Yamaha MT-03 2016 Service Manual
  1. Manuals
  2. Brands
  3. Yamaha Manuals
  4. Motorcycle
  5. MT-03 2016
  6. Service manual
Yamaha MT-03 2016 Service Manual

Yamaha MT-03 2016 Service Manual

Hide thumbs
1
2
3
4
5
6
Table Of Contents
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
140
141
142
143
144
145
146
147
148
149
150
151
152
153
154
155
156
157
158
159
160
161
162
163
164
165
166
167
168
169
170
171
172
173
174
175
176
177
178
179
180
181
182
183
184
185
186
187
188
189
190
191
192
193
194
195
196
197
198
199
200
201
202
203
204
205
206
207
208
209
210
211
212
213
214
215
216
217
218
219
220
221
222
223
224
225
226
227
228
229
230
231
232
233
234
235
236
237
238
239
240
241
242
243
244
245
246
247
248
249
250
251
252
253
254
255
256
257
258
259
260
261
262
263
264
265
266
267
268
269
270
271
272
273
274
275
276
277
278
279
280
281
282
283
284
285
286
287
288
289
290
291
292
293
294
295
296
297
298
299
300
301
302
303
304
305
306
307
308
309
310
311
312
313
314
315
316
317
318
319
320
321
322
323
324
325
326
327
328
329
330
331
332
333
334
335
336
337
338
339
340
341
342
343
344
345
346
347
348
349
350
351
352
353
354
355
356
357
358
359
360
361
362
363
364
365
366
367
368
369
370
371
372
373
374
375
376
377
378
379
380
381
382
383
384
385
386
387
388
389
390
391
392
393
394
395
396
397
398
399
400
401
402
403
404
405
406
407
408
409
410
411
412
413
414
415
416
417
418
419
420
421
422
423
424
425
426
427
428
429
430
431
432
433
434
435
436
437
438
439
440
441
442
443
444
445
446
447
448
449
450
451
452
453
454
455
456
457
458
459
460
461
462
463
464
465
466
467
468
469
470
471
472
473
474
475
476
477
478
479
Table of Contents

Advertisement

Quick Links

Download this manual
2016
SERVICE MANUAL
MTN320-A
B08-F8197-E0

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the MT-03 2016 and is the answer not in the manual?

Questions and answers

Related Manuals for Yamaha MT-03 2016

Summary of Contents for Yamaha MT-03 2016

  • Page 1 2016 SERVICE MANUAL MTN320-A B08-F8197-E0...
  • Page 2 EAS20002 MTN320-A SERVICE MANUAL ©2015 by PT Yamaha Indonesia Motor Manufacturing First edition, November 2015 All rights reserved. Any reproduction or unauthorized use without the written permission of PT Yamaha Indonesia Motor Manufacturing is expressly prohibited.

  • Page 3: Important Manual Information

    This manual was produced by the PT Yamaha Indonesia Motor Manufacturing primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a me- chanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles.

  • Page 4: 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 explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. •...
  • Page 5 EAS20005 SYMBOLS The following symbols are used in this manual for easier understanding. The following symbols are not relevant to every vehicle. SYMBOL DEFINITION SYMBOL DEFINITION Serviceable with engine mounted Gear oil Filling fluid Molybdenum disulfide oil Lubricant Brake fluid Special tool Wheel bearing grease Tightening torque...

  • Page 7: Table Of Contents

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

  • Page 9: General Information

    GENERAL INFORMATION IDENTIFICATION .................... 1-1 VEHICLE IDENTIFICATION NUMBER .............1-1 MODEL LABEL..................1-1 FEATURES...................... 1-2 MULTI-FUNCTION METER UNIT ............. 1-2 IMPORTANT INFORMATION ................. 1-7 PREPARATION FOR REMOVAL AND DISASSEMBLY......1-7 REPLACEMENT PARTS................1-7 GASKETS, OIL SEALS AND O-RINGS ............ 1-7 LOCK WASHERS/PLATES AND COTTER PINS ........1-7 BEARINGS AND OIL SEALS ..............

  • Page 10: Identification

    IDENTIFICATION EAS20007 IDENTIFICATION EAS30002 VEHICLE IDENTIFICATION NUMBER The vehicle identification number “1” is stamped into the frame under the passenger seat. 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: Features

    FEATURES EAS20008 FEATURES EAS30982 Tachometer MULTI-FUNCTION METER UNIT km/h km/L L/100km 1. Tachometer 2. Tachometer red zone 1. “SEL” button The tachometer allows the rider to monitor the 2. “RES” button engine speed and keep it within the ideal power 3.
  • Page 12 FEATURES [To set the clock] Coolant temperature meter 1. Turn the key to “ ”. 2. Push the “SEL” button and “RES” button to- gether for at least two seconds. 3. When the hour digits start flashing, push the “RES” button to set the hours. 4.
  • Page 13 FEATURES Multi-function display If you do not reset the fuel reserve tripmeter manually, it resets itself automatically and the display returns to the prior mode after refueling and traveling 5 km (3 mi). Instantaneous fuel consumption display 1. Multi-function display The multi-function display is equipped with the following: •...
  • Page 14 FEATURES This display shows the average fuel consump- Shift timing indicator light tion since it was last reset. • “AVE_ _._ km/L”: The average distance that can be traveled on 1.0 L of fuel is shown. • “AVE_ _._ L/100 km”: The average amount of fuel necessary to travel 100 km is shown.
  • Page 15 FEATURES 2. Push the “SEL” button to confirm the selected 1. Push the “RES” button to select the desired flashing pattern. The shift timing indicator engine speed for deactivating the indicator light changes to the activation point setting light. mode. 2.

  • Page 16: Important Information

    5. Keep all parts away from any source of fire. EAS30007 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace- ments. Use oil and grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but...

  • Page 17: Bearings And Oil Seals

    IMPORTANT INFORMATION EAS30010 EAS30012 BEARINGS AND OIL SEALS RUBBER PARTS Install bearings “1” and oil seals “2” so that the Check rubber parts for deterioration during in- manufacturer marks or numbers are visible. spection. Some of the rubber parts are sensitive When installing oil seals, lubricate the oil seal to gasoline, flammable oil, grease, etc.

  • Page 18: Basic Service Information

    BASIC SERVICE INFORMATION EAS20010 BASIC SERVICE INFORMATION EAS30013 QUICK FASTENERS Rivet type 1. Remove: • Quick fastener To remove the quick fastener, push its pin with a screwdriver, then pull the fastener out. Screw type 1. Remove: • Quick fastener To remove the quick fastener, loosen the screw with a screwdriver, then pull the fastener out.

  • Page 19: Electrical System

    BASIC SERVICE INFORMATION ECA16760 EAS30014 NOTICE ELECTRICAL SYSTEM Be sure to connect the battery leads to the correct battery terminals. Reversing the bat- Electrical parts handling tery lead connections could damage the ECA16600 NOTICE electrical components. Never disconnect a battery lead while the en- gine is running;...
  • Page 20 BASIC SERVICE INFORMATION ECA16620 Checking the electrical system NOTICE Handle electrical components with special Before checking the electrical system, make care, and do not subject them to strong shocks. sure that the battery voltage is at least 12 V. ECA16630 ECA14371 NOTICE NOTICE...
  • Page 21 BASIC SERVICE INFORMATION 2. Check: Checking the connections • Lead Check the leads, couplers, and connectors for • Coupler stains, rust, moisture, etc. • Connector 1. Disconnect: Moisture → Dry with an air blower. • Lead Rust/stains → Connect and disconnect sev- •...
  • Page 22 BASIC SERVICE INFORMATION • As a quick remedy, use a contact revitalizer available at most part stores. 4. Connect: • Lead • Coupler • Connector • When connecting a coupler or connector, push both sections of the coupler or connector to- gether until they are connected securely.
  • Page 23 BASIC SERVICE INFORMATION 1-14...

  • Page 24: Special Tools

    8-127, 8-128, 8-129, 8-129, 8-130 Thickness gauge 3-6, 3-6, 4-25, 90890-03180 4-34, 5-54 Feeler gauge set YU-26900-9 Valve lapper 90890-04101 90890-04101 Valve lapping tool YM-A8998 YM-A8998 Yamaha diagnostic tool 3-8, 3-11, 4-66, 90890-03231 4-67, 7-13, 7-13, 8-36, 8-86, 8-108 1-15...
  • Page 25 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Vacuum gauge 90890-03094 Vacuummate YU-44456 YU-44456 Carburetor angle driver 2 90890-03173 Steering nut wrench 3-19, 4-85 90890-01403 Exhaust flange nut wrench YU-A9472 Oil filter wrench 3-22, 5-73 90890-01426 Oil filter wrench YU-38411 Damper rod holder 4-77, 4-79 90890-01460...
  • Page 26 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Fork seal driver attachment (ø41) 4-80, 4-80 90890-01381 Replacement 41 mm YM-A5142-2 Extension 90890-04136 Compression gauge 90890-03081 90890-03081 Engine compression tester YU-33223 YU-33223 Rotor holding tool 5-16, 5-18 90890-01235 Universal magneto and rotor holder YU-01235 Valve spring compressor 5-28, 5-33...
  • Page 27 Rotor holding tool 5-43, 5-43, 5-44, 90890-04166 5-45 YM-04166 Flywheel puller 5-43 90890-01404 Flywheel puller YM-01404 Yamaha bond No. 1215 5-45, 5-74, 5-75 90890-85505 (Three bond No.1215®) Digital circuit tester 5-48, 8-126 90890-03174 Model 88 Multimeter with tachometer YU-A1927 Universal clutch holder...
  • Page 28 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Radiator cap tester 90890-01325 Mityvac cooling system tester kit YU-24460-A YU-24460-A Radiator cap tester adapter 90890-01352 Pressure tester adapter YU-33984 YU-33984 Mechanical seal installer 90890-04145 ø30 ø10 Middle driven shaft bearing driver 90890-04058 Middle drive bearing installer 40 &...
  • Page 29 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Ignition checker 8-125 90890-06754 Oppama pet–4000 spark checker YM-34487 Test harness– lean angle sensor (6P) 8-125 90890-03209 Test harness– lean angle sensor (6P) YU-03209 1-20...
  • Page 30 SPECIAL TOOLS 1-21...

  • Page 31: Specifications

    SPECIFICATIONS GENERAL SPECIFICATIONS ................ 2-1 ENGINE SPECIFICATIONS ................2-2 CHASSIS SPECIFICATIONS ................2-7 ELECTRICAL SPECIFICATIONS ..............2-10 TIGHTENING TORQUES ................2-12 GENERAL TIGHTENING TORQUE SPECIFICATIONS......2-12 ENGINE TIGHTENING TORQUES............2-13 CHASSIS TIGHTENING TORQUES............2-18 LUBRICATION POINTS AND LUBRICANT TYPES ........2-22 ENGINE....................2-22 CHASSIS....................2-24 LUBRICATION SYSTEM CHART AND DIAGRAMS........

  • Page 32: General Specifications

    GENERAL SPECIFICATIONS EAS20013 GENERAL SPECIFICATIONS Model Model B081 (AUS,NZL) B082 (EUR) B083 (GBR) B084 (RUS) Dimensions Overall length 2090 mm (82.3 in) Overall width 745 mm (29.3 in) Overall height 1035 mm (40.7 in) Seat height 780 mm (30.7 in) Wheelbase 1380 mm (54.3 in) Ground clearance...

  • Page 33: Engine Specifications

    ENGINE SPECIFICATIONS EAS20014 ENGINE SPECIFICATIONS Engine Engine type Liquid cooled 4–stroke, DOHC Displacement 321 cm³ Cylinder arrangement Inline 2–cylinder Bore × stroke 68.0 × 44.1 mm (2.68 × 1.74 in) Compression ratio 11.2 : 1 Compression pressure 1252–1612 kPa/390 r/min (12.5–16.1 kgf/cm²/390 r/min, 178.2–229.4 psi/390 r/min) Starting system Electric starter...
  • Page 34 ENGINE SPECIFICATIONS Radiator core Width 145.8 mm (5.74 in) Height 270.0 mm (10.63 in) Depth 24.0 mm (0.94 in) Water pump Water pump type Single suction centrifugal pump Reduction ratio 41/23 (1.783) Spark plug(s) Manufacturer/model NGK/CR8E Spark plug gap 0.7–0.8 mm (0.028–0.031 in) Cylinder head Combustion chamber volume 10.80–11.60 cm³...
  • Page 35 ENGINE SPECIFICATIONS Valve stem runout 0.010 mm (0.0004 in) Valve spring Free length (intake) 38.21 mm (1.50 in) Limit 36.30 mm (1.43 in) Free length (exhaust) 38.21 mm (1.50 in) Limit 36.30 mm (1.43 in) Installed length (intake) 32.00 mm (1.26 in) Installed length (exhaust) 32.00 mm (1.26 in) Spring rate K1 (intake)
  • Page 36 ENGINE SPECIFICATIONS Oil ring End gap (installed) 0.10–0.35 mm (0.0039–0.0138 in) Connecting rod Oil clearance 0.036–0.060 mm (0.0014–0.0024 in) Bearing color code 1. Blue 2. Black 3. Brown 4. Green Crankshaft Runout limit 0.030 mm (0.0012 in) Journal oil clearance 0.021–0.045 mm (0.0008–0.0018 in) Bearing color code 1.Blue 2.Black 3.Brown 4.Green 5.Yellow...
  • Page 37 ENGINE SPECIFICATIONS Fuel pump Pump type Electrical Maximum consumption amperage 1.7 A Fuel injector Model/quantity 2370/2 Throttle body Type/quantity SE 32EHDW-2B/1 ID mark 2MS2 00 Throttle position sensor Output voltage (at idle) 0.63–0.73 V Fuel injection sensor 192–288 Ω Crankshaft position sensor resistance Intake air pressure sensor output voltage 3.88–4.12 V at 101.3 kPa (3.88–4.12 V at 1.01 kgf/cm², 3.88–4.12 V at 14.7 psi)

  • Page 38: Chassis Specifications

    CHASSIS SPECIFICATIONS EAS20015 CHASSIS SPECIFICATIONS Chassis Frame type Diamond Caster angle 25.0 ° Trail 95 mm (3.7 in) Front wheel Wheel type Cast wheel Rim size 17M/C x MT2.75 Rim material Aluminum Wheel travel 130 mm (5.1 in) Radial wheel runout limit 1.0 mm (0.04 in) Lateral wheel runout limit 0.5 mm (0.02 in)
  • Page 39 CHASSIS SPECIFICATIONS Brake pad lining thickness (outer) 5.3 mm (0.21 in) Limit 0.8 mm (0.03 in) Master cylinder inside diameter 11.00 mm (0.43 in) Caliper cylinder inside diameter 26.99 mm (1.06 in) Caliper cylinder inside diameter 26.99 mm (1.06 in) Specified brake fluid DOT 4 Rear brake...
  • Page 40 CHASSIS SPECIFICATIONS Drive chain Size/manufacturer 520VF/DAIDO Number of links 15-link length limit 239.3 mm (9.42 in) Drive chain slack 35.0–45.0 mm (1.38–1.77 in) Drive chain slack (fully extension of rear suspension) 40.0–50.0 mm (1.57–1.97 in)

  • Page 41: Electrical Specifications

    ELECTRICAL SPECIFICATIONS EAS20016 ELECTRICAL SPECIFICATIONS Voltage System voltage 12 V Ignition system Ignition system Ignition timing (B.T.D.C.) 5.0 °/1400 r/min Engine control unit Model/manufacturer TBDFR0/DENSO Ignition coil Minimum ignition spark gap 6.0 mm (0.24 in) 2.16–2.64 Ω Primary coil resistance Secondary coil resistance 8.64–12.96 kΩ...
  • Page 42 ELECTRICAL SPECIFICATIONS Oil pressure warning light High beam indicator light Engine trouble warning light Shift timing indicator light ABS warning light Starter motor Power output 0.40 kW 0.0630–0.0770 Ω Armature coil resistance Brush overall length 7.0 mm (0.28 in) Limit 3.00 mm (0.12 in) Brush spring force 6.08–9.12 N (620–930 gf, 21.89–32.83 oz)

  • Page 43: Tightening Torques

    TIGHTENING TORQUES EAS20017 TIGHTENING TORQUES EAS30015 GENERAL TIGHTENING TORQUE SPECIFICATIONS This chart specifies tightening torques for stan- dard fasteners with a standard ISO thread pitch. Tightening torque specifications for special com- ponents or assemblies are provided for each chapter of this manual. To avoid warpage, tight- en multi-fastener assemblies in a crisscross pat- tern and progressive stages until the specified tightening torque is reached.

  • Page 44: Engine Tightening Torques

    TIGHTENING TORQUES EAS30016 ENGINE TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Air filter case joint clamp screw 2.5 Nm (0.25 m·kgf, 1.8 ft·lbf) Air filter case bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Air filter case side cover screw (left) 2.5 Nm (0.25 m·kgf, 1.8 ft·lbf) Air filter case side cover screw (right) 1.3 Nm (0.13 m·kgf, 0.94 ft·lbf)
  • Page 45 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Clutch spring bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Clutch cover bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Clutch cable holder bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Shift shaft spring stopper 22 Nm (2.2 m·kgf, 16 ft·lbf) Oil pump cover screw 2.0 Nm (0.20 m·kgf, 1.4 ft·lbf)
  • Page 46 Tighten the crankcase bolts “1”–“21” in the proper tightening sequence as follows: 1. Lubricate the crankcase bolts “1”–“15” and “17”–“21” threads, mating surfaces with the engine oil. 2. Lubricate the mating surface of the bolt “16” with engine oil and apply Yamaha bond No. 1215 to the bolt threads.
  • Page 47 TIGHTENING TORQUES 5. Tighten the crankcase bolts “7”–“8” to 20 Nm (2.0 m·kgf, 14 ft·lbf). 6. Loosen and retighten the crankcase bolts “7”–“8” to 26 Nm (2.6 m·kgf, 19 ft·lbf) in the proper tight- ening sequence (after loosening a bolt, retighten it before loosening the next bolt). 7.
  • Page 48 TIGHTENING TORQUES ×3 ×2 ×3 ×3 A. Lower crankcase B. Upper crankcase Connecting rod bolt 1. Lubricate the connecting rod bolts threads and connecting rod nuts mating surface with molybde- num disulfide oil. 2. Tighten the connecting rod bolts to 15 Nm (1.5 m·kgf, 11 ft·lbf), and then tighten them further to reach the specified angle 145–155°.

  • Page 49: Chassis Tightening Torques

    TIGHTENING TORQUES EAS30017 CHASSIS TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Engine mounting nut (rear upper 68 Nm (6.8 m·kgf, 49 ft·lbf) side) Sidestand bracket bolt 66 Nm (6.6 m·kgf, 48 ft·lbf) Engine mounting nut (rear lower 68 Nm (6.8 m·kgf, 49 ft·lbf) side) Engine mounting bolt (right front 68 Nm (6.8 m·kgf, 49 ft·lbf)
  • Page 50 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Headlight assembly bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Headlight side cover bolt (upper) 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Headlight side cover bolt (lower) 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Headlight bracket screw 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf) Front brake hose holder bolt...
  • Page 51 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Rear brake hose union bolt (hydrau- 29 Nm (2.9 m·kgf, 21 ft·lbf) lic unit side) Rear brake light switch bracket bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Footrest assembly bolt 30 Nm (3.0 m·kgf, 22 ft·lbf) Rear brake master cylinder bolt 23 Nm (2.3 m·kgf, 17 ft·lbf) Rear brake pedal bolt...
  • Page 52 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Drive sprocket cover bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Drive sprocket nut 75 Nm (7.5 m·kgf, 54 ft·lbf) Shift arm pinch bolt 14 Nm (1.4 m·kgf, 10 ft·lbf) Shift rod locknut (shift arm side) 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Left-hand Shift rod locknut (shift pedal side)

  • Page 53: Lubrication Points And Lubricant Types

    LUBRICATION POINTS AND LUBRICANT TYPES EAS20018 LUBRICATION POINTS AND LUBRICANT TYPES EAS30018 ENGINE Lubrication point Lubricant Bearings O-rings Oil seal lips Cylinder head bolt seats, cylinder head bolt threads and washers Crankshaft big ends Connecting rod bolts Generator rotor bolt thread and washer Crankshaft journals Balancer gear and damper Balancer shaft journals...
  • Page 54 LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant Shift fork and transmission gear contact surface Shift drum assembly Shift forks and shift fork guide bars Shift shaft moving surface Shift shaft washer 2-23...

  • Page 55: Chassis

    LUBRICATION POINTS AND LUBRICANT TYPES EAS30019 CHASSIS Lubrication point Lubricant Steering bearings and bearing races (upper and lower) Throttle grip inner surface and throttle cable end Brake lever pivotting point and metal-to-metal moving parts Clutch lever pivotting point and metal-to-metal moving parts Clutch cable end Swingarm pivot shaft spacer Swingarm pivot shaft bearings...

  • Page 56: Lubrication System Chart And Diagrams

    LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20019 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS30020 ENGINE OIL LUBRICATION CHART 2-25...
  • Page 57 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil strainer 2. Oil pump 3. Relief valve 4. Oil filter cartridge 5. Sub gallery 6. Oil pressure switch 7. Main gallery 8. Crankshaft 9. Oil nozzle 10. Balancer shaft assembly 11. Timing chain tensioner 12.

  • Page 58: Lubrication Diagrams

    LUBRICATION SYSTEM CHART AND DIAGRAMS EAS30021 LUBRICATION DIAGRAMS Crankcase, cylinder, and cylinder head (right side view) 2-27...
  • Page 59 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Timing chain tensioner 2. Intake camshaft 3. Exhaust camshaft 4. Crankshaft 5. Balancer shaft assembly 6. Oil filter cartridge 7. Oil strainer 8. Oil pump 9. Transmission shower 2-28...
  • Page 60 LUBRICATION SYSTEM CHART AND DIAGRAMS Crankcase and cylinder (left side view) 2-29...
  • Page 61 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Crankshaft 2. Balancer shaft assembly 3. Connecting rod 4. Oil drain bolt 5. Oil filter cartridge 6. Oil pressure switch 2-30...
  • Page 62 LUBRICATION SYSTEM CHART AND DIAGRAMS Oil pump (right side view) 2-31...
  • Page 63 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil pump 2. Relief valve 2-32...
  • Page 64 LUBRICATION SYSTEM CHART AND DIAGRAMS Oil strainer (bottom view) 2-33...
  • Page 65 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Main gallery 2. Oil filter cartridge 3. Sub gallery 4. Oil strainer 2-34...
  • Page 66 LUBRICATION SYSTEM CHART AND DIAGRAMS Camshaft (top view) 2-35...
  • Page 67 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Intake camshaft 2. Exhaust camshaft 3. Cylinder head 2-36...
  • Page 68 LUBRICATION SYSTEM CHART AND DIAGRAMS Crankshaft (rear view) 2-37...
  • Page 69 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Crankshaft 2. Oil nozzle 3. Piston 4. Main gallery 5. Sub gallery 2-38...

  • Page 71: Cable Routing

    CABLE ROUTING 1. Throttle cable (accelerator cable) 2. Throttle cable (decelerator cable) 3. Front brake hose (brake master cylinder to hose joint) 4. Wire harness 5. Clutch cable 6. Handlebar switch lead (right handlebar switch) 7. Main switch lead 8. Ignition coil lead 9.
  • Page 72 CABLE ROUTING Engine (right side view) 2-47...
  • Page 73 CABLE ROUTING 1. Engine bracket (right) 2. Engine mounting bolt (right upper side) 3. Fuel tank overflow hose 4. Clutch cable 5. O sensor lead 6. Negative battery sub-wire harness coupler 7. Coolant temperature sensor coupler 8. Starter motor lead 9.
  • Page 74 CABLE ROUTING Rear fender (right side view) 2-49...
  • Page 75 CABLE ROUTING 1. Fuse box lead 2. Rear wheel sensor lead 3. Rear brake light switch coupler 4. Rear brake light switch lead 5. Down tube 6. Rear wheel sensor coupler 7. Fuel tank overflow hose 8. Stay 9. Engine stay 10.
  • Page 76 CABLE ROUTING Handlebar (left side view) 2-51...
  • Page 77 CABLE ROUTING 1. Headlight lead 2. Headlight bracket 3. Horn lead 4. Upper bearing cover 5. Handlebar switch lead (left handlebar switch) 6. Throttle cable (accelerator cable) 7. Throttle cable (decelerator cable) 8. Front wheel sensor lead 9. Front brake hose (brake hose joint to front brake caliper) 10.
  • Page 78 CABLE ROUTING Engine (left side view) 2-53...
  • Page 79 CABLE ROUTING 1. Sidestand switch lead K. After fixing the band, push lead to the inside of the vehicle from the face of insertion part of recovery 2. Coolant temperature sensor lead tank. 3. Coolant reservoir hose L. Route the gear position switch lead negative 4.
  • Page 80 CABLE ROUTING Rear fender (left side view) 2-55...
  • Page 81 3 mm (0.12 in) or less. 5. Starter relay coupler N. Insert the projection on the wire harness holder 6. Yamaha diagnostic tool coupler into the hole in the rear fender. 7. Tail/brake light lead O. Fasten the starter motor lead and negative battery 8.
  • Page 82 CABLE ROUTING Handlebar (top view) 2-57...
  • Page 83 CABLE ROUTING 1. Clutch cable 2. Horn lead 3. Front turn signal light lead (left turn signal light) 4. Headlight lead 5. Front turn signal light connector (left turn signal light) 6. Auxiliary light coupler 7. Front turn signal light connector (right turn signal light) 8.
  • Page 84 CABLE ROUTING Engine (top view) 2-59...
  • Page 85 CABLE ROUTING 1. Wire harness 2. Throttle cable (accelerator cable) 3. Front brake hose (brake hose joint to brake caliper) 4. Front brake hose (brake master cylinder to brake hose joint) 5. Fuel tank overflow hose 6. Negative battery sub-wire harness 7.
  • Page 86 CABLE ROUTING Rear fender (top view) 13 11 2-61...
  • Page 87 ECU (engine control unit). C. Route the rear turn signal light leads, license plate light lead, and Yamaha diagnostic tool coupler lead through the guide on the rear fender. D. Fasten the wire harness to the frame with a plastic locking tie.
  • Page 89 CABLE ROUTING 1. Radiator 2. Radiator outlet hose 3. Coolant reservoir hose 4. Coolant reservoir cap 5. Coolant reservoir breather hose 6. Coolant reservoir 7. Radiator inlet hose 8. Coolant hose ° A. 13 B. Face the white paint mark on the coolant reservoir hose upward.
  • Page 90 CABLE ROUTING Radiator (left side view) 2-77...
  • Page 91 CABLE ROUTING 1. Coolant reservoir hose 2. Electrical components tray 3. Coolant reservoir cap 4. Coolant reservoir breather hose 5. Frame 6. Coolant reservoir 7. Thermostat cover 8. Radiator inlet hose 9. Radiator A. Insert the end of the coolant reservoir breather hose into the frame pipe.
  • Page 92 CABLE ROUTING Radiator (right side view) 2-79...
  • Page 93 CABLE ROUTING 1. Coolant reservoir hose 2. Radiator 3. Radiator outlet hose 4. Water pump housing A. Connect the end of the radiator outlet hose that is identified by the white paint mark to the radiator. B. Install the radiator outlet hose completely onto the hose fitting of the water pump housing.
  • Page 94 CABLE ROUTING 2-81...

  • Page 95: Periodic Checks And Adjustments

    PERIODIC CHECKS AND ADJUSTMENTS PERIODIC MAINTENANCE ................3-1 INTRODUCTION ..................3-1 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM ....................3-1 GENERAL MAINTENANCE AND LUBRICATION CHART .......3-1 CHECKING THE FUEL LINE ..............3-4 CHECKING THE SPARK PLUGS ............. 3-4 ADJUSTING THE VALVE CLEARANCE ..........3-5 CHECKING THE ENGINE IDLING SPEED ..........3-8 SYNCHRONIZING THE THROTTLE BODIES..........
  • Page 96 ADJUSTING THE REAR BRAKE LIGHT SWITCH .........3-26 CHECKING AND LUBRICATING THE CABLES ........3-26 CHECKING THE THROTTLE GRIP OPERATION .........3-26 CHECKING THE SWITCHES, LIGHTS AND SIGNALS ......3-27 REPLACING THE HEADLIGHT BULBS ..........3-27 ADJUSTING THE HEADLIGHT BEAM ...........3-29...

  • Page 98: Periodic Maintenance

    UK, a mileage-based maintenance, is performed instead. • From 50000 km (30000 mi), repeat the maintenance intervals starting from 10000 km (6000 mi). • Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
  • Page 99 PERIODIC MAINTENANCE ODOMETER READING CHECK OR MAINTENANCE ANNUAL ITEM CHECK 1000 km 10000 km 20000 km 30000 km 40000 km (600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi) • Check operation, fluid level √ √ √ √ √ √...
  • Page 100 PERIODIC MAINTENANCE ODOMETER READING CHECK OR MAINTENANCE ANNUAL ITEM CHECK 1000 km 10000 km 20000 km 30000 km 40000 km (600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi) • Check coolant level and vehi- √ √ √ √ √...

  • Page 101: Checking The Fuel Line

    PERIODIC MAINTENANCE EAS30619 CHECKING THE FUEL LINE Rear fuel tank bracket bolt 1. Remove: (frame) • Rider seat 12 Nm (1.2 m·kgf, 8.7 ft·lbf) Refer to “GENERAL CHASSIS (1)” on page Front fuel tank bracket bolt (frame) 4-1. 12 Nm (1.2 m·kgf, 8.7 ft·lbf) •...

  • Page 102: Adjusting The Valve Clearance

    PERIODIC MAINTENANCE • Insulator “2” Abnormal color → Replace the spark plug. Valve clearance adjustment should be made on Normal color is medium-to-light tan. a cold engine, at room temperature. 6. Clean: 1. Remove: • Spark plug • Rider seat (with a spark plug cleaner or wire brush) Refer to “GENERAL CHASSIS (1)”...
  • Page 103 PERIODIC MAINTENANCE • Measure the valve clearance in the following e. Measure the valve clearance #2 with a thick- sequence. ness gauge. Thickness gauge Valve clearance measuring sequence 90890-03180 Cylinder #1 → #2 Feeler gauge set YU-26900-9 ▲ ▲▲▲ ▲ ▲▲▲ ▲...
  • Page 104 PERIODIC MAINTENANCE Last digit Rounded value 3, 4, 5, 6 7, 8, 9 Refer to the following table for the available valve pads. Valve pad range No. 150–240 1.50–2.40 mm Valve pad thickness b. Calculate the difference between the speci- (0.0590–0.0944 in) fied valve clearance and the measured valve 19 thicknesses in 0.050...

  • Page 105: Checking The Engine Idling Speed

    ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect the Yamaha diagnostic tool. Use the diagnostic code number “67”. Refer to “SELF-DIAGNOSTIC FUNCTION 4. Install: AND DIAGNOSTIC CODE TABLE” on page • Vacuum gauge hose #1 “1” 9-5.
  • Page 106 PERIODIC MAINTENANCE • If a bypass air screw was removed, turn the screw in fully and be sure to synchronize the throttle bodies. • If the throttle body synchronization can not be adjusted using the bypass air screw, clean or replace the throttle bodies.

  • Page 107: Checking The Throttle Body Joint

    PERIODIC MAINTENANCE 5. Adjust: EAS30625 CHECKING THE EXHAUST SYSTEM • Throttle grip free play 1. Remove: Refer to “CHECKING THE THROTTLE GRIP • Coolant reservoir OPERATION” on page 3-26. Refer to “RADIATOR” on page 6-1. • Footrest assembly (right) Throttle grip free play Refer to “REAR BRAKE”...

  • Page 108: Adjusting The Exhaust Gas Volume

    For more information, refer to the opera- replace the air filter element. tion manual of the Yamaha diagnostic tool. 1. Connect the Yamaha diagnostic tool to the coupler. For information about connecting the Yamaha diagnostic tool, refer to “YAMAHA DIAGNOSTIC TOOL”...

  • Page 109: Adjusting The Clutch Lever Free Play

    PERIODIC MAINTENANCE 4. Check: 2. Adjust: • Air filter element • Clutch lever free play Damage → Replace. ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ Handlebar side The air filter needs more frequent service if you a.

  • Page 110: Checking The Brake Operation

    PERIODIC MAINTENANCE 1. Operate the brake. Clutch cable locknut 2. Check: 7 Nm (0.7 m·kgf, 5.1 ft·lbf) • Rear brake pad Wear indicator grooves “a” almost disap- peared → Replace the brake pads as a set. Refer to “REAR BRAKE” on page 4-47. ▲...

  • Page 111: Bleeding The Hydraulic Brake System (Abs)

    PERIODIC MAINTENANCE 3. Hold the vehicle upright and apply the rear brake several times. 4. Check: • Brake hose Brake fluid leakage → Replace the damaged hose. Refer to “REAR BRAKE” on page 4-47. EAS30637 BLEEDING THE HYDRAULIC BRAKE SYSTEM (ABS) EWA14000 WARNING Always bleed the brake system when the...

  • Page 112: Checking The Brake Fluid Level

    PERIODIC MAINTENANCE l. Tighten the bleed screw to specification. EWA13090 WARNING Brake caliper bleed screw • Use only the designated brake fluid. Other 6 Nm (0.6 m·kgf, 4.3 ft·lbf) brake fluids may cause the rubber seals to deteriorate, causing leakage and poor m.
  • Page 113 250 kPa (2.5 kgf/cm², 36 psi) en if a tire combination other than one Front (2 persons) approved by Yamaha is used on this vehicle. 200 kPa (2.00 kgf/cm², 29 psi) Rear (2 persons) Front tire 250 kPa (2.5 kgf/cm², 36 psi)

  • Page 114: Checking The Wheel Bearings

    PERIODIC MAINTENANCE • Install the tire with the mark pointing in the di- EAS30644 ADJUSTING THE DRIVE CHAIN SLACK rection of wheel rotation. ECA13550 • Align the mark “2” with the valve installation NOTICE point. 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.

  • Page 115: Lubricating The Drive Chain

    PERIODIC MAINTENANCE 4. Remove the drive chain puller cap “1”, and c. Tighten the wheel axle nut to specification. then loosen the axle nut “2”. Rear wheel axle nut 57 Nm (5.7 m·kgf, 41 ft·lbf) Apply lithium-soap-based grease to the contact surface and threads of the rear wheel axle nut.

  • Page 116: Lubricating The Steering Head

    PERIODIC MAINTENANCE 2. Check: EWA13140 WARNING • Steering head Do not overtighten the lower ring nut. Grasp the bottom of the front fork legs and gently rock the front fork. Blinding/looseness → Adjust the steering Lower ring nut (final tightening torque) head.

  • Page 117: Lubricating The Brake Lever

    PERIODIC MAINTENANCE Refer to “CHASSIS TIGHTENING TORQUES” 2. Check: on page 2-18. • Inner tube Damage/scratches → Replace. EAS30804 • Front fork leg LUBRICATING THE BRAKE LEVER Oil leaks between inner tube and outer tube Lubricate the pivoting point and metal-to-metal →...

  • Page 118: Checking The Engine Oil Level

    PERIODIC MAINTENANCE 2. Start the engine, warm it up for several min- utes, and then turn it off. 3. Check: • Engine oil level The engine oil level should be between the minimum level mark “a” and maximum level mark “b”. Below the minimum level mark →...

  • Page 119: Changing The Engine Oil

    PERIODIC MAINTENANCE EAS30657 CHANGING THE ENGINE OIL 1. Start the engine, warm it up for several min- utes, and then turn it off. 2. Place a container under the engine oil drain bolt. 3. Remove: • Bottom cowling Refer to “GENERAL CHASSIS (3)” on page 4-8.

  • Page 120: Checking The Coolant Level

    PERIODIC MAINTENANCE 8. Fill: e. Tighten the oil check bolts to specification. • Oil pan Engine oil check bolt (with the specified amount of the recom- 15 Nm (1.5 m·kgf, 11 ft·lbf) mended engine oil) ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲...

  • Page 121: Checking The Cooling System

    PERIODIC MAINTENANCE EAS30812 CHECKING THE COOLING SYSTEM 1. Check: • Radiator “1” • Radiator inlet hose “2” • Radiator outlet hose “3” • Thermostat cover “4” • Thermostat “5” Cracks/damage → Replace. Refer to “RADIATOR” on page 6-1, “THER- MOSTAT” on page 6-5 and “WATER PUMP” 3.
  • Page 122 PERIODIC MAINTENANCE 6. Drain: • If coolant comes into contact with painted • Coolant surfaces, immediately wash them with wa- (from the engine and radiator) ter. 7. Install: • Do not mix different types of antifreeze. • Coolant drain bolt 10.Install: (along with the copper washer •...

  • Page 123: Checking The Brake Light Switches

    PERIODIC MAINTENANCE EAS30660 CHECKING AND LUBRICATING THE Before checking the coolant level, wait a few CABLES minutes until the coolant has settled. The following procedure applies to all of the in- ner and outer cables. EAS30658 EWA13270 CHECKING THE BRAKE LIGHT SWITCHES WARNING 1.

  • Page 124: Checking The Switches, Lights And Signals

    PERIODIC MAINTENANCE 3. Check: • Throttle grip free play “a” Make sure that the adjusting nut is covered com- Out of specification → Adjust. pletely by the rubber cover. Throttle grip free play ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲...
  • Page 125 PERIODIC MAINTENANCE 8. Install: • Headlight bulb Secure the new headlight bulb with the head- light bulb holder. ECA13690 NOTICE Avoid touching the glass part of the head- light bulb to keep it free from oil, otherwise the transparency of the glass, the life of the bulb and the luminous flux will be adversely affected.

  • Page 126: Adjusting The Headlight Beam

    PERIODIC MAINTENANCE 2. Adjust: • Headlight beam (horizontally) ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ To adjust the headlight beam (horizontally), in- sert a crosshead screwdriver into the opening “a”...

  • Page 127: Chassis

    CHASSIS GENERAL CHASSIS (1) ................. 4-1 REMOVING THE CENTER COVER ............4-2 INSTALLING THE BATTERY..............4-2 INSTALLING THE RIDER SEAT............... 4-2 INSTALLING THE CENTER COVER............4-2 INSTALLING THE PASSENGER SEAT............ 4-2 GENERAL CHASSIS (2) ................. 4-3 REMOVING THE SIDE PANEL ASSEMBLIES......... 4-6 REMOVING THE UPPER TAIL PANEL ............
  • Page 128 REAR WHEEL ....................4-26 REMOVING THE REAR WHEEL ............4-30 DISASSEMBLING THE REAR WHEEL ..........4-30 CHECKING THE REAR WHEEL............. 4-30 CHECKING THE REAR WHEEL DRIVE HUB ........4-30 CHECKING AND REPLACING THE REAR WHEEL SPROCKET ..4-31 MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR....................
  • Page 129 FRONT FORK....................4-74 REMOVING THE FRONT FORK LEGS..........4-77 DISASSEMBLING THE FRONT FORK LEGS ........4-77 CHECKING THE FRONT FORK LEGS ..........4-78 ASSEMBLING THE FRONT FORK LEGS ..........4-78 INSTALLING THE FRONT FORK LEGS ..........4-81 STEERING HEAD..................4-83 REMOVING THE LOWER BRACKET.............4-85 CHECKING THE STEERING HEAD ............4-85 INSTALLING THE STEERING HEAD .............4-85 SWINGARM AND REAR SHOCK ABSORBER ASSEMBLY ......4-87...

  • Page 130: General Chassis (1)

    GENERAL CHASSIS (1) EAS20026 GENERAL CHASSIS (1) Removing the seats and battery 1.8 Nm (0.18 m kgf, 1.3 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • Order Job/Parts to remove ’ Remarks Passenger seat ’...

  • Page 131: Removing The Center Cover

    GENERAL CHASSIS (1) EAS31189 REMOVING THE CENTER COVER 1. Remove: • Center cover “1” Unhook the projections “a” on the center cover from the rear upper side cowlings. EAS31190 INSTALLING THE CENTER COVER 1. Install: • Center cover “1” Center cover screw 1.8 Nm (0.18 m·kgf, 1.3 ft·lbf) EAS30697 INSTALLING THE BATTERY...

  • Page 132: General Chassis (2)

    GENERAL CHASSIS (2) EAS20155 GENERAL CHASSIS (2) Removing the rear side cowlings 1.8 Nm (0.18 m kgf, 1.3 ft Ibf) 21 Nm (2.1 m kgf, 15 ft Ibf) • • • • 21 Nm (2.1 m kgf, 15 ft Ibf) •...
  • Page 133 GENERAL CHASSIS (2) Removing the rear side cowlings 1.8 Nm (0.18 m kgf, 1.3 ft Ibf) 21 Nm (2.1 m kgf, 15 ft Ibf) • • • • 21 Nm (2.1 m kgf, 15 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...
  • Page 134 GENERAL CHASSIS (2) Removing the rear side cowlings 1.8 Nm (0.18 m kgf, 1.3 ft Ibf) 21 Nm (2.1 m kgf, 15 ft Ibf) • • • • 21 Nm (2.1 m kgf, 15 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...

  • Page 135: Removing The Side Panel Assemblies

    GENERAL CHASSIS (2) EAS31786 REMOVING THE SIDE PANEL ASSEMBLIES The following procedure applies to both of the side panel assemblies. 1. Remove: • Side panel assembly “1” ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼...

  • Page 136: Installing The Rear Side Cowling Assembly

    GENERAL CHASSIS (2) 2. Install: • Side panel assembly “1” ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Fit the portion “a” of the side panel assembly over the projection “b” on the air scoop “2”, and insert the projection “c”...

  • Page 137: General Chassis (3)

    GENERAL CHASSIS (3) EAS20156 GENERAL CHASSIS (3) Removing the fuel tank covers 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • 1.8 Nm (0.18 m kgf, 1.3 ft Ibf) • • 5 Nm (0.5 m kgf, 3.6 ft Ibf) •...

  • Page 138: Removing The Air Scoops

    GENERAL CHASSIS (3) EAS31772 REMOVING THE AIR SCOOPS The following procedure applies to both of the air scoops. 1. Remove: • Air scoop “1” ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼...

  • Page 139: Disassembling The Fuel Tank Cover Assembly

    GENERAL CHASSIS (3) EAS31354 DISASSEMBLING THE FUEL TANK COVER ASSEMBLY The following procedure applies to both of the fuel tank side covers. 1. Remove the fuel tank cover screws. 2. Remove the projections “a” on the fuel tank side cover assembly “1” from the holes “b” in the fuel tank center cover “2”.

  • Page 140: Installing The Fuel Tank Cover Assembly

    GENERAL CHASSIS (3) EAS31456 INSTALLING THE FUEL TANK COVER ASSEMBLY 1. Install: • Fuel tank cover assembly “1” Fuel tank cover bolt (front side) 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Fuel tank cover bolt (rear side) 5 Nm (0.5 m·kgf, 3.6 ft·lbf) •...

  • Page 141: General Chassis (4)

    GENERAL CHASSIS (4) EAS20157 GENERAL CHASSIS (4) Removing the headlight assembly and meter assembly 7 Nm (0.7 m kgf, 5.1 ft Ibf) 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • • • 1.3 Nm (0.13 m kgf, 0.94 ft Ibf) •...
  • Page 142 GENERAL CHASSIS (4) Removing the headlight assembly and meter assembly 7 Nm (0.7 m kgf, 5.1 ft Ibf) 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • • • 1.3 Nm (0.13 m kgf, 0.94 ft Ibf) • • 1.5 Nm (0.15 m kgf, 1.1 ft Ibf)

  • Page 143: Installing The Headlight Assembly

    GENERAL CHASSIS (4) EAS30825 INSTALLING THE HEADLIGHT ASSEMBLY 1. Install: • Headlight assembly “1” • Headlight assembly bolts Headlight assembly bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Fit the holes “a” in the headlight assembly with the projections “b” on the headlight lower brack- EAS31774 INSTALLING THE METER ASSEMBLY 1.

  • Page 144: General Chassis (5)

    GENERAL CHASSIS (5) EAS20158 GENERAL CHASSIS (5) Removing the air filter case 2.5 Nm (0.25 m kgf, 1.8 ft Ibf) 1.3 Nm (0.13 m kgf, 0.94 ft Ibf) • • • • 2.5 Nm (0.25 m kgf, 1.8 ft Ibf) •...
  • Page 145 GENERAL CHASSIS (5) Removing the air filter case 1.3 Nm (0.13 m kgf, 0.94 ft Ibf) 2.5 Nm (0.25 m kgf, 1.8 ft Ibf) • • • • 2.5 Nm (0.25 m kgf, 1.8 ft Ibf) • • 2.5 Nm (0.25 m kgf, 1.8 ft Ibf) •...

  • Page 146: Installing The Air Filter Case

    GENERAL CHASSIS (5) 3. Install: EAS31064 INSTALLING THE AIR FILTER CASE • Air filter case cover “1” 1. Install: • Flap stay “1” Install the air filter case cover as shown in the il- • Flap “2” lustration, and then install the quick fasteners Flap stay bolt (black) “2”...

  • Page 147: Front Wheel

    FRONT WHEEL EAS20028 FRONT WHEEL Removing the front wheel and brake disc 52 Nm (5.2 m kgf, 38 ft Ibf) • • 35 Nm (3.5 m kgf, 25 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...
  • Page 148 FRONT WHEEL Disassembling the front wheel ’ Order Job/Parts to remove Remarks Oil seal Wheel bearing Spacer 4-19...

  • Page 149: Removing The Front Wheel

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

  • Page 151: Rear Wheel

    REAR WHEEL Disassembling the rear wheel ’ Order Job/Parts to remove Remarks Oil seal Wheel bearing (right) Wheel bearing (left) Spacer 4-29...

  • Page 152: Removing The Rear Wheel

    REAR WHEEL EAS30156 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, etc.) away from the rear wheel sensor or rear wheel sensor rotor;...

  • Page 153: Checking And Replacing The Rear Wheel Sprocket

    REAR WHEEL EAS30161 CHECKING AND REPLACING THE REAR WHEEL SPROCKET 1. Check: • Rear wheel sprocket More than 1/4 tooth “a” wear → Replace the drive chain sprockets as a set. Bent teeth → Replace the drive chain sprock- ets as a set. ▲...

  • Page 154: Assembling The Rear Wheel

    REAR WHEEL 3. Measure: • Wheel sensor rotor deflection Refer to “MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR” on page 4-21. Wheel sensor rotor deflection limit 0.25 mm (0.0098 in) EAS30163 ASSEMBLING THE REAR WHEEL ▲ ▲▲▲ ▲ ▲▲▲ ▲...
  • Page 155 REAR WHEEL • Brake caliper bracket “1” ECA21011 NOTICE • Rear wheel • Do not drop the wheel sensor rotor or sub- • Rear wheel axle ject it to shocks. • Washers • If any solvent gets on the wheel sensor ro- •...
  • Page 156 REAR WHEEL Drive chain slack Distance “a” (between the rear 35.0–45.0 mm (1.38–1.77 in) wheel sensor rotor and rear Drive chain slack (fully extension wheel sensor) of rear suspension) 0.81–1.57 mm (0.032–0.062 in) 40.0–50.0 mm (1.57–1.97 in) 9. Tighten: Measure the distance between the rear wheel •...

  • Page 157: Front Brake

    FRONT BRAKE EAS20030 FRONT BRAKE Removing the front brake pads 35 Nm (3.5 m kgf, 25 ft Ibf) • • 6 Nm (0.6 m kgf, 4.3 ft Ibf) • • ’ Order Job/Parts to remove Remarks Front brake caliper bolt Front wheel sensor lead holder Front brake caliper Brake pad clip...
  • Page 158 FRONT BRAKE Removing the front brake master cylinder 1.5 Nm (0.15 m kgf, 1.1 ft Ibf) • • 6 Nm (0.6 m kgf, 4.3 ft Ibf) • • 29 Nm (2.9 m kgf, 21 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...
  • Page 159 FRONT BRAKE Disassembling the front brake master cylinder ’ Order Job/Parts to remove Remarks Brake master cylinder kit Brake master cylinder body 4-37...
  • Page 160 FRONT BRAKE Removing the front brake caliper 35 Nm (3.5 m kgf, 25 ft Ibf) • • 29 Nm (2.9 m kgf, 21 ft Ibf) • • ’ Order Job/Parts to remove Remarks Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM (ABS)”...
  • Page 161 FRONT BRAKE Disassembling the front brake caliper 6 Nm (0.6 m kgf, 4.3 ft Ibf) • • ’ Order Job/Parts to remove Remarks Brake pad clip Brake pad pin Brake pad (inner) Brake pad (outer) Brake pad spring Front brake caliper bracket Brake caliper piston Brake caliper piston dust seal Brake caliper piston seal...

  • Page 162: Introduction

    FRONT BRAKE e. Measure the deflection 1.5 mm (0.06 in) be- EAS30168 INTRODUCTION low the edge of the brake disc. EWA14101 WARNING Disc brake components rarely require disas- sembly. Therefore, always follow these pre- ventive measures: • Never disassemble brake components un- less absolutely necessary.

  • Page 163: Replacing The Front Brake Pads

    FRONT BRAKE d. Measure the brake disc deflection. A. Inner e. If out of specification, repeat the adjustment B. Outer steps until the brake disc deflection is within 2. Install: specification. • Brake pad spring f. If the brake disc deflection cannot be brought •...

  • Page 164: Removing The Front Brake Caliper

    FRONT BRAKE d. Install a new brake pad spring and new brake pads. ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 3. Install: • Brake pad pin • Brake pad clips •...

  • Page 165: Checking The Front Brake Caliper

    FRONT BRAKE • Whenever a brake caliper is disassembled, EAS30173 CHECKING THE FRONT BRAKE CALIPER replace the brake caliper piston dust seals Recommended brake component and brake caliper piston seals. replacement schedule Brake pads If necessary Specified brake fluid DOT 4 Piston seals Every two years Piston dust seals...

  • Page 166: Removing The Front Brake Master Cylinder

    FRONT BRAKE 4. Fill: EAS30179 REMOVING THE FRONT BRAKE MASTER • Brake master cylinder reservoir CYLINDER (with the specified amount of the specified brake fluid) Before removing the front brake master cylinder, Specified brake fluid drain the brake fluid from the entire brake sys- DOT 4 tem.

  • Page 167: Assembling The Front Brake Master Cylinder

    FRONT BRAKE 4. Check: 2. Install: • Brake hose • Brake hose Cracks/damage/wear → Replace. • Brake hose gaskets • Brake hose union bolt EAS30181 ASSEMBLING THE FRONT BRAKE MASTER Front brake hose union bolt CYLINDER (master cylinder side) EWA13520 29 Nm (2.9 m·kgf, 21 ft·lbf) WARNING •...
  • Page 168 FRONT BRAKE EWA13540 WARNING • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. • Refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake performance.

  • Page 169: Rear Brake

    REAR BRAKE EAS20031 REAR BRAKE Removing the rear brake pads 6 Nm (0.6 m kgf, 4.3 ft Ibf) • • 23 Nm (2.3 m kgf, 17 ft Ibf) • • ’ Order Job/Parts to remove Remarks Brake pad pin Rear brake caliper bolt Brake pad (inner) Brake pad shim (inner) Brake pad (outer)
  • Page 170 REAR BRAKE Removing the rear brake master cylinder 7 Nm (0.7 m kgf, 5.1 ft Ibf) 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 30 Nm (3.0 m kgf, 22 ft Ibf) •...
  • Page 171 REAR BRAKE Removing the rear brake master cylinder 7 Nm (0.7 m kgf, 5.1 ft Ibf) 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 30 Nm (3.0 m kgf, 22 ft Ibf) •...
  • Page 172 REAR BRAKE Disassembling the rear brake master cylinder 17 Nm (1.7 m kgf, 12 ft Ibf) • • ’ Order Job/Parts to remove Remarks Brake master cylinder joint Brake master cylinder kit Hose joint Brake master cylinder body 4-50...
  • Page 173 REAR BRAKE Removing the rear brake caliper 29 Nm (2.9 m kgf, 21 ft Ibf) • • 23 Nm (2.3 m kgf, 17 ft Ibf) • • ’ Order Job/Parts to remove Remarks Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM (ABS)”...
  • Page 174 REAR BRAKE Disassembling the rear brake caliper 6 Nm (0.6 m kgf, 4.3 ft Ibf) • • ’ Order Job/Parts to remove Remarks Brake pad spring Brake caliper piston Brake caliper piston dust seal Brake caliper piston seal Brake caliper bleed screw Spacer 4-52...

  • Page 175: Introduction

    REAR BRAKE EAS30183 INTRODUCTION Brake disc thickness limit EWA14101 4.0 mm (0.16 in) WARNING Disc brake components rarely require disas- 5. Adjust: sembly. Therefore, always follow these pre- • Brake disc deflection ventive measures: Refer to “CHECKING THE FRONT BRAKE •...
  • Page 176 REAR BRAKE The longer tangs “a” of the brake pad spring must point in the direction of the brake caliper piston. A. Inner B. Outer 2. Install: • Brake pad shims ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲...

  • Page 177: Removing The Rear Brake Caliper

    REAR BRAKE Refer to “BLEEDING THE HYDRAULIC • Never try to pry out the brake caliper pis- BRAKE SYSTEM (ABS)” on page 3-14. ton. EAS30186 REMOVING THE REAR BRAKE CALIPER Before disassembling the brake caliper, drain the brake fluid from the entire brake system. 1.

  • Page 178: Assembling The Rear Brake Caliper

    REAR BRAKE • Rear brake caliper “1” Refer to “REPLACING THE REAR BRAKE PADS” on page 4-53. • Brake hose gaskets “2” • Brake hose “3” • Rear brake hose union bolt “4” Rear brake caliper bolt 23 Nm (2.3 m·kgf, 17 ft·lbf) Rear brake hose union bolt (brake caliper side) 2.

  • Page 179: Removing The Rear Brake Master Cylinder

    REAR BRAKE EWA13090 WARNING To collect any remaining brake fluid, place a • Use only the designated brake fluid. Other container under the master cylinder and the end brake fluids may cause the rubber seals to of the brake hose. deteriorate, causing leakage and poor brake performance.

  • Page 180: Assembling The Rear Brake Master Cylinder

    REAR BRAKE 2. Install: EAS30195 ASSEMBLING THE REAR BRAKE MASTER • Brake hose “1” CYLINDER • Brake hose gaskets “2” EWA13520 • Brake hose union bolt “3” WARNING • Before installation, all internal brake com- Rear brake hose union bolt (mas- ponents should be cleaned and lubricated ter cylinder side) with clean or new brake fluid.
  • Page 181 REAR BRAKE ECA13540 NOTICE Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. 4. Bleed: • Brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM (ABS)” on page 3-14. 5. Check: •...

  • Page 182: Abs (Anti-Lock Brake System)

    ABS (ANTI-LOCK BRAKE SYSTEM) EAS20032 ABS (ANTI-LOCK BRAKE SYSTEM) Removing the hydraulic unit assembly 7 Nm (0.7 m kgf, 5.1 ft Ibf) 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • • • 29 Nm (2.9 m kgf, 21 ft Ibf) •...
  • Page 183 ABS (ANTI-LOCK BRAKE SYSTEM) Removing the hydraulic unit assembly 7 Nm (0.7 m kgf, 5.1 ft Ibf) 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • • • 29 Nm (2.9 m kgf, 21 ft Ibf) • • 29 Nm (2.9 m kgf, 21 ft Ibf) •...
  • Page 184 ABS (ANTI-LOCK BRAKE SYSTEM) Removing the hydraulic unit assembly 7 Nm (0.7 m kgf, 5.1 ft Ibf) 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • • • 29 Nm (2.9 m kgf, 21 ft Ibf) • • 29 Nm (2.9 m kgf, 21 ft Ibf) •...

  • Page 185: Removing The Hydraulic Unit Assembly

    ABS (ANTI-LOCK BRAKE SYSTEM) EAS30197 REMOVING THE HYDRAULIC UNIT Do not operate the brake lever and brake pedal ASSEMBLY while removing the brake hoses. ECA21091 NOTICE ECA14530 Unless necessary, avoid removing and in- NOTICE stalling the brake hoses of the hydraulic unit When removing the brake hoses, cover the assembly.
  • Page 186 ABS (ANTI-LOCK BRAKE SYSTEM) joint to hydraulic unit) “2”, and then temporar- ily tighten the union bolt for the front brake Do not allow any foreign materials to enter the hose (hydraulic unit to brake hose joint). hydraulic unit assembly or the brake hoses e.

  • Page 187: Hydraulic Unit Operation Tests

    • For the brake line routing confirmation, use the leading to poor brake performance. diagnosis mode of the Yamaha diagnostic tool. • When refilling, be careful that water does • Before performing the brake line routing confir- not enter the brake fluid reservoir.
  • Page 188 “1”, brake pedal “2”, and again in the brake lever “1”, in this order. 6. Start the Yamaha diagnostic tool and display the diagnosis mode screen. 7. Select code No. 2, “Brake line routing confir- mation”.
  • Page 189 ABS ECU and that the wheels are not rotating. 1. Place the vehicle on a suitable stand. 6. Start the Yamaha diagnostic tool and display 2. Turn the main switch to “OFF”. the diagnosis mode screen.

  • Page 190: Checking The Abs Warning Light

    12.Turn the main switch to “OFF”. 13.Remove the Yamaha diagnostic tool from the Yamaha diagnostic tool coupler, and then in- stall the protective cap. 14.Turn the main switch to “ON”.

  • Page 191: Handlebar

    HANDLEBAR EAS20033 HANDLEBAR Removing the handlebar 17 Nm (1.7 m kgf, 12 ft Ibf) • • 28 Nm (2.8 m kgf, 20 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 17 Nm (1.7 m kgf, 12 ft Ibf) •...
  • Page 192 HANDLEBAR Removing the handlebar 17 Nm (1.7 m kgf, 12 ft Ibf) • • 28 Nm (2.8 m kgf, 20 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 17 Nm (1.7 m kgf, 12 ft Ibf) •...

  • Page 193: Removing The Handlebar

    HANDLEBAR EAS30203 REMOVING THE HANDLEBAR Upper handlebar holder bolt 1. Stand the vehicle on a level surface. 28 Nm (2.8 m·kgf, 20 ft·lbf) EWA13120 WARNING ECA18300 NOTICE Securely support the vehicle so that there is no danger of it falling over. First, tighten the bolts on the front side of the handlebar holder, and then on the rear side.
  • Page 194 HANDLEBAR ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Apply a thin coat of rubber adhesive onto the end of the handlebar. b. Slide the handlebar grip over the end of the handlebar.
  • Page 195 HANDLEBAR • Align the mating surfaces of the front brake master cylinder holder with the punch mark “b” • Align the projection “a” on the grip end with the on the handlebar. slot “b” in the handlebar weight. • First, tighten the upper bolt, then tighten the •...

  • Page 196: Front Fork

    FRONT FORK EAS20034 FRONT FORK Removing the front fork legs 21 Nm (2.1 m kgf, 15 ft Ibf) • • 30 Nm (3.0 m kgf, 22 ft Ibf) • • 23 Nm (2.3 m kgf, 17 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf)
  • Page 197 FRONT FORK Disassembling the front fork legs 30 Nm (3.0 m kgf, 22 ft Ibf) • • ’ Order Job/Parts to remove Remarks The following procedure applies to both of the front fork legs. Removing the protector only when neces- Protector sary.
  • Page 198 FRONT FORK Disassembling the front fork legs 30 Nm (3.0 m kgf, 22 ft Ibf) • • ’ Order Job/Parts to remove Remarks Damper rod Damper rod ring Rebound spring Inner tube Oil seal Washer Outer tube bushing Inner tube bushing Oil flow stopper Spring Outer tube...

  • Page 199: Removing The Front Fork Legs

    FRONT FORK EAS30206 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. 2.

  • Page 200: Checking The Front Fork Legs

    FRONT FORK 4. Remove: • Inner tube ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Hold the front fork leg horizontally. b. Securely clamp the brake caliper bracket in a vise with soft jaws.
  • Page 201 ▲ ▲▲▲ ▲ ▲▲▲ 2. Lubricate: • Inner tube’s outer surface Recommended oil Yamaha fork oil 10WT b. Install the damper rod ring onto the damper rod. 3. Install: • Inner tube (in the outer tube) Fit the damper rod ring into the damper rod 4.
  • Page 202 FRONT FORK 6. Install: • Outer tube bushing “1” • Washer “2” (with the fork seal driver attachment “3” and fork seal driver weight “4”) Fork seal driver weight 90890-01367 Replacement hammer YM-A9409-7 Fork seal driver attachment (ø41) 90890-01381 Replacement 41 mm YM-A5142-2 8.

  • Page 203: Installing The Front Fork Legs

    FRONT FORK • Tighten the front fork cap bolt specified torque, when installing the front fork with lower brack- EAS30210 INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Install: • Front fork leg “1” Temporarily tighten the lower bracket pinch 10.Fill: bolt “2”.
  • Page 204 FRONT FORK Align the edge “a” of each front fender bracket with the stopper “b” on the front fork “2”. Make sure to fit the front fender bracket under the stop- per on the front fork. 4-82...

  • Page 205: Steering Head

    STEERING HEAD EAS20035 STEERING HEAD Removing the upper bracket and lower bracket 7 Nm (0.7 m kgf, 5.1 ft Ibf) 95 Nm (9.5 m kgf, 69 ft Ibf) • • • • 1st 48 Nm (4.8 m kgf, 35 ft lbf) •...
  • Page 206 STEERING HEAD Removing the upper bracket and lower bracket 95 Nm (9.5 m kgf, 69 ft Ibf) 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • • • 1st 48 Nm (4.8 m kgf, 35 ft lbf) • • 2nd 18 Nm (1.8 m kgf, 13 ft lbf)

  • Page 207: Removing The Lower Bracket

    STEERING HEAD ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ EAS30213 REMOVING THE LOWER BRACKET a. Remove the bearing races from the steering 1. Stand the vehicle on a level surface. head pipe “1”...
  • Page 208 STEERING HEAD 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” on page 3-18. 4-86...

  • Page 209: Swingarm And Rear Shock Absorber Assembly

    SWINGARM AND REAR SHOCK ABSORBER ASSEMBLY EAS20197 SWINGARM AND REAR SHOCK ABSORBER ASSEMBLY Removing the swingarm and rear shock absorber assembly 58 Nm (5.8 m kgf, 42 ft Ibf) • • 115 Nm (11.5 m kgf, 83 ft lbf) • •...
  • Page 210 SWINGARM AND REAR SHOCK ABSORBER ASSEMBLY Removing the swingarm and rear shock absorber assembly 58 Nm (5.8 m kgf, 42 ft Ibf) • • 115 Nm (11.5 m kgf, 83 ft lbf) • • 58 Nm (5.8 m kgf, 42 ft Ibf) •...

  • Page 211: Removing The Rear Shock Absorber Assembly

    SWINGARM AND REAR SHOCK ABSORBER ASSEMBLY If the swingarm vertical movement is not EAS31304 REMOVING THE REAR SHOCK ABSORBER smooth or if there is binding, check the pivot ASSEMBLY shaft, spacer, bearings, and dust covers. 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is...

  • Page 212: Installing The Swingarm

    SWINGARM AND REAR SHOCK ABSORBER ASSEMBLY • Bearings “3” Damage/pitting → Replace. 4. Adjust: • Drive chain slack Refer to “ADJUSTING THE DRIVE CHAIN EAS31308 INSTALLING THE SWINGARM SLACK” on page 3-17. 1. Lubricate: Drive chain slack • Spacer 35.0–45.0 mm (1.38–1.77 in) •...
  • Page 213 SWINGARM AND REAR SHOCK ABSORBER ASSEMBLY ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 4-91...

  • Page 214: Chain Drive

    CHAIN DRIVE EAS20038 CHAIN DRIVE Removing the drive sprocket and drive chain 75 Nm (7.5 m kgf, 54 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • ’ Order Job/Parts to remove Remarks Coolant reservoir Refer to “RADIATOR”...

  • Page 215: Removing The Drive Chain

    CHAIN DRIVE EAS30229 REMOVING THE DRIVE CHAIN 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 suitable stand so that the rear wheel is elevated.

  • Page 216: Checking The Drive Sprocket

    CHAIN DRIVE EAS30231 CHECKING THE DRIVE SPROCKET 1. Check: • Drive sprocket More than 1/4 tooth “a” wear → Replace the drive chain sprocket, drive chain, and rear wheel sprocket as a set. Bent teeth → Replace the drive chain sprock- et, drive chain, and rear wheel sprocket as a set.

  • Page 217: Installing The Drive Chain

    CHAIN DRIVE EAS30234 INSTALLING THE DRIVE CHAIN 1. Install: • Drive chain • Drive chain guide • Drive sprocket cover Route the gear position switch lead, oil pressure switch lead, and fuel tank breather hose through the guide on the drive sprocket cover. Refer to “CABLE ROUTING”...

  • Page 218: Engine

    ENGINE ENGINE INSPECTION ..................5-1 MEASURE THE COMPRESSION PRESSURE........5-1 ENGINE REMOVAL ..................5-3 INSTALLING THE ENGINE..............5-10 ASSEMBLING THE MUFFLER ...............5-11 INSTALLING THE EXHAUST PIPE AND MUFFLER ASSEMBLY ..5-11 CAMSHAFTS....................5-13 REMOVING THE CAMSHAFTS..............5-15 CHECKING THE CAMSHAFTS ..............5-16 CHECKING THE CAMSHAFT SPROCKETS .........5-17 CHECKING THE TIMING CHAIN TENSIONER........
  • Page 219 ELECTRIC STARTER ...................5-46 CHECKING THE STARTER MOTOR .............5-48 ASSEMBLING THE STARTER MOTOR..........5-49 INSTALLING THE STARTER MOTOR ...........5-49 CLUTCH ......................5-50 REMOVING THE CLUTCH ..............5-53 CHECKING THE FRICTION PLATES.............5-53 CHECKING THE CLUTCH PLATES ............5-54 CHECKING THE CLUTCH SPRINGS.............5-54 CHECKING THE CLUTCH HOUSING ............5-54 CHECKING THE CLUTCH BOSS............
  • Page 220 CRANKSHAFT AND BALANCER SHAFT ...........5-79 REMOVING THE BALANCER SHAFT JOURNAL BEARINGS ....5-82 REMOVING THE CRANKSHAFT JOURNAL BEARINGS ......5-82 REMOVING THE CONNECTING RODS ..........5-82 CHECKING THE BALANCER SHAFT ............5-82 CHECKING THE CRANKSHAFT ............5-84 CHECKING THE CONNECTING RODS..........5-85 INSTALLING THE CONNECTING RODS..........

  • Page 221: Engine Inspection

    ENGINE INSPECTION EAS20041 ENGINE INSPECTION Extension 90890-04136 EAS30249 Compression gauge MEASURE THE COMPRESSION PRESSURE 90890-03081 The following procedure applies to all of the cyl- Engine compression tester inders. YU-33223 Insufficient compression pressure will result in a loss of performance. 1. Measure: •...
  • Page 222 ENGINE INSPECTION Compression pressure (with oil applied into the cylinder) Reading Diagnosis Piston ring(s) wear or Higher than without oil damage → Repair. Pistons, valves, cylinder head gasket or piston Same as without oil ring(s) possibly defec- tive → Repair. ▲...

  • Page 223: Engine Removal

    ENGINE REMOVAL EAS20042 ENGINE REMOVAL Removing the muffler and exhaust pipe 25 Nm (2.5 m kgf, 18 ft Ibf) • • 20 Nm (2.0 m kgf, 14 ft Ibf) • • 8 Nm (0.8 m kgf, 5.8 ft Ibf) • •...
  • Page 224 ENGINE REMOVAL Removing the muffler and exhaust pipe 25 Nm (2.5 m kgf, 18 ft Ibf) • • 20 Nm (2.0 m kgf, 14 ft Ibf) • • 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • 20 Nm (2.0 m kgf, 14 ft Ibf) •...
  • Page 225 ENGINE REMOVAL Disconnecting the leads and cable 3.5 Nm (0.35 m kgf, 2.5 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • ’ Order Job/Parts to remove Remarks Fuel tank cover assembly/Front side cowling as- Refer to “GENERAL CHASSIS (3)”...
  • Page 226 ENGINE REMOVAL Disconnecting the leads and cable 3.5 Nm (0.35 m kgf, 2.5 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • ’ Order Job/Parts to remove Remarks Radiator inlet hose Refer to “THERMOSTAT”...
  • Page 227 ENGINE REMOVAL Disconnecting the leads and cable 3.5 Nm (0.35 m kgf, 2.5 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • ’ Order Job/Parts to remove Remarks Coolant temperature sensor coupler Disconnect.
  • Page 228 ENGINE REMOVAL Removing the engine 68 Nm (6.8 m kgf, 49 ft Ibf) • • 68 Nm (6.8 m kgf, 49 ft Ibf) • • 68 Nm (6.8 m kgf, 49 ft Ibf) • • 66 Nm (6.6 m kgf, 48 ft Ibf) •...
  • Page 229 ENGINE REMOVAL Removing the engine 68 Nm (6.8 m kgf, 49 ft Ibf) • • 68 Nm (6.8 m kgf, 49 ft Ibf) • • 68 Nm (6.8 m kgf, 49 ft Ibf) • • 66 Nm (6.6 m kgf, 48 ft Ibf) •...

  • Page 230: Installing The Engine

    ENGINE REMOVAL EAS30251 INSTALLING THE ENGINE Engine mounting nut (rear upper 1. Install: side) • Plates “1” 68 Nm (6.8 m·kgf, 49 ft·lbf) (to the engine) Sidestand bracket bolt 66 Nm (6.6 m·kgf, 48 ft·lbf) • Engine “2” Engine mounting nut (rear lower •...

  • Page 231: Assembling The Muffler

    ENGINE REMOVAL Temporarily tighten the bolt and nuts. 3. Tighten: • Exhaust pipe nuts “3” • Exhaust pipe bolt “4” • Exhaust pipe bolt “5” Exhaust pipe nut 15 Nm (1.5 m·kgf, 11 ft·lbf) Exhaust pipe bolt 20 Nm (2.0 m·kgf, 14 ft·lbf) EAS31309 ASSEMBLING THE MUFFLER 1.
  • Page 232 ENGINE REMOVAL 5-12...

  • Page 233: Camshafts

    CAMSHAFTS EAS20043 CAMSHAFTS Removing the cylinder head cover 13 Nm (1.3 m kgf, 9.4 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 13 Nm (1.3 m kgf, 9.4 ft Ibf) • • ’ Order Job/Parts to remove Remarks Refer to “GENERAL CHASSIS (1)”...
  • Page 234 CAMSHAFTS Removing the camshafts 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.5 m kgf, 11 ft Ibf) • • 20 Nm (2.0 m kgf, 14 ft Ibf) 2.0 Nm (0.20 m kgf, 1.4 ft...

  • Page 235: Removing The Camshafts

    CAMSHAFTS ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ EAS30256 REMOVING THE CAMSHAFTS a. Insert the hexagon wrench “2” (part No.: 1. Remove: 1WS-12228-00) into the timing chain tension- • Crankshaft end cover “1” •...

  • Page 236: Checking The Camshafts

    CAMSHAFTS 6. Remove: • Camshaft sprocket “1” While holding the camshaft sprocket with the ro- tor holding tool “2”, loosen the camshaft sprock- et bolts in the proper sequence as shown. Rotor holding tool 90890-01235 Universal magneto and rotor holder YU-01235 3.

  • Page 237: Checking The Camshaft Sprockets

    CAMSHAFTS Camshaft journal diameter 22.459–22.472 mm (0.8842– 0.8847 in) c. Install the camshaft caps. • Tighten the camshaft cap bolts in the tighten- ing sequence as shown. • Do not turn the camshaft when measuring the EAS30936 camshaft journal-to-camshaft cap clearance CHECKING THE CAMSHAFT SPROCKETS 1.

  • Page 238: Installing The Camshafts

    CAMSHAFTS • Install the camshaft sprockets so that cam lobe #1 “a” and cam lobe #2 “b” are positioned as shown in the illustration. • Tighten the camshaft sprocket bolts with the rotor holding tool “3”. Tighten the camshaft sprocket bolt identified by the round mark “c” on each camshaft sprocket first.
  • Page 239 CAMSHAFTS 4. Install: • Exhaust camshaft cap “1” • Intake camshaft cap “2” • Make sure each camshaft cap is installed in its original place. Refer to the identification marks as follows: “EX”: Exhaust camshaft cap mark “a” “IN”: Intake camshaft cap mark “b” •...
  • Page 240 CAMSHAFTS 6. Install: • Timing chain tensioner gasket • Timing chain tensioner ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. While lightly pressing the timing chain ten- sioner rod by hand, turn the timing chain ten- sioner rod fully counterclockwise with a hexagon wrench “1”...

  • Page 241: Installing The Cylinder Head Cover

    CAMSHAFTS 9. Measure: • Valve clearance Out of specification → Adjust. Refer to “ADJUSTING THE VALVE CLEAR- ANCE” on page 3-5. 10.Install: • Timing mark accessing bolt “1” Timing mark accessing bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) • Crankshaft end cover “2” Crankshaft end cover 2.0 Nm (0.20 m·kgf, 1.4 ft·lbf) EAS30274...

  • Page 242: Cylinder Head

    CYLINDER HEAD EAS20044 CYLINDER HEAD Removing the cylinder head 10 Nm (1.0 m kgf, 7.2 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • • • 30 Nm (3.0 m kgf, 22 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) *3rd...
  • Page 243 CYLINDER HEAD Removing the cylinder head 10 Nm (1.0 m kgf, 7.2 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • • • 30 Nm (3.0 m kgf, 22 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) *3rd...
  • Page 244 CYLINDER HEAD Removing the cylinder head 10 Nm (1.0 m kgf, 7.2 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • • • 30 Nm (3.0 m kgf, 22 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) *3rd...

  • Page 245: Removing The Cylinder Head

    CYLINDER HEAD • Cylinder head water jacket EAS30276 REMOVING THE CYLINDER HEAD Mineral deposits/rust → Eliminate. 1. Remove: 3. Measure: • Cylinder head bolt (M6) (×2) • Cylinder head warpage • Cylinder head bolt (M10) (×6) Out of specification → Resurface the cylinder head.
  • Page 246 CYLINDER HEAD • Align the projection “c” on the engine mounting ECA20890 NOTICE bolt cap with the portion “d” of the front cowling Do not use a torque wrench to tighten the assembly stay. bolt to the specified angle. Tighten the cylinder head bolts in the tightening sequence as shown and torque them in 3 stag- ×2 ×6...

  • Page 247: Valves And Valve Springs

    VALVES AND VALVE SPRINGS EAS20045 VALVES AND VALVE SPRINGS Removing the valves and valve springs ’ Order Job/Parts to remove Remarks Cylinder head Refer to “CYLINDER HEAD” on page 5-22. Valve lifter Valve pad Valve cotter Valve spring retainer Valve spring Intake valve Exhaust valve Valve stem seal...

  • Page 248: Removing The Valves

    VALVES AND VALVE SPRINGS EAS30283 REMOVING THE VALVES Remove the valve cotters by compressing the The following procedure applies to all of the valve spring with the valve spring compressor valves and related components. “1” and the valve spring compressor attachment “2”.
  • Page 249 VALVES AND VALVE SPRINGS 1. Measure: • Valve-stem-to-valve-guide clearance Out of specification → Replace the valve guide. • Valve-stem-to-valve-guide clearance = Valve guide inside diameter “a” - Valve stem diameter “b” Valve-stem-to-valve-guide clear- ance (intake) b. Install the new valve guide with the valve 0.010–0.037 mm (0.0004–0.0015 guide installer “2”...

  • Page 250: Checking The Valve Seats

    VALVES AND VALVE SPRINGS 2. Check: Valve guide remover (ø4.5) • Valve seat 90890-04116 Pitting/wear → Replace the cylinder head. Valve guide remover (4.5 mm) 3. Measure: YM-04116 • Valve seat width “a” Valve guide installer (ø4.5) Out of specification → Replace the cylinder 90890-04117 head.

  • Page 251: Checking The Valve Springs

    VALVES AND VALVE SPRINGS After replacing the cylinder head or replacing the valve and valve guide, the valve seat and valve face should be lapped. ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼...

  • Page 252: Checking The Valve Lifters

    VALVES AND VALVE SPRINGS 2. Measure: EAS30287 CHECKING THE VALVE LIFTERS • Compressed valve spring force “a” Out of specification → Replace the valve The following procedure applies to all of the valve lifters. spring. 1. Check: Installed compression spring •...
  • Page 253 VALVES AND VALVE SPRINGS Valve spring compressor 90890-04019 Valve spring compressor YM-04019 Valve spring compressor attach- ment 90890-04108 Valve spring compressor adapt- er 22 mm YM-04108 4. Install: • Valve spring seat “1” (into the cylinder head) • Valve stem seal “2” •...
  • Page 254 VALVES AND VALVE SPRINGS • The valve lifter must move smoothly when ro- tated with a finger. • Each valve lifter and valve pad must be rein- stalled in their original position. 5-34...

  • Page 255: Cylinder And Pistons

    CYLINDER AND PISTONS EAS20046 CYLINDER AND PISTONS Removing the cylinder and pistons Order Job/Parts to remove ’ Remarks Cylinder head Refer to “CYLINDER HEAD” on page 5-22. Cylinder Cylinder gasket Dowel pin Piston pin clip Piston pin Piston Top ring 2nd ring Oil ring 5-35...

  • Page 256: Removing The Pistons

    CYLINDER AND PISTONS • Oil ring EAS30289 REMOVING THE PISTONS The following procedure applies to both of the When removing a piston ring, open the end gap pistons. with your fingers and lift the other side of the ring 1. Remove: over the piston crown.

  • Page 257: Checking The Piston Rings

    CYLINDER AND PISTONS 1. Measure: • Piston ring side clearance Out of specification → Replace the piston and piston rings as a set. Before measuring the piston ring side clearance, eliminate any carbon deposits from the piston ring grooves and piston rings. Piston ring b.

  • Page 258: Checking The Piston Pins

    CYLINDER AND PISTONS Piston ring Top ring End gap (installed) 0.15–0.25 mm (0.0059–0.0098 Limit 0.50 mm (0.0197 in) 2nd ring End gap (installed) 0.35–0.50 mm (0.0138–0.0197 3. Measure: Limit • Piston pin bore diameter “b” 0.85 mm (0.0335 in) Out of specification → Replace the piston. Oil ring End gap (installed) Piston pin bore inside diameter...
  • Page 259 CYLINDER AND PISTONS • Install the oil ring expander as shown in the il- lustration. • Be sure to install the piston rings so that the manufacturer marks “a” face up. 3. Lubricate: • Piston • Piston rings • Cylinder (with the recommended lubricant) 2.
  • Page 260 CYLINDER AND PISTONS 5-40...

  • Page 261: Generator And Starter Clutch

    GENERATOR AND STARTER CLUTCH EAS20140 GENERATOR AND STARTER CLUTCH Removing the stator coil, generator rotor and starter clutch 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 14 Nm (1.4 m kgf, 10 ft Ibf) • • 60 Nm (6.0 m kgf, 43 ft Ibf) •...
  • Page 262 GENERATOR AND STARTER CLUTCH Removing the stator coil, generator rotor and starter clutch 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 14 Nm (1.4 m kgf, 10 ft Ibf) • • 60 Nm (6.0 m kgf, 43 ft Ibf) •...

  • Page 263: Removing The Generator

    GENERATOR AND STARTER CLUTCH • Generator rotor “2” EAS30867 REMOVING THE GENERATOR • Starter clutch “3” 1. Remove: • Generator rotor bolt “1” • While holding the generator rotor with the rotor • Washer holding tool “4”, loosen the starter clutch bolts. •...

  • Page 264: Installing The Starter Clutch

    GENERATOR AND STARTER CLUTCH • Starter clutch gear Burrs/chips/roughness/wear → Replace the defective part(s). 3. Check: • Starter clutch gear contact surfaces Damage/pitting/wear → Replace the starter clutch gear. 4. Check: • Starter clutch operation ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼...

  • Page 265: Installing The Generator

    • Sealant 1. Install: (onto the stator coil lead grommet) • Woodruff key • Generator rotor assembly Yamaha bond No. 1215 • Washer “1” 90890-85505 • Generator rotor bolt (Three bond No.1215®) • Clean the tapered portion of the crankshaft and the generator rotor hub.

  • Page 266: Electric Starter

    ELECTRIC STARTER EAS20052 ELECTRIC STARTER Removing the starter motor 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 3.5 Nm (0.35 m kgf, 2.5 ft Ibf) • • ’ Order Job/Parts to remove Remarks Refer to “GENERAL CHASSIS (1)” on page Rider seat 4-1.
  • Page 267 ELECTRIC STARTER Disassembling the starter motor 1.5 Nm (0.15 m kgf, 1.1 ft Ibf) • • 1.5 Nm (0.15 m kgf, 1.1 ft Ibf) • • 3.5 Nm (0.35 m kgf, 2.5 ft Ibf) • • ’ Order Job/Parts to remove Remarks Starter motor front cover Gasket...

  • Page 268: Checking The Starter Motor

    ELECTRIC STARTER ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ EAS30325 CHECKING THE STARTER MOTOR a. Measure the armature assembly resistances 1. Check: with the digital circuit tester. • Commutator Dirt →...

  • Page 269: Assembling The Starter Motor

    ELECTRIC STARTER Brush spring force Starter motor bolt 6.08–9.12 N (620–930 gf, 21.89– 10 Nm (1.0 m·kgf, 7.2 ft·lbf) 32.83 oz) Starter motor lead screw 3.5 Nm (0.35 m·kgf, 2.5 ft·lbf) Install the engine ground lead terminal so that the crimped section “a” of the terminal that se- cures the ground leads is facing forward.

  • Page 270: Clutch

    CLUTCH EAS20055 CLUTCH Removing the clutch cover and pull lever shaft 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • • •...
  • Page 271 CLUTCH Removing the clutch cover and pull lever shaft 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • • • ’ Order Job/Parts to remove Remarks...
  • Page 272 CLUTCH Removing the clutch 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 100 Nm (10 m kgf, 72 ft lbf) • • ’ Order Job/Parts to remove Remarks Compression spring Pressure plate Pull rod Bearing Friction plate Clutch plate Clutch boss nut Lock washer Clutch boss...

  • Page 273: Removing The Clutch

    CLUTCH 5. Loosen: EAS30346 REMOVING THE CLUTCH • Clutch boss nut “1” 1. Remove: • Clutch cover “1” While holding the clutch boss “2” with the univer- • Clutch cover gasket sal clutch holder “3”, loosen the clutch boss nut. Loosen each bolt 1/4 of a turn at a time, in stag- Universal clutch holder es and in a crisscross pattern.

  • Page 274: Checking The Clutch Plates

    CLUTCH EAS30349 CHECKING THE CLUTCH PLATES The following procedure applies to all of the clutch plates. 1. Check: • Clutch plate Damage → Replace the clutch plates as a set. 2. Measure: • Clutch plate warpage (with a surface plate and thickness gauge “1”) Out of specification →...

  • Page 275: Checking The Pressure Plate

    CLUTCH Pitting on the clutch boss splines will cause er- ratic clutch operation. EAS30358 CHECKING THE PULL LEVER SHAFT AND PULL ROD 1. Check: • Pull lever shaft pinion gear teeth “1” EAS30354 CHECKING THE PRESSURE PLATE • Pull rod teeth “2” 1.
  • Page 276 CLUTCH • Bend the lock washer tab “a” along a flat side • Clutch spring bolts “4” of the nut. Clutch spring bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Universal clutch holder 90890-04086 Universal clutch holder • Apply lithium-soap-based grease onto the pull YM-91042 rod.
  • Page 277 CLUTCH 5. Install: • Dowel pins “1” • Install the clutch cable so that the clutch cable • Clutch cover gasket “2” length “a” is 52.6–64.1 mm (2.07–2.52 in) as • Clutch cover “3” shown in the illustration. • Clutch cable holder “4” •...

  • Page 278: Shift Shaft

    SHIFT SHAFT EAS20057 SHIFT SHAFT Removing the shift pedal 30 Nm (3.0 m kgf, 22 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 14 Nm (1.4 m kgf, 10 ft Ibf) • • Order Job/Parts to remove ’...
  • Page 279 SHIFT SHAFT Removing the shift shaft and stopper lever 22 Nm (2.2 m kgf, 16 ft Ibf) • • ’ Order Job/Parts to remove Remarks Refer to “GENERAL CHASSIS (3)” on page Bottom cowling 4-8. Drain. Engine oil Refer to “CHANGING THE ENGINE OIL” on page 3-22.
  • Page 280 SHIFT SHAFT Removing the shift shaft and stopper lever 22 Nm (2.2 m kgf, 16 ft Ibf) • • ’ Order Job/Parts to remove Remarks Shift shaft Washer Circlip Shift shaft spring Stopper lever spring Shift shaft spring stopper Stopper lever Oil seal Bearing 5-60...

  • Page 281: Checking The Shift Shaft

    SHIFT SHAFT EAS30377 CHECKING THE SHIFT SHAFT 1. Check: • Shift shaft “1” Bends/damage/wear → Replace. • Shift shaft spring “2” Damage/wear → Replace. 2. Install: • Stopper lever • Collar • Shift shaft spring stopper • Stopper lever spring •...
  • Page 282 SHIFT SHAFT Align the match mark “a” of the shift shaft with the punch mark “b” of the shift arm. c. Tighten both locknuts. The shift rod locknut (shift pedal side) has left- hand thread. 2. Measure: • Installed shift rod length “a” Shift rod locknut (shift arm side) Incorrect →...

  • Page 283: Oil Pump

    OIL PUMP EAS20054 OIL PUMP Removing the oil pump 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • ’ Order Job/Parts to remove Remarks Refer to “GENERAL CHASSIS (3)” on page Bottom cowling 4-8. Drain. Engine oil Refer to “CHANGING THE ENGINE OIL” on page 3-22.
  • Page 284 OIL PUMP Disassembling the oil pump 2.0 Nm (0.20 m kgf, 1.4 ft Ibf) • • ’ Order Job/Parts to remove Remarks Oil pump cover Oil pump driven gear Oil pump rotor assembly Oil pump inner rotor Oil pump outer rotor Hold down the washer and do not scratch Circlip housing when removing the circlip.

  • Page 285: Checking The Oil Pump Idle Gear

    OIL PUMP 3. Check: EAS31312 CHECKING THE OIL PUMP IDLE GEAR • Oil pump operation 1. Check: Rough movement → Repeat steps (1) and • Oil pump drive gear (2) or replace the oil pump assembly. Damage/wear → Replace the oil pump idle gear, oil pump assembly and clutch housing as a set.

  • Page 286: Installing The Oil Pump

    OIL PUMP • Oil pump cover screw “6” Oil pump cover screw 2.0 Nm (0.20 m·kgf, 1.4 ft·lbf) Align the pin in the oil pump shaft with the grooves “a” in the inner rotor. 4. Check: • Oil pump operation Refer to “CHECKING THE OIL PUMP”...

  • Page 287: Oil Pan

    OIL PAN EAS20177 OIL PAN Removing the oil pan 20 Nm (2.0 m kgf, 14 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • F W D (11) 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...
  • Page 288 OIL PAN Removing the oil pan 20 Nm (2.0 m kgf, 14 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • F W D (11) 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • ’...

  • Page 289: Checking The Oil Strainer

    OIL PAN 3. Install: EAS31069 CHECKING THE OIL STRAINER • Gasket “1” 1. Check: • Engine oil drain bolt “2” • Oil strainer Damage → Replace. Engine oil drain bolt Contaminants → Clean with solvent. 20 Nm (2.0 m·kgf, 14 ft·lbf) EAS31070 INSTALLING THE OIL PAN 1.

  • Page 290: Crankcase

    CRANKCASE EAS20059 CRANKCASE Removing the crankcase breather cover and switches 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 17 Nm (1.7 m kgf, 12 ft Ibf) • • 70 Nm (7.0 m kgf, 51 ft Ibf) • • 1.8 Nm (0.18 m kgf, 1.3 ft Ibf)
  • Page 291 CRANKCASE Removing the crankcase breather cover and switches 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 17 Nm (1.7 m kgf, 12 ft Ibf) • • 70 Nm (7.0 m kgf, 51 ft Ibf) • • 1.8 Nm (0.18 m kgf, 1.3 ft Ibf) •...
  • Page 292 CRANKCASE Separating the crankcase 10 Nm (1.0 m kgf, 7.2 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...

  • Page 293: Disassembling The Crankcase

    CRANKCASE • M6 × 35 mm bolt (×2): “1”, “2” EAS30389 DISASSEMBLING THE CRANKCASE • M6 × 45 mm bolt (×5): “3”, “7”, “8”, “12”, “13” 1. Remove: • M6 × 45 mm bolt (×1) (with copper washer): • Oil filter cartridge “1” “12A”...

  • Page 294: Checking The Balancer Drive Gear

    Work slowly and carefully 2. Apply: and make sure the crankcase halves sepa- • Sealant rate evenly. (onto the crankcase mating surfaces) Yamaha bond No. 1215 EAS31378 CHECKING THE BALANCER DRIVE GEAR 90890-85505 1. Check: (Three bond No.1215®) •...
  • Page 295 • Lubricate the bolts “1”–“15” and “17”–“21” threads and mating surfaces with engine oil. • Lubricate the mating surface of the bolt “16” with engine oil and apply Yamaha bond No. 1215 to the bolt threads. • Finger tighten the crankcase bolts.
  • Page 296 CRANKCASE Crankcase bolts “1”–“6” 1st: 20 Nm (2.0 m·kgf, 14 ft·lbf) *2nd: Loosen and retighten the bolts one at a time to 24 Nm (2.4 ×2 ×1 m·kgf, 17 ft·lbf). Crankcase bolts “7”–“8” 1st: 20 Nm (2.0 m·kgf, 14 ft·lbf) *2nd: Loosen and retighten the bolts one at a time to 26 Nm (2.6 m·kgf, 19 ft·lbf).

  • Page 297: Installing The Oil Pressure Switch And Gear Position Switch

    CRANKCASE 10.Install: 11.Install: • Timing chain guide (lower side) • Holder 2 “1” • Timing chain sprocket • Holder 1 “2” • Timing chain • Primary drive gear “1” • Position the holder 2 within the range shown in • Washer “2” the illustration.
  • Page 298 CRANKCASE • Apply locking agent (LOCTITE®) to the threads “a” of the oil pressure switch. However, do not apply locking agent (LOCTITE®) to the portion “b” of the oil pressure switch. • Install the oil pressure switch lead terminal with the lead routed upward.

  • Page 299: Crankshaft And Balancer Shaft

    CRANKSHAFT AND BALANCER SHAFT EAS20178 CRANKSHAFT AND BALANCER SHAFT Removing the crankshaft, connecting rod and balancer shaft 1st 15 Nm (1.5 m kgf, 11 ft lbf) • • 2nd Specified angle 145–155˚ Order Job/Parts to remove ’ Remarks Separate. Crankcase Refer to “CRANKCASE”...
  • Page 300 CRANKSHAFT AND BALANCER SHAFT Removing the crankshaft, connecting rod and balancer shaft 1st 15 Nm (1.5 m kgf, 11 ft lbf) • • 2nd Specified angle 145–155˚ ’ Order Job/Parts to remove Remarks Oil nozzle 5-80...
  • Page 301 CRANKSHAFT AND BALANCER SHAFT Disassembling the balancer shaft assembly 35 Nm (3.5 m kgf, 25 ft Ibf) • • ’ Order Job/Parts to remove Remarks Balancer driven gear bolt Washer Balancer driven gear assembly Straight key Buffer boss Spring Dowel pin Balancer driven gear Balancer shaft 5-81...

  • Page 302: Removing The Balancer Shaft Journal Bearings

    CRANKSHAFT AND BALANCER SHAFT Dirt → Clean. EAS31072 REMOVING THE BALANCER SHAFT • Bearings JOURNAL BEARINGS Damage/wear → Replace. 1. Remove: 3. Measure: • Balancer shaft journal lower bearings • Balancer shaft-journal-to-balancer shaft-jour- (from the lower crankcase) nal-bearing clearance • Balancer shaft journal upper bearings Out of specification →...
  • Page 303 CRANKSHAFT AND BALANCER SHAFT 4. Select: • Balancer shaft journal bearings (J –J • The numbers “A” stamped into the lower crank- case and the numbers “B” stamped into the balancer shaft web are used to determine the replacement balancer shaft journal bearing siz- •...

  • Page 304: Checking The Crankshaft

    CRANKSHAFT AND BALANCER SHAFT EAS31075 CHECKING THE CRANKSHAFT 1. Measure: • Crankshaft runout Out of specification → Replace the crank- shaft. Runout limit 0.030 mm (0.0012 in) c. Put a piece of Plastigauge® “2” on each crankshaft journal. Do not put the Plastigauge® over the oil hole in the crankshaft journal.

  • Page 305: Checking The Connecting Rods

    CRANKSHAFT AND BALANCER SHAFT If the crankshaft-journal-to-crankshaft-jour- J1 J2 J3 nal-bearing clearance is out of specification, select replacement crankshaft journal bear- ings. 3 3 3 For example, if the crankcase J and crank- shaft web J numbers are 5 and 3 respective- ly, then the bearing size for J (crankcase) –...
  • Page 306 CRANKSHAFT AND BALANCER SHAFT f. Remove the connecting rod and big end bearings. Refer to “REMOVING THE CONNECTING RODS” on page 5-82. g. Measure the compressed Plastigauge® width “f” on the crankshaft pin. If the crankshaft-pin-to-big-end-bearing clearance is out of specification, select re- placement big end bearings.

  • Page 307: Installing The Connecting Rods

    CRANKSHAFT AND BALANCER SHAFT • Make sure the “Y” marks “c” on the connecting rods face towards the left side of the crank- shaft. • Make sure the characters “d” on both the con- necting rod and connecting rod cap are aligned.

  • Page 308: Installing The Crankshaft

    CRANKSHAFT AND BALANCER SHAFT • Align the projections “a” on the crankshaft jour- nal bearings “1” with the notches “b” in the crankcase. • Be sure to install each crankshaft journal bear- ing in its original place. c. Tighten the connecting rod nuts further to reach the specified angle 145–155°.

  • Page 309: Installing The Balancer Shaft Assembly

    CRANKSHAFT AND BALANCER SHAFT • Lubricate the balancer driven gear bolt threads and mating surface with engine oil. • Make sure that the balancer shaft “3” is insert- ed into the washer, and then temporarily tight- en the balancer driven gear bolt. •...

  • Page 310: Transmission

    TRANSMISSION EAS20062 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • Order Job/Parts to remove ’ Remarks Separate. Crankcase Refer to “CRANKCASE”...
  • Page 311 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • ’ Order Job/Parts to remove Remarks Shift fork guide bar retainer 2 Shift fork guide bar Spring “...
  • Page 312 TRANSMISSION Disassembling the main axle assembly ’ Order Job/Parts to remove Remarks 2nd pinion gear 6th pinion gear 3rd pinion gear Circlip Washer 5th pinion gear Circlip Bearing Main axle 5-92...
  • Page 313 TRANSMISSION Disassembling the drive axle assembly ’ Order Job/Parts to remove Remarks Washer 1st wheel gear Collar Washer 5th wheel gear Circlip Washer 4th wheel gear 3rd wheel gear 6th wheel gear Circlip Washer 2nd wheel gear Bearing Drive axle 5-93...

  • Page 314: Checking The Shift Forks

    TRANSMISSION EAS30431 EAS30432 CHECKING THE SHIFT FORKS CHECKING THE SHIFT DRUM ASSEMBLY The following procedure applies to all of the shift 1. Check: forks. • Shift drum groove Damage/scratches/wear → Replace the shift 1. Check: • Shift fork cam follower “1” drum assembly.

  • Page 315: Assembling The Main Axle And Drive Axle

    TRANSMISSION 3. Check: 2. Install: • Transmission gears • Circlip “1” Blue discoloration/pitting/wear → Replace the defective gear(s). Align the opening between the ends “a” of the • Transmission gear dogs circlip with a groove “b” in the axle. Cracks/damage/rounded edges → Replace the defective gear(s).
  • Page 316 TRANSMISSION Shift fork guide bar retainer bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) LOCTITE® • The embossed marks on the shift forks should face towards the right side of the engine. • Install the shift fork guide bar retainers with the “OUT”...
  • Page 317 TRANSMISSION 5-97...

  • Page 318: Cooling System

    COOLING SYSTEM RADIATOR ...................... 6-1 CHECKING THE RADIATOR..............6-3 INSTALLING THE RADIATOR..............6-3 THERMOSTAT ....................6-5 CHECKING THE THERMOSTAT.............. 6-6 INSTALLING THE THERMOSTAT............6-6 WATER PUMP....................6-7 DISASSEMBLING THE WATER PUMP............ 6-9 CHECKING THE WATER PUMP .............. 6-9 ASSEMBLING THE WATER PUMP............6-9 INSTALLING THE CLUTCH COVER ............6-10...

  • Page 319: Radiator

    RADIATOR EAS20063 RADIATOR Removing the radiator 9 Nm (0.9 m kgf, 6.5 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 1.5 Nm (0.15 m kgf, 1.1 ft Ibf) • • 9 Nm (0.9 m kgf, 6.5 ft Ibf) •...
  • Page 320 RADIATOR Removing the radiator 9 Nm (0.9 m kgf, 6.5 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 1.5 Nm (0.15 m kgf, 1.1 ft Ibf) • • 9 Nm (0.9 m kgf, 6.5 ft Ibf) •...

  • Page 321: Checking The Radiator

    RADIATOR EAS30439 CHECKING THE RADIATOR 1. Check: • Radiator fins Obstruction → Clean. Apply compressed air to the rear of the radia- tor. Damage → Repair or replace. Straighten any flattened fins with a thin, flat-head screwdriver. b. Apply the specified pressure for ten seconds and make sure there is no drop in pressure.
  • Page 322 RADIATOR 3. Install • Radiator side cover “1” Radiator side cover bolt 9 Nm (0.9 m·kgf, 6.5 ft·lbf) • Align the projection “a” on the radiator side cov- er with the hole “b” in the radiator side cover bracket. • Align the projection “c” on the radiator side cov- er with the slot “d”...

  • Page 323: Thermostat

    THERMOSTAT EAS20065 THERMOSTAT Removing the thermostat 2.0 Nm (0.20 m kgf, 1.4 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) 15 Nm (1.5 m kgf, 11 ft Ibf) • • • • • • Order Job/Parts to remove ’...

  • Page 324: Checking The Thermostat

    THERMOSTAT 2. Check: EAS30443 CHECKING THE THERMOSTAT • Thermostat cover 1. Check: Cracks/damage → Replace. • Thermostat Does not open at 80.5–83.5 °C (176.90– EAS30939 INSTALLING THE THERMOSTAT 182.30 °F) → Replace. 1. Install: • Thermostat “1” (to the thermostat cover) •...

  • Page 325: Water Pump

    WATER PUMP EAS20066 WATER PUMP Removing the water pump 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 2.0 Nm (0.20 m kgf, 1.4 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) 10 Nm (1.0 m...
  • Page 326 WATER PUMP Removing the water pump 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 2.0 Nm (0.20 m kgf, 1.4 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) 10 Nm (1.0 m...

  • Page 327: Disassembling The Water Pump

    WATER PUMP EAS30446 DISASSEMBLING THE WATER PUMP 1. Remove: • Mechanical seal assembly “1” Remove the mechanical seal assembly from the inside of the clutch cover “2”. 3. Mechanical seal installer 4. Middle driven shaft bearing driver A. Push down EAS30447 CHECKING THE WATER PUMP 1.

  • Page 328: Installing The Clutch Cover

    WATER PUMP 2. Connect: EAS31117 • Clutch cable “1” INSTALLING THE CLUTCH COVER 1. Install: Clutch cable locknut • Dowel pins “1” 7 Nm (0.7 m·kgf, 5.1 ft·lbf) • Clutch cover gasket “2” • Clutch cover “3” • Bottom cowling bracket (front right) •...
  • Page 329 WATER PUMP 4. Fill: • Cooling system (with the specified amount of the recom- mended coolant) Refer to “CHANGING THE COOLANT” on page 3-24. 5. Check: • Cooling system Leaks → Repair or replace the faulty part. 6. Measure: • Radiator cap opening pressure Below the specified pressure →...

  • Page 330: 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 INSTALLING THE FUEL PUMP..............7-3 INSTALLING THE FUEL TANK..............7-4 THROTTLE BODIES ..................7-5 CHECKING THE INJECTORS (BEFORE REMOVING) ......7-8 REMOVING THE INJECTORS ..............7-8 CHECKING THE INJECTORS ..............7-8 CHECKING THE THROTTLE BODIES.............7-8 CHECKING THE THROTTLE BODIES AND ISC...
  • Page 331 FUEL TANK EAS20067 FUEL TANK Removing the fuel tank and fuel pump 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) •...

  • Page 332: Fuel Tank

    FUEL TANK Removing the fuel tank and fuel pump 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) •...

  • Page 333: Removing The Fuel Tank

    FUEL TANK EAS30450 ECA14721 REMOVING THE FUEL TANK NOTICE 1. Extract the fuel in the fuel tank through the • Do not drop the fuel pump or give it a fuel tank cap with a pump. strong shock. 2. Remove: •...

  • Page 334: Installing The Fuel Tank

    FUEL TANK EAS30457 INSTALLING THE FUEL TANK 1. Install: • Fuel hose ECA18420 NOTICE When installing the fuel hose, make sure that it is securely connected, and that the fuel hose connector cover on the fuel hose is in the correct position; otherwise, the fuel hose will not be properly installed.

  • Page 335: Throttle Bodies

    THROTTLE BODIES EAS20070 THROTTLE BODIES Removing the throttle bodies 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 2.5 Nm (0.25 m kgf, 1.8 ft Ibf) •...
  • Page 336 THROTTLE BODIES Removing the throttle bodies 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 2.5 Nm (0.25 m kgf, 1.8 ft Ibf) •...
  • Page 337 THROTTLE BODIES Removing the fuel injectors and ISC valve 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • 3.5 Nm (0.35 m kgf, 2.5 ft Ibf) • • ’ Order Job/Parts to remove Remarks ISC (Idle Speed Control) unit plate ISC (Idle Speed Control) unit Spring Fuel rail...

  • Page 338: Checking The Injectors (Before Removing)

    THROTTLE BODIES EAS30475 EAS30479 CHECKING THE INJECTORS (BEFORE CHECKING THE THROTTLE BODIES REMOVING) 1. Check: Before checking the throttle bodies, check the • Injectors following items: Use the diagnostic code numbers “36–37”. • Valve clearance Refer to “SELF-DIAGNOSTIC FUNCTION • Spark plugs AND DIAGNOSTIC CODE TABLE”...
  • Page 339 Remove the carbon deposits from the inside Recommended cleaning agent: of each throttle body in a downward direction, Yamaha oil & brake cleaner from the air filter case side of the throttle body to the engine side.
  • Page 340 THROTTLE BODIES ECA21920 NOTICE ISC (Idle Speed Control) unit plate screw • Be sure to use the recommended cleaning 5 Nm (0.5 m·kgf, 3.6 ft·lbf) agent. • Do not spray the cleaning agent directly ECA21800 onto the ISC unit or throttle bodies and do NOTICE not immerse them in the cleaning agent.

  • Page 341: Checking The Throttle Body Joint

    THROTTLE BODIES 3. Adjust: EAS30481 CHECKING THE INJECTOR PRESSURE • Throttle bodies synchronizing Out of specification → Replace the throttle • After installing the fuel injectors, perform the bodies. following steps to check the injector pressure. Refer to “SYNCHRONIZING THE THROT- •...

  • Page 342: Checking The Fuel Pressure

    THROTTLE BODIES Pressure drops → Check the pressure gauge c. Connect the pressure gauge “3” and adapter and adapter. “4” to the fuel hose “2”. Check the seals and O-rings, and then rein- Pressure gauge stall. 90890-03153 Replace the fuel injectors. Pressure gauge ▲...

  • Page 343: Replacing The Throttle Bodies

    AND DIAGNOSTIC CODE TABLE” on page 9-5. Yamaha diagnostic tool 90890-03231 4. Reset: • A/F control learning valves using the Yamaha diagnostic tool. Execute the diagnostic mode (code No. 87) Refer to “SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE” on page 9-5.
  • Page 344 THROTTLE BODIES 7-14...

  • Page 345: Air Induction System

    AIR INDUCTION SYSTEM EAS20071 AIR INDUCTION SYSTEM 7-15...
  • Page 346 AIR INDUCTION SYSTEM 1. Air induction system hose (Air filter case to air cut-off valve) 2. Air cut-off valve 3. Air induction system hose (air cut-off valve to reed valve cover) 4. Reed valve assembly 5. Air filter case 7-16...
  • Page 347 AIR INDUCTION SYSTEM Removing the air cut-off valve and reed valve 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • ’ Order Job/Parts to remove Remarks Refer to “GENERAL CHASSIS (1)” on page Rider seat 4-1. Refer to “GENERAL CHASSIS (2)” on page Side panel assemblies 4-3.

  • Page 348: Checking The Air Induction System

    AIR INDUCTION SYSTEM 2. Check: EAS30488 CHECKING THE AIR INDUCTION SYSTEM • Reed valve • Reed valve stopper Air injection • Reed valve seat The air induction system burns unburned ex- Cracks/damage → Replace the reed valve haust gases by injecting fresh air (secondary air) assembly.
  • Page 349 AIR INDUCTION SYSTEM 7-19...

  • Page 350: Electrical System

    TROUBLESHOOTING ................8-23 COOLING SYSTEM..................8-29 CIRCUIT DIAGRAM ................8-29 TROUBLESHOOTING ................8-31 FUEL INJECTION SYSTEM................8-33 CIRCUIT DIAGRAM ................8-33 ECU SELF-DIAGNOSTIC FUNCTION............8-35 TROUBLESHOOTING METHOD............8-35 YAMAHA DIAGNOSTIC TOOL ...............8-36 TROUBLESHOOTING DETAILS ............8-39 FUEL PUMP SYSTEM...................8-73 CIRCUIT DIAGRAM ................8-73 TROUBLESHOOTING ................8-75...
  • Page 351 ABS (ANTI-LOCK BRAKE SYSTEM)............8-77 CIRCUIT DIAGRAM ................8-77 ABS COUPLER LOCATION CHART ............8-79 MAINTENANCE OF THE ABS ECU ............8-81 ABS TROUBLESHOOTING OUTLINE............8-81 BASIC INSTRUCTIONS FOR TROUBLESHOOTING ......8-82 BASIC PROCESS FOR TROUBLESHOOTING ........8-83 [A] CHECKING THE ABS WARNING LIGHT..........8-85 [A-1] ONLY THE ABS WARNING LIGHT FAILS TO COME ON.....

  • Page 353: Ignition System

    IGNITION SYSTEM EAS20072 IGNITION SYSTEM EAS30490 CIRCUIT DIAGRAM...
  • Page 354 IGNITION SYSTEM 1. Main switch 2. Diode 1 3. Ignition fuse 12.Crankshaft position sensor 14.Battery 15.Engine ground 16.Main fuse 20.Diode 3 21.Sidestand switch 31.Lean angle sensor 32.ECU (Engine Control Unit) 33.Ignition coil #1 34.Spark plug #1 35.Ignition coil #2 36.Spark plug #2 61.Gear position switch 76.Handlebar switch (right) 79.Engine stop switch...

  • Page 355: Engine Stopping Due To Sidestand Operation

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

  • Page 356: Troubleshooting

    IGNITION SYSTEM EAS30492 TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). • Before troubleshooting, remove the following part(s): 1. Passenger seat 2. Center cover 3. Rider seat 4. Side panel assemblies 5. Fuel tank NG → 1.
  • Page 357 IGNITION SYSTEM NG → 8. Check the main switch. Refer to “CHECKING THE Replace the main switch. SWITCHES” on page 8-113. OK ↓ NG → 9. Check the engine stop switch. • The engine stop switch is faulty. Refer to “CHECKING THE •...
  • Page 358 IGNITION SYSTEM...

  • Page 359: Electric Starting System

    ELECTRIC STARTING SYSTEM EAS20073 ELECTRIC STARTING SYSTEM EAS30493 CIRCUIT DIAGRAM...
  • Page 360 ELECTRIC STARTING SYSTEM 1. Main switch 2. Diode 1 3. Ignition fuse 14.Battery 15.Engine ground 16.Main fuse 17.Starter relay 18.Starter motor 19.Diode 2 20.Diode 3 21.Sidestand switch 22.Starting circuit cut-off relay 23.Diode 4 61.Gear position switch 63.Handlebar switch (left) 68.Clutch switch 76.Handlebar switch (right) 78.Start switch 79.Engine stop switch...

  • Page 361: Starting Circuit Cut-Off System Operation

    ELECTRIC STARTING SYSTEM EAS30494 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the engine stop switch is set to “ ” and the main switch is set to “ON” (both switches are closed), the starter motor can only operate if at least one of the following conditions is met: •...

  • Page 362: Troubleshooting

    ELECTRIC STARTING SYSTEM EAS30495 TROUBLESHOOTING The starter motor fails to turn. • Before troubleshooting, remove the following part(s): 1. Passenger seat 2. Center cover 3. Rider seat 4. Side panel assemblies 5. Fuel tank 6. Air filter case 7. Throttle bodies NG →...
  • Page 363 ELECTRIC STARTING SYSTEM NG → 8. Check the main switch. Refer to “CHECKING THE Replace the main switch. SWITCHES” on page 8-113. OK ↓ NG → 9. Check the gear position switch. Refer to “CHECKING THE GEAR Replace the gear position switch. POSITION SWITCH”...
  • Page 364 ELECTRIC STARTING SYSTEM 8-12...

  • Page 365: Charging System

    CHARGING SYSTEM EAS20074 CHARGING SYSTEM EAS30496 CIRCUIT DIAGRAM 8-13...
  • Page 366 CHARGING SYSTEM 11.AC magneto 13.Rectifier/regulator 14.Battery 15.Engine ground 16.Main fuse 8-14...

  • Page 367: Troubleshooting

    CHARGING SYSTEM EAS30497 TROUBLESHOOTING The battery is not being charged. • Before troubleshooting, remove the following part(s): 1. Passenger seat 2. Center cover 3. Rider seat 4. Side panel assembly (left) NG → 1. Check the fuse. (Main) Replace the fuse. Refer to “CHECKING THE FUS- ES”...
  • Page 368 CHARGING SYSTEM 8-16...

  • Page 369: Lighting System

    LIGHTING SYSTEM EAS20075 LIGHTING SYSTEM EAS30498 CIRCUIT DIAGRAM 8-17...
  • Page 370 LIGHTING SYSTEM 1. Main switch 3. Ignition fuse 4. Signaling system fuse 7. Headlight fuse 14.Battery 15.Engine ground 16.Main fuse 32.ECU (Engine Control Unit) 48.Meter assembly 57.High beam indicator light 59.Meter light 63.Handlebar switch (left) 64.Pass switch 65.Dimmer switch 72.Headlight 75.Auxiliary light 81.Tail/brake light 82.License plate light...

  • Page 371: Troubleshooting

    LIGHTING SYSTEM EAS30499 TROUBLESHOOTING Any of the following fail to light: headlight, high beam indicator light, taillight, license plate light, auxiliary light or meter light. • Before troubleshooting, remove the following part(s): 1. Headlight assembly 2. Mudguard assembly cover 3. Passenger seat 4.
  • Page 372 LIGHTING SYSTEM NG → 7. Check the headlight relay. Refer to “CHECKING THE RE- Replace the headlight relay. LAYS” on page 8-121. OK ↓ NG → 8. Check the entire lighting system wiring. Properly connect or replace the wiring har- Refer to “CIRCUIT DIAGRAM”...

  • Page 373: Signaling System

    SIGNALING SYSTEM EAS20076 SIGNALING SYSTEM EAS30500 CIRCUIT DIAGRAM 8-21...
  • Page 374 15.Engine ground 16.Main fuse 26.Fuel sender 32.ECU (Engine Control Unit) 41.Coolant temperature sensor 43.Rear wheel sensor 46.ABS ECU 47.Yamaha diagnostic tool coupler 48.Meter assembly 50.Oil pressure warning light 51.Neutral indicator light 52.Tachometer 53.Multi-function meter 1 55.Shift timing indicator light 56.Multi-function meter 2 58.Turn signal indicator light...

  • Page 375: Troubleshooting

    SIGNALING SYSTEM EAS30501 TROUBLESHOOTING • Any of the following fail to light: a turn signal light, the brake light or an indicator light. • The horn fails to sound. • The fuel meter fails to come on. • The speedometer fails to operate. •...
  • Page 376 SIGNALING SYSTEM NG → 2. Check the entire signaling system wiring. Properly connect or replace the wiring har- Refer to “CIRCUIT DIAGRAM” on ness. page 8-21. OK ↓ Replace the horn. The tail/brake light fails to come on. NG → 1.
  • Page 377 SIGNALING SYSTEM NG → 4. Check the entire signaling system wiring. Properly connect or replace the wiring har- Refer to “CIRCUIT DIAGRAM” on ness. page 8-21. OK ↓ Replace the meter assembly. The neutral indicator light fails to come on. NG →...
  • Page 378 SIGNALING SYSTEM NG → 2. Check the engine oil pressure. Check the engine oil leakage, oil viscosity, Refer to “CHANGING THE EN- oil seal, oil filter, or oil pump. GINE OIL” on page 3-22. OK ↓ Replace the oil pressure switch. The fuel meter fails to come on.
  • Page 379 SIGNALING SYSTEM NG → 2. Check the entire rear wheel sensor wiring. Properly connect or replace the wiring har- Refer to “CIRCUIT DIAGRAM” on ness. page 8-21. OK ↓ Replace the ECU or meter assembly. Refer to “REPLACING THE ECU (en- gine control unit)”...
  • Page 380 SIGNALING SYSTEM 8-28...

  • Page 381: Cooling System

    COOLING SYSTEM EAS20077 COOLING SYSTEM EAS30502 CIRCUIT DIAGRAM 8-29...
  • Page 382 COOLING SYSTEM 1. Main switch 3. Ignition fuse 8. Radiator fan motor fuse 14.Battery 15.Engine ground 16.Main fuse 32.ECU (Engine Control Unit) 41.Coolant temperature sensor 85.Radiator fan motor relay 86.Radiator fan motor 8-30...

  • Page 383: Troubleshooting

    COOLING SYSTEM EAS30503 TROUBLESHOOTING The radiator fan motor fails to turn. • Before troubleshooting, remove the following part(s): 1. Passenger seat 2. Center cover 3. Rider seat 4. Side panel assemblies 5. Fuel tank NG → 1. Check the fuses. (Ignition, radiator fan motor, and main) Replace the fuse(s).
  • Page 384 COOLING SYSTEM NG → 7. Check the entire cooling system wiring. Properly connect or replace the wiring har- Refer to “CIRCUIT DIAGRAM” on ness. page 8-29. OK ↓ Replace the ECU. Refer to “REPLAC- ING THE ECU (engine control unit)” on page 8-117.

  • Page 385: Fuel Injection System

    FUEL INJECTION SYSTEM EAS20078 FUEL INJECTION SYSTEM EAS30504 CIRCUIT DIAGRAM 8-33...
  • Page 386 38.Fuel injector #2 39.Air induction system solenoid 40.ISC (Idle Speed Control) unit 41.Coolant temperature sensor 43.Rear wheel sensor 46.ABS ECU 47.Yamaha diagnostic tool coupler 48.Meter assembly 53.Multi-function meter 1 54.Engine trouble warning light 61.Gear position switch 68.Clutch switch 76.Handlebar switch (right) 79.Engine stop switch...

  • Page 387: Ecu Self-Diagnostic Function

    FUEL INJECTION SYSTEM EAS30505 ECU SELF-DIAGNOSTIC FUNCTION The ECU is equipped with a self-diagnostic function in order to ensure that the fuel injection system is operating normally. If this function detects a malfunction in the system, it immediately operates the en- gine under substitute characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the system.

  • Page 388: Yamaha Diagnostic Tool

    EAS30951 YAMAHA DIAGNOSTIC TOOL This model uses the Yamaha diagnostic tool to identify malfunctions. For information about using the Yamaha diagnostic tool, refer to the operation manual that is included with the tool. Yamaha diagnostic tool 90890-03231 Features of the Yamaha diagnostic tool You can use the Yamaha diagnostic tool to identify malfunctions quicker than with conventional meth- ods.
  • Page 389 Disconnect the Yamaha diagnostic tool coupler “1”, and then connect the Yamaha diagnostic tool “2” to the coupler. When the Yamaha diagnostic tool is connected to the vehicle, “Er-1” or “Er-4” will be displayed on the multi-function meter. Operation of the Yamaha diagnostic tool (Malfunction mode) Malfunction results are displayed in the top part of the window area.
  • Page 390 FUEL INJECTION SYSTEM 1. Recovered The item list of the malfunction detected in the past (already recovered) are displayed. 2. Detected The item list of the malfunction currently occurred are displayed. 3. Code The following icons and the fault code numbers for the detected malfunctions are displayed. A.

  • Page 391: Troubleshooting Details

    FUEL INJECTION SYSTEM 6. Condition The current conditions are displayed. (Detected/Recovered) 7. Symptom The symptoms of the detected malfunction are displayed. 8. Diagnosis code The diagnosis codes related to the detected malfunction are displayed. 9. FFD (only for models that can display freeze frame data) The mark “...
  • Page 392 FUEL INJECTION SYSTEM Fault code No. Crankshaft position sensor: no normal signals are received from the Item crankshaft position sensor. Improperly connected → Con- Connection of ECU coupler. Crank the engine. Check the locking condition of nect the coupler securely or re- Fault code number is not dis- played →...
  • Page 393 FUEL INJECTION SYSTEM Fault code No. Item Intake air pressure sensor: open or short circuit detected. Probable cause of malfunc- Confirmation of service com- Item Maintenance job tion and check pletion Improperly connected → Con- Connection of intake air pres- Turn the main switch to “ON”.
  • Page 394 FUEL INJECTION SYSTEM Fault code No. Item Intake air pressure sensor: open or short circuit detected. Defective intake air pressure Execute the diagnostic mode. Turn the main switch to “ON”. sensor. (Code No. 03) Fault code number is not dis- played →...
  • Page 395 FUEL INJECTION SYSTEM Fault code No. Intake air pressure sensor: hose system malfunction (clogged hole Item or loose). Installed condition of sensor. Check the mounting section for Start the engine and let it idle for loose or pinched mounting. approximately 5 seconds. Fault code number is not dis- played →...
  • Page 396 FUEL INJECTION SYSTEM Fault code No. Item Throttle position sensor: open or short circuit detected. Improperly connected → Con- Connection of throttle position Turn the main switch to “ON”. sensor coupler. nect the coupler securely or re- Fault code number is not dis- played →...
  • Page 397 FUEL INJECTION SYSTEM Fault code No. 16 ECA20500 NOTICE Do not remove the throttle body sensor assembly from the throttle body. Fault code No. Throttle position sensor: stuck throttle position sensor is detected. Item (signal from throttle position sensor will not change) Able to start engine Fail-safe system Able to drive vehicle...
  • Page 398 FUEL INJECTION SYSTEM Fault code No. Sidestand switch: a break or disconnection of the black/red lead of Item the ECU is detected. Sidestand switch Tool display • “ON” (normal signal) • “OFF” (abnormal signal) Procedure Extend and retract the sidestand (with the transmission in gear) Probable cause of malfunc- Confirmation of service com- Item...
  • Page 399 FUEL INJECTION SYSTEM Fault code No. 21 Fault code No. Item Coolant temperature sensor: open or short circuit detected. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. When engine is cold: Displays temperature closer to air temperature. Tool display When engine is hot: Displays current coolant temperature.
  • Page 400 FUEL INJECTION SYSTEM Fault code No. Item Coolant temperature sensor: open or short circuit detected. Malfunction in ECU. Replace the ECU. Refer to “REPLACING THE ECU (engine control unit)” on page 8-117. Fault code No. 22 ECA20500 NOTICE Do not remove the throttle body sensor assembly from the throttle body. Fault code No.
  • Page 401 FUEL INJECTION SYSTEM Fault code No. Item Intake air temperature sensor: open or short circuit detected. Defective intake air tempera- Execute the diagnostic mode. Turn the main switch to “ON”. ture sensor. (Code No. 05) Fault code number is not dis- played →...
  • Page 402 FUEL INJECTION SYSTEM Fault code No. sensor: no normal signals are received from the O sensor. Item Open or short circuit → Replace Wire harness continuity. Start the engine, warm it up, the wire harness. and then race it, or execute the Between O sensor coupler and diagnostic mode.
  • Page 403 Diagnostic code No. Actuates the cylinder-#1 ignition coil five times at one-second intervals. The “CHECK” indicator and “ ” on the Yamaha diagnostic tool screen Actuation comes on each time the ignition coil is actuated. Check that a spark is generated five times.
  • Page 404 Actuates the cylinder-#2 ignition coil five times at one-second intervals. Actuation The “CHECK” indicator and “ ” on the Yamaha diagnostic tool screen comes on each time the ignition coil is actuated. Check that a spark is generated five times.
  • Page 405 Actuates fuel injector #1 five times at one-second intervals. Actuation The “CHECK” indicator and “ ” on the Yamaha diagnostic tool screen comes on each time the fuel injector is actuated. Disconnect the fuel pump coupler, and then check that fuel injector #1 is Procedure actuated five times by listening for the operating sound.
  • Page 406 FUEL INJECTION SYSTEM Fault code No. Item Fuel injector: open or short circuit detected. Identify the malfunctioning fuel Execute the diagnostic mode. injector (Code Nos. 36, 37) Identify the fuel injector that does not produce an operating sound. Perform the following proce- dures for the defective fuel injec- tor.
  • Page 407 FUEL INJECTION SYSTEM Fault code No. 41 Fault code No. Item Lean angle sensor: open or short circuit detected. Unable to start engine Fail-safe system Unable to drive vehicle Diagnostic code No. Lean angle sensor output voltage Tool display • 0.4–1.4 (upright) •...
  • Page 408 FUEL INJECTION SYSTEM Fault code No. 42 Fault code No. Wheel sensor: no normal signals are received from the wheel sensor. Item Gear position switch: open or short circuit is detected. Clutch switch: open or short circuit is detected. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No.
  • Page 409 FUEL INJECTION SYSTEM Fault code No. Wheel sensor: no normal signals are received from the wheel sensor. Item Gear position switch: open or short circuit is detected. Clutch switch: open or short circuit is detected. Improperly connected → Con- Connection of ECU coupler. Execute the diagnostic mode.
  • Page 410 FUEL INJECTION SYSTEM Fault code No. Wheel sensor: no normal signals are received from the wheel sensor. Item Gear position switch: open or short circuit is detected. Clutch switch: open or short circuit is detected. Probable cause of malfunc- Confirmation of service com- Item Maintenance job tion and check...
  • Page 411 FUEL INJECTION SYSTEM Fault code No. Wheel sensor: no normal signals are received from the wheel sensor. Item Gear position switch: open or short circuit is detected. Clutch switch: open or short circuit is detected. Defective diode. Check the diode 1. Execute the diagnostic mode.
  • Page 412 FUEL INJECTION SYSTEM Fault code No. Wheel sensor: no normal signals are received from the wheel sensor. Item Gear position switch: open or short circuit is detected. Clutch switch: open or short circuit is detected. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No.
  • Page 413 FUEL INJECTION SYSTEM Fault code No. Wheel sensor: no normal signals are received from the wheel sensor. Item Gear position switch: open or short circuit is detected. Clutch switch: open or short circuit is detected. Improperly connected → Con- Connection of clutch switch cou- Execute the diagnostic mode.
  • Page 414 FUEL INJECTION SYSTEM Fault code No. Wheel sensor: no normal signals are received from the wheel sensor. Item Gear position switch: open or short circuit is detected. Clutch switch: open or short circuit is detected. Defective clutch switch. Check the clutch switch. Execute the diagnostic mode.
  • Page 415 FUEL INJECTION SYSTEM Fault code No. Fuel system voltage: incorrect voltage supplied to the fuel injector Item and fuel pump. Open or short circuit → Replace Wire harness continuity. Start the engine and let it idle for the wire harness. approximately 5 seconds.
  • Page 416 FUEL INJECTION SYSTEM Fault code No. EEPROM fault code number: an error is detected while reading or Item writing on EEPROM. EEPROM fault code display • 00 (no history) • 01–02: Cylinder fault code number (history exists) If more than one cylinder is defective, the display switches every two Tool display seconds to show the cylinder fault code numbers of all defective cylin- ders in a repeating cycle.
  • Page 417 FUEL INJECTION SYSTEM Fault code No. Item Power shut off: incorrect back up voltage is supplied to ECU. Tool display — Procedure — Probable cause of malfunc- Confirmation of service com- Item Maintenance job tion and check pletion Improperly connected → Con- Installed condition of battery Set the main switch to “ON”.
  • Page 418 FUEL INJECTION SYSTEM Fault code No. Item Charging voltage is abnormal. Malfunction in charging system. Check the charging system. Start the engine and let it idle for Refer to “CHARGING SYSTEM” approximately 5 seconds. on page 8-13. Fault code number is not dis- played →...
  • Page 419 Fault code No. Waiting for connection (Yamaha diagnostic tool) ECU (engine control unit) internal malfunction (output signal error): Item Signals cannot be transmitted between the ECU and Yamaha diag- nostic tool. Able to start engine (unable when ECU is malfunctioning) Fail-safe system Able to drive vehicle (unable when ECU is malfunctioning) Diagnostic code No.
  • Page 420 Fault code No. Waiting for connection (Yamaha diagnostic tool) ECU (engine control unit) internal malfunction (output signal error): Item Signals cannot be transmitted between the ECU and Yamaha diag- nostic tool. Improperly connected → Con- Connection of wire harness Connect the Yamaha diagnostic ECU coupler.
  • Page 421 Turn the main switch to “ON”. the wire harness. Fault code number is not dis- played → Service is finished. Between ECU coupler and Yamaha diagnostic tool coupler. Fault code number is displayed → Go to item 4. yellow/blue–yellow/blue Between Yamaha diagnostic tool coupler and meter assem- bly coupler.
  • Page 422 Turn the main switch to “ON”. the wire harness. Fault code number is not dis- played → Service is finished. Between ECU coupler and Yamaha diagnostic tool coupler. Fault code number is displayed → Go to item 4. yellow/blue–yellow/blue Between Yamaha diagnostic tool coupler and meter assem- bly coupler.
  • Page 423 Fault code No. Er-4 (Yamaha diagnostic tool) ECU (engine control unit) internal malfunction (input signal error): Item no normal signals are received from the Yamaha diagnostic tool. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No.
  • Page 424 Fault code No. Er-4 (Yamaha diagnostic tool) ECU (engine control unit) internal malfunction (input signal error): Item no normal signals are received from the Yamaha diagnostic tool. Improperly connected → Con- Connection of wire harness Connect the Yamaha diagnostic ECU coupler.

  • Page 425: Fuel Pump System

    FUEL PUMP SYSTEM EAS20081 FUEL PUMP SYSTEM EAS30513 CIRCUIT DIAGRAM 8-73...
  • Page 426 FUEL PUMP SYSTEM 1. Main switch 3. Ignition fuse 14.Battery 15.Engine ground 16.Main fuse 24.Fuel pump relay 25.Fuel pump 32.ECU (Engine Control Unit) 76.Handlebar switch (right) 79.Engine stop switch 8-74...
  • Page 427 FUEL PUMP SYSTEM EAS30514 TROUBLESHOOTING If the fuel pump fails to operate. • Before troubleshooting, remove the following part(s): 1. Passenger seat 2. Center cover 3. Rider seat 4. Side panel assemblies 5. Fuel tank NG → 1. Check the fuses. (Ignition, and main) Replace the fuse(s).
  • Page 428 FUEL PUMP SYSTEM 8-76...
  • Page 429 ABS (ANTI-LOCK BRAKE SYSTEM) EAS20085 ABS (ANTI-LOCK BRAKE SYSTEM) EAS30843 CIRCUIT DIAGRAM 8-77...
  • Page 430 32.ECU (Engine Control Unit) 42.Front wheel sensor 43.Rear wheel sensor 44.ABS ECU coupler 45.ABS test coupler 46.ABS ECU 47.Yamaha diagnostic tool coupler 48.Meter assembly 49.ABS warning light 53.Multi-function meter 1 76.Handlebar switch (right) 77.Front brake light switch 80.Rear brake light switch 81.Tail/brake light...

  • Page 431: Abs Coupler Location Chart

    ABS (ANTI-LOCK BRAKE SYSTEM) EAS30844 ABS COUPLER LOCATION CHART Br/R Gy W/L G/R Sb/W Y/W W/R 8-79...
  • Page 432 ABS (ANTI-LOCK BRAKE SYSTEM) 1. ABS ECU coupler 2. Rear wheel sensor coupler 3. ABS test coupler 4. Meter assembly coupler 5. Front wheel sensor coupler 8-80...

  • Page 433: Maintenance Of The Abs Ecu

    The following troubleshooting describes the problem identification and service method using the Yamaha diagnostic tool. For information about using the Yamaha diagnostic tool, refer to “[B-2] DIAG- NOSIS USING THE FAULT CODES” on page 8-86. For troubleshooting items other than the following items, follow the normal service method.

  • Page 434: Basic Instructions For Troubleshooting

    Previous malfunctions can be checked since the ABS ECU also stores the mal- function history. The fault codes recorded in the ABS ECU can be checked using the Yamaha diagnostic tool. When the service is finished, check the normal operation of the vehicle, and then delete the fault code(s). For in- formation about deleting the fault codes, refer to “[B-3] DELETING THE FAULT CODES”...

  • Page 435: Basic Process For Troubleshooting

    • Can the tool communicate with is defective. the ABS ECU? Can communicate [A-5] ABS ECU and FI ECU The connection with the Yamaha • Return to [A]. fail to communicate. diagnostic tool is defective. • The wire harness is defective.
  • Page 436 ABS (ANTI-LOCK BRAKE SYSTEM) EWA16710 WARNING When maintenance or checks have been performed on components related to the ABS, be sure to perform a final check before delivering the vehicle to the customer. To final check, refer to “[C-1] FINAL CHECK” on page 8-108. 8-84...

  • Page 437: [A] Checking The Abs Warning Light

    EAS31162 [A-3] THE ABS WARNING LIGHT COMES ON Connect the Yamaha diagnostic tool to the ABS test coupler and execute functional diagnosis. (For in- formation about how to execute functional diagnosis, refer to the operation manual that is included with the tool.)
  • Page 438 ABS test coupler. EAS31165 [B-1] MALFUNCTION ARE CURRENTLY DETECTED When the Yamaha diagnostic tool is connected to the ABS test coupler, the fault codes will be displayed on the computer screen. • A fault code is displayed. [B-2] •...
  • Page 440 EAS31167 [B-3] DELETING THE FAULT CODES To delete the fault codes, use the Yamaha diagnostic tool. For information about deleting the fault codes, refer to the operation manual of the Yamaha diagnostic tool. Check that all the displayed fault codes are deleted.

  • Page 441: Electrical Components

    ELECTRICAL COMPONENTS EAS20089 ELECTRICAL COMPONENTS 8-109...
  • Page 442 ELECTRICAL COMPONENTS 1. Main switch 2. Clutch switch 3. Front brake light switch 4. Ignition coil 5. Fuse box 6. Diode 1 7. Starter relay 8. Main fuse 9. Rectifier/regulator 10. ECU (Engine Control Unit) 11. Diode 2 12. Diode 3 13.
  • Page 443 ELECTRICAL COMPONENTS 8-111...
  • Page 444 ELECTRICAL COMPONENTS 1. Headlight relay 2. Radiator fan motor relay 3. Fuel pump relay 4. Fuel pump 5. Throttle body sensor assembly 6. Fuel injector 7. Lean angle sensor 8. Starting circuit cut-off relay 9. Turn signal relay 10. Rear wheel sensor 11.

  • Page 445: Checking The Switches

    ELECTRICAL COMPONENTS EAS30549 CHECKING THE SWITCHES R Br/R R Br/R B/R L/Y LOCK R/B Br L/W B Br/W L/B Y L/Y B Br R/W R/B L/B Y Br/W Br P 8-113...
  • Page 446 ELECTRICAL COMPONENTS 1. Main switch 2. Start switch 3. Engine stop switch 4. Front brake light switch 5. Rear brake light switch 6. Sidestand switch 7. Horn switch 8. Turn signal switch 9. Pass switch 10. Dimmer switch 11. Clutch switch 8-114...
  • Page 447 ELECTRICAL COMPONENTS Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. ECA18520 NOTICE Never insert the tester probes into the coupler terminal slots “a”. Always insert the probes from the opposite end of the coupler, taking care not to loosen or damage the leads.
  • Page 448 ELECTRICAL COMPONENTS EAS30550 ECA14381 CHECKING THE BULBS AND BULB NOTICE SOCKETS • Be sure to hold the socket firmly when re- moving the bulb. Never pull the lead, other- Do not check any of the lights that use LEDs. wise it may be pulled out of the terminal in the coupler.

  • Page 449: Checking The Fuses

    ELECTRICAL COMPONENTS b. Install a new fuse of the correct amperage Pocket tester rating. 90890-03112 c. Set on the switches to verify if the electrical Analog pocket tester circuit is operational. YU-03112-C d. If the fuse immediately blows again, check the electrical circuit.

  • Page 450: Checking And Charging The Battery

    ELECTRICAL COMPONENTS 4. Check: EAS30552 CHECKING AND CHARGING THE BATTERY • Engine idling speed EWA13290 Start the engine, warm it up, and then mea- WARNING sure the engine idling speed. Batteries generate explosive hydrogen gas and contain electrolyte which is made of poi- Engine idling speed sonous and highly caustic sulfuric acid.
  • Page 451 ELECTRICAL COMPONENTS specific gravity of the electrolyte. Therefore, the Example charge of the battery has to be checked by mea- Open-circuit voltage = 12.0 V Charging time = 6.5 hours suring the voltage at the battery terminals. Charge of the battery = 20–30% 1.
  • Page 452 ELECTRICAL COMPONENTS • When charging a battery, be sure to remove it from the vehicle. (If charging has to be Voltage should be measured 30 minutes after done with the battery mounted on the vehi- the engine is stopped. cle, disconnect the negative battery lead b.

  • Page 453: Checking The Relays

    ELECTRICAL COMPONENTS c. Make sure that the current is higher than the 10.Install: standard charging current written on the bat- • Rider seat tery. • Center cover • Passenger seat Refer to “GENERAL CHASSIS (1)” on page If the current is lower than the standard charging 4-1.

  • Page 454: Checking The Diodes

    ELECTRICAL COMPONENTS Starting circuit cut-off relay 2. Negative battery terminal 3. Positive tester probe 4. Negative tester probe Result Continuity (between “3” and “4”) R/B, Turn signal relay 1. Positive battery terminal 2. Negative battery terminal 3. Positive tester probe 4.

  • Page 455: Checking The Spark Plug Caps

    ELECTRICAL COMPONENTS Diode 1 Continuity Positive tester probe → sky blue “1” Negative tester probe → blue/yellow “2” Continuity Positive tester probe → sky blue “1” Negative tester probe → yel- low/black “3” No continuity Positive tester probe → blue/yellow “2” Negative tester probe →...

  • Page 456: Checking The Ignition Coils

    ELECTRICAL COMPONENTS Secondary coil resistance 8.64–12.96 kΩ ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Disconnect the spark plug cap from the igni- tion coil. b. Connect the pocket tester (Ω × 1 k) to the ig- nition coil as shown.

  • Page 457: Checking The Lean Angle Sensor

    ELECTRICAL COMPONENTS Ignition checker 90890-06754 Oppama pet–4000 spark checker YM-34487 b. Measure the crankshaft position sensor re- sistance. ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ EAS30561 CHECKING THE LEAN ANGLE SENSOR 1.

  • Page 458: Checking The Starter Motor Operation

    ELECTRICAL COMPONENTS EAS30566 CHECKING THE STATOR COIL 1. Disconnect: • Stator coil coupler 45˚ 45˚ (from the wire harness) 2. Check: • Stator coil resistance Out of specification → Replace the stator coil assembly (Stator coil/Crankshaft position sensor). c. Set the main switch to “ON”. Stator coil resistance d.

  • Page 459: Checking The Fuel Sender

    ELECTRICAL COMPONENTS Charging voltage Pocket tester 14.1–14.9 V at 5000 r/min 90890-03112 Analog pocket tester ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ YU-03112-C a. Connect the pocket tester (DC 20 V) to the battery terminals as shown.

  • Page 460: Checking The Radiator Fan Motor

    ELECTRICAL COMPONENTS Coolant temperature sensor re- sistance 2521–2786 Ω at 20 °C (2521– 2786 Ω at 68 °F) Coolant temperature sensor re- sistance 210–220 Ω at 100 °C (210–220 Ω at 212 °F) ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼...

  • Page 461: Checking The Air Induction System Solenoid

    ELECTRICAL COMPONENTS Coolant temperature sensor Pocket tester 15 Nm (1.5 m·kgf, 11 ft·lbf) 90890-03112 Analog pocket tester YU-03112-C EAS30587 CHECKING THE AIR INDUCTION SYSTEM SOLENOID Result 1. Check: Neutral position • Air induction system solenoid resistance Continuity Out of specification → Replace. Positive tester probe sky blue “1”...

  • Page 462: Checking The Fuel Injectors

    ELECTRICAL COMPONENTS O Y/W EAS30681 CHECKING THE FUEL INJECTORS The following procedure applies to all of the fuel injectors. 1. Remove: • Fuel injector Refer to “THROTTLE BODIES” on page 7-5. 2. Check: • Fuel injector resistance Out of specification → Replace the fuel injec- tor.
  • Page 463 ELECTRICAL COMPONENTS 8-131...

  • Page 464: Troubleshooting

    FAULTY LIGHTING OR SIGNALING SYSTEM ........9-4 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE....9-5 SELF-DIAGNOSTIC FUNCTION TABLE ..........9-5 COMMUNICATION ERROR WITH THE METER OR YAMAHA DIAGNOSTIC TOOL ................9-5 DIAGNOSTIC CODE: SENSOR OPERATION TABLE ......9-6 DIAGNOSTIC CODE: ACTUATOR OPERATION TABLE ......9-8...

  • Page 465: Troubleshooting

    TROUBLESHOOTING • Sucked-in air EAS20090 TROUBLESHOOTING Electrical system EAS30599 1. Battery GENERAL INFORMATION • Discharged battery • Faulty battery The following guide for troubleshooting does not 2. Fuse(s) cover all the possible causes of trouble. It should • Blown, damaged or incorrect fuse be helpful, however, as a guide to basic trouble- •...

  • Page 466: Poor Medium-And-High-Speed Performance

    TROUBLESHOOTING • Improper throttle grip free play Transmission • Flooded throttle body • Seized transmission gear • Faulty air induction system • Foreign object between transmission gears • Improperly assembled transmission Electrical system EAS30605 1. Battery JUMPS OUT OF GEAR •...

  • Page 467: Overheating

    TROUBLESHOOTING • Worn brake disc EAS30607 OVERHEATING • Air in hydraulic brake system • Leaking brake fluid Engine • Faulty brake caliper kit 1. Clogged coolant passages • Faulty brake caliper seal • Cylinder head and piston(s) • Loose union bolt •...

  • Page 468: Faulty Lighting Or Signaling System

    TROUBLESHOOTING Swingarm • Burnt-out turn signal bulb • Worn bearing or bushing • Incorrect connection • Bent or damaged swingarm • Damaged or faulty wire harness • Improperly grounded circuit Rear shock absorber assembly • Faulty battery • Faulty rear shock absorber spring •...

  • Page 469: Self-Diagnostic Function And Diagnostic Code Table

    Faulty ECU memory. (When this malfunction is detected in the ECU, the fault code number might not appear on the meter display.) Engine idling stop EAS31373 COMMUNICATION ERROR WITH THE METER OR YAMAHA DIAGNOSTIC TOOL For details of the fault code, refer to “TROUBLESHOOTING METHOD” on page 8-35. Fault code No. Item...

  • Page 470: Diagnostic Code: Sensor Operation Table

    Waiting for connection (Yamaha ECU (engine control unit) internal malfunction (output signal error): Sig- diagnostic tool) nals cannot be transmitted between the ECU and Yamaha diagnostic tool. ECU (engine control unit) internal malfunction (output signal error): no Er-2 signals are received from the ECU within the specified duration.
  • Page 471 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Diagnostic Item Meter display Procedure code No. Sidestand switch Extend and retract the side- stand (with the transmission in gear). • Stand retracted • Stand extended Neutral switch and clutch Operate the transmission switch and clutch lever.

  • Page 472: Diagnostic Code: Actuator Operation Table

    • Connect an ignition check- The “CHECK” indicator and “ ” on the Yamaha diag- nostic tool screen come on each time the ignition coil is actuated. Cylinder-#2 ignition coil Actuates cylinder-#2 ignition...
  • Page 473 Check that fuel injector #1 is The “CHECK” indicator and actuated five times by listen- “ ” on the Yamaha diag- ing for the operating sound. nostic tool screen come on each time the fuel injector is actuated. Fuel injector #2...
  • Page 474 ISC valve operates. Fully closes the ISC valve, and then opens the valve. This operation takes approxi- mately 6 seconds. The “CHECK” indicator and “ ” on the Yamaha diag- nostic tool screen come on during the operation. 9-10...

  • Page 475: Wiring Diagram

    42. Front wheel sensor 43. Rear wheel sensor 44. ABS ECU coupler 45. ABS test coupler 46. ABS ECU 47. Yamaha diagnostic tool coupler 48. Meter assembly 49. ABS warning light 50. Oil pressure warning light 51. Neutral indicator light 52.
  • Page 478 MTN320-A 2016 MTN320-A 2016 MTN320-A 2016 MTN320-A 2016 MTN320-A 2016 WIRING DIAGRAM SCHÉMA DE CÂBLAGE SCHALTPLAN SCHEMA ELETTRICO DIAGRAMA ELÉCTRICO B/W,B P/B R/W Gy/R G/Y Or Sb P Gy/G Br/W L/W G/B B/Y P/L R/GG/B B/L Br/R W R R/L P/B Y/B Gy/R Gy/R P/W Br/W...
  • Page 479 MTN320-A 2016 MTN320-A 2016 MTN320-A 2016 MTN320-A 2016 MTN320-A 2016 WIRING DIAGRAM SCHÉMA DE CÂBLAGE SCHALTPLAN SCHEMA ELETTRICO DIAGRAMA ELÉCTRICO § µ ® • ¶ ß º START æ ¥ ç £ ™ © † ¢ å...

This manual is also suitable for:

Mtn320-a

Table of Contents