Yamaha TRACER MT09TRAF Manuals

Manuals and User Guides for Yamaha TRACER MT09TRAF. We have 1 Yamaha TRACER MT09TRAF manual available for free PDF download: Service Manual

Yamaha TRACER MT09TRAF Service Manual

Yamaha TRACER MT09TRAF Service Manual (560 pages)

Brand: Yamaha | Category: Motorcycle | Size: 33.89 MB

Table of Contents

Table of Contents

7
- How to Use this Manual
  5
- General Information
  9
  - Identification
    10
    
    Vehicle Identification Number
    10
    
    Model Label
    10
  - Features
    11
    
    Outline of the Fi System
    11
    
    Fi System
    12
    
    YCC-T (Yamaha Chip Controlled Throttle)
    13
    
    Outline of the Abs
    14
    
    Abs Component Functions
    19
    
    Abs Operation
    24
    
    Abs Warning Light and Operation
    27
    
    OUTLINE of the TCS (Traction Control System)
    28
    
    Multi-Function Meter Unit
    32
    
    D-Mode (Drive Mode)
    40
  - Important Information
    42
    
    Preparation for Removal and Disassembly
    42
    
    Replacement Parts
    42
    
    Gaskets, Oil Seals and O-Rings
    42
    
    Lock Washers/Plates and Cotter Pins
    42
    
    Bearings and Oil Seals
    42
    
    Circlips
    43
    
    Rubber Parts
    43
  - Basic Service Information
    44
    
    Quick Fasteners
    44
    
    Electrical System
    45
  - Special Tools
    49
Specifications

57
- General Specifications
  58
- Engine Specifications
  59
- Chassis Specifications
  64
- Electrical Specifications
  67
- Tightening Torques
  70
- Lubrication Points and Lubricant Types
  79
  - Engine
    79
  - Chassis
    80
- Lubrication System Chart and Diagrams
  82
  - Engine Oil Lubrication Chart
    82
  - Lubrication Diagrams
    84
- Cooling System Diagrams
  94
- Cable Routing
  98
Periodic Checks and Adjustments

129
- General Maintenance and Lubrication Chart
  131
- Introduction
  131
- Periodic Maintenance
  131
- Periodic Maintenance Chart for the Emission Control System
  131
- Checking the Fuel Line
  134
- Checking the Spark Plugs
  134
- Adjusting the Valve Clearance
  135
- Checking the Engine Idling Speed
  138
- Synchronizing the Throttle Bodies
  138
- Adjusting the Exhaust Gas Volume
  140
- Checking the Throttle Body Joints
  140
- Checking the Air Induction System
  141
- Checking the Cylinder Head Breather Hose
  141
- Replacing the Air Filter Element
  141
- Adjusting the Clutch Lever Free Play
  142
- Adjusting the Front Disc Brake
  143
- Checking the Brake Fluid Level
  143
- Checking the Brake Operation
  143
- Adjusting the Rear Disc Brake
  144
- Checking the Front Brake Pads
  144
- Bleeding the Hydraulic Brake System (Abs)
  145
- Checking the Rear Brake Pads
  145
- Checking the Front Brake Hoses
  146
- Checking the Rear Brake Hose
  146
- Checking the Tires
  146
- Checking the Wheels
  146
- Adjusting the Drive Chain Slack
  148
- Checking the Swingarm Operation
  148
- Checking the Wheel Bearings
  148
- Lubricating the Swingarm Pivot
  148
- Checking and Adjusting the Steering Head
  149
- Lubricating the Drive Chain
  149
- Checking the Chassis Fasteners
  150
- Lubricating the Brake Lever
  150
- Lubricating the Clutch Lever
  150
- Lubricating the Pedal
  150
- Lubricating the Steering Head
  150
- Adjusting the Shift Pedal
  151
- Checking the Centerstand
  151
- Checking the Front Fork
  151
- Checking the Sidestand
  151
- Checking the Sidestand Switch
  151
- Lubricating the Centerstand
  151
- Lubricating the Sidestand
  151
- Adjusting the Front Fork Legs
  152
- Adjusting the Rear Shock Absorber Assembly
  153
- Checking the Rear Shock Absorber Assembly
  153
- Checking the Connecting Arm and Relay Arm
  154
- Checking the Engine Oil Level
  154
- Changing the Engine Oil
  155
- Engine
  156
  - Measuring the Engine Oil Pressure
    156
  - Checking the Coolant Level
    157
  - Checking the Cooling System
    157
  - Changing the Coolant
    157
- Cooling System
  158
  - Checking the Front Brake Light Switch
    159
  - Adjusting the Rear Brake Light Switch
    159
  - Checking and Lubricating the Cables
    159
  - Checking the Throttle Grip
    160
  - Checking and Charging the Battery
    160
  - Checking the Fuses
    160
  - Adjusting the Headlight Beams
    160
Chassis

163
- General Chassis (1)
  
  166
  - Installing the Seats
    169
- General Chassis (2)
  
  170
  - Removing the Fuel Tank Front Cover
    175
  - Installing the Fuel Tank
    175
  - Removing the Front Side Cowlings
    175
  - Installing the Front Side Cowlings
    176
  - Adjusting the Windshield Height
    177
- General Chassis (3)
  
  177
  - Removing the Fuel Tank Covers
    182
  - Installing the Fuel Tank Covers
    182
- Front Wheel
  
  184
  - Removing the Front Wheel
    186
  - Disassembling the Front Wheel
    186
  - Checking the Front Wheel
    186
  - Assembling the Front Wheel
    187
  - Maintenance of the Front Wheel Sensor and Sensor Rotor
    188
  - Adjusting the Front Wheel Static Balance
    189
  - Installing the Front Wheel (Disc Brake)
    190
  - Rear Wheel
    192
  - Removing the Rear Wheel
    195
  - Disassembling the Rear Wheel
    195
  - Checking the Rear Wheel
    196
  - Checking the Rear Wheel Drive Hub
    196
  - Checking and Replacing the Rear Wheel Sprocket
    196
  - Assembling the Rear Wheel
    196
  - Maintenance of the Rear Wheel Sensor and Sensor Rotor
    197
  - Adjusting the Rear Wheel Static Balance
    197
  - Installing the Rear Wheel (Disc Brake)
    197
- Front Brake
  
  200
- Rear Brake
  
  213
  - Introduction
    219
  - Checking the Rear Brake Disc
    219
  - Replacing the Rear Brake Pads
    219
  - Removing the Rear Brake Caliper
    220
  - Disassembling the Rear Brake Caliper
    221
  - Checking the Rear Brake Caliper
    221
  - Assembling the Rear Brake Caliper
    222
  - Installing the Rear Brake Caliper
    222
  - Removing the Rear Brake Master Cylinder
    223
  - Checking the Rear Brake Master Cylinder
    223
  - Assembling the Rear Brake Master Cylinder
    224
  - Installing the Rear Brake Master Cylinder
    224
- Abs (Anti-Lock Brake System)
  
  225
  - Abs Components Chart
    227
  - Removing the Hydraulic Unit Assembly
    228
  - Checking the Hydraulic Unit Assembly
    228
  - Installing the Hydraulic Unit Assembly
    228
  - Hydraulic Unit Operation Tests
    230
  - Checking the Abs Warning Light
    233
- Handlebar
  
  234
  - Adjusting the Handlebar Position
    236
  - Removing the Handlebar
    237
  - Checking the Handlebar
    237
  - Installing the Handlebar
    237
  - Installing the Rearview Mirrors and Handguards
    239
- Front Fork
  
  241
  - Removing the Front Fork Legs
    244
  - Disassembling the Front Fork Legs
    244
  - Checking the Front Fork Legs
    245
  - Assembling the Front Fork Legs
    246
  - Installing the Front Fork Legs
    251
- Steering Head
  
  252
  - Removing the Lower Bracket
    254
  - Checking the Steering Head
    254
  - Installing the Steering Head
    255
- Rear Shock Absorber Assembly
  
  256
- Swingarm
  
  260
  - Removing the Swingarm
    261
  - Checking the Swingarm
    261
  - Installing the Swingarm
    262
- Chain Drive
  
  263
  - Removing the Drive Chain
    264
  - Checking the Drive Chain
    264
  - Checking the Drive Sprocket
    265
  - Checking the Rear Wheel Sprocket
    265
  - Checking the Rear Wheel Drive Hub
    265
  - Installing the Drive Chain
    266
Engine

269
- Engine Inspection
  
  272
  - Measure the Compression Pressure
    272
- Engine Removal
  
  274
  - Removing the Engine
    278
  - Installing the Engine
    278
- Camshafts
  
  280
  - Removing the Camshafts
    282
  - Checking the Camshafts
    283
  - Checking the Timing Chain and Camshaft Sprocket
    284
  - Checking the Timing Chain Guides
    284
  - Checking the Timing Chain Tensioner
    285
  - Installing the Camshafts
    285
- Cylinder Head
  
  290
- Valves and Valve Springs
  
  294
  - Removing the Valves
    294
  - Checking the Valves and Valve Guides
    294
  - Checking the Valve Seats
    296
  - Checking the Valve Springs
    297
  - Checking the Valve Lifters
    298
  - Installing the Valves
    298
- Generator and Starter Clutch
  
  301
  - Removing the Generator
    303
  - Removing the Starter Clutch
    303
  - Checking the Starter Clutch
    303
  - Installing the Starter Clutch
    304
  - Installing the Generator
    304
  - Electric Starter
    306
  - Checking the Starter Motor
    308
  - Assembling the Starter Motor
    309
  - Installing the Starter Motor
    309
- Clutch
  
  310
  - Removing the Clutch
    313
  - Checking the Friction Plates
    314
  - Checking the Clutch Plates
    314
  - Checking the Clutch Springs
    314
  - Checking the Clutch Housing
    315
  - Checking the Clutch Boss
    315
  - Checking the Pressure Plate
    315
  - Checking the Primary Drive Gear
    316
  - Checking the Primary Driven Gear
    316
  - Checking the Pull Lever Shaft and Pull Rod
    316
  - Installing the Clutch
    316
- Shift Shaft
  
  320
  - Checking the Shift Shaft
    320
  - Checking the Stopper Lever
    320
  - Installing the Shift Shaft
    320
- Oil Pump
  
  321
  - Checking the Sprocket and Chain
    323
  - Checking the Oil Pump
    323
  - Checking the Relief Valve
    324
  - Assembling the Oil Pump
    324
  - Installing the Oil Pump
    324
- Oil Pan
  
  325
  - Removing the Oil Pan
    326
  - Checking the Oil Strainer
    326
  - Installing the Oil Pan
    326
- Crankcase
  
  327
  - Disassembling the Crankcase
    328
  - Checking the Crankcase
    328
  - Assembling the Crankcase
    328
- Connecting Rods and Pistons
  
  332
  - Removing the Connecting Rods and Pistons
    332
  - Checking the Cylinder and Piston
    332
  - Checking the Piston Rings
    333
  - Checking the Piston Pin
    334
  - Checking the Connecting Rods
    334
  - Installing the Connecting Rod and Piston
    337
- Crankshaft and Balancer Shaft
  
  341
  - Removing the Crankshaft and Balancer Shaft
    342
  - Checking the Oil Nozzles
    342
  - Checking the Crankshaft
    342
  - Checking the Balancer Shaft
    344
  - Installing the Crankshaft
    345
  - Installing the Balancer Assembly
    346
- Transmission
  
  347
  - Removing the Transmission
    351
  - Checking the Shift Forks
    351
Cooling System

355
- Radiator
  
  356
  - Checking the Radiator
    357
  - Installing the Radiator
    357
- Oil Cooler
  
  359
  - Checking the Oil Cooler
    360
  - Installing the Oil Cooler
    360
- Thermostat
  
  361
  - Checking the Thermostat
    362
  - Installing the Thermostat Assembly
    362
- Water Pump
  
  363
  - Disassembling the Water Pump
    365
  - Checking the Water Pump
    365
  - Assembling the Water Pump
    365
Fuel System

367
- Fuel Tank
  
  368
  - Removing the Fuel Tank
    369
    
    Removing the Fuel Pump
    369
    
    Checking the Fuel Pump Body
    369
    
    Checking the Fuel Pump Operation
    369
    
    Installing the Fuel Pump
    369
    
    Installing the Fuel Tank
    370
- Throttle Bodies
  
  374
  - Checking the Injectors (before Removing)
    374
    
    Removing the Fuel Hose (Fuel Rail Side)
    374
    
    Removing the Injectors
    374
    
    Checking the Injectors
    374
    
    Checking and Cleaning the Throttle Bodies
    374
    
    Replacing the Throttle Bodies
    376
    
    Installing the Injectors
    376
    
    Checking the Injector Pressure
    376
    
    Checking the Fuel Pressure
    377
    
    Installing the Fuel Hose (Fuel Rail Side)
    378
    
    Adjusting the Throttle Position Sensor
    378
    
    Adjusting the Accelerator Position Sensor
    379
- Air Induction System
  
  382
  - Checking the Air Induction System
    386
  - Installing the Air Induction System
    386
Electrical System

389
- Ignition System
  
  392
  - Circuit Diagram
    392
  - Engine Stopping Due to Sidestand Operation
    394
  - Troubleshooting
    395
- Electric Starting System
  
  398
  - Circuit Diagram
    398
  - Starting Circuit Cut-Off System Operation
    400
  - Troubleshooting
    402
- Charging System
  
  404
  - Circuit Diagram
    404
  - Troubleshooting
    406
- Lighting System
  
  408
  - Circuit Diagram
    408
  - Troubleshooting
    410
- Signaling System
  
  412
  - Circuit Diagram
    412
  - Troubleshooting
    414
- Cooling System
  
  418
  - Circuit Diagram
    418
  - Troubleshooting
    420
- Fuel Injection System
  
  422
  - Circuit Diagram
    422
  - Ecu Self-Diagnostic Function
    424
  - Troubleshooting Method
    426
  - Diagnostic Mode
    427
  - Yamaha Diagnostic Tool
    428
  - Troubleshooting Details
    429
Troubleshooting

541
- Troubleshooting
  
  542
  - General Information
    542
  - Starting Failures
    542
  - Incorrect Engine Idling Speed
    542
  - Poor Medium-And-High-Speed Performance
    543
  - Faulty Gear Shifting
    543
  - Shift Pedal Does Not Move
    543
  - Jumps out of Gear
    543
  - Faulty Clutch
    543
  - Overheating
    543
  - Overcooling
    544
  - Poor Braking Performance
    544
  - Faulty Front Fork Legs
    544
  - Unstable Handling
    544
  - Faulty Lighting or Signaling System
    544
  - Troubleshooting at the Abs Warning Light
    545
- Self-Diagnostic Function and Diagnostic Code Table
  
  546
- Event Code Table
  
  552
  - Wiring Diagram
    555

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