT DIAGRAM .................. 8-7 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION ......8-9 TROUBLESHOOTING ................8-10 CHARGING SYSTEM..................8-13 CIRCUIT DIAGRAM ................8-13 TROUBLESHOOTING ................8-15 LIGHTING SYSTEM ..................8-17 CIRCUIT DIAGRAM ................
  • Page 420 CHECKING THE HORN................8-46 CHECKING THE FUEL SENDER ............8-46 CHECKING THE FUEL LEVEL WARNING ICON........8-46 CHECKING THE RADIATOR FAN MOTORS.........8-47 CHECKING THE COOLANT TEMPERATURE SENSOR.......8-47 CHECKING THE THROTTLE SERVO MOTOR ........8-47 CHECKING THE AIR INDUCTION SYSTEM SOLENOID ......8-48 CHECKING THE CYLINDER IDENTIFICATION SENSOR ....8-48 CHECKING THE INTAKE AIR TEMPERATURE SENSOR ....8-49 CHECKING THE FUEL INJECTORS............8-49...

  • Page 422: Ignition System

    IGNITION SYSTEM EAS20072 IGNITION SYSTEM EAS30490 CIRCUIT DIAGRAM...
  • Page 423 IGNITION SYSTEM 3. Main switch 5. Main fuse 6. Joint coupler 12. Fuse box 1 16. Backup fuse 19. Fuse box 2 20. Ignition fuse 22. Signaling system fuse 25. Battery 26. Engine ground 30. Relay unit 36. Handlebar switch (right) 38.

  • Page 424: Engine Stopping Due To Sidestand Operation

    IGNITION SYSTEM EAS30491 ENGINE STOPPING DUE TO SIDESTAND OPERATION When the engine is running and the transmission is in gear, the engine will stop if the sidestand is moved down. This is because the electric current from the ECU does not flow to the ignition coils or fuel injectors when the neutral switch or sidestand switch is open.

  • Page 425: 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. Auxiliary light 3. Air scoop (right) 4. Throttle body assembly 5. Air cut-off valve 1.
  • Page 426 IGNITION SYSTEM OK↓ 8. Check the main switch. Refer to “CHECKING THE NG→ Replace the main switch. SWITCHES” on page 8-39. OK↓ 9. Check the start/engine stop switch. Refer to “CHECKING THE NG→ Replace the handlebar switch (right). SWITCHES” on page 8-39. OK↓...
  • Page 427 IGNITION SYSTEM...

  • Page 428: Electric Starting System

    ELECTRIC STARTING SYSTEM EAS20073 ELECTRIC STARTING SYSTEM EAS30493 CIRCUIT DIAGRAM...
  • Page 429 ELECTRIC STARTING SYSTEM 3. Main switch 5. Main fuse 6. Joint coupler 12. Fuse box 1 16. Backup fuse 19. Fuse box 2 20. Ignition fuse 25. Battery 26. Engine ground 28. Starter relay 29. Starter motor 30. Relay unit 31.

  • Page 430: 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 start/engine stop switch is pushed, the starter motor can only operate if at least one of the following conditions is met: •...
  • Page 431 ELECTRIC STARTING SYSTEM EAS30495 TROUBLESHOOTING The starter motor fails to turn. • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Auxiliary light 3. Air scoop (right) 4. Thermostat 1. Check the fuses. (Main, ignition and backup) NG→ Replace the fuse(s). Refer to “CHECKING THE FUS- ES”...
  • Page 432 ELECTRIC STARTING SYSTEM 8. Check the main switch. Refer to “CHECKING THE NG→ Replace the main switch. SWITCHES” on page 8-39. OK↓ 9. Check the neutral switch. Refer to “CHECKING THE NG→ Replace the neutral switch. SWITCHES” on page 8-39. OK↓...
  • Page 433 ELECTRIC STARTING SYSTEM 8-12...

  • Page 434: Charging System

    CHARGING SYSTEM EAS20074 CHARGING SYSTEM EAS30496 CIRCUIT DIAGRAM 8-13...
  • Page 435 CHARGING SYSTEM 1. AC magneto 2. Rectifier/regulator 5. Main fuse 25. Battery 26. Engine ground 8-14...
  • Page 436 CHARGING SYSTEM EAS30497 TROUBLESHOOTING The battery is not being charged. • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Air scoop stay (left) 1. Check the fuse. (Main) NG→ Replace the fuse. Refer to “CHECKING THE FUS- ES” on page 8-40. OK↓...
  • Page 437 CHARGING SYSTEM 8-16...

  • Page 438: Lighting System

    LIGHTING SYSTEM EAS20075 LIGHTING SYSTEM EAS30498 CIRCUIT DIAGRAM 8-17...
  • Page 439 LIGHTING SYSTEM 3. Main switch 5. Main fuse 6. Joint coupler 12. Fuse box 1 16. Backup fuse 19. Fuse box 2 20. Ignition fuse 22. Signaling system fuse 23. Headlight fuse 25. Battery 26. Engine ground 56. ECU (Engine Control Unit) 76.
  • Page 440 LIGHTING SYSTEM EAS30499 TROUBLESHOOTING Any of the following fail to light: headlight, auxiliary light, high beam indicator light, tail/brake light, li- cense plate light or meter light. • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Headlight assembly 3.
  • Page 441 LIGHTING SYSTEM 8-20...

  • Page 442: Signaling System

    SIGNALING SYSTEM EAS20076 SIGNALING SYSTEM EAS30500 CIRCUIT DIAGRAM 8-21...
  • Page 443 SIGNALING SYSTEM 3. Main switch 5. Main fuse 6. Joint coupler 7. Fuse box 3 8. Brake light fuse 12. Fuse box 1 16. Backup fuse 19. Fuse box 2 20. Ignition fuse 21. ABS ECU fuse 22. Signaling system fuse 25.
  • Page 444 SIGNALING SYSTEM EAS30501 TROUBLESHOOTING • Any of the following fail to light: turn signal light, brake light or an indicator light. • The horn fails to sound. • The speedometer fails to operate. • Before troubleshooting, remove the following part(s): 1.
  • Page 445 SIGNALING SYSTEM Checking the signaling system The horn fails to sound. 1. Check the horn switch. Refer to “CHECKING THE NG→ Replace the handlebar switch (left). SWITCHES” on page 8-39. OK↓ 2. Check the horn. Refer to “CHECKING THE HORN” NG→...
  • Page 446 SIGNALING SYSTEM OK↓ 2. Check the hazard switch. Refer to “CHECKING THE NG→ Replace the handlebar switch (left). SWITCHES” on page 8-39. OK↓ 3. Check the entire signaling sys- tem’s wiring. Properly connect or repair the signaling NG→ Refer to “CIRCUIT DIAGRAM” on system’s wiring.
  • Page 447 SIGNALING SYSTEM OK↓ Replace the oil pressure switch. The oil pressure and coolant temperature warning light remains on after the engine is started. 1. Check the entire signaling sys- tem’s wiring. Properly connect or replace the wiring har- NG→ Refer to “CIRCUIT DIAGRAM” on ness.
  • Page 448 SIGNALING SYSTEM Replace the ECU or meter assembly. Refer to “REPLACING THE ECU (En- gine Control Unit)” on page 8-41. Quick shift system does not operate. 1. Check that the MIL does not come NG→ Repair the faulty parts. OK↓ Check the quick shift system operating 2.
  • Page 449 SIGNALING SYSTEM 9. Check the entire signaling sys- tem’s wiring. Properly connect or repair the signaling NG→ Refer to “CIRCUIT DIAGRAM” on system’s wiring. page 8-21. OK↓ Replace the ECU. Refer to “REPLACING THE ECU (En- gine Control Unit)” on page 8-41. The speedometer fails to operate.

  • Page 450: Cooling System

    COOLING SYSTEM EAS20077 COOLING SYSTEM EAS30502 CIRCUIT DIAGRAM 8-29...
  • Page 451 COOLING SYSTEM 3. Main switch 4. Radiator fan motor relay 5. Main fuse 12. Fuse box 1 16. Backup fuse 17. Sub radiator fan motor fuse 18. Radiator fan motor fuse 19. Fuse box 2 20. Ignition fuse 25. Battery 26.

  • Page 452: Troubleshooting Tip

    COOLING SYSTEM EAS30503 TROUBLESHOOTING • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Auxiliary light 3. Air scoop (left) 4. Throttle body assembly 1. Check the fuses. (Main, ignition, backup, radiator fan motor and sub radiator fan motor) NG→...
  • Page 453 COOLING SYSTEM Replace the ECU. Refer to “REPLACING THE ECU (En- gine Control Unit)” on page 8-41. 8-32...

  • Page 454: Fuel Pump System

    FUEL PUMP SYSTEM EAS20081 FUEL PUMP SYSTEM EAS30513 CIRCUIT DIAGRAM 8-33...
  • Page 455 FUEL PUMP SYSTEM 3. Main switch 5. Main fuse 6. Joint coupler 12. Fuse box 1 14. Fuel injection system fuse 16. Backup fuse 19. Fuse box 2 20. Ignition fuse 25. Battery 26. Engine ground 30. Relay unit 32. Fuel pump relay 36.
  • Page 456 FUEL PUMP SYSTEM EAS30514 TROUBLESHOOTING If the fuel pump fails to operate. • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Auxiliary light 3. Air scoop (right) 4. Air filter case 1. Check the fuses. (Main, ignition, backup and fuel in- jection system) NG→...
  • Page 457 FUEL PUMP SYSTEM Replace the ECU. Refer to “REPLACING THE ECU (En- gine Control Unit)” on page 8-41. 8-36...

  • Page 458: Electrical Components

    ELECTRICAL COMPONENTS EAS20089 ELECTRICAL COMPONENTS 1. Clutch switch 18. Starter motor 2. Front brake light switch 19. Radiator fan motor 20. Horn 3. Accelerator position sensor 4. SCU (Suspension Control Unit) (for 21. Headlight control unit MT10SPN/MT10SPNC) 22. Main switch 5.
  • Page 459 ELECTRICAL COMPONENTS 1. Front fork stepping motor (for MT10SPN/ 19. O sensor MT10SPNC) 20. Oil pressure switch 2. Atmospheric pressure sensor 21. Gear position sensor 3. Intake air temperature sensor 22. Front wheel sensor 4. Ignition coil 23. Cylinder identification sensor 5.

  • Page 460: 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. R Br/L Br/R R/B G/W G/Y Y/W Y/B Br/L Br/R L/W B...

  • Page 461: Checking The Fuses

    ELECTRICAL COMPONENTS EAS30551 Amper- CHECKING THE FUSES Fuses Q’ty age rating The following procedure applies to all of the fus- Main 50 A ECA13680 Headlight 10 A NOTICE Signaling system 7.5 A To avoid a short circuit, always set the main switch to “OFF”...

  • Page 462: Checking The Relays

    ELECTRICAL COMPONENTS EAS31006 8. Check: REPLACING THE ECU (Engine Control Unit) • Battery terminal 1. Turn the main switch to “OFF”. Dirt → Clean with a wire brush. 2. Replace the ECU (Engine Control Unit). Loose connection → Connect properly. 3.

  • Page 463: Checking The Relay Unit (Diode)

    ELECTRICAL COMPONENTS Relay unit (starting circuit cut-off relay) Radiator fan motor relay L/Y R/W L/B L/Y Sb B/Y Sb/W 1. Positive battery terminal 1. Positive battery terminal 2. Negative battery terminal 2. Negative battery terminal 3. Positive tester probe 3. Positive tester probe 4.

  • Page 464: Checking The Ignition Coils

    ELECTRICAL COMPONENTS a. Disconnect the relay unit coupler from the wire harness. The digital circuit tester readings are shown in b. Connect the digital circuit tester (Ω) to the the following table. relay unit terminal as shown. c. Check the relay unit (diode) for continuity. Continuity d.

  • Page 465: Checking The Ignition Spark Gap

    ELECTRICAL COMPONENTS a. Connect the digital circuit tester (Ω) to the ignition coil as shown. Digital circuit tester (CD732) 90890-03243 Model 88 Multimeter with ta- chometer YU-A1927 G089048 • Negative tester probe Ignition coil terminal “1” 2. Ignition coil • Positive tester probe c.

  • Page 466: Checking The Starter Motor Operation

    ELECTRICAL COMPONENTS 2. Check: • Stator coil resistance Out of specification → Replace the stator coil assembly. Stator coil resistance 0.112–0.168 Ω a. Connect the digital circuit tester to the stator coil coupler as shown. b. Measure the crankshaft position sensor re- sistance.

  • Page 467: Checking The Horn

    ELECTRICAL COMPONENTS Battery charging voltage Digital circuit tester (CD732) above 14 V at 5000 r/min 90890-03243 Model 88 Multimeter with ta- chometer a. Connect the digital circuit tester to the bat- YU-A1927 tery terminal. • Positive tester probe → Digital circuit tester (CD732) Fuel sender terminal “1”...

  • Page 468: Checking The Radiator Fan Motors

    ELECTRICAL COMPONENTS EAS30577 CHECKING THE RADIATOR FAN MOTORS Digital circuit tester (CD732) 1. Check: 90890-03243 • Radiator fan motor Model 88 Multimeter with ta- Faulty/rough movement → Replace. chometer a. Disconnect the radiator fan motor coupler YU-A1927 from the wire harness. b.

  • Page 469: Checking The Air Induction System Solenoid

    ELECTRICAL COMPONENTS c. Measure the air induction system solenoid resistance. EAS30589 CHECKING THE CYLINDER IDENTIFICATION SENSOR 1. Remove: • Fuel tank Refer to “FUEL TANK” on page 7-1. • Air filter case A. Check that the throttle valves “2” open. Refer to “AIR FILTER CASE”...

  • Page 470: Checking The Intake Air Temperature Sensor

    ELECTRICAL COMPONENTS a. Connect the digital circuit tester (Ω) to the • Positive tester probe intake air temperature sensor terminal as white/black (wire harness color) shown. • Negative tester probe black/blue (wire harness color) Digital circuit tester (CD732) 90890-03243 Model 88 Multimeter with ta- chometer YU-A1927 b.
  • Page 471 ELECTRICAL COMPONENTS d. Connect the digital circuit tester (DC V) to Digital circuit tester (CD732) the handlebar switch coupler (right) as 90890-03243 shown. Model 88 Multimeter with ta- chometer Digital circuit tester (CD732) YU-A1927 90890-03243 Model 88 Multimeter with ta- •...
  • Page 472 ELECTRICAL COMPONENTS 8-51...

  • Page 473: Self Diagnostic

    SELF DIAGNOSTIC SELF-DIAGNOSTIC FUNCTION..............9-1 GLOSSARY....................9-1 OUTLINE ....................9-1 CHECKING THE WARNING LIGHT ............9-2 YDT ......................9-3 PARTS CONNECTED TO THE ECU ............9-4 PARTS CONNECTED TO THE SCU (for MT10SPN/MT10SPNC)...9-4 PARTS CONNECTED TO THE ABS ECU..........9-5 PRECAUTIONS FOR ROAD TEST ............9-5 SYSTEM DIAGRAM ..................9-6 ECU CIRCUIT DIAGRAM................9-6 ECU COUPLER LAYOUT .................
  • Page 474 [A-4] ONLY THE ABS ECU FAILS TO COMMUNICATE ......9-32 [A-5] ABS ECU AND FI ECU FAIL TO COMMUNICATE ......9-32 [B-1] MALFUNCTION ARE CURRENTLY DETECTED ......9-32 [B-2] DIAGNOSIS USING THE DTC ............9-32 [B-3] DELETING THE DTC ..............9-33 [C-1] FINAL CHECK ................
  • Page 475 C1003 ......................9-98 TROUBLESHOOTING ................9-98 C1007 ......................9-104 TROUBLESHOOTING ................9-104 P0030......................9-105 TROUBLESHOOTING ................9-105 P0050......................9-109 TROUBLESHOOTING ................9-109 P0069......................9-113 TROUBLESHOOTING ................9-113 P00D1, P2195....................9-115 TROUBLESHOOTING ................9-115 P00D3, P2197....................9-119 TROUBLESHOOTING ................9-119 P0107, P0108 ....................9-123 TROUBLESHOOTING ................9-123 P0112, P0113 ....................9-127 TROUBLESHOOTING ................9-127 P0117, P0118 ....................9-131 TROUBLESHOOTING ................9-131 P0122, P0123, P0222, P0223 ..............9-135 TROUBLESHOOTING ................9-135 P0132......................9-139...
  • Page 476 P0202......................9-148 TROUBLESHOOTING ................9-148 P0203......................9-151 TROUBLESHOOTING ................9-151 P0204......................9-154 TROUBLESHOOTING ................9-154 P0335......................9-157 TROUBLESHOOTING ................9-157 P0340......................9-160 TROUBLESHOOTING ................9-160 P0351......................9-163 TROUBLESHOOTING ................9-163 P0352......................9-167 TROUBLESHOOTING ................9-167 P0353......................9-171 TROUBLESHOOTING ................9-171 P0354......................9-175 TROUBLESHOOTING ................9-175 P0475, P0476, P048B .................9-179 TROUBLESHOOTING ................9-179 P0480......................
  • Page 477 P0560 (FI), P0563..................9-201 TROUBLESHOOTING ................9-201 P0560 (SCU)....................9-202 TROUBLESHOOTING ................9-202 P0564......................9-203 TROUBLESHOOTING ................9-203 P056C ......................9-209 TROUBLESHOOTING ................9-209 P0601......................9-216 TROUBLESHOOTING ................9-216 P0606......................9-217 TROUBLESHOOTING ................9-217 P062F ......................9-218 TROUBLESHOOTING ................9-218 P0638......................9-219 TROUBLESHOOTING ................9-219 P0657......................9-223 TROUBLESHOOTING ................9-223 P0916, P0917 ....................9-227 TROUBLESHOOTING ................9-227 P1400......................9-231 TROUBLESHOOTING ................9-231 P1600......................9-235 TROUBLESHOOTING ................9-235 P1601......................9-239...
  • Page 478 P1806, P1807 ....................9-247 TROUBLESHOOTING ................9-247 P2122, P2123, P2127, P2128, P2138 ............9-251 TROUBLESHOOTING ................9-251 P2135......................9-255 TROUBLESHOOTING ................9-255 P2158 (FI) ....................9-258 TROUBLESHOOTING ................9-258 P2158 (SCU)....................9-263 TROUBLESHOOTING ................9-263 P2228, P2229 ....................9-264 TROUBLESHOOTING ................9-264 U0100 ......................9-268 TROUBLESHOOTING ................9-268 U0121 ......................9-271 TROUBLESHOOTING ................9-271 U0125 (FI) ....................
  • Page 479 13, 26_ABS ....................9-290 TROUBLESHOOTING ................9-290 14, 27_ABS ....................9-291 TROUBLESHOOTING ................9-291 15_ABS .......................9-292 TROUBLESHOOTING ................9-292 16_ABS .......................9-294 TROUBLESHOOTING ................9-294 21_ABS .......................9-296 TROUBLESHOOTING ................9-296 31_ABS .......................9-297 TROUBLESHOOTING ................9-297 33_ABS .......................9-299 TROUBLESHOOTING ................9-299 34_ABS .......................9-301 TROUBLESHOOTING ................9-301 41_ABS .......................9-302 TROUBLESHOOTING ................9-302 42_ABS .......................9-303 TROUBLESHOOTING ................9-303 43, 45_ABS ....................9-304 TROUBLESHOOTING ................9-304...
  • Page 480 55_ABS .......................9-309 TROUBLESHOOTING ................9-309 56_ABS .......................9-310 TROUBLESHOOTING ................9-310 57_ABS .......................9-311 TROUBLESHOOTING ................9-311 62_ABS .......................9-315 TROUBLESHOOTING ................9-315 68_ABS .......................9-316 TROUBLESHOOTING ................9-316 89_ABS .......................9-317 TROUBLESHOOTING ................9-317 90_ABS .......................9-320 TROUBLESHOOTING ................9-320 91_ABS .......................9-323 TROUBLESHOOTING ................9-323...

  • Page 481: Self-Diagnostic Function

    Generic diagnostic tool that complies with OBD standards. (Generic scan tool) (Yamaha diagnostic Diagnostic tool developed especially for Yamaha vehicles. tool) EAS32858 OUTLINE The control unit is equipped with a self-diagnostic function in order to ensure that the system is operat- ing normally.
  • Page 482 SELF-DIAGNOSTIC FUNCTION EAS32859 CHECKING THE WARNING LIGHT The warning light comes on after the main switch has been set to “ON”. Refer to the following table for lighting up time. If the warning light still comes on, refer to a check item of a troubleshooting of each system, check and repair it.
  • Page 483 90890-03264 • Yamaha diagnostic tool (A/I) (90890-03264) includes YDT sub harness (6P) (90890-03266). • If you already have Yamaha diagnostic tool (A/I) (90890-03262), YDT sub harness (6P) (90890- 03266) is separately required. • A GST can also be used to identify malfunctions.
  • Page 484 SELF-DIAGNOSTIC FUNCTION EAS32864 PARTS CONNECTED TO THE ECU The following parts are connected to the ECU. When checking for a power short circuit, the couplers must be disconnected from all of the following parts beforehand. • Crankshaft position sensor • Fuel pump •...
  • Page 485 SELF-DIAGNOSTIC FUNCTION EAS32918 PARTS CONNECTED TO THE ABS ECU The following parts are connected to the hydraulic unit assembly (ABS ECU). When checking for a power short circuit, the couplers must be disconnected from all of the following parts beforehand. •...

  • Page 486: System Diagram

    SYSTEM DIAGRAM EAS20387 SYSTEM DIAGRAM EAS32920 ECU CIRCUIT DIAGRAM 2. Electronic throttle valve fuse 41. Fuel injector #1 10. Fuel pump 3. Backup fuse 42. Fuel injector #2 relay 4. Fuel injection 9. Start/engine 43. Fuel injector #3 11. Fuel pump system fuse stop switch 44.
  • Page 487 SYSTEM DIAGRAM 50. Grip 51. Grip 29. EXUP servo motor warmer (left) warmer (right) (OPTION) (OPTION) 30. Atmospheric pressure sensor 31. Intake air pressure sensor 29. EXUP servo motor 32. Coolant temperature sensor 33. Intake air temperature sensor 34. Shift sensor 52.
  • Page 488 SYSTEM DIAGRAM 1. ECU (Engine Control Unit) 54. Dimmer switch 2. Electronic throttle valve fuse 55. Pass switch 3. Backup fuse 56. Headlight control unit 4. Fuel injection system fuse 57. Meter assembly 5. Ignition fuse 58. CAN communication circuit 6.
  • Page 489 SYSTEM DIAGRAM EAS33369 ECU COUPLER LAYOUT 1 2 3 4 5 6 7 8 9 35 36 37 38 39 40 41 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 10 11 12 13 14 15 16 17 42 43 44 45 46 47 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 18 19 20 21 22 23 24 25...
  • Page 490 SYSTEM DIAGRAM Wire harness Wire harness Connected parts Connected parts color color Throttle position Crankshaft position sensor sensor — — CAN communica- tion circuit Accelerator position sensor — — — — — — EXUP servo motor Starting circuit cut- off relay, clutch Accelerator position switch sensor...
  • Page 491 SYSTEM DIAGRAM Wire harness Connected parts color — — Brake light relay Lg/B — — sensor 2 (right Gy/Y side) — — Coolant tempera- ture sensor Gear position sen- — — Hydraulic unit as- Gy/B sembly (ABS ECU) — — Hydraulic unit as- sembly (ABS ECU) —...

  • Page 492: Fuel Injection System

    FUEL INJECTION SYSTEM EAS20440 FUEL INJECTION SYSTEM EAS32871 CIRCUIT DIAGRAM 9-12...
  • Page 493 FUEL INJECTION SYSTEM 3. Main switch 75. IMU (Inertial Measurement Unit) 4. Radiator fan motor relay 76. Meter assembly 5. Main fuse 79. MIL (Malfunction indicator light) 6. Joint coupler 82. Multi-function meter 12. Fuse box 1 85. Stability control indicator light 14.

  • Page 494: 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 495 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. Check and repair the malfunction according to applicable DTC troubleshooting. 3. Turn the main switch from “OFF” to “ON”, and then check the DTC of “malfunction” is not displayed. •...

  • Page 496: Cruise Control System

    CRUISE CONTROL SYSTEM EAS20441 CRUISE CONTROL SYSTEM EAS32875 CIRCUIT DIAGRAM 9-16...
  • Page 497 CRUISE CONTROL SYSTEM 3. Main switch 5. Main fuse 6. Joint coupler 7. Fuse box 3 8. Brake light fuse 9. Cruise control fuse 12. Fuse box 1 16. Backup fuse 19. Fuse box 2 20. Ignition fuse 22. Signaling system fuse 25.

  • Page 498: Cruise Control Circuit Operation

    CRUISE CONTROL SYSTEM EAS32876 CRUISE CONTROL CIRCUIT OPERATION 4. Ignition 7. Cruise control 8. Cruise control fuse fuse power switch 9.Cruise control setting switch 11.Front brake 12.Rear brake 10.Clutch light switch light switch switch 15.ECU (Engine 5. Signaling 6. Brake Control Unit) system light...

  • Page 499: Basic Instructions For Troubleshooting

    CRUISE CONTROL SYSTEM EAS32877 BASIC INSTRUCTIONS FOR TROUBLESHOOTING 1. Check the DTC of “malfunction” using the YDT. 2. Check and repair the malfunction according to applicable DTC troubleshooting. 3. Turn the main switch from “OFF” to “ON”, and then check the DTC of “malfunction” is not displayed. •...
  • Page 500 CRUISE CONTROL SYSTEM EAS32878 BASIC PROCESS FOR TROUBLESHOOTING When turning the main switch to Check the MIL (LED). “ON”, does the MIL come on? The MIL goes off after 2 seconds? Fails to come on Push the cruise control The cruise control power switch is •...
  • Page 501 CRUISE CONTROL SYSTEM EAS32879 [A] CHECKING THE CRUISE CONTROL SYSTEM INDICATOR LIGHT Turn the main switch to “ON”, and then push the cruise control power switch. 1. The cruise control system indicator light does not come on. • Check the cruise control power switch for continuity. Refer to “CHECKING THE SWITCHES” on page 8-39.
  • Page 502 CRUISE CONTROL SYSTEM Automatic deactivation of the cruise control system The cruise control system for this model is electronically controlled and is linked with the other control systems. The cruise control system will automatically deactivate under the following conditions: • The cruise control system is not able to maintain the set cruising speed. •...
  • Page 503 CRUISE CONTROL SYSTEM 9-23...
  • Page 504 ABS (Anti-lock Brake System) EAS20443 ABS (Anti-lock Brake System) EAS32890 CIRCUIT DIAGRAM 9-24...
  • Page 505 ABS (Anti-lock Brake System) 3. Main switch 5. Main fuse 6. Joint coupler 7. Fuse box 3 8. Brake light fuse 12. Fuse box 1 13. ABS solenoid fuse 16. Backup fuse 19. Fuse box 2 20. Ignition fuse 21. ABS ECU fuse 22.

  • Page 506: Abs Components Chart

    ABS (Anti-lock Brake System) EAS32891 ABS COMPONENTS CHART 1. Meter assembly 2. Hydraulic unit assembly (ABS ECU) 3. Starter relay (ABS motor fuse) 4. YDT coupler 5. Fuse box 2 (ABS ECU fuse) 6. Fuse box 1 (ABS solenoid fuse) 7.

  • Page 507: Abs Coupler Location Chart

    ABS (Anti-lock Brake System) EAS32892 ABS COUPLER LOCATION CHART B/W R/W Br/W Br/B Dg Ch W/L W/Y Br/Y L/W L/B G/W R/G L/B R/GR/G Sb/W G/L G/Y G G/B W/B W/G G/O Y (Gy) Gy/B L Y G Br/B B L/W G/O W/L L B W W L/B 1.

  • Page 508: 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 509 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 510 ABS (Anti-lock Brake System) Fails to Turn the main switch to “ON”, • The ABS warning light (LED) is [A-1] Does only the ABS come on and check the ABS warning Return to [A]. warning light fail to defective. light. come on? •...

  • Page 511: [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 512 [B-2] DIAGNOSIS USING THE DTC This model uses the YDT to identify malfunctions. For information about using the YDT, refer to the operation manual that is included with the tool. Yamaha diagnostic tool USB (US) 90890-03269 Yamaha diagnostic tool (A/I)
  • Page 513 ABS (Anti-lock Brake System) • Yamaha diagnostic tool (A/I) (90890-03264) includes YDT sub harness (6P) (90890-03266). • If you already have Yamaha diagnostic tool (A/I) (90890-03262), YDT sub harness (6P) (90890- 03266) is separately required. Details about the displayed DTCs are shown in the following chart. Refer to this chart and check the ve- hicle.
  • Page 514 ABS (Anti-lock Brake System) 5. Checking the ABS warning light. Confirm the ABS warning light go off. If the ABS warning light does not come on or does not go off, refer to “[A] CHECKING THE ABS WARNING LIGHT” on page 9-31. If the ABS warning light does not turn off, the possible causes are following: •...
  • Page 515 ABS (Anti-lock Brake System) 9-35...
  • Page 516 ELECTRONICALLY ADJUSTABLE SUSPENSION SYSTEM (for MT10SPN/MT10SPNC) EAS20446 ELECTRONICALLY ADJUSTABLE SUSPENSION SYSTEM (for MT10SPN/ MT10SPNC) EAS32914 CIRCUIT DIAGRAM 9-36...
  • Page 517 ELECTRONICALLY ADJUSTABLE SUSPENSION SYSTEM (for MT10SPN/MT10SPNC) 3. Main switch 5. Main fuse 6. Joint coupler 10. Fuse box 4 11. SCU fuse 12. Fuse box 1 16. Backup fuse 19. Fuse box 2 20. Ignition fuse 21. ABS ECU fuse 22.
  • Page 518 ELECTRONICALLY ADJUSTABLE SUSPENSION SYSTEM (for MT10SPN/MT10SPNC) EAS32915 MAINTENANCE OF THE SCU (suspension control unit) Checking the SCU (suspension control unit) 1. Check: • Terminals “1” of the SCU Cracks/damages → Replace the SCU. • Terminals “2” of the SCU couplers Connection defective, contaminated, come-off →...

  • Page 519: Self-Diagnostic Function And Diagnostic Code Table

    SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE EAS20551 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE EAS33149 DTC TABLE Fail-safe system Diagnos- Symptom Starting the Driving the tic code engine vehicle Front wheel sensor (intermittent pulses “11_ABS” — — — or no pulses) Rear wheel sensor (intermittent pulses or “12_ABS”...
  • Page 520 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Fail-safe system Diagnos- Symptom Starting the Driving the tic code engine vehicle Power supply voltage failure in pressure “62_ABS” — — — sensor Defective hydraulic unit assembly (de- “68_ABS” — — — fective front pressure sensor) “70_EVEN Engine forcibly stops when the vehicle is Unable...
  • Page 521 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Fail-safe system Diagnos- Symptom Starting the Driving the tic code engine vehicle [P00D3] O sensor 2: heater perfor- mance is deteriorated. Normal signal is not received from the O sensor while “P00D3, driving the O sensor 2 heater.
  • Page 522 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Fail-safe system Diagnos- Symptom Starting the Driving the tic code engine vehicle sensor 2: short to power circuit is de- “P0152” tected. Normal signal is not received Able Able — from the O sensor 2. Able Able Fuel injector #1: malfunction in fuel injec-...
  • Page 523 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Fail-safe system Diagnos- Symptom Starting the Driving the tic code engine vehicle Cylinder-#4 ignition coil: open or short Able Able circuit is detected in the primary lead of (depending (depending “P0354” the cylinder-#4 ignition coil. Normal sig- on the num- on the num- nal is not received from the ignition cir-...
  • Page 524 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Fail-safe system Diagnos- Symptom Starting the Driving the tic code engine vehicle [P0560 (FI)] Battery charging voltage is abnormal. Poor charging performance (Discharged condition). Vehicle system power voltage is abnormal. (Regulator is not operated properly or battery is not “P0560 charged properly.) (FI),...
  • Page 525 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Fail-safe system Diagnos- Symptom Starting the Driving the tic code engine vehicle [P0916] Gear position sensor: open or short to ground circuit is detected. Nor- mal signal is not received from the gear “P0916, position sensor to ECU.
  • Page 526 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Fail-safe system Diagnos- Symptom Starting the Driving the tic code engine vehicle Throttle position sensor: output voltage Able Able deviation error. Normal signal is not re- (depending (depending “P2135” 01, 13 ceived from the throttle position sensor on the situa- on the situa- circuit.
  • Page 527 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE EAS33028 SELF-DIAGNOSTIC FUNCTION TABLE (FOR FUEL INJECTION SYSTEM) For details of the DTC, refer to “BASIC PROCESS FOR TROUBLESHOOTING” on page 9-14. Probable cause of Fail-safe system Item Vehicle symptom malfunction operation 30_EVEN Overturn is detect- •...
  • Page 528 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Probable cause of Fail-safe system Item Vehicle symptom malfunction operation P0050 sensor 2 heater: • Open or short cir- (When the O sen- Display only (If the cuit in wire har- sensor 2 does defective heater or sor 2 does not oper- ness.
  • Page 529 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Probable cause of Fail-safe system Item Vehicle symptom malfunction operation P00D1 sensor 1: heater • Improperly in- Increased exhaust feedback is not stalled O sensor emissions. performance is de- carried out. teriorated. Normal learning is not signal is not re- •...
  • Page 530 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Probable cause of Fail-safe system Item Vehicle symptom malfunction operation P0107 [P0107] Intake air [P0107] Low voltage Engine idling speed Intake air pressure P0108 pressure sensor: of the intake air is unstable. difference is fixed to short to ground cir- pressure sensor cir- Engine response is...
  • Page 531 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Probable cause of Fail-safe system Item Vehicle symptom malfunction operation P0112 [P0112] Intake air [P0112] Low voltage Engine is difficult to Intake air tempera- P0113 temperature sensor: of the intake air tem- start. ture is fixed to 20 short to ground cir- perature sensor cir- Increased exhaust...
  • Page 532 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Probable cause of Fail-safe system Item Vehicle symptom malfunction operation P0117 [P0117] Coolant [P0117] Low voltage Engine is difficult to Radiator fan motor P0118 temperature sensor: of the coolant tem- start. relay is ON only short to ground cir- perature sensor cir- Increased exhaust...
  • Page 533 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Probable cause of Fail-safe system Item Vehicle symptom malfunction operation P0122 [P0122] Throttle po- [P0122, P0222] Low Engine idling speed Change in the throt- P0123 sition sensor: short voltage of the throt- is high. tle opening is 0 P0222 to ground circuit is...
  • Page 534 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Probable cause of Fail-safe system Item Vehicle symptom malfunction operation P0132 sensor 1: short to • High voltage of the Increased exhaust feedback is not sensor 1 circuit emissions. power circuit is de- carried out. tected.
  • Page 535 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Probable cause of Fail-safe system Item Vehicle symptom malfunction operation P0201 [P0201] Fuel injec- • Defective coupler Loss of engine pow- feedback is not P0202 tor #1: malfunction between fuel injec- carried out. P0203 in fuel injector #1.
  • Page 536 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Probable cause of Fail-safe system Item Vehicle symptom malfunction operation P0340 Cylinder identifica- • Defective coupler Engine cannot be The vehicle is oper- tion sensor: normal between cylinder started. ated using only the signals are not re- identification sen- cylinder identifica- ceived from the cyl-...
  • Page 537 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Probable cause of Fail-safe system Item Vehicle symptom malfunction operation P0351 [P0351] Cylinder-#1 • Defective coupler Engine stops. Injection to the ap- P0352 ignition coil: open or between ignition Loss of engine pow- plicable cylinder P0353 short circuit is de- coil and ECU.
  • Page 538 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Probable cause of Fail-safe system Item Vehicle symptom malfunction operation P0475 EXUP servo motor: • Defective coupler Loss of engine pow- EXUP learning val- performance deteri- between EXUP ues are fixed. oration. EXUP servo servo motor and feedback is not motor positioning...
  • Page 539 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Probable cause of Fail-safe system Item Vehicle symptom malfunction operation P048B EXUP servo motor: • Defective coupler Loss of engine pow- EXUP learning val- signal stuck. EXUP between EXUP ues are fixed. servo motor posi- servo motor and feedback is not tioning signal is not...
  • Page 540 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Probable cause of Fail-safe system Item Vehicle symptom malfunction operation P0500 Rear wheel sensor: • Open or short cir- Vehicle speed is not Vehicle speed dis- open or short circuit cuit in wire har- displayed on the played on the meter is detected.
  • Page 541 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Probable cause of Fail-safe system Item Vehicle symptom malfunction operation P0564 Cruise control set- • Open or short cir- Cruise control / Cruise control / ting switch “RES+”: cuit in wire har- YVSL cannot be YVSL fixed to OFF.
  • Page 542 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Probable cause of Fail-safe system Item Vehicle symptom malfunction operation P0606 Internal malfunction • Malfunction in Engine cannot be Engine cannot be in ECU. (When this ECU (Processor started. started. malfunction is de- error). Engine response is Ignition and injec- tected in the ECU,...
  • Page 543 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Probable cause of Fail-safe system Item Vehicle symptom malfunction operation P0657 Fuel system volt- • Open or short cir- Engine is difficult to Monitor voltage = 12 age: incorrect volt- cuit in wire har- start.
  • Page 544 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Probable cause of Fail-safe system Item Vehicle symptom malfunction operation P1500 Neutral switch: open • Open or short cir- Vehicle speed is not Vehicle speed dis- or short circuit is de- cuit in wire har- displayed on the played on the meter tected.
  • Page 545 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Probable cause of Fail-safe system Item Vehicle symptom malfunction operation P1601 Sidestand switch: • Defective coupler Engine cannot be Engine is forcefully open or short circuit between relay unit started. stopped (the injector in wire harness of and ECU.
  • Page 546 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Probable cause of Fail-safe system Item Vehicle symptom malfunction operation P2122 [P2122] Accelerator [P2122, P2127] Low Engine response is No change in accel- P2123 position sensor: voltage of the accel- poor. erator opening P2127 open or short to erator position sen- Loss of engine pow-...
  • Page 547 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Probable cause of Fail-safe system Item Vehicle symptom malfunction operation P2195 sensor 1: open • Signal voltage is Increased exhaust feedback is not 0.18–0.49 V. emissions. circuit is detected. carried out. • Improperly in- Normal signal is not feedback learn- stalled O...
  • Page 548 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Probable cause of Fail-safe system Item Vehicle symptom malfunction operation α–N is fixed. P2228 [P2228] Atmospher- [P2228] Low voltage Engine is difficult to P2229 ic pressure sensor: of the atmospheric start. Intake air pressure short to ground cir- pressure sensor cir- Increased exhaust...
  • Page 549 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE EAS33286 SELF-DIAGNOSTIC FUNCTION TABLE (FOR ABS (Anti-lock Brake System)) For details of the DTC, refer to “BASIC INSTRUCTIONS FOR TROUBLESHOOTING” on page 9-29. Item Symptom Check point Front wheel sensor (inter- Front wheel sensor signal •...
  • Page 550 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Item Symptom Check point Front wheel sensor (open Open or short circuit is de- • Defective coupler be- or short circuit) tected in the front wheel tween the front wheel sensor. sensor and the hydraulic unit assembly •...
  • Page 551 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Item Symptom Check point Front wheel ABS (intermit- • Pulses from the front • Incorrect installation of tent wheel speed pulses or wheel sensor are re- the front wheel sensor incorrect depressuriza- ceived intermittently •...
  • Page 552 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Item Symptom Check point Vehicle system power Power voltage supplied to • Defective battery supply (voltage of ABS the ABS ECU in the hy- • Defective coupler be- ECU power supply is low) draulic unit assembly is tween the battery and the too low.
  • Page 553 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Item Symptom Check point CAN communication (be- Transmitted data from the • Defective coupler be- tween ECU and hydraulic FI ECU cannot be normal- tween FI ECU and hy- unit assembly) ly received. draulic unit assembly •...
  • Page 554 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE EAS33288 SELF-DIAGNOSTIC FUNCTION TABLE (FOR ELECTRONICALLY ADJUSTABLE SUSPENSION SYSTEM) (for MT10SPN/MT10SPNC) For details of the DTC, refer to “BASIC INSTRUCTIONS FOR TROUBLESHOOTING” on page 9-38. Probable cause of Fail-safe system Item Vehicle symptom malfunction operation C0044 Abnormal ABS...
  • Page 555 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Probable cause of Fail-safe system Item Vehicle symptom malfunction operation P0500 Abnormal rear • Open or short cir- • ERS adjustments — wheel sensor (Sen- cuit in wire har- cannot be per- sor value is not nor- ness between rear formed.
  • Page 556 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Probable cause of Fail-safe system Item Vehicle symptom malfunction operation U0121 Abnormal CAN • Defective connec- • ERS adjustments — communication (be- tion of wire har- cannot be per- tween ABS ECU ness, ABS ECU, formed.

  • Page 557: Communication Error With The Meter

    SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE EAS33030 COMMUNICATION ERROR WITH THE METER Probable cause of Fail-safe system Item Vehicle symptom malfunction operation U0155 [U0155 (FI)] Multi- Communication be- Defective meter dis- Map switching: (YDT) function meter: sig- tween the ECU and play.
  • Page 558 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Diagnostic Item Tool display Procedure code No. Intake air temperature Displays the intake air Compare the actually temperature. measured air temperature -30–120 °C with the tool displayed val- When engine is cold: Displays temperature clos- er to air temperature.
  • Page 559 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Diagnostic Item Tool display Procedure code No. Accelerator position sen- 0–125 sor signal 2 • Fully closed position 14–18 Check with throttle grip ful- ly closed position. • Fully opened position 82–92 Check with throttle grip ful- ly opened position.
  • Page 560 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Diagnostic Item Tool display Procedure code No. EEPROM DTC display — • No history • No malfunctions detect- ed (If the DTC P062F is indicated, the ECU is de- fective.) • History exists 01–04 (CO adjustment val- •...
  • Page 561 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Diagnostic Item Tool display Procedure code No. Cruise control cancel cir- Operate the clutch lever, cuit brake lever and brake ped- • Clutch lever is squeezed ON • Clutch lever is released • Brake lever is squeezed •...

  • Page 562: 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 Check that a spark is gen- ignition coil five times at erated five times. one-second intervals. •...
  • Page 563 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Diagnostic Item Actuation Procedure code No. Fuel injector #4 Actuates the fuel injector Disconnect the fuel pump #4 five times at one-sec- coupler before doing this ond intervals. procedure. The “check” indicator on Check that fuel injector #4 the YDT screen comes on is actuated five times by each time the fuel injector...
  • Page 564 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE EAS33289 DIAGNOSTIC CODE TABLE (SCU) (for MT10SPN/MT10SPNC) Diagnostic Item Tool display Procedure code No. Monitor voltage Displays the SCU power Check the displayed SCU voltage. power supply voltage. 0–18.7 V Standard voltage: Approx. 12.0 V 9-84...

  • Page 565: Event Code Table

    EVENT CODE TABLE EAS20707 EVENT CODE TABLE The event code numbers listed below cannot be displayed on the meter. To display the event code numbers, use the YDT. Item Symptom Possible causes Note Intake air pres- Brief abnormality Same as for DTC num- Perform the inspection sure sensor detected in the in-...
  • Page 566 EVENT CODE TABLE Item Symptom Possible causes Note sensor During O feed- • Open or short circuit • If a DTC is occurring, in the wire harness respond to that first. (Stuck at the back, the adjust- between the sensor * Rarely, Code 241 oc- lower limit for ment is maintained...
  • Page 567 EVENT CODE TABLE Item Symptom Possible causes Note Cruise control Automatic turning While setting the Cruise control system OFF detected in the cruise control system: turns OFF automatically, cruise control sys- • Unable to maintain but it is not system fail- tem.
  • Page 568 30_EVENT EAS20552 30_EVENT EAS33033 TROUBLESHOOTING Item Overturn is detected. Fail-safe system • Unable to start engine • Unable to drive vehicle Procedure 1. The vehicle has overturned. • Raise the overturned vehicle vertically and check again. • Turn the main switch to “ON”, then to “OFF”, and then back to “ON”. Is the MIL on? →...
  • Page 569 30_EVENT Is the MIL on? → Go to step 4. → Service is completed. 4. Malfunction in ECU. • Replace the ECU, and complete the service. Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-41. 9-89...
  • Page 570 70_EVENT EAS20554 70_EVENT EAS33034 TROUBLESHOOTING Item Engine forcibly stops when the vehicle is left idling for a long period. Procedure If another error code is displayed at the same time, check the other error code first and repair it. 1. Allow to idle for a long period. •...
  • Page 571 C0044 EAS20559 C0044 EAS33039 TROUBLESHOOTING Item Abnormal ABS (Brake fluid pressure value is not normal.) Fail-safe system • Able to start engine • Able to drive vehicle Procedure 1. Abnormal ABS (Brake fluid pressure value is not normal.) • Check the items of DTCs 62 and 68 for the ABS. Refer to “[B-2] DIAGNOSIS USING THE DTC”...
  • Page 572 C0520 (FI) EAS20689 C0520 (FI) EAS33319 TROUBLESHOOTING Item Abnormal IMU (Normal signal is not received from the IMU or failure signal is received from IMU.) Fail-safe system • Able/Unable to start engine (depending on the situation) • Able/Unable to drive vehicle (depending on the situation) Procedure 1.
  • Page 573 C0520 (FI) blue/white–blue/white Between ECU coupler and joint coupler blue/black–blue/black blue/white–blue/white Between joint coupler and IMU coupler blue/black–blue/black Between IMU coupler and signaling system red/white–brown fuse holder Between IMU coupler and ECU coupler black/white–black/white Lg/R G/Y Br/R R/L B/W O/W Lg/L P/W P G/LGy/G Br/W...
  • Page 574 C0520 (FI) Lines short circuit check “B” blue/white–any other coupler terminal ECU coupler blue/black–any other coupler terminal blue/white–any other coupler terminal Joint coupler “2” blue/black–any other coupler terminal blue/white–any other coupler terminal IMU coupler blue/black–any other coupler terminal red/white–any other coupler terminal O/W Lg/L P/W P O/W Lg/L...
  • Page 575 C0520 (FI) Is check result OK? → Go to step 5. a. Fix the IMU installation condition. b. Turn the main switch to “ON”, and then check the DTC using the malfunction mode of the YDT. Is it in the “Recovered” condition? →...
  • Page 576 C0520 (SCU) EAS20664 C0520 (SCU) EAS33290 TROUBLESHOOTING Item Abnormal IMU (IMU sensor value is not normal.) Fail-safe system • Unable to start engine • Able/Unable to drive vehicle (depending on the situation) Procedure 1. Abnormal IMU (IMU sensor value is not normal.) •...
  • Page 577 C1002 EAS20562 C1002 EAS33042 TROUBLESHOOTING Item Abnormal SCU EEPROM (SCU internal data is not normal.) Fail-safe system • Able to start engine • Able to drive vehicle Procedure 1. Confirmation after correction of abnormality. • Turn the main switch to “OFF” and back to “ON”. •...
  • Page 578 C1003 EAS20563 C1003 EAS33043 TROUBLESHOOTING Item Stepping motor is not driving properly. Fail-safe system • Able to start engine • Able to drive vehicle Procedure 1. Connection of stepping motor coupler. • Check the locking condition of the coupler. Front fork stepping motor (left) Front fork stepping motor (right) Rear shock absorber assembly stepping motor (×2) •...
  • Page 579 C1003 3. Connection of stepping motor sub-wire harness 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? →...
  • Page 580 C1003 white–white Between SCU coupler “1” and rear shock ab- white/black–white/black sorber assembly stepping motor (compression white/red–white/red damping) “2” white/green–white/green Br/W P/L G/B W/R W/B yellow–yellow Between SCU coupler “1” and rear shock ab- yellow/black–yellow/black sorber assembly stepping motor (rebound yellow/red–yellow/red damping) “2”...
  • Page 581 C1003 green–black Between front fork stepping motor (left) “1” and green/black–black power ground “2” green/red–black green/blue–black pink–black Between front fork stepping motor (right) “3” and pink/black–black power ground “2” pink/white–black pink/blue–black white–black Between rear shock absorber assembly step- white/black–black ping motor (compression damping) “4” and white/red–black power ground “2”...
  • Page 582 C1003 Is it in the “Recovered” condition? → Service is completed. → Go to step 5. 5. Malfunction in stepping motor. a. Connect the digital circuit tester (Ω) to the stepping motor. • Positive tester probe “1” • Negative tester probe “2” 2 3 4 A.
  • Page 583 C1003 Is it in the “Recovered” condition? → Service is completed. → Go to step 6. 6. Malfunction in SCU. • Replace the SCU. Refer to “GENERAL CHASSIS (3)” on page 4-16. • Turn the main switch to “OFF” and back to “ON”, and then check the DTC using the malfunction mode of the YDT.
  • Page 584 C1007 EAS20566 C1007 EAS33046 TROUBLESHOOTING Item Abnormal SCU inside 1 (SCU does not operate properly.) Fail-safe system • Able to start engine • Able to drive vehicle Procedure 1. Malfunction in SCU. • Replace the SCU. Refer to “GENERAL CHASSIS (3)” on page 4-16. •...
  • Page 585 P0030 EAS20397 P0030 EAS33134 TROUBLESHOOTING Item sensor 1 heater: defective heater or heater driver ON / OFF command and error signal is mismatch- ing. 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 586 P0030 Is it in the “Recovered” condition? → Go to step 6, and complete the service. → Start the engine, and then check the DTC. Is it in the “Recovered” condition? → Go to step 6, and complete the service. →...
  • Page 587 P0030 For this check, also set the start/engine stop switch to “ON”. • Short circuit check Disconnect the ECU related connectors before checking. Refer to “PARTS CONNECTED TO THE ECU” on page 9-4. Ground short circuit check “A” red/white–ground Between O sensor 1 coupler “1”...
  • Page 588 P0030 Is it in the “Recovered” condition? → Go to step 6, and complete the service. → Start the engine, and then check the DTC. Is it in the “Recovered” condition? → Go to step 6, and complete the service. →...
  • Page 589 P0050 EAS20398 P0050 EAS33135 TROUBLESHOOTING Item sensor 2 heater: defective heater or heater driver ON / OFF command and error signal is mismatch- ing. 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 590 P0050 Is it in the “Recovered” condition? → Go to step 6, and complete the service. → Start the engine, and then check the DTC. Is it in the “Recovered” condition? → Go to step 6, and complete the service. →...
  • Page 591 P0050 For this check, also set the start/engine stop switch to “ON”. • Short circuit check Disconnect the ECU related connectors before checking. Refer to “PARTS CONNECTED TO THE ECU” on page 9-4. Ground short circuit check “A” red/white–ground Between O sensor 2 coupler “1”...
  • Page 592 P0050 Is it in the “Recovered” condition? → Go to step 6, and complete the service. → Start the engine, and then check the DTC. Is it in the “Recovered” condition? → Go to step 6, and complete the service. →...
  • Page 593 P0069 EAS20390 P0069 EAS33136 TROUBLESHOOTING Item Intake air pressure sensor or atmospheric pressure sensor: when the main switch is turned to “ON”, the intake air pressure sensor voltage and atmospheric pressure sensor voltage differ greatly. Fail-safe system • Able to start engine •...
  • Page 594 P0069 Is it in the “Recovered” condition? → Go to step 4, and complete the service. → Go to step 3. 3. Malfunction in ECU. • Replace the ECU, and complete the service. Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-41. 4.
  • Page 595 P00D1, P2195 EAS20660 P00D1, P2195 EAS33115 TROUBLESHOOTING Item • [P00D1] O sensor 1: heater performance is deteriorated. Normal signal is not received from the O sensor while driving the O sensor 1 heater. • [P2195] O sensor 1: open circuit is detected. Normal signal is not received from the O sensor.
  • Page 596 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 597 P00D1, P2195 Disconnect the ECU related connectors before checking. Refer to “PARTS CONNECTED TO THE ECU” on page 9-4. Ground short circuit check “A” gray/green–ground pink/black–ground Between O sensor 1 coupler “1” and ground black/blue–ground red/white–ground Lines short circuit check “B” gray/green–any other coupler terminal pink/black–any other coupler terminal sensor 1 coupler...
  • Page 598 P00D1, P2195 Is check result OK? → Go to step 6. a. Replace the fuel pump. Refer to “REMOVING THE FUEL PUMP” on page 7-3. b. Start the engine and let it idle for approximately 1 minute. c. Check the DTC using the malfunction mode of the YDT. Is it in the “Recovered”...
  • Page 599 P00D3, P2197 EAS20661 P00D3, P2197 EAS33338 TROUBLESHOOTING Item • [P00D3] O sensor 2: heater performance is deteriorated. Normal signal is not received from the O sensor while driving the O sensor 2 heater. • [P2197] O sensor 2: open circuit is detected. Normal signal is not received from the O sensor.
  • Page 600 P00D3, P2197 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 601 P00D3, P2197 Disconnect the ECU related connectors before checking. Refer to “PARTS CONNECTED TO THE ECU” on page 9-4. Ground short circuit check “A” gray/yellow–ground pink/white–ground Between O sensor 2 coupler “1” and ground black/blue–ground red/white–ground Lines short circuit check “B” gray/yellow–any other coupler terminal pink/white–any other coupler terminal sensor 2 coupler...
  • Page 602 P00D3, P2197 Is check result OK? → Go to step 6. a. Replace the fuel pump. Refer to “REMOVING THE FUEL PUMP” on page 7-3. b. Start the engine and let it idle for approximately 1 minute. c. Check the DTC using the malfunction mode of the YDT. Is it in the “Recovered”...
  • Page 603 P0107, P0108 EAS20567 P0107, P0108 EAS33047 TROUBLESHOOTING Item • [P0107] Intake air pressure sensor: short to ground circuit is detected. Normal signal is not received from the intake air pressure sensor circuit. • [P0108] Intake air pressure sensor: open or short to power circuit is detected. Normal signal is not re- ceived from the intake air pressure sensor circuit.
  • Page 604 P0107, P0108 3. Wire harness continuity. • Disconnect the intake air pressure sensor coupler “1” and ECU coupler “2”. • Open circuit check [P0108] blue–blue Between intake air pressure sensor coupler and [P0107, P0108] pink/white–pink/white ECU coupler [P0108] black/blue–black/blue O/W Lg/L P/W P B/L P/W L G/LGy/G...
  • Page 605 P0107, P0108 B/L P/W L B/L P/W L O/W Lg/L P/W P G/LGy/G Br/W Lg/B Gy/Y G/W G Gy/B Is resistance ∞ Ω? → Go to step 4. a. Replace the wire harness. b. Turn the main switch to “ON”, and then check the DTC using the malfunction mode of the YDT. Is it in the “Recovered”...
  • Page 606 P0107, P0108 • When engine is cranking: Make sure that the indication value changes. Is check result OK? → Go to step 6. a. Replace the intake air pressure sensor. Refer to “THROTTLE BODIES” on page 7-9. b. Turn the main switch to “ON”, and then check the DTC using the malfunction mode of the YDT. Is it in the “Recovered”...
  • Page 607 P0112, P0113 EAS20568 P0112, P0113 EAS33048 TROUBLESHOOTING Item • [P0112] Intake air temperature sensor: short to ground circuit is detected. Normal signal is not re- ceived from the intake air temperature sensor circuit. • [P0113] Intake air temperature sensor: short to power circuit is detected. Normal signal is not received from the intake air temperature sensor circuit.
  • Page 608 P0112, P0113 3. Wire harness continuity. • Disconnect the intake air temperature sensor coupler “1” and ECU coupler “2”. • Open circuit check Between intake air temperature sensor coupler [P0112, P0113] brown/white–brown/white and ECU coupler [P0113] black/blue–black/blue O/W Lg/L P/W P Br/W G/LGy/G Br/W...
  • Page 609 P0112, P0113 Br/W Br/W O/W Lg/L P/W P G/LGy/G Br/W Lg/B Gy/Y G/W G Gy/B Is resistance ∞ Ω? → Go to step 4. a. Replace the wire harness. b. Turn the main switch to “ON”, and then check the DTC using the malfunction mode of the YDT. Is it in the “Recovered”...
  • Page 610 P0112, P0113 Is check result OK? → Go to step 6. a. Replace the intake air temperature sensor. Refer to “AIR INDUCTION SYSTEM” on page 7-18. b. Turn the main switch to “ON”, and then check the DTC using the malfunction mode of the YDT. Is it in the “Recovered”...
  • Page 611 P0117, P0118 EAS20569 P0117, P0118 EAS33049 TROUBLESHOOTING Item • [P0117] Coolant temperature sensor: short to ground circuit is detected. Normal signal is not received from the coolant temperature sensor circuit. • [P0118] Coolant temperature sensor: short to power circuit is detected. Normal signal is not received from the coolant temperature sensor circuit.
  • Page 612 P0117, P0118 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 613 P0117, P0118 Disconnect the ECU related connectors before checking. Refer to “PARTS CONNECTED TO THE ECU” on page 9-4. Ground short circuit check “A” Between coolant temperature sensor coupler [P0117, P0118] green/white–ground “1” and ground Between wire harness coupler (sub-wire har- [P0117, P0118] green/white–ground ness side) “3”...
  • Page 614 P0117, P0118 Is check result OK? → Go to step 6. a. Reinstall or replace the sensor. b. Turn the main switch to “ON”, and then check the DTC using the malfunction mode of the YDT. Is it in the “Recovered” condition? →...
  • Page 615 P0122, P0123, P0222, P0223 EAS20813 P0122, P0123, P0222, P0223 EAS33050 TROUBLESHOOTING Item • [P0122] Throttle position sensor: short to ground circuit is detected. Normal signal is not received from the throttle position sensor circuit. • [P0123] Throttle position sensor: open or short to power circuit is detected. Normal signal is not re- ceived from the throttle position sensor circuit.
  • Page 616 P0122, P0123, P0222, P0223 3. Wire harness continuity. • Disconnect the throttle position sensor coupler “1” and ECU coupler “2”. • Open circuit check [P0122, P0123, P0222, P0223] white–white Between throttle position sensor coupler and [P0123, P0223] black/green–black/green ECU coupler [P0122, P0222] blue–blue [P0122, P0123, P0222, P0223] black–black Br/Y...
  • Page 617 P0122, P0123, P0222, P0223 Lines short circuit check “B” [P0122, P0123, P0222, P0223] white–any other coupler terminal [P0123, P0223] black/green–any other coupler Throttle position sensor coupler terminal [P0122, P0222] blue–any other coupler terminal [P0122, P0123, P0222, P0223] black–any other coupler terminal [P0122, P0123, P0222, P0223] white–any other coupler terminal [P0123, P0223] black/green–any other coupler...
  • Page 618 P0122, P0123, P0222, P0223 Is it in the “Recovered” condition? → Go to step 8, and complete the service. → Go to step 5. 5. Defective throttle position sensor. • Check throttle position sensor signal 1. • Execute the diagnostic mode. (Code 01) When the throttle valves are fully closed 11–21 When throttle valves are fully open...
  • Page 619 P0132 EAS20571 P0132 EAS33051 TROUBLESHOOTING Item sensor 1: short to power circuit is detected. Normal signal is not received from the O2 sensor 1. Fail-safe system • Able to start engine • Able to drive vehicle Procedure 1. Installed condition of O sensor 1.
  • Page 620 P0132 Is the coupler condition normal? → Go to step 4. a. Connect the coupler securely or replace the wire harness. b. Turn the main switch to “ON”, and then check the DTC using the malfunction mode of the YDT. Is it in the “Recovered”...
  • Page 621 P0132 Ground short circuit check “A” Between O sensor 1 coupler “1” and ground gray/green–ground Lines short circuit check “B” black/blue–any other coupler terminal sensor 1 coupler gray/green–any other coupler terminal black/blue–any other coupler terminal ECU coupler “2” gray/green–any other coupler terminal R/W P/B R/W P/B Gy/G B/L...
  • Page 622 P0152 EAS20572 P0152 EAS33052 TROUBLESHOOTING Item sensor 2: short to power circuit is detected. Normal signal is not received from the O sensor 2. Fail-safe system • Able to start engine • Able to drive vehicle Procedure 1. Installed condition of O sensor 2.
  • Page 623 P0152 Is the coupler condition normal? → Go to step 4. a. Connect the coupler securely or replace the wire harness. b. Turn the main switch to “ON”, and then check the DTC using the malfunction mode of the YDT. Is it in the “Recovered”...
  • Page 624 P0152 Ground short circuit check “A” Between O sensor 2 coupler “1” and ground gray/yellow–ground Lines short circuit check “B” black/blue–any other coupler terminal sensor 2 coupler gray/yellow–any other coupler terminal black/blue–any other coupler terminal ECU coupler “2” gray/yellow–any other coupler terminal R/W P/W R/W P/W Gy/Y B/L...
  • Page 625 P0201 EAS20574 P0201 EAS33054 TROUBLESHOOTING Item Fuel injector #1: malfunction in fuel injector #1. Normal signal is not received from the fuel injector cir- cuit. Fail-safe system • Able to start engine (depending on the number of faulty cylinder) • Able to drive vehicle (depending on the number of faulty cylinder) Procedure 1.
  • Page 626 P0201 Is the coupler condition normal? → Go to step 4. a. Connect the coupler securely or replace the wire harness. b. Execute the diagnostic mode. (Code 36) Is it hear operating sound? → Go to step 6. → Go to step 4. 4.
  • Page 627 P0201 Ground short circuit check “A” red/black–ground Between fuel injector #1 coupler “1” and ground red/blue–ground Lines short circuit check “B” red/black–any other coupler terminal Fuel injector #1 coupler red/blue–any other coupler terminal ECU coupler “2” red/black–any other coupler terminal Relay unit coupler “3”...
  • Page 628 P0202 EAS20575 P0202 EAS33055 TROUBLESHOOTING Item Fuel injector #2: malfunction in fuel injector #2. Normal signal is not received from the fuel injector cir- cuit. Fail-safe system • Able to start engine (depending on the number of faulty cylinder) • Able to drive vehicle (depending on the number of faulty cylinder) Procedure 1.
  • Page 629 P0202 Is the coupler condition normal? → Go to step 4. a. Connect the coupler securely or replace the wire harness. b. Execute the diagnostic mode. (Code 37) Is it hear operating sound? → Go to step 6. → Go to step 4. 4.
  • Page 630 P0202 Ground short circuit check “A” green/black–ground Between fuel injector #2 coupler “1” and ground red/blue–ground Lines short circuit check “B” green/black–any other coupler terminal Fuel injector #2 coupler red/blue–any other coupler terminal ECU coupler “2” green/black–any other coupler terminal Relay unit coupler “3”...
  • Page 631 P0203 EAS20576 P0203 EAS33056 TROUBLESHOOTING Item Fuel injector #3: malfunction in fuel injector #3. Normal signal is not received from the fuel injector cir- cuit. Fail-safe system • Able to start engine (depending on the number of faulty cylinder) • Able to drive vehicle (depending on the number of faulty cylinder) Procedure 1.
  • Page 632 P0203 Is the coupler condition normal? → Go to step 4. a. Connect the coupler securely or replace the wire harness. b. Execute the diagnostic mode. (Code 38) Is it hear operating sound? → Go to step 6. → Go to step 4. 4.
  • Page 633 P0203 Ground short circuit check “A” blue/black–ground Between fuel injector #3 coupler “1” and ground red/blue–ground Lines short circuit check “B” blue/black–any other coupler terminal Fuel injector #3 coupler red/blue–any other coupler terminal ECU coupler “2” blue/black–any other coupler terminal Relay unit coupler “3”...
  • Page 634 P0204 EAS20577 P0204 EAS33057 TROUBLESHOOTING Item Fuel injector #4: malfunction in fuel injector #4. Normal signal is not received from the fuel injector cir- cuit. Fail-safe system • Able to start engine (depending on the number of faulty cylinder) • Able to drive vehicle (depending on the number of faulty cylinder) Procedure 1.
  • Page 635 P0204 Is the coupler condition normal? → Go to step 4. a. Connect the coupler securely or replace the wire harness. b. Execute the diagnostic mode. (Code 39) Is it hear operating sound? → Go to step 6. → Go to step 4. 4.
  • Page 636 P0204 Ground short circuit check “A” orange/black–ground Between fuel injector #4 coupler “1” and ground red/blue–ground Lines short circuit check “B” orange/black–any other coupler terminal Fuel injector #4 coupler red/blue–any other coupler terminal ECU coupler “2” orange/black–any other coupler terminal Relay unit coupler “3”...
  • Page 637 P0335 EAS20578 P0335 EAS33058 TROUBLESHOOTING Item Crankshaft position sensor: normal signals are not received from the crankshaft position sensor. Fail-safe system • Unable to start engine • Unable to drive vehicle Procedure 1. Connection of crankshaft position sensor coupler. • Check the locking condition of the coupler. •...
  • Page 638 P0335 O/W Lg/L P/W P B/L Gy G/LGy/G Br/W Lg/B Gy/Y G/W G Gy/B Is resistance 0 Ω? → Go to “Short circuit check”. a. Replace the wire harness. b. Crank the engine, and then check the DTC using the malfunction mode of the YDT. Is it in the “Recovered”...
  • Page 639 P0335 Is resistance ∞ Ω? → Go to step 4. a. Replace the wire harness. b. Crank the engine, and then check the DTC using the malfunction mode of the YDT. Is it in the “Recovered” condition? → Go to step 7, and complete the service. →...
  • Page 640 P0340 EAS20579 P0340 EAS32839 TROUBLESHOOTING Item • Cylinder identification sensor: normal signal is not received from the cylinder identification sensor. Fail-safe system • Unable 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 641 P0340 3. Wire harness continuity. • Disconnect the cylinder identification sensor coupler “1” and ECU coupler “2”. • Open circuit check white/black–white/black Between cylinder identification sensor coupler blue–blue and ECU coupler black/blue–black/blue O/W Lg/L P/W P L W/B G/LGy/G Br/W Lg/B Gy/Y G/W G...
  • Page 642 P0340 Is it in the “Recovered” condition? → Go to step 7, and complete the service. → Go to step 6. 6. Malfunction in ECU. • Replace the ECU, and complete the service. Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-41. 7.
  • Page 643 P0351 EAS20580 P0351 EAS33060 TROUBLESHOOTING Item Cylinder-#1 ignition coil: open or short circuit is detected in the primary lead of the cylinder-#1 ignition coil. Normal signal is not received from the ignition circuit. Fail-safe system • Able to start engine (depending on the number of faulty cylinder) •...
  • Page 644 P0351 3. Wire harness continuity. • Disconnect the cylinder-#1 ignition coil coupler “1”, ECU coupler “2” and handlebar switch (right) coupler “3”. • Open circuit check Between cylinder-#1 ignition coil coupler and orange/blue–orange/blue ECU coupler Between cylinder-#1 ignition coil coupler and red/white–red/white handlebar switch (right) coupler “3”...
  • Page 645 P0351 O/L R/W O/L R/W Br/Y Lg/R G/Y Br/R R/L B/W Is resistance ∞ Ω? → Go to step 4. a. Replace the wire harness. b. Start the engine and let it idle for approximately 5 seconds. c. Check the DTC using the malfunction mode of the YDT. Is it in the “Recovered”...
  • Page 646 P0351 Is it in the “Recovered” condition? → Go to step 7, and complete the service. → Go to step 6. 6. Malfunction in ECU. • Execute the diagnostic mode. (Code 30) • Confirm that spark plug does not sparking. •...
  • Page 647 P0352 EAS20581 P0352 EAS33061 TROUBLESHOOTING Item Cylinder-#2 ignition coil: open or short circuit is detected in the primary lead of the cylinder-#2 ignition coil. Normal signal is not received from the ignition circuit. Fail-safe system • Able to start engine (depending on the number of faulty cylinder) •...
  • Page 648 P0352 3. Wire harness continuity. • Disconnect the cylinder-#2 ignition coil coupler “1”, ECU coupler “2” and handlebar switch (right) coupler “3”. • Open circuit check Between cylinder-#2 ignition coil coupler and gray–gray ECU coupler Between cylinder-#2 ignition coil coupler and red/white–red/white handlebar switch (right) coupler Br/Y...
  • Page 649 P0352 Gy R/W Gy R/W Br/Y Lg/R G/Y Br/R R/L B/W Is resistance ∞ Ω? → Go to step 4. a. Replace the wire harness. b. Start the engine and let it idle for approximately 5 seconds. c. Check the DTC using the malfunction mode of the YDT. Is it in the “Recovered”...
  • Page 650 P0352 Is it in the “Recovered” condition? → Go to step 7, and complete the service. → Go to step 6. 6. Malfunction in ECU. • Execute the diagnostic mode. (Code 31) • Confirm that spark plug does not sparking. •...
  • Page 651 P0353 EAS20582 P0353 EAS33062 TROUBLESHOOTING Item Cylinder-#3 ignition coil: open or short circuit is detected in the primary lead of the cylinder-#3 ignition coil. Normal signal is not received from the ignition circuit. Fail-safe system • Able to start engine (depending on the number of faulty cylinder) •...
  • Page 652 P0353 3. Wire harness continuity. • Disconnect the cylinder-#3 ignition coil coupler “1”, ECU coupler “2” and handlebar switch (right) coupler “3”. • Open circuit check Between cylinder-#3 ignition coil coupler and orange/blue–orange/blue ECU coupler Between cylinder-#3 ignition coil coupler and red/white–red/white handlebar switch (right) coupler Br/Y...
  • Page 653 P0353 O/L R/W O/L R/W Br/Y Lg/R G/Y Br/R R/L B/W Is resistance ∞ Ω? → Go to step 4. a. Replace the wire harness. b. Start the engine and let it idle for approximately 5 seconds. c. Check the DTC using the malfunction mode of the YDT. Is it in the “Recovered”...
  • Page 654 P0353 Is it in the “Recovered” condition? → Go to step 7, and complete the service. → Go to step 6. 6. Malfunction in ECU. • Execute the diagnostic mode. (Code 32) • Confirm that spark plug does not sparking. •...
  • Page 655 P0354 EAS20583 P0354 EAS33063 TROUBLESHOOTING Item Cylinder-#4 ignition coil: open or short circuit is detected in the primary lead of the cylinder-#4 ignition coil. Normal signal is not received from the ignition circuit. Fail-safe system • Able to start engine (depending on the number of faulty cylinder) •...
  • Page 656 P0354 3. Wire harness continuity. • Disconnect the cylinder-#4 ignition coil coupler “1”, ECU coupler “2” and handlebar switch (right) coupler “3”. • Open circuit check Between cylinder-#4 ignition coil coupler and gray–gray ECU coupler Between cylinder-#4 ignition coil coupler and red/white–red/white handlebar switch (right) coupler Br/Y...
  • Page 657 P0354 Gy R/W Gy R/W Br/Y Lg/R G/Y Br/R R/L B/W Is resistance ∞ Ω? → Go to step 4. a. Replace the wire harness. b. Start the engine and let it idle for approximately 5 seconds. c. Check the DTC using the malfunction mode of the YDT. Is it in the “Recovered”...
  • Page 658 P0354 Is it in the “Recovered” condition? → Go to step 7, and complete the service. → Go to step 6. 6. Malfunction in ECU. • Execute the diagnostic mode. (Code 33) • Confirm that spark plug does not sparking. •...
  • Page 659 P0475, P0476, P048B EAS20672 P0475, P0476, P048B EAS32841 TROUBLESHOOTING Item • [P0475] EXUP servo motor: performance deterioration. EXUP servo motor positioning signal changes slowly, when during it control. • [P0476] EXUP servo motor: stuck EXUP servo motor is detected. EXUP servo motor positioning sig- nal is not changed, when during it control.
  • Page 660 P0475, P0476, P048B Is it in the “Recovered” condition? → Go to step 7, and complete the service. → Go to step 3. 3. Wire harness continuity. • Disconnect the EXUP servo motor coupler “1” and ECU coupler “2”. • Open circuit check Between EXUP servo motor coupler and ECU black/green–black/green coupler...
  • Page 661 P0475, P0476, P048B Br/Y G B/G G B/G Is resistance ∞ Ω? → Go to step 4. a. Replace the wire harness. b. Turn the main switch to “ON”, and then check the DTC using the malfunction mode of the YDT. Is it in the “Recovered”...
  • Page 662 P0475, P0476, P048B Is it in the “Recovered” condition? → Go to step 7, and complete the service. → Go to step 6. a. Replace the exhaust chamber. Refer to “ENGINE REMOVAL” on page 5-11. b. Turn the main switch to “ON”, and then check the DTC using the malfunction mode of the YDT. Is it in the “Recovered”...
  • Page 663 P0480 EAS20585 P0480 EAS33065 TROUBLESHOOTING Item Radiator fan motor relay: open or short circuit is detected. Normal signal is not received from the radi- ator fan motor relay. Fail-safe system • Able to start engine • Able to drive vehicle Procedure 1.
  • Page 664 P0480 3. Wire harness continuity. • Disconnect the radiator fan motor relay “1”, ECU coupler “2” and ignition fuse “3”. • Open circuit check Between radiator fan motor relay and ignition red/white–red/white fuse holder Between radiator fan motor relay and ECU cou- green/yellow–green/yellow pler Lg/R...
  • Page 665 P0480 Lg/R G/Y Br/R R/L B/W Is resistance ∞ Ω? → Go to step 4. a. Replace the wire harness. b. Turn the main switch to “ON”, and then check the DTC using the malfunction mode of the YDT. Is it in the “Recovered” condition? →...
  • Page 666 P048D, P048E EAS20586 P048D, P048E EAS33066 TROUBLESHOOTING Item • [P048D] EXUP servo motor: open or short to ground circuit is detected. Normal signal is not received from the EXUP servo motor circuit to ECU. • [P048E] EXUP servo motor: short to power circuit is detected. Normal signal is not received from the EXUP servo motor circuit to ECU.
  • Page 667 P048D, P048E 3. Wire harness continuity. • Disconnect the EXUP servo motor coupler “1” and ECU coupler “2”. • Open circuit check blue–blue Between EXUP servo motor coupler and ECU white/yellow–white/yellow coupler black/blue–black/blue Br/Y O/W Lg/L P/W P G B/G G/LGy/G Br/W Lg/B...
  • Page 668 P048D, P048E Br/Y G B/G G B/G O/W Lg/L P/W P G/LGy/G Br/W Lg/B Gy/Y G/W G Gy/B Is resistance ∞ Ω? → Go to step 4. a. Replace the wire harness. b. Turn the main switch to “ON”, and then check the DTC using the malfunction mode of the YDT. Is it in the “Recovered”...
  • Page 669 P0500 (FI), P1500 EAS20674 P0500 (FI), P1500 EAS33303 TROUBLESHOOTING Item • [P0500 (FI)] Rear wheel sensor: open or short circuit is detected. Normal signal is not received from the rear wheel sensor or ABS unit to ECU. • [P1500] Neutral switch: open or short circuit is detected. Normal signal is not received from the rear wheel sensor to ECU when the gear-in •...
  • Page 670 P0500 (FI), P1500 b. Execute the diagnostic mode. (Code 21) When the transmission is in gear with the clutch lever squeezed and the sidestand retracted Is check result OK? → Go to step 20, and complete the service. → Go to step 14. Perform the procedure from step 14 to step 20.
  • Page 671 P0500 (FI), P1500 4. Connection of ECU coupler. • Check the locking condition of the coupler. • Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the pins). Is the coupler condition normal? → Go to step 5. a.
  • Page 672 P0500 (FI), P1500 Disconnect the ECU related connectors before checking. Refer to “PARTS CONNECTED TO THE ECU” on page 9-4. Ground short circuit check “A” black–ground Between ABS ECU coupler “2” and ground white–ground white/blue–ground Lines short circuit check “B” black–any other coupler terminal Rear wheel sensor coupler “1”...
  • Page 673 P0500 (FI), P1500 7. Malfunction in hydraulic unit assembly (ABS ECU). • Replace the hydraulic unit assembly (ABS ECU). Refer to “ABS (Anti-lock Brake System)” on page 4-63. • Go to step 20, and complete the service. 8. Connection of neutral switch coupler. •...
  • Page 674 P0500 (FI), P1500 10.Wire harness continuity. • Disconnect the relay unit coupler “1”, ECU coupler “2” and neutral switch coupler “3”. • Open circuit check Between relay unit coupler and ECU coupler black/yellow–black/yellow Between relay unit coupler and neutral switch sky blue–sky blue coupler O/W Lg/L...
  • Page 675 P0500 (FI), P1500 L/W L/Y Sb/W O/W Lg/L P/W P L/W L/Y Sb/W G/LGy/G Br/W Lg/B Gy/Y G/W G Gy/B Is resistance ∞ Ω? → Go to step 11. 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 676 P0500 (FI), P1500 Is check result OK? → Go to step 13. a. Replace the shift drum. Refer to “TRANSMISSION” on page 5-93. 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 20, and complete the service.
  • Page 677 P0500 (FI), P1500 Is it correct indication? → Go to step 20, and complete the service. → Go to step 16. 16.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).
  • Page 678 P0500 (FI), P1500 Is resistance 0 Ω? → Go to “Short circuit check”. a. Replace the wire harness. b. Execute the diagnostic mode. (Code 21) When the clutch lever is released with the transmission in gear and when the sidestand is retracted When the clutch lever is squeezed with the transmission in gear and when the sidestand is retracted Is it correct indication?
  • Page 679 P0500 (FI), P1500 When the clutch lever is released with the transmission in gear and when the sidestand is retracted When the clutch lever is squeezed with the transmission in gear and when the sidestand is retracted Is it correct indication? →...
  • Page 680 P0500 (SCU) EAS20588 P0500 (SCU) EAS33068 TROUBLESHOOTING Item Abnormal rear wheel sensor (Sensor value is not normal.) Fail-safe system • Able to start engine • Able to drive vehicle Procedure 1. Abnormal rear wheel sensor (Sensor value is not normal.) •...
  • Page 681 P0560 (FI), P0563 EAS20675 P0560 (FI), P0563 EAS33304 TROUBLESHOOTING Item • [P0560 (FI)] Battery charging voltage is abnormal. Poor charging performance (Discharged condi- tion). Vehicle system power voltage is abnormal. (Regulator is not operated properly or battery is not charged properly.) •...
  • Page 682 P0560 (SCU) EAS20593 P0560 (SCU) EAS33073 TROUBLESHOOTING Item Abnormal SCU power supply voltage. (Regulator is not operated properly or battery is not charged properly.) Fail-safe system • Able to start engine • Able to drive vehicle Procedure 1. Malfunction in charging system. •...
  • Page 683 P0564 EAS20594 P0564 EAS33074 TROUBLESHOOTING Item • Cruise control setting switch “RES+”: open or short circuit is detected. Normal signal is not sent to ECU. • Cruise control setting switch “SET–”: open or short circuit is detected. Normal signal is not sent to ECU.
  • Page 684 P0564 c. Confirm that it is defective. d. Go to step 6. Perform the procedure from step 6 to step 10. 3. Check the fuse. • Check the ignition fuse and cruise control fuse. Is check result OK? →Go to step 4. a.
  • Page 685 P0564 Is it in the “Recovered” condition? →Go to step 10, and complete the service. →Go to “Short circuit check”. • Short circuit check Disconnect the ECU related connectors before checking. Refer to “PARTS CONNECTED TO THE ECU” on page 9-4. Ground short circuit check “A”...
  • Page 686 P0564 Is it in the “Recovered” condition? →Go to step 10, and complete the service. →Go to step 9. 6. Check the fuse. • Check the main fuse, ignition fuse and cruise control fuse. Is check result OK? →Go to step 7. a.
  • Page 687 P0564 Is resistance 0 Ω? →Go to “Short circuit check”. a. Replace the wire harness. b. Turn the main switch to “ON”. c. Push and “SET–” side of the cruise control setting switch, and then check the DTC using the malfunction mode of the YDT.
  • Page 688 P0564 Is it in the “Recovered” condition? →Go to step 10, and complete the service. →Go to step 8. 8. Defective cruise control setting switch. • Replace the handlebar switch (left). • Turn the main switch to “ON”. • Push the “RES+” side and “SET–” side of the cruise control setting switch, and then check the DTC using the malfunction mode of the YDT.
  • Page 689 P056C EAS20595 P056C EAS33075 TROUBLESHOOTING Item • Front brake light switch: open or short circuit is detected. Normal signal is not sent to ECU. • Rear brake light switch: open or short circuit is detected. Normal signal is not sent to ECU. Fail-safe system •...
  • Page 690 P056C Is it in the “Recovered” condition? →Go to step 11, and complete the service. →Go to step 3. 3. Check the fuse. • Check the signaling system fuse and brake light fuse. Is check result OK? →Go to step 4. a.
  • Page 691 P056C G/W Y/B O/W Lg/L P/W P G/LGy/G Br/W R/W Br Br Br Lg/B Gy/Y G/W G Gy/B Y/B G/Y Lg/L Lg/B Lg/B Is resistance 0 Ω? →Go to “Short circuit check”. a. Replace the wire harness. b. Turn the main switch to “ON”. c.
  • Page 692 P056C G/W Y/B G/W Y/B O/W Lg/L P/W P G/LGy/G Br/W Lg/B Lg/B Gy/Y G/W G Gy/B Lg/B R/W Br Br Br Y/B G/Y Lg/L Lg/B Is resistance ∞ Ω? →Go to step 5. a. Replace the wire harness. b. Turn the main switch to “ON”. c.
  • Page 693 P056C Is it in the “Recovered” condition? →Go to step 11, and complete the service. →Go to step 7. 7. Check the fuse. • Check the signaling system fuse and brake light fuse. Is check result OK? →Go to step 8. a.
  • Page 694 P056C G/W Y/B O/W Lg/L P/W P G/LGy/G Br/W R/W Br Br Br Lg/B Gy/Y G/W G Gy/B Y/B G/Y Lg/L Lg/B Lg/B Is resistance 0 Ω? →Go to “Short circuit check”. a. Replace the wire harness. b. Turn the main switch to “ON”. c.
  • Page 695 P056C G/W Y/B G/W Y/B O/W Lg/L P/W P G/LGy/G Br/W Lg/B Lg/B Gy/Y G/W G Gy/B Lg/B R/W Br Br Br Y/B G/Y Lg/L Lg/B Is resistance ∞ Ω? →Go to step 9. a. Replace the wire harness. b. Turn the main switch to “ON”. c.
  • Page 696 P0601 EAS20676 P0601 EAS33305 TROUBLESHOOTING Item ROM error. Internal malfunction in ECU. (When this malfunction is detected in the ECU, the DTC might not appear on the tool display.) Fail-safe system • Unable to start engine • Unable to drive vehicle Procedure 1.
  • Page 697 P0606 EAS20677 P0606 EAS33306 TROUBLESHOOTING Item Processor error. Internal malfunction in ECU. (When this malfunction is detected in the ECU, the DTC might not appear on the tool display.) Fail-safe system • Able/Unable to start engine (depending on the situation) •...
  • Page 698 P062F EAS20598 P062F EAS33078 TROUBLESHOOTING Item EEPROM DTC: an error is detected while reading or writing on EEPROM. Fail-safe system • Able/Unable to start engine (depending on the situation) • Able/Unable to drive vehicle (depending on the situation) Procedure 1. Locate the malfunction. •...
  • Page 699 P0638 EAS20599 P0638 EAS33079 TROUBLESHOOTING Item YCC-T drive system: malfunction detected. Fail-safe system • Able to start engine (depending on the situation) • Able to drive vehicle (depending on the situation) Procedure 1. Connection of throttle servo motor coupler. • Check the locking condition of the coupler. •...
  • Page 700 P0638 3. Check the electronic throttle valve fuse. Is check result OK? → Go to step 4. a. Replace the electronic throttle valve fuse. b. Turn the main switch to “ON”, and then check the DTC using the malfunction mode of the YDT. Is it in the “Recovered”...
  • Page 701 P0638 Ground short circuit check “A” yellow/red–ground Between ECU coupler “2” and ground light green/red–ground red/blue–ground Lines short circuit check “B” yellow/red–any other coupler terminal Throttle servo motor coupler “1” light green/red–any other coupler terminal yellow/red–any other coupler terminal ECU coupler light green/red–any other coupler terminal red/blue–any other coupler terminal Lg/R...
  • Page 702 P0638 6. Malfunction in ECU. • Replace the ECU, and complete the service. Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-41. 7. Delete the DTC and check that the MIL goes off. • Confirm that the DTC has a condition of “Recovered” using the YDT, and then delete the DTC. 9-222...
  • Page 703 P0657 EAS20601 P0657 EAS33081 TROUBLESHOOTING Item Fuel system voltage: incorrect voltage supplied to the fuel injector, fuel pump and relay unit. Fail-safe system • Able to start engine • Able to drive vehicle Procedure If more than one DTC is detected at the same time, perform troubleshooting of DTC listed below first. •...
  • Page 704 P0657 3. Connection of ECU coupler. • Check the locking condition of the coupler. • Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the pins). Is the coupler condition normal? → Go to step 4. a.
  • Page 705 P0657 Is it in the “Recovered” condition? → Go to step 8, and complete the service. → Go to “Short circuit check”. • Short circuit check Disconnect the ECU related connectors before checking. Refer to “PARTS CONNECTED TO THE ECU” on page 9-4. Ground short circuit check “A”...
  • Page 706 P0657 Is it in the “Recovered” condition? → Go to step 8, and complete the service. → Go to step 5. 5. Defective relay unit. • Execute the diagnostic mode. (Code 50) • Check the operating sound of the relay. Is check result OK? →...
  • Page 707 P0916, P0917 EAS20611 P0916, P0917 EAS33091 TROUBLESHOOTING Item • [P0916] Gear position sensor: open or short to ground circuit is detected. Normal signal is not received from the gear position sensor to ECU. • [P0917] Gear position sensor: short to power circuit is detected. Normal signal is not received from the gear position sensor to ECU.
  • Page 708 P0916, P0917 3. Wire harness continuity. • Disconnect the gear position sensor coupler “1” and ECU coupler “2”. • Open circuit check white–white Between gear position sensor coupler and ECU green–green coupler blue/red–blue/red O/W Lg/L P/W P G/LGy/G Br/W L/R G W Lg/B Gy/Y G/W G...
  • Page 709 P0916, P0917 L/R G W O/W Lg/L P/W P L/R G W G/LGy/G Br/W Lg/B Gy/Y G/W G Gy/B Is resistance ∞ Ω? → Go to step 4. a. Replace the wire harness. b. Turn the main switch to “ON”, and then check the DTC using the malfunction mode of the YDT. Is it in the “Recovered”...
  • Page 710 P0916, P0917 Is it in the “Recovered” condition? → Go to step 7, and complete the service. → Go to step 6. 6. Malfunction in ECU. • Replace the ECU, and complete the service. Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-41. 7.
  • Page 711 P1400 EAS20612 P1400 EAS33092 TROUBLESHOOTING Item Air induction system solenoid: open or short to ground circuit is detected. Normal signal is not received from the air induction system solenoid. Fail-safe system • Able to start engine • Able to drive vehicle Procedure 1.
  • Page 712 P1400 Is it in the “Recovered” condition? → Go to step 6, and complete the service. → Start the engine and check the status of the DTC. Is it in the “Recovered” condition? → Go to step 6, and complete the service. →...
  • Page 713 P1400 Check that the start/engine stop switch is turned to “ON” then. • Short circuit check Disconnect the ECU related connectors before checking. Refer to “PARTS CONNECTED TO THE ECU” on page 9-4. Ground short circuit check “A” Between air induction system solenoid coupler brown/red–ground “1”...
  • Page 714 P1400 4. Defective air induction system solenoid. • Check the air induction system solenoid. Refer to “CHECKING THE AIR INDUCTION SYSTEM SOLENOID” on page 8-48. • Turn the main switch to “ON”, and then check the DTC using the malfunction mode of the YDT. Is it in the “Recovered”...
  • Page 715 P1600 EAS20613 P1600 EAS33093 TROUBLESHOOTING Item Lean angle sensor: open or short circuit is detected. Normal signal is not received from IMU or defective IMU. Fail-safe system • Unable to start engine • Unable to drive vehicle Procedure If more than one DTC is detected at the same time, perform troubleshooting of DTC listed below first. •...
  • Page 716 P1600 3. Wire harness continuity. • Disconnect the ECU coupler “1”, joint coupler “2”, IMU coupler “3” and signaling system fuse “4”. • Open circuit check blue/white–blue/white Between ECU coupler and joint coupler blue/black–blue/black blue/white–blue/white Between joint coupler and IMU coupler blue/black–blue/black Between ECU coupler and IMU coupler black/white–black/white...
  • Page 717 P1600 Ground short circuit check “A” blue/white–ground Between ECU coupler “1” and ground blue/black–ground blue/white–ground Between IMU coupler “3” and ground blue/black–ground red/white–ground Lines short circuit check “B” blue/white–any other coupler terminal ECU coupler black/black–any other coupler terminal blue/white–any other coupler terminal Joint coupler “2”...
  • Page 718 P1600 Is it in the “Recovered” condition? → Go to step 7, and complete the service. → Go to step 4. 4. Installed condition of IMU. • Check the installed direction and condition of the sensor. • Check the grommet for cracks. Is check result OK? →...
  • Page 719 P1601 EAS20614 P1601 EAS33094 TROUBLESHOOTING Item Sidestand switch: open or short circuit in wire harness of the ECU is detected. Normal signal is not re- ceived from the sidestand switch. Fail-safe system • Unable to start engine • Unable to drive vehicle Procedure 1.
  • Page 720 P1601 Is the coupler condition normal? → Go to step 4. a. Connect the coupler securely or replace the wire harness. b. Turn the main switch to “ON”, and then extend and retract the sidestand. c. Check the DTC using the malfunction mode of the YDT. Is it in the “Recovered”...
  • Page 721 P1601 Is resistance 0 Ω? → Go to “Short circuit check”. a. Replace the wire harness. b. Turn the main switch to “ON”, and then extend and retract the sidestand. c. Check the DTC using the malfunction mode of the YDT. Is it in the “Recovered”...
  • Page 722 P1601 Is resistance ∞ Ω? → Go to step 6. a. Replace the wire harness. b. Turn the main switch to “ON”, and then extend and retract the sidestand. c. Check the DTC using the malfunction mode of the YDT. Is it in the “Recovered”...
  • Page 723 P1602 EAS20615 P1602 EAS33095 TROUBLESHOOTING Item Malfunction in ECU internal circuit (malfunction of ECU power cut-off function). Fail-safe system • Able/Unable to start engine (depending on the situation) • Able/Unable to drive vehicle (depending on the situation) Procedure 1. Installed condition of battery leads. •...
  • Page 724 P1602 Is the coupler condition normal? → Go to step 4. a. Connect the coupler securely or replace the wire harness. b. Turn the main switch to “ON”, and then check the DTC using the malfunction mode of the YDT. Is it in the “Recovered”...
  • Page 725 P1602 Lg/R G/Y Br/R R/L B/W Br/L Br/R Br/Y Is resistance 0 Ω? → Go to “Short circuit check”. a. Replace the wire harness. b. Turn the main switch to “ON”, and then check the DTC using the malfunction mode of the YDT. Is it in the “Recovered”...
  • Page 726 P1602 Br/Y Lg/R Lg/R G/Y Br/R G/Y Br/R R/L B/W R/L B/W Br/Y Br/L Br/L Br/R Br/R Is resistance ∞ Ω? → Go to step 6. a. Replace the wire harness. b. Turn the main switch to “ON”, and then check the DTC using the malfunction mode of the YDT. Is it in the “Recovered”...
  • Page 727 P1806, P1807 EAS20623 P1806, P1807 EAS33103 TROUBLESHOOTING Item • [P1806] Shift sensor: open or short to ground circuit is detected. Normal signal is not received from the shift sensor to ECU. • [P1807] Shift sensor: short to power circuit is detected. Normal signal is not received from the shift sensor to ECU.
  • Page 728 P1806, P1807 3. Wire harness continuity • Disconnect the shift sensor coupler “1” and ECU coupler “2”. • Open circuit check black/blue–black/blue Between shift sensor coupler and ECU coupler violet–violet blue–blue O/W Lg/L P/W P B/L V L G/LGy/G Br/W Lg/B Gy/Y G/W G...
  • Page 729 P1806, P1807 B/L V L B/L V L O/W Lg/L P/W P G/LGy/G Br/W Lg/B Gy/Y G/W G Gy/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 auxiliary system warning. Is the auxiliary system warning off? →...
  • Page 730 P1806, P1807 Is check result OK? → Go to step 6. a. Replace the shift sensor. Refer to “CHAIN DRIVE” on page 4-113. b. Turn the main switch to “ON”, and then check the condition of the auxiliary system warning. Is the auxiliary system warning off? →...
  • Page 731 P2122, P2123, P2127, P2128, P2138 EAS20632 P2122, P2123, P2127, P2128, P2138 EAS33112 TROUBLESHOOTING Item • [P2122] Accelerator position sensor: open or short to ground circuit is detected. Normal signal is not received from the accelerator position sensor. • [P2123] Accelerator position sensor: short to power circuit is detected. Normal signal is not received from the accelerator position sensor.
  • Page 732 P2122, P2123, P2127, P2128, P2138 Is it in the “Recovered” condition? → Go to step 6, and complete the service. → Go to step 3. 3. Wire harness continuity. • Disconnect the accelerator position sensor coupler “1” and ECU coupler “2”. •...
  • Page 733 P2122, P2123, P2127, P2128, P2138 Ground short circuit check “A” [P2122, P2123, P2127, P2128, P2138] white– ground Between accelerator position sensor coupler “1” [P2122, P2123, P2127, P2128, P2138] black– and ground ground [P2122, P2127] blue/yellow–ground [P2122, P2127] blue–ground Lines short circuit check “B” [P2122, P2123, P2127, P2128, P2138] white–...
  • Page 734 P2122, P2123, P2127, P2128, P2138 Is it in the “Recovered” condition? → Go to step 6, and complete the service. → Go to step 4. 4. Defective accelerator position sensor. • Execute the diagnostic mode. (Code 14) (Accelerator position sensor signal 1.) When the throttle valves are fully closed 14–18 When the throttle valves are fully open...
  • Page 735 P2135 EAS20812 P2135 EAS33652 TROUBLESHOOTING Item Throttle position sensor: output voltage deviation error. Normal signal is not received from the throttle position sensor circuit. Fail-safe system • Able to start engine (depending on the situation) • Able to drive vehicle (depending on the situation) Procedure If more than one DTC is detected at the same time, perform troubleshooting of DTC listed below first.
  • Page 736 P2135 3. Connection of ECU coupler. • Check the locking condition of the coupler. • Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the pins). Is the coupler condition normal? → Go to step 4. a.
  • Page 737 P2135 Is it in the “Recovered” condition? → Go to step 8, and complete the service. → Go to step 6. 6. Defective throttle position sensor. • Check throttle position sensor signal 2. • Execute the diagnostic mode. (Code 13) When the throttle valves are fully closed 9–23 When throttle valves are fully open...
  • Page 738 P2158 (FI) EAS20633 P2158 (FI) EAS33113 TROUBLESHOOTING Item Front wheel sensor: normal signal is not received from the front wheel sensor. Fail-safe system • Able to start engine • Able to drive vehicle Procedure 1. Locate the malfunction. • Check the ABS warning light. Is the ABS warning light on? →...
  • Page 739 P2158 (FI) Is the coupler condition normal? → Go to step 5. a. Connect the coupler securely or replace the wire harness. b. Execute the diagnostic mode. (Code 16) c. Rotate the front wheel by hand and check that the indicated value increases. Is that value increased? →...
  • Page 740 P2158 (FI) Is resistance 0 Ω? → Go to “Short circuit check”. a. Replace the wire harness. b. Execute the diagnostic mode. (Code 16) c. Rotate the front wheel by hand and check that the indicated value increases. Is that value increased? →...
  • Page 741 P2158 (FI) Gy/B L Y G Br/B B L/W G/O W/L L B W W L/B Gy/B L Y G Br/B B L/W G/O W/L L B W W L/B O/W Lg/L P/W P G/LGy/G Br/W Lg/B Gy/Y G/W G Gy/B Is resistance ∞...
  • Page 742 P2158 (FI) Is that value increased? → Go to step 10, and complete the service. → Go to step 8. 8. Malfunction in ECU. • Replace the ECU. Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-41. • Execute the diagnostic mode. (Code 16) •...
  • Page 743 P2158 (SCU) EAS20634 P2158 (SCU) EAS33114 TROUBLESHOOTING Item Abnormal front wheel sensor. (Sensor value is not normal.) Fail-safe system • Able to start engine • Able to drive vehicle Procedure 1. Abnormal front wheel sensor. (Sensor value is not normal.) •...
  • Page 744 P2228, P2229 EAS20641 P2228, P2229 EAS33121 TROUBLESHOOTING Item • [P2228] Atmospheric pressure sensor: short to ground circuit is detected. Normal signal is not re- ceived from the atmospheric pressure sensor. • [P2229] Atmospheric pressure sensor: open or short to power circuit is detected. Normal signal is not received from the atmospheric pressure sensor.
  • Page 745 P2228, P2229 3. Wire harness continuity. • Disconnect the atmospheric pressure sensor coupler “1” and ECU coupler “2”. • Open circuit check [P2228, P2229] pink–pink Between atmospheric pressure sensor coupler [P2228] blue–blue and ECU coupler [P2229] black/blue–black/blue O/W Lg/L P/W P B/L P L G/LGy/G Br/W...
  • Page 746 P2228, P2229 B/L P L B/L P L O/W Lg/L P/W P G/LGy/G Br/W Lg/B Gy/Y G/W G Gy/B Is resistance ∞ Ω? → Go to step 4. a. Replace the wire harness. b. Turn the main switch to “ON”, and then check the DTC using the malfunction mode of the YDT. Is it in the “Recovered”...
  • Page 747 P2228, P2229 Is check result OK? → Go to step 6. a. Replace the atmospheric pressure sensor. Refer to “AIR INDUCTION SYSTEM” on page 7-18. b. Turn the main switch to “ON”, and then check the DTC using the malfunction mode of the YDT. Is it in the “Recovered”...
  • Page 748 U0100 EAS20644 U0100 EAS33124 TROUBLESHOOTING Item Abnormal CAN communication (between ECU and SCU) Fail-safe system • Able to start engine • Able to drive vehicle Procedure 1. 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).
  • Page 749 U0100 Br/W P/L G/B W/R W/B O/W Lg/L P/W P G/LGy/G Br/W Lg/B Gy/Y G/W G Gy/B L/W L/W L/W L/W L/W L/W L/R L/R L/B L/B L/B L/B L/B L/B *. MT10SPN/MT10SPNC Is resistance 0 Ω? → Go to “Short circuit check”. a.
  • Page 750 U0100 Br/W Br/W P/L G/B P/L G/B W/R W/B W/R W/B O/W Lg/L P/W P O/W Lg/L P/W P G/LGy/G Br/W G/LGy/G Br/W Lg/B Gy/Y G/W G Gy/B Lg/B Gy/Y G/W G Gy/B L/W L/W L/W L/W L/W L/W L/R L/R L/B L/B L/B L/B L/B L/B *.
  • Page 751 U0121 EAS20646 U0121 EAS33126 TROUBLESHOOTING Item Abnormal CAN communication (between ABS ECU and SCU) Fail-safe system • Able to start engine • Able to drive vehicle Procedure 1. Connection of ABS ECU coupler. • Check the locking condition of the coupler. •...
  • Page 752 U0121 Br/W P/L G/B W/R W/B Gy/B L Y G Br/B B L/W G/O W/L L B W W L/B L/W L/W L/W L/W L/W L/W L/R L/R L/B L/B L/B L/B L/B L/B *. MT10SPN/MT10SPNC Is resistance 0 Ω? →...
  • Page 753 U0121 Br/W Br/W P/L G/B P/L G/B W/R W/B W/R W/B Gy/B L Y G Br/B B L/W Gy/B L Y G Br/B B L/W G/O W/L L B W W L/B G/O W/L L B W W L/B L/W L/W L/W L/W L/W L/W L/R L/R L/B L/B L/B L/B L/B L/B *.
  • Page 754 U0125 (FI) EAS20647 U0125 (FI) EAS33127 TROUBLESHOOTING Item Signals cannot be transmitted between the ECU and the IMU. Fail-safe system • Unable to start engine • Able/Unable to drive vehicle (depending on the situation) Procedure If more than one DTC is detected at the same time, perform troubleshooting of DTC listed below first. •...
  • Page 755 U0125 (FI) blue/white–blue/white Between ECU coupler and joint coupler blue/black–blue/black blue/white–blue/white Between joint coupler and IMU coupler blue/black–blue/black Between IMU coupler and signaling system red/white–brown fuse holder Between IMU coupler and ECU coupler black/white–black/white Lg/R G/Y Br/R R/L B/W O/W Lg/L P/W P G/LGy/G Br/W...
  • Page 756 U0125 (FI) Lines short circuit check “B” blue/white–any other coupler terminal ECU coupler blue/black–any other coupler terminal blue/white–any other coupler terminal Joint coupler “2” blue/black–any other coupler terminal blue/white–any other coupler terminal IMU coupler blue/black–any other coupler terminal red/white–any other coupler terminal O/W Lg/L P/W P O/W Lg/L...
  • Page 757 U0125 (FI) 4. Malfunction in IMU. • Replace the IMU. Refer to “GENERAL CHASSIS (1)” on page 4-1. • Turn the main switch to “ON”, and then check the DTC using the malfunction mode of the YDT. Is it in the “Recovered” condition? →...
  • Page 758 U0125 (SCU) EAS20648 U0125 (SCU) EAS33128 TROUBLESHOOTING Item Abnormal CAN communication (between IMU and SCU) Fail-safe system • Able to start engine • Able to drive vehicle Procedure 1. Connection of IMU coupler. • Check the locking condition of the coupler. •...
  • Page 759 U0125 (SCU) Br/W P/L G/B W/R W/B L/W L/W L/W L/W L/W L/W L/R L/R L/B L/B L/B L/B L/B L/B *. MT10SPN/MT10SPNC Is resistance 0 Ω? → Go to “Short circuit check”. a. Replace the wire harness. b. Turn the main switch to “OFF” and back to “ON”, and then check the DTC using the malfunction mode of the YDT.
  • Page 760 U0125 (SCU) Br/W Br/W P/L G/B P/L G/B W/R W/B W/R W/B L/W L/W L/W L/W L/W L/W L/R L/R L/B L/B L/B L/B L/B L/B *. MT10SPN/MT10SPNC Is resistance ∞ Ω? → Go to step 3. a. Replace the wire harness. b.
  • Page 761 U0155 or Err (FI) EAS20649 U0155 or Err (FI) EAS33129 TROUBLESHOOTING Item Multi-function meter: signals cannot be transmitted between the ECU and the multi-function meter. Fail-safe system • Able to start engine • Able to drive vehicle Procedure “Err” is displayed on the clock display of the multi-function meter, but the MIL does not come on. 1.
  • Page 762 U0155 or Err (FI) 3. Wire harness continuity. • Disconnect the meter assembly coupler “1”, joint coupler “2” and ECU coupler “3”. • Open circuit check Between meter assembly coupler and joint cou- blue/white–blue/white pler blue/black–blue/black blue/white–blue/white Between joint coupler and ECU coupler blue/black–blue/black B/W R/W Br/W Br/B...
  • Page 763 U0155 or Err (FI) Lines short circuit check “B” blue/white–any other coupler terminal Meter assembly coupler blue/black–any other coupler terminal blue/white–any other coupler terminal Joint coupler “2” blue/black–any other coupler terminal blue/white–any other coupler terminal ECU coupler blue/black–any other coupler terminal B/W R/W Br/W Br/B Dg Ch W/L W/Y...
  • Page 764 U0155 or Err (FI) 5. Malfunction in ECU. • Replace the ECU, and complete the service. Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-41. 6. Delete the DTC and check that the MIL goes off. • Confirm that the DTC has a condition of “Recovered” using the YDT, and then delete the DTC. 9-284...
  • Page 765 U0155 or Err (SCU) EAS20650 U0155 or Err (SCU) EAS33130 TROUBLESHOOTING Item Abnormal CAN communication (between meter assembly and SCU) Fail-safe system • Able to start engine • Able to drive vehicle Procedure 1. Connection of meter assembly coupler. • Check the locking condition of the coupler. •...
  • Page 766 U0155 or Err (SCU) Br/W B/W R/W Br/W Br/B Dg Ch W/L W/Y Br/Y L/B G/W P/L G/B R/GR/G Sb/W G/L G/Y G G/B W/B W/G G/O Y W/R W/B L/W L/W L/W L/W L/W L/W L/R L/R L/B L/B L/B L/B L/B L/B *.
  • Page 767 U0155 or Err (SCU) Br/W Br/W P/L G/B P/L G/B W/R W/B W/R W/B B/W R/W Br/W Br/B Dg Ch W/L W/Y Br/Y L/B G/W B/W R/W Br/W Br/B Dg Ch W/L W/Y Br/Y L/B G/W R/GR/G Sb/W G/L G/Y G G/B W/B W/G G/O Y R/GR/G Sb/W G/L G/Y...
  • Page 768 11_ABS EAS20685 11_ABS EAS33314 TROUBLESHOOTING Item Front wheel sensor (intermittent pulses or no pulses) Procedure If the rear wheel continues to turn for more than 20 seconds after the front wheel has stopped, this will be recorded. 1. Foreign material adhered around the front wheel sensor •...
  • Page 769 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 770 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 771 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 772 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 773 15_ABS Ground short circuit check “A” white–ground Between ABS ECU coupler “1” and ground black–ground Lines short circuit check “B” white–any other coupler terminal ABS ECU coupler black–any other coupler terminal Gy/B L Y G Br/B B L/W Gy/B L Y G Br/B B L/W G/O W/L L B W W L/B G/O W/L L B W W L/B Is resistance ∞...
  • Page 774 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 775 16_ABS Ground short circuit check “A” white–ground Between ABS ECU coupler “1” and ground black–ground Lines short circuit check “B” white–any other coupler terminal ABS ECU coupler black–any other coupler terminal Gy/B L Y G Br/B B L/W Gy/B L Y G Br/B B L/W G/O W/L L B W W L/B G/O W/L L B W W L/B Is resistance ∞...
  • Page 776 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 4-63. 9-296...
  • Page 777 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 8-40. Is check result OK? → Go to step 2. →...
  • Page 778 31_ABS Disconnect the ABS ECU related connectors before checking. Refer to “PARTS CONNECTED TO THE ABS ECU” on page 9-5. Ground short circuit check “A” Between ABS ECU coupler “2” and ground red–ground Lines short circuit check “B” ABS ECU coupler red–any other coupler terminal Gy/B L Y G Br/B B L/W Gy/B L Y G Br/B B L/W...
  • Page 779 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 8-40. Is check result OK? → Go to step 2. →...
  • Page 780 33_ABS • Short circuit check Disconnect the ABS ECU related connectors before checking. Refer to “PARTS CONNECTED TO THE ABS ECU” on page 9-5. 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 Gy/B L Y G Br/B B L/W...
  • Page 781 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 4-63. 9-301...
  • Page 782 41_ABS EAS20694 41_ABS EAS33331 TROUBLESHOOTING Item Front wheel ABS (intermittent wheel speed pulses or incorrect depressurization) Procedure 1. Incorrect installation of the front wheel sensor • Check the components for looseness, distortion, and bends. Refer to “MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR” on page 4- Is check result OK? →...
  • Page 783 42_ABS EAS20695 42_ABS EAS33324 TROUBLESHOOTING Item Rear wheel ABS (intermittent wheel speed pulses or incorrect depressurization) Procedure 1. Incorrect installation of the rear wheel sensor • Check the components for looseness, distortion, and bends. Refer to “MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR” on page 4- Is check result OK? →...
  • Page 784 43, 45_ABS EAS20696 43, 45_ABS EAS33330 TROUBLESHOOTING Item Front wheel sensor (missing pulses) Procedure After the DTC 45 is recorded, DTC 43 will be recorded if a certain speed and time are exceeded. 1. Foreign material adhered around the front wheel sensor •...
  • Page 785 44, 46_ABS EAS20697 44, 46_ABS EAS33325 TROUBLESHOOTING Item Rear wheel sensor (missing pulses) Procedure After the DTC 46 is recorded, DTC 44 will be recorded if a certain speed and time are exceeded. 1. Foreign material adhered around the rear wheel sensor •...
  • Page 786 51_ABS EAS20698 51_ABS EAS33326 TROUBLESHOOTING Item Vehicle system power supply (voltage of ABS ECU power supply is high) Procedure 1. Defective battery • Recharge or replace the battery, and check again. Refer to “CHECKING AND CHARGING THE BATTERY” on page 8-41. 2.
  • Page 787 53_ABS EAS20699 53_ABS EAS33327 TROUBLESHOOTING Item Vehicle system power supply (voltage of ABS ECU power supply is low) Procedure 1. Defective battery • Recharge or replace the battery, and check again. Refer to “CHECKING AND CHARGING THE BATTERY” on page 8-41. 2.
  • Page 788 53_ABS Ground short circuit check “A” Between ABS ECU coupler “2” and ground brown/black–ground Lines short circuit check “B” ABS ECU coupler brown/black–any other coupler terminal Gy/B L Y G Br/B B L/W Gy/B L Y G Br/B B L/W G/O W/L L B W W L/B G/O W/L L B W W L/B Is resistance ∞...
  • Page 789 55_ABS EAS20700 55_ABS EAS33328 TROUBLESHOOTING Item Hydraulic unit assembly (defective ABS ECU) Procedure 1. Defective hydraulic unit assembly • Replace the hydraulic unit assembly. Refer to “ABS (Anti-lock Brake System)” on page 4-63. 9-309...
  • Page 790 56_ABS EAS20701 56_ABS EAS33329 TROUBLESHOOTING Item Hydraulic unit assembly (abnormal internal circuit) Procedure 1. Defective hydraulic unit assembly • Replace the hydraulic unit assembly. Refer to “ABS (Anti-lock Brake System)” on page 4-63. 9-310...
  • Page 791 57_ABS EAS20666 57_ABS EAS33292 TROUBLESHOOTING Item Vehicle CAN communication line or power source of vehicle system Procedure 1. Wire harness continuity. • Disconnect the ECU coupler “1”, joint coupler “2” and ABS ECU coupler “3”. • Open circuit check blue/white–blue/white Between ECU coupler and joint coupler blue/black–blue/black Between the joint coupler and ABS ECU cou-...
  • Page 792 57_ABS Ground short circuit check “A” blue/white–ground Between ECU coupler “1” and ground blue/black–ground blue/white–ground Between ABS ECU coupler “3” and ground blue/black–ground Lines short circuit check “B” blue/white–any other coupler terminal ECU coupler blue/black–any other coupler terminal blue/white–any other coupler terminal Joint coupler “2”...
  • Page 793 57_ABS Is check result OK? → Go to step 4. → If there is a malfunction, repair it and connect the coupler securely. 4. Wire harness continuity • Disconnect the ABS ECU fuse “1”, ABS solenoid fuse “2” and ABS ECU coupler “3”. •...
  • Page 794 57_ABS Gy/B L Y G Br/B B L/W Gy/B L Y G Br/B B L/W G/O W/L L B W W L/B G/O W/L L B W W L/B Is resistance ∞ Ω? → Go to step 5. → Replace the wire harness. 5.
  • Page 795 62_ABS EAS20702 62_ABS EAS33333 TROUBLESHOOTING Item Power supply voltage failure in pressure sensor Procedure 1. Defective hydraulic unit assembly • Replace the hydraulic unit assembly. Refer to “ABS (Anti-lock Brake System)” on page 4-63. 9-315...
  • Page 796 68_ABS EAS20705 68_ABS EAS33336 TROUBLESHOOTING Item Defective hydraulic unit assembly (defective front pressure sensor) Procedure 1. Defective front brake line • Check the front brake line. Is check result OK? → Go to step 2. → If there is bending or blocking, replace the front brake line. 2.
  • Page 797 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 798 89_ABS • Short circuit check Disconnect the ABS ECU related connectors before checking. Refer to “PARTS CONNECTED TO THE ABS ECU” on page 9-5. Ground short circuit check “A” Between meter assembly coupler “1” and blue/white–ground ground blue/black–ground blue/white–ground Between ABS ECU coupler “3” and ground blue/black–ground Lines short circuit check “B”...
  • Page 799 89_ABS 4. Defective hydraulic unit assembly • Replace the hydraulic unit assembly. Refer to “ABS (Anti-lock Brake System)” on page 4-63. 9-319...
  • Page 800 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 801 90_ABS Is resistance 0 Ω? → Go to “Short circuit check”. → Replace the wire harness. • Short circuit check Disconnect the ECU and ABS ECU related connectors before checking. Refer to “PARTS CONNECTED TO THE ECU” on page 9-4 and “PARTS CONNECTED TO THE ABS ECU”...
  • Page 802 90_ABS 3. Defective ECU • Replace the ECU, and check again. Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-41. 4. Defective hydraulic unit assembly • Replace the hydraulic unit assembly. Refer to “ABS (Anti-lock Brake System)” on page 4-63. 9-322...
  • Page 803 91_ABS EAS20671 91_ABS EAS33301 TROUBLESHOOTING Item CAN communication (between IMU and hydraulic unit assembly) Procedure 1. Defective coupler between the IMU and the hydraulic unit assembly • Check the coupler for any pins that may be pulled out. • Check the locking condition of the coupler. Turn the main switch to “OFF”...
  • Page 804 91_ABS • Short circuit check Disconnect the ABS ECU related connectors before checking. Refer to “PARTS CONNECTED TO THE ABS ECU” on page 9-5. Ground short circuit check “A” blue/white–ground Between IMU coupler “1” and ground blue/black–ground blue/white–ground Between ABS ECU coupler “3” and ground blue/black–ground Lines short circuit check “B”...

  • Page 805: Wiring Diagram

    54. Coolant temperature sensor 103.Front fork stepping motor (left) EAS20091 WIRING DIAGRAM 55. Intake air temperature sensor (compression damping) (for MT10SPN/MT10SPNC) 56. ECU (Engine Control Unit) MT10N/MT10NC/MT10SPN/ 57. Ignition coil #1 104.Front fork stepping motor MT10SPNC 2022 58. Ignition coil #2 (right) (rebound damping) (for 1.

  • Page 806: Color Code

    EAS30613 Yellow/Black COLOR CODE Yellow/Green Black Yellow/Blue Brown Yellow/Red Chocolate Yellow/White Dark green Green Gray Blue Light green Pink Sky blue Violet White Yellow Black/Green Black/Blue Black/Red Black/White Black/Yellow Br/B Brown/Black Br/L Brown/Blue Br/R Brown/Red Br/W Brown/White Br/Y Brown/Yellow Green/Black Green/Blue Green/Orange Green/Red...
  • Page 809 MT10N/MT10NC/MT10SPN/MT10SPNC 2022 WIRING DIAGRAM Br/W B R/WR/W L/W L/B Br/W R/W R/W R/W R/W R/W R/L R/L G/W B/L R/W R/W R/L R/L B/W R/W L/W L/B R/WR/W W W W (Gy) O/L R/W W W W Gy R/W W W W Br/L Br/L Br/R...
  • Page 810 MT10N/MT10NC/MT10SPN/MT10SPNC 2022 WIRING DIAGRAM (Gy) (Gy) (Gy) START 10 11 (Gy) (Dl) (Gy) (Gy) 14 13 (Dl) (Gy) 17 16 21 20 FREE PUSH PUSH FREE DOWN PASS (Gy) (Gy) (Gy) (Gy)

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