Yamaha MT-10 2022 Manuals

Manuals and User Guides for Yamaha MT-10 2022. We have 1 Yamaha MT-10 2022 manual available for free PDF download: Service Manual

Yamaha MT-10 2022 Service Manual (810 pages)

Brand: Yamaha | Category: Motorcycle | Size: 29 MB

Important Manual Information
3
How to Use this Manual
4
Table of Contents
7
General Information
9
Identification
10
Vehicle Identification Number
10
Model Label
10
Glossary
11
Display
11
Menu Screen
17
Basic Service Information
26
Electrical System
26
Special Tools
27
Specifications
35
General Specifications
36
Engine Specifications
37
Chassis Specifications
42
Electrical Specifications
45
Tightening Torques
47
Engine Tightening Torques
47
Chassis Tightening Torques
47
Cable Routing
50
Periodic Checks and Adjustments
113
Periodic Maintenance
115
Introduction
115
Periodic Maintenance Chart for the Emission Control System
115
General Maintenance and Lubrication Chart
115
Checking the Vehicle Using the Yamaha Diagnostic Tool
118
Checking the Fuel Line
118
Checking the Spark Plugs
119
Adjusting the Valve Clearance
119
Checking the Engine Idling Speed
123
Synchronizing the Throttle Bodies
123
Checking the Throttle Body Joints
125
Checking the Crankcase Breather Hose
125
Checking the Exhaust System
125
CHECKING the CANISTER (for California)
126
Checking the Air Induction System
126
Replacing the Air Filter Element
126
Adjusting the Clutch Lever Free Play
127
Checking the Brake Operation
127
Checking the Brake Fluid Level
128
Adjusting the Front Disc Brake
128
Checking the Front Brake Pads
129
Adjusting the Rear Disc Brake
129
Checking the Rear Brake Pads
129
Checking the Front Brake Hose
129
Checking the Rear Brake Hose
130
Bleeding the Hydraulic Brake System (Abs)
130
Checking the Wheels
131
Checking the Tires
131
Checking the Wheel Bearings
132
Checking the Swingarm Operation
132
Lubricating the Swingarm Pivot
132
Drive Chain Slack
132
Lubricating the Drive Chain
133
Checking and Adjusting the Steering Head
134
Lubricating the Steering Head
135
Checking the Steering Damper
135
Checking the Chassis Fasteners
135
Lubricating the Brake Lever
135
Lubricating the Clutch Lever
135
Lubricating the Pedal
135
Adjusting the Shift Pedal
135
Checking the Sidestand
135
Lubricating the Sidestand
135
Checking the Sidestand Switch
135
ADJUSTING the PRELOAD of the FRONT FORK LEGS (for MT10SPN/MT10SPNC)
137
ADJUSTING the DAMPING FORCE of the FRONT FORK LEGS and REAR SHOCK ABSORBER (for MT10SPN/MT10SPNC)
138
Checking the Rear Shock Absorber Assembly
139
ADJUSTING the REAR SHOCK ABSORBER ASSEMBLY (for MT10N/MT10NC)
139
ADJUSTING the PRELOAD of the REAR SHOCK ABSORBER ASSEMBLY (for MT10SPN/MT10SPNC)
142
Checking the Connecting Arm and Relay Arm
142
Checking the Engine Oil Level
142
Changing the Engine Oil
143
Measuring the Engine Oil Pressure
144
Checking the Coolant Level
145
Checking the Cooling System
146
Changing the Coolant
146
Adjusting the Exup Cables
148
Checking the Front Brake Light Switch
149
Adjusting the Rear Brake Light Switch
149
Checking and Lubricating the Cables
150
Checking the Throttle Grip
150
Checking and Charging the Battery
150
Checking the Fuses
150
Adjusting the Headlight Beams
150
Chassis
153
General Chassis (1)
156
Removing the Seat
161
Removing the Rear Cowling (Center)
161
REMOVING the ECU (Engine Control Unit)
161
Installing the Imu
161
INSTALLING the ECU (Engine Control Unit)
162
Installing the Rear Cowling (Center)
162
Installing the Seat
162
General Chassis (2)
162
Removing the Air Scoop
167
Removing the Side Cover (Left)
167
Removing the Side Cover (Right)
167
Removing the Fuel Tank Cover
168
Removing the Fuel Tank Side Cover Assembly
168
Installing the Fuel Tank Side Cover Assembly
168
Installing the Fuel Tank Cover
168
Installing the Side Cover (Left)
169
Installing the Side Cover (Right)
169
Installing the Air Duct Cover
169
Installing the Air Scoop
170
General Chassis (3)
170
Front Wheel
176
Removing the Front Wheel
179
Disassembling the Front Wheel
179
Checking the Front Wheel
179
Assembling the Front Wheel
180
Maintenance of the Front Wheel Sensor and Sensor Rotor
181
Adjusting the Front Wheel Static Balance
182
Installing the Front Wheel (Disc Brake)
182
Rear Wheel
185
Removing the Rear Wheel
188
Disassembling the Rear Wheel
188
Checking the Rear Wheel
189
Checking the Rear Wheel Drive Hub
189
Checking and Replacing the Rear Wheel Sprocket
189
Checking the Rear Wheel Sprocket Bracket
189
Assembling the Rear Wheel
189
Maintenance of the Rear Wheel Sensor and Sensor Rotor
191
Adjusting the Rear Wheel Static Balance
191
Installing the Rear Wheel (Disc Brake)
191
Front Brake
194
Introduction
200
Checking the Front Brake Discs
200
Replacing the Front Brake Pads
200
Removing the Front Brake Calipers
202
Disassembling the Front Brake Calipers
202
Checking the Front Brake Calipers
202
Assembling the Front Brake Calipers
203
Installing the Front Brake Calipers
203
Removing the Front Brake Master Cylinder
204
Checking the Front Brake Master Cylinder
204
Assembling the Front Brake Master Cylinder
204
Installing the Front Brake Master Cylinder
204
Rear Brake
206
Introduction
212
Checking the Rear Brake Disc
212
Replacing the Rear Brake Pads
212
Removing the Rear Brake Caliper
213
Disassembling the Rear Brake Caliper
214
Checking the Rear Brake Caliper
214
Assembling the Rear Brake Caliper
214
Installing the Rear Brake Caliper
214
Removing the Rear Brake Master Cylinder
215
Checking the Rear Brake Master Cylinder
216
Assembling the Rear Brake Master Cylinder
216
Installing the Rear Brake Master Cylinder
216
ABS (Anti-Lock Brake System)
218
Removing the Hydraulic Unit Assembly
220
Checking the Hydraulic Unit Assembly
221
Checking the Brake Pipes
221
Installing the Hydraulic Unit Assembly
221
Hydraulic Unit Operation Test
222
Checking the Abs Warning Light
225
Handlebar
226
Removing the Handlebar
228
Checking the Handlebar
228
Installing the Handlebar
228
FRONT FORK (for MT10N/MT10NC)
231
Removing the Front Fork Legs
233
Disassembling the Front Fork Legs
233
Checking the Front Fork Legs
235
Assembling the Front Fork Legs
235
Installing the Front Fork Legs
239
FRONT FORK (for MT10SPN/MT10SPNC)
241
Removing the Front Fork Legs
243
Disassembling the Front Fork Leg
243
Checking the Front Fork Legs
244
Assembling the Front Fork Legs
245
Installing the Front Fork Legs
248
Steering Head
251
Removing the Lower Bracket
253
Checking the Steering Head
253
Installing the Steering Head
254
Checking the Steering Damper
254
Rear Shock Absorber Assembly
255
Handling the Rear Shock Absorber
259
Disposing of a Rear Shock Absorber
259
Removing the Rear Shock Absorber Assembly
259
Disassembling the Rear Shock Absorber Assembly
260
Checking the Rear Shock Absorber Assembly
261
Checking the Connecting Arm and Relay Arm
261
Assembling the Rear Shock Absorber Assembly
261
Installing the Relay Arm
261
Installing the Rear Shock Absorber Assembly
262
Swingarm
263
Removing the Swingarm
265
Checking the Swingarm
266
Installing the Swingarm
266
Chain Drive
268
Removing the Drive Chain
270
Checking the Drive Chain
270
Checking the Drive Sprocket
271
Checking the Rear Wheel Sprocket
271
Checking the Rear Wheel Drive Hub
271
Installing the Drive Chain
272
Adjusting the Shift Pedal
273
Lubrication System Chart and Diagrams
278
Engine Oil Lubrication Chart
278
Lubrication Diagrams
279
Engine Inspection
286
Measure the Compression Pressure
286
Engine Removal
288
Removing the Engine
292
Installing the Engine
292
Installing the Exhaust Pipe and Muffler
293
Camshafts
294
Engine
298
Removing the Camshafts
299
Removing the Rocker Arms and Rocker Arm Shafts
299
Checking the Camshafts
299
Checking the Rocker Arms and Rocker Arm Shafts
301
Checking the Timing Chain and Camshaft Sprocket
301
Checking the Timing Chain Guides
301
Checking the Timing Chain Tensioner
302
Assembling the Timing Chain Cover
302
Installing the Rocker Arms and Rocker Arm Shafts
302
Installing the Timing Chain Cover
303
Installing the Camshafts
304
Cylinder Head
308
Removing the Cylinder Head
309
Checking the Cylinder Head
309
Installing the Cylinder Head
309
Valves and Valve Springs
311
Removing the Valves
313
Checking the Valves and Valve Guides
313
Checking the Valve Seats
315
Checking the Valve Springs
316
Checking the Valve Spring Seat
317
Installing the Valves
317
Generator
319
Removing the Generator
321
Installing the Generator
321
Starter Clutch
323
Removing the Starter Clutch
324
Checking the Starter Clutch
324
Installing the Starter Clutch
324
Electric Starter
325
Checking the Starter Motor
327
Assembling the Starter Motor
327
Oil Pump
328
Removing the Oil Pan
331
Checking the Sprocket and Chain
331
Checking the Oil Pump
331
Checking the Relief Valve
331
Checking the Oil Delivery Pipes
331
Checking the Oil Strainer
331
Assembling the Oil Pump
331
Installing the Oil Pump
332
Installing the Oil Pan
333
Clutch
334
Removing the Clutch
338
Checking the Friction Plates
338
Checking the Clutch Plates
338
Checking the Clutch Springs
339
Checking the Clutch Housing
339
Checking the Clutch Boss
340
Checking the Pressure Plate
340
Checking the Primary Drive Gear
340
Checking the Primary Driven Gear
340
Checking the Pull Lever Shaft and Pull Rod
340
Installing the Clutch
340
Shift Shaft
343
Checking the Shift Shaft
344
Checking the Stopper Lever
344
Installing the Shift Shaft
344
Crankcase
345
Disassembling the Crankcase
348
Checking the Crankcase
348
Assembling the Crankcase
348
Installing the Oil Pressure Switch
351
Installing the Gear Position Sensor
351
Connecting Rods and Pistons
352
Removing the Connecting Rods and Pistons
353
Checking the Cylinder and Piston
353
Checking the Piston Rings
354
Checking the Piston Pin
355
Checking the Connecting Rods
355
Installing the Connecting Rod and Piston
358
Crankshaft and Balancer Shaft
363
Removing the Crankshaft and Balancer Shaft
364
Checking the Oil Nozzles
364
Checking the Crankshaft
364
Checking the Balancer Shaft
366
Installing the Crankshaft
368
Installing the Thrust Bearing
368
Installing the Balancer Assembly
369
Transmission
370
Removing the Transmission
374
Checking the Shift Forks
374
Checking the Shift Drum Assembly
375
Checking the Transmission
375
Assembling the Main Axle and Drive Axle
376
Installing the Transmission
376
Cooling System
379
Cooling System Diagrams
380
Radiator
382
Removing the Radiator
383
Checking the Radiator
383
Installing the Radiator
384
Oil Cooler
385
Checking the Oil Cooler
386
Installing the Oil Cooler
386
Thermostat
387
Removing the Thermostat Assembly
388
Checking the Thermostat
388
Assembling the Thermostat Assembly
388
Installing the Thermostat Assembly
388
Water Pump
390
Disassembling the Water Pump
392
Checking the Water Pump
392
Assembling the Water Pump
392
Installing the Water Pump
393
Fuel System
395
Fuel Tank
396
Removing the Fuel Tank
398
Removing the Fuel Pump
398
Checking the Fuel Pump Body
398
Checking the Fuel Pump Operation
398
CHECKING the PURGE CUT VALVE (for California)
399
Installing the Fuel Pump
399
Installing the Fuel Tank
399
Air Filter Case
401
Removing the Air Filter Case
402
Removing the Intake Funnel Assembly
402
Checking the Air Filter Case Seal
402
Checking the Intake Funnel
402
Installing the Intake Funnel and Air Filter Case
402
Installing the Air Filter Case Cover
402
Installing the Air Duct Cover
403
Throttle Bodies
404
Checking the Injectors (before Removing)
407
Removing the Fuel Hose (Fuel Rail Side)
407
Removing the Injectors
407
Checking the Injectors
407
Checking and Cleaning the Throttle Bodies
408
Replacing the Throttle Bodies
409
Installing the Injectors
410
Checking the Injector Pressure
410
Checking the Fuel Pressure
411
Installing the Fuel Hose (Fuel Rail Side)
411
Adjusting the Throttle Position Sensor
412
Air Induction System
413
Checking the Air Induction System
416
Installing the Air Induction System
417
Electrical System
419
Ignition System
422
Circuit Diagram
422
Engine Stopping Due to Sidestand Operation
424
Troubleshooting
425
Electric Starting System
428
Starting Circuit Cut-Off System Operation
430
Charging System
434
Lighting System
438
Signaling System
442
Cooling System
450
Troubleshooting Tip
452
Fuel Pump System
454
Electrical Components
458
Checking the Switches
460
Checking the Fuses
461
Checking the Relays
462
Checking the Relay Unit (Diode)
463
Checking the Ignition Coils
464
Checking the Ignition Spark Gap
465
Checking the Crankshaft Position Sensor
465
Checking the Starter Motor Operation
466
Checking the Stator Coil
466
Checking the Rectifier/Regulator
466
Checking the Horn
467
Checking the Fuel Sender
467
Checking the Radiator Fan Motors
468
Checking the Coolant Temperature Sensor
468
Checking the Throttle Servo Motor
468
Checking the Air Induction System Solenoid
469
Checking the Cylinder Identification Sensor
469
Checking the Intake Air Temperature Sensor
470
Checking the Fuel Injectors
470
Self Diagnostic
473
Self-Diagnostic Function
481
System Diagram
486
Fuel Injection System
492
Basic Process for Troubleshooting
494
Cruise Control System
496
Cruise Control Circuit Operation
498
Basic Instructions for Troubleshooting
499
Abs Components Chart
506
Abs Coupler Location Chart
507
Maintenance of the Abs Ecu
508
Abs Troubleshooting Outline
508
[A] Checking the Abs Warning Light
511
Self-Diagnostic Function and Diagnostic Code Table
519
Dtc Table
519
Communication Error with the Meter
557
Diagnostic Code: Sensor Operation Table
557
Diagnostic Code: Actuator Operation Table
562
Event Code Table
565
Wiring Diagram
805
Color Code
806

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